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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally directed toward a method and system for inhibiting torque steer in a vehicle equipped with steerable wheels that are power driven.
2. Description of Related Art
Vehicles equipped with steerable wheels that are power driven such as front-wheel drive vehicles and four-wheel drive vehicles have the potential to generate a difference in left/right side tire longitudinal force under the application of engine torque. This difference in left/right side tire longitudinal force can be observed in most vehicles, but is especially noticeable in vehicles equipped with a traction enhancement device such as a limited slip differential or another type of torque splitting control device. The mismatch in left/right driving torque creates a difference in the suspension restoring torque between the left side and the right side of the vehicle that ultimately leads to perturbations in steering wheel torque, which is commonly referred to as “torque steer”.
The dynamic conditions that operate to cause torque steer in a vehicle equipped with power-driven, steerable wheels, are well known in the art. Generally, when the vehicle's power-driven steerable wheels are turned to the left under the application of engine torque, the left side tire longitudinal force is smaller than the right side tire longitudinal force. This translates into a torque steer that the driver of the vehicle feels in the steering wheel as a pull to the left. Factors such as the amount of engine torque applied and the transmission gear selected contribute to the overall level of driving torque delivered to the front axle, the resulting left/right driving torque difference amount, and the resulting level of torque steer.
A variety of traction control systems are known that control the slip rate of the driving axle in order to enhance vehicle stability and maneuverability. These known traction control systems generally become active upon the occurrence of a wheel-slip condition or upon the occurrence of a difference in driving wheel speed. Upon sensing such a condition, such systems may incorporate engine throttle or torque control and/or brake system control to improve traction and to mitigate torque steer. The intent of such systems is to intervene in the event of excessive wheel slip so as to keep the tire slip rate within a desired range.
One such system is described in Schmitt et al., U.S. Pat. No. 6,151,546. This patent discloses a method and device for controlling traction in a motor vehicle in which a maximum transmittable driving torque is calculated as a function of various operating parameters of the vehicle and its turning performance. When a skidding tendency of at least one driving wheel occurs, the system engages and reduces engine torque to a calculated maximum transmittable torque value.
In many driving situations however, the left/right difference in longitudinal tire force can lead to a persistent torque steer before the onset of appreciable wheel slip. This situation is especially problematic when high levels of engine torque are applied as a vehicle is being steered in a direction other than straight on a high adhesion surface. In such situations, the torque steer condition occurs before a typical wheel-slip-based traction control system activates. Thus, conventional wheel-slip based traction control systems are generally ineffective to mitigate or inhibit torque steer before a wheel-slip condition occurs.
SUMMARY OF THE INVENTION
The present invention provides a method and system for inhibiting torque steer in a vehicle equipped with steerable wheels that are power driven. The method and system according to the invention inhibit torque steer by limiting the actual amount of engine torque applied to the wheels to the lower of an estimated driver-requested engine torque and a maximum engine torque limit. The method and system effectively inhibits torque steer before appreciable wheel-slip occurs, and thus operates to inhibit torque steer before activation of a conventional wheel-slip based traction control device.
The method according to the invention includes the steps of determining a maximum engine torque limit as a function of steering angle and transmission gear position, comparing the maximum engine torque limit with an estimated driver-requested engine torque, and adjusting or controlling engine operation so as to have actual engine torque be substantially equal to the lower of the maximum engine torque limit and the estimated driver-requested engine torque. The controlling step preferably includes providing a calculated engine throttle angle signal to an engine throttle controller, which adjusts engine throttle position. The torque steer inhibiting throttle command can be subordinate to one or more higher priority commands sent to the engine control system, such as a traction control throttle command sent to the throttle controller by a wheel-slip-based traction control system.
The system according to the invention comprises sensors that measure steering angle and transmission gear position, one or more controllers that calculate the maximum engine torque limit and estimated driver-requested engine torque, a comparator that selects a lower of the maximum engine torque and the estimated driver-requested engine torque, and a throttle angle calculator that determines the throttle angle based upon the selected engine torque and the engine speed. Because the system determines the maximum engine torque limit as a function of steering angle, the system allows for greater straight-line acceleration performance as compared to when the vehicle is being steered in a direction other than in a straight line. The invention improves the overall steering feel of vehicles equipped with steerable wheels that are power driven.
BRIEF DESCRIPTION OF THE DRAWINGS
These and further features of the invention will be apparent with reference to the following description and drawings, wherein:
FIG. 1 schematically illustrates a torque steer inhibiting system according to the present invention;
FIG. 2 is a graph showing an exemplary plot of the maximum transmittable torque limit as a function of steering angle for three transmission gear positions in a vehicle; and,
FIGS. 3 a through 3 f are graphs comparing selected operating conditions as a function of time in a vehicle equipped with a system according to the invention ( FIGS. 3 b , 3 d , and 3 f ) with the same operating conditions as a function of time in a vehicle that is not equipped with a system according to the invention ( FIGS. 3 a , 3 c , 3 e ).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 , the system 10 according to the present invention includes a steering angle sensor 12 , a gear position sensor 14 , an atmospheric pressure-sensor 16 , a throttle angle sensor 18 , an engine speed sensor 20 , a torque limit calculator 22 , a throttle adjustment angle adjustment calculator 24 , an engine torque estimator 26 , a comparator/selector 28 , a throttle angle calculator 30 , and an engine throttle controller 32 . As will be appreciated from the following description, the engine speed sensor 20 , throttle angle sensor 18 , atmospheric pressure sensor 16 , throttle angle adjustment calculator 24 , and engine torque estimator 26 define an estimated engine torque portion 10 a of the system 10 , whereas the gear position sensor 14 , steering angle position sensor 12 , and torque limit calculator 22 define a maximum calculated torque portion 10 b section of the system 10 .
The steering angle sensor 12 measures steering angle. Steering angle can, but need not be, measured in terms of a positive or negative angle of steering wheel rotation from a neutral position, which is straight ahead driving (0° steering angle). In such an arrangement, a steering wheel turned a quarter revolution to the left from the neutral position would be a −90° steering angle. Likewise, a steering wheel turned a half revolution to the right from the neutral position would be a +180° steering wheel angle. The steering angle sensor 12 senses the position of the steering wheel relative to neutral and generates a steering angle signal 12 a that is transmitted to the torque limit calculator.
The transmission gear position sensor 14 measures or detects transmission gear position. Transmission gear position is typically measured as an integer, where the first transmission gear is 1, the second transmission gear is 2, and so on. The transmission gear position sensor 14 senses the transmission gear position and generates a transmission gear position signal 14 a that is transmitted to the torque limit calculator 22 .
The torque limit calculator 22 receives the steering angle signal 12 a from the steering angle sensor 12 and the transmission gear position signal 14 a from the transmission gear position sensor 14 and uses this data, in combination with a software algorithm containing vehicle-specific parameters, to calculate a maximum engine torque limit. The torque limit calculator 22 transmits a maximum torque limit signal 22 a to the comparator 28 .
The maximum engine torque limit is the maximum amount of engine torque that can be applied in the particular transmission gear at the particular steering angle without producing an unacceptable amount of torque steer. This value must be calculated for each vehicle design, and will vary from vehicle to vehicle due to different suspension set-ups, weights, drag, steering ratios, etc. In all cases, however, the maximum engine torque limit will be much higher when the steering wheel is a neutral position for straight ahead driving (e.g., steering angle=0°) than when the steering wheel is turned away from the neutral position (e.g., steering angle is greater than or less than 0°).
FIG. 2 shows an exemplary plot of the maximum engine torque limit for a vehicle as a function of steering angle from 0° to 180° (e.g., a right turn) in three transmission gear positions. It will be appreciated that the maximum engine torque limit for a right turn may be the same as for a left turn, or may be different. However, the maximum engine torque limit for a vehicle will always be higher when the steering wheel is at or near a neutral position as compared to when the steering wheel is turned significantly to the right or left of the neutral position.
Driver-requested engine torque is the amount of torque demanded or requested by the driver at any given moment in time. Driver-requested engine-torque is typically related to accelerator pedal position, but will vary due to factors that affect engine performance. While it may, in some circumstances, be acceptable to employ a sensor that senses accelerator pedal position for estimating driver-requested engine torque, it is more accurate and preferable for the system to employ a plurality of sensors that measure various engine operating and environmental conditions, and to use the sensed conditions to estimate the driver-requested engine torque.
In the illustrated and preferred embodiment of the invention, the estimated torque calculating portion 10 a of the system 10 includes the engine speed sensor 20 that measures engine speed and generates an engine speed signal 20 a , the atmospheric pressure sensor 16 that measures atmospheric pressure and generates an atmospheric pressure signal 16 a , and the throttle angle sensor 18 that measures driver-requested throttle position or angle and generates a driver-requested throttle angle signal 18 a . The atmospheric pressure signal 16 a and the throttle position signal 18 a are fed to the throttle angle adjustment calculator 24 , which calculates an atmospheric pressure-adjustment for the throttle angle, and outputs a throttle angle adjustment signal 24 a to the engine torque estimator 26 . The engine torque estimator 26 receives the throttle angle adjustment signal 24 a and the engine speed signal 20 a , and outputs an estimated driver-requested engine torque signal 26 a to the comparator 28 .
The comparator 28 receives the maximum torque limit signal 22 a from the torque limit calculator 22 and the estimated driver-requested engine torque signal 26 a from the engine torque estimator 26 . The comparator 28 compares the maximum engine torque limit with driver-requested engine torque and passes a torque signal 28 a corresponding to the lower of the estimated engine torque (driver-requested engine torque signal) and the calculated maximum torque (maximum torque limit signal) to the throttle angle calculator 30 .
The throttle angle calculator 30 receives the torque signal 28 a from the comparator 28 and the engine speed signal 20 a from the engine speed sensor 20 , and calculates the engine throttle angle that would produce the selected torque at the given engine speed. A calculated engine throttle angle signal 30 a is transmitted from the throttle angle calculator 30 to the engine throttle control system 32 . The engine throttle controller 32 , in turn, adjusts the throttle angle to correspond with the calculated engine throttle setting and thereby controls the actual engine torque to substantially approximate the value of the torque signal 28 a passed by the comparator 28 .
The sensors 12 , 14 , 16 , 18 , 20 used in the system according to the invention can be utilized exclusively by the system or can be shared with other vehicle systems. Preferably, the sensors measure and transmit data continuously so that calculations and adjustments are made on a real time basis. Further, the calculators 22 , 24 , 30 , estimator 26 , comparator 28 , and controller 32 are preferably provided in one or more microprocessors incorporating or utilizing appropriate control software, as will be appreciated by those skilled in the art, and may be dedicated to the system 10 or shared by other vehicle systems. Thus, the system is dynamic, and allows for immediate adjustments in throttle angle and, hence, actual engine torque in response to changes that are being made to steering angle, transmission gear position, and/or driver requested engine torque. The throttle angle adjustment signal 30 a sent by the throttle angle calculator 30 can be granted a priority, which is either superior to or subordinate to one or more engine throttle commands sent to the engine throttle control system by other vehicle systems (i.e., the wheel-slip based traction control system).
The preferred method of inhibiting torque steer according to the present invention involves determining a maximum engine torque limit as a function of steering angle and transmission gear position, comparing the maximum engine torque limit with driver-requested engine torque, and controlling or adjusting actual engine torque (by adjustment of the throttle angle) to the lower of the maximum engine torque limit and the driver-requested engine torque. Unlike conventional methods, the method of the present invention effectively inhibits torque steer before a wheel-slip condition occurs.
It will be appreciated that the torque steer inhibiting system and method according to the present invention can be used on vehicle that is equipped with a conventional wheel-slip based traction control system. In such situations, the torque steer inhibiting system will be operational before the wheel-slip based traction control system.
It is preferable that the throttle angle adjustment signal 30 a sent by the throttle angle calculator 30 be subordinate to, or to be given a lower priority than, any throttle commands that may be sent to the engine throttle control system 30 by the wheel-slip-based traction control system. Thus, the throttle control system of the present invention will be operable before any traction control system but, when a wheel-slip condition occurs, throttle commands transmitted to the engine throttle control system 32 or the like by the wheel-slip based traction control system take precedence over throttle commands 30 a transmitted to the engine throttle control system 32 by the throttle angle calculator 30 .
FIGS. 3 a through 3 f are graphs comparing selected operating conditions as a function of time in a vehicle equipped with a system according to the invention ( FIGS. 3 b , 3 d , and 3 f ) with the same operating conditions as a function of time in a vehicle that is not equipped with a system according to the invention ( FIGS. 3 a , 3 c , and 3 e ). FIGS. 3 a and 3 b show accelerator pedal position and engine throttle position as a function of time. In FIG. 3 a , engine throttle position tracks accelerator pedal position. In FIG. 3 b , engine throttle position initially tracks the accelerator pedal position until a point “A” at which throttle position or angle is retarded relative to accelerator pedal position due to operation of the system of the present invention. More specifically, and as will be appreciated from the foregoing description, at the point “A” the user requested engine torque exceeds the maximum engine torque limit and, therefore, the throttle angle is controlled so that the actual engine torque does not exceed the maximum permissible engine torque as embodied in the torque signal 28 a . Accordingly, the throttle signal 30 a to the engine throttle controller 32 serves to adjust the throttle position and, thus, actual engine torque to the maximum transmittable torque limit for the particular steering angle and transmission gear position and thereby inhibits torque steer.
FIGS. 3 c and 3 d show the torque steer experienced by the driver of the vehicle under the same conditions and time as in FIGS. 3 a and 3 b . It is noted that a significant amount of torque steer is created or experienced in the vehicle of FIG. 3 c (in which the inventive system is not employed), whereas torque steer is substantially prevented or inhibited in the vehicle depicted in FIG. 3 d , wherein the system of the present invention is utilized.
FIGS. 3 e and 3 f compare driver-requested engine torque, actual engine torque, and limit torque value under conditions similar to those of FIGS. 3 a - 3 d . In FIG. 3 e , it is noted that the driver-requested, actual, and limit torques are equal to one another. However, FIG. 3 f shows that, in a vehicle equipped with the system of the present invention, actual engine torque is limited to the lower of driver-requested engine torque and the maximum engine torque limit (maximum permissible torque). Thus, the actual engine torque tracks the driver-requested engine torque until point “A” at which the maximum engine torque limit is lower than the driver-requested engine torque, at which point the actual engine torque tracks the maximum engine torque limit.
The system according to the invention limits actual engine torque to a value that prevents or minimizes torque steer, and does so well before a wheel-slip based traction control system could activate and intervene. Thus, the system of the present invention is proactive rather than reactive. Furthermore, since the system and method of the invention operate before a wheel-slip based traction control systems can intervene, the system can effectively inhibit torque steer at low levels of transverse acceleration when wheel-slip conditions do not occur. This means that the vehicle need not be at its limit of turning performance for the system to operate to inhibit torque steer.
The system according to the present invention may operate much more frequently to inhibit torque steer than wheel-slip-based traction control systems, especially under high driver-requested engine torque conditions on high adhesion surfaces. On low adhesion surfaces, sufficient wheel slip may occur before the torque steer limit torque is reached, and the wheel-slip based traction control system therefore may become active such that torque steer function limit control is not used.
While the preferred embodiment of the present invention has been disclosed herein, the present invention is not limited thereto. Rather, the method of the present invention is capable of numerous modification and improvements and, therefore, the scope of the present invention is only defied by the claims appended hereto.
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A method and system for inhibiting torque steer in a vehicle equipped with steerable wheels that are power driven. The method determines a maximum engine torque limit, determines an estimated driver-desired torque, and controls the actual torque, by adjustment of the throttle angle, to be the smaller of the maximum engine torque limit and the estimated driver-desired torque. Sensors measure steering angle and transmission gear position and a calculator determines the maximum engine torque limit based upon the steering angle and transmission gear position. Further sensors measure engine speed, throttle angle, and atmospheric pressure, and a calculator estimates driver-desired torque based upon the measured engine speed, throttle angle, and atmospheric pressure. A comparator selects the lower of the maximum engine torque limit and the driver-desired engine torque and uses the selected torque to control throttle angle to inhibit torque steer.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of and claims priority under 35 U.S.C. §120 to PCT Application No. PCT/EP2013/001040 filed on Apr. 9, 2013, which claimed priority to German Application No. DE 10 2012 205 907.5, filed on Apr. 11, 2012. The contents of both of these priority applications are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to methods, devices and systems for machine maintenance using a service computer, particularly using different maintenance applications.
BACKGROUND
[0003] The global orientation of today's machine manufacturers with clients/machine users located worldwide demands to be able to perform maintenance, fault detection and also repairs of the machine not only directly on site, but increasingly via remote access. In that application, under the term “machines” all machine facilities are summarized, e.g., for machining via laser, for punching or bending, and devices as, e.g., laser beam sources, plasma generators or induction generators. Dial-in directly from a service computer via an analogue modem or an ISDN-connection to a machine as it was common in the past will be replaced by recent communication technologies, especially by the so called Virtual Private Network (abbreviated VPN) allowing an encrypted remote access via the Internet. A remote access via VPN puts high requirements on the infrastructure and safety. The fact that the remote access via VPN is dependent on the technology applied by the machine operator is particularly problematic. A simple universal solution on the side of the machine manufacturer is thereby hindered that it is hitherto not possible to apply different VPN-software simultaneously within one operating system, e.g., on a service computer.
[0004] A system and a method for remote communication between a central computer and a machine controller are known from the European patent application EP 1 715 395 A1. The known remote communication system 1 shown in FIG. 1 comprises a central computer 5 which is protected by a firewall 6 to the outside. Several virtual machines 7 are installed on the central computer 5 which are executable simultaneously and can have different operating systems and application programs especially telepresence programs and antivirus programs. For each machine controller 3 there is a specific configured virtual machine 7 over which a communication link 8 will be established from the central computer 5 to the machine controller 3 . The service computer 2 is not directly connected to the machine controller 3 , but the connection of the service computer 2 is effected via the central computer 5 which is connected with the service computer 2 via a communication link 9 . In a database 10 connected with the central computer 5 all data (dial-in technology, passwords, VPN-software) about the client and the machine 4 is stored. The central computer 5 determines the assigned communication link 8 on the basis of the data stored in the database 10 and the assigned virtual machine 7 and establishes the communication link 8 from the virtual machine 7 to the machine controller 3 . The communication link 9 between the service computer 2 and the central computer 5 as well as the communication link 8 between the central computer 5 and the machine controller 3 are effected via the Internet 11 , e.g., via a protected VPN-connection.
[0005] For remote access to a machine controller 3 of the machine 4 a service person at first prepares the communication link 9 between his service computer 2 and the central computer 5 . On the basis of the data stored in the database 10 , the central computer 5 determines the communication link 8 which is assigned to the machine controller 3 and selects the executable virtual machine 7 which is adapted to the machine controller 3 and the communication link 8 for the connection with the machine controller 3 and starts that virtual machine 7 . The service person performs functions of the machine controller 3 via the communication link 8 or exchanges data between the machine controller 3 and the central computer 5 .
[0006] A further advancement of the system and the method for remote communication from EP 1 715 395 A1 is known from DE 10 2008 030 317 A1. There it is disclosed that the executable virtual machine 7 is not permanently stored in the central computer 5 , but virtual machine templates designed for different kinds of machine controllers and communication links. If required an executable virtual machine 7 is started and used as an executable embedded copy of that virtual machine template which is adapted to the respective machine controller and the respective communication link. After termination of the executable virtual machine 7 the executable embedded copy can be deleted.
[0007] It is a consequence of that system, that by the fact that the required maintenance software has to be provided in each virtual machine or machine template separately, here it comes to redundant application and data management. That leads to the result that for the virtual machine template, on the one hand large amounts of data have to be stored on the central computer, and on the other hand, because of the complexity of the virtual machine template, long starting times of the executable virtual machine 7 are to be expected. Further, for each of the virtual machine templates including a certain software required for maintenance, corresponding software updates have to be executed often to keep the environment up to date. That, in turn, leads to high maintenance effort.
SUMMARY
[0008] One aspect of the invention features a system for remote communication between a computing system and at least one machine controller. The system includes at least one machine controller via which a machine can be controlled and a computing system defining at least one virtual machine and having at least one application server on which application software for operation or for maintenance of the machine controller or the machine is installed. The machine controller can be connected with the virtual machine such that a remote communication between the virtual machine and the machine controller can be established, and the virtual machine can be connected with the application server via a further communication link by means of a remote-desktop-protocol such that the application server or the application software which is installed on the application server can be operated via the virtual machine.
[0009] By the use of the system, required maintenance effort can be reduced, the amount of data can be narrowed, and/or the complexity of the system can be decreased. By the use of that structure, the application software can be limited to one installation at the application server and the maintenance effort can be limited correspondingly. Alternatively or additionally it is achieved that application software can be used which is not compatible with the system of the virtual machine and therefore not installable on that.
[0010] The computing system can include a central computer defining the at least one virtual machine is provided and an additional computer configured to function as the at least one application server.
[0011] In some implementations, the computing system includes a central computer defining at least one virtual machine and also defining a further virtual machine configured to function as the at least one application server, on which application software for operation or for maintenance of the machine controller or the machine is installed. The machine controller can be connected to the virtual machine via a first communication link such that a remote communication between the virtual machine and the machine controller can be ensured and the virtual machine can be connected to the application server via a further communication link by means of a remote-desktop-protocol such that the application server or the application software installed at the application server is operatable via the virtual machine.
[0012] Another aspect of the invention features a method for remote communication between a central computer and at least one machine controller for a machine is disclosed. The method includes: establishing a first communication link between the machine controller and a virtual machine provided on the central computer, establishing of a further communication link between the virtual machine and an application server via a remote-desktop-protocol, and operating of application software installed on the application server by the virtual machine, the application software being configured to operate or maintain at least one of the machine controller or the machine.
[0013] Other advantages and advantageous embodiments of the subject-matter of the invention will be appreciated from the description, the claims and the drawings. The features mentioned above and those set out below may also be used individually per se or together in any combination. The embodiment shown and described is not intended to be understood to be a conclusive listing but is instead of exemplary character for describing the invention.
DESCRIPTION OF DRAWINGS
[0014] FIG. 1 shows a remote communication system between a service computer and a machine controller by interposition of a central computer.
[0015] FIG. 2 shows a first embodiment of a system for remote communication.
[0016] FIG. 3 shows a second embodiment of the system for remote communication.
[0017] FIG. 4 shows an example method for remote communication.
DETAILED DESCRIPTION
[0018] In FIG. 2 a first embodiment of a system 101 for remote communication between a service computer 102 , a central computer 105 and a machine controller 103 of a machine 104 is described.
[0019] The machine 104 is a machine tool or a machining unit, e.g., for laser machining, for punching or bending, and devices like, e.g., laser beam sources, plasma generators or induction generators or another machine for manipulation of a workpiece. The machine 104 includes a machine controller 103 and an internal machine communication network 142 via which data communication and control operations between the machine controller 103 and a numeric control (NC) or Programmable Logic Controller (PLC) 151 or further technical controllers 152 , 153 and 154 will be performed.
[0020] The machine controller 103 is an electronic data processing device, e.g., an industrial PC via which the machine tool 104 can be programmed, operated and maintained and which monitors the operation of the machine tool. The machine controller 103 is connected with a communication network 132 , e.g., a communication network of the machine user which is operated on the basis of Ethernet for in-house data transmission and data processing. Via the communication network 132 the machine controller 103 is able to access data processing devices 133 which are connected via the communication network 132 . On the machine controller 103 application software is installed, which is able to display the content of the desktop of remote computers and which allows to operate the remote computers by means of the Remote-Desktop-Protocol (RDP). On the one hand, i.a. graphical user interface information of the remote computer is transmitted to the machine controller 103 such that either the entire screen surface of the remote computer, or only the image information of single programs of the remote computer, are displayed on the machine controller. On the other hand, user interface input information, for example via mouse or keyboard, is transmitted from the machine controller 103 to the remote computer such that the remote computer or a remote application software can be operated from the machine controller.
[0021] The use of the Remote-Desktop-Protocol is not required necessarily. Other protocols can be used which have similar functionality, like for example the “Independent Computing Architecture” (ICA), “Remote Frame Buffer” (RFB) or others. Protocols like that allowing the access to graphical user interfaces of operating systems or remote application software on remote computers by that they transmit pixel information of an operating system or an application on a remote computer in one direction to a user computer and input information like mouse movement or keyboard input from the user computer to the remote computer in the opposite direction, are called foreign desktop protocols in the following.
[0022] The service computer 102 is an electronic data processing device, e.g., a laptop which is usable for conventional data processing. The service computer 102 is connected with a communication network 122 (not shown in FIG. 2 ), e.g., a communication network of the machine manufacturer which is operated on the basis of Ethernet for in-house data transmitting and data processing. Alternatively the service computer 102 can be connected with a wide-area network like the Internet as well. Application software is installed on the service computer 102 , which is able to display the content of desktops of remote computers and which permits operating the remote computers via Remote-Desktop-Protocol (RDP). Other foreign desktop protocols are possible.
[0023] The central computer 105 is an electronic data processing device which implements a tele presence system. For example, a “TRUMPF-Internet-Telepräsenz-Portal” can be installed on the central computer 105 . In such a system a host operating system is installed on the central computer 105 . In the embodiment, the host operating system can be a Linux-based operating system. Via a hypervisor, a specific kind of software for virtualization, an environment for virtual machines is provided. In this embodiment, as the hypervisor, a VM-product of the manufacturer VMWare Inc. can be used. Alternatively, a so called “bare metal hypervisor” can be used, which is executable on the central computer 105 without an underlying complete host operating system.
[0024] One or more virtual machines 107 can be operated on the hypervisor in parallel. A virtual machine 107 is an environment in which interfaces are provided to a guest operating system which allows the guest operating system to perform as it is installed on an own device and operated on that without an underlying hypervisor. On the central computer, virtual machine templates 107 ′ (not shown in FIG. 2 ) adapted to the respective operating system and the respective operating software of the machine controller 103 are stored. The virtual machine template 107 ′ is designed such that a virtual machine made thereof can be connected via a first communication link 108 with the machine controller 103 . The actual remote access to the machine controller 103 occurs via a virtual machine 107 generated by copying the machine template suitable to the machine controller 103 . In the embodiment, Microsoft Windows XP can be used as a guest operating system. This provides the possibility for other computers to access the desktop, applications and data of the guest operating system via the Remote-Desktop-Protocol via the included service “Terminal Services”. Other guest operating systems are possible as well which are able to provide that functionality either by their own or via programs. Furthermore, application software is installed on the virtual machine 107 allowing a remote access to remote computers or remote applications by means of a foreign-desktop-protocol—RDP in the case of the embodiment. Additionally, maintenance software and operation software for the machine controller 103 or the machine 104 can be installed on the virtual machine 107 .
[0025] Between the virtual machine 107 and the machine controller 103 the first communication link 108 can be established. In the embodiment, that connection can be provided via the Internet. For protecting the first communication link 108 , implemented via an encrypted tunnel and so, a VPN-connection can be established.
[0026] Between the virtual machine 107 and the service computer 102 , a second communication link 109 is established. In the embodiment, that connection can be established via an internal communication network of the machine manufacturer. The second communication link 109 can also be established via the Internet and protected via a VPN-tunnel.
[0027] The first and the second communication links 108 , 109 from and to the central computer 102 are isolated via a firewall 106 so that no direct connection is possible between the service computer 102 and the machine controller 103 . That means that on each layer of the ISO-OSI-reference model, no direct protocol connections are possible between the instances of these layers on the service computer 102 and the machine controller 103 . Via the second communication link 109 , a connection with the virtual machine 107 is established via the Remote-Desktop-Protocol in such a way that by use of the service computer 102 , the application software installed on the virtual machine 107 can be operated.
[0028] The application server 160 is an electronic data processing device, e.g., a conventional PC, on which a server operating system is installed, for example, Windows 2008 R2. That operating system allows access to desktop, applications and data of the server operating system by means of the service “terminal services” and RDP for other computers, via the Remote-Desktop-Protocol. On the application server 160 several application software is installed, e.g., a number of diagnostic tools 161 , 162 , 163 , application software for machine programming 164 or further application software necessary or desired for the operation or the maintenance of the machine 104 or the machine controller 103 .
[0029] Between the virtual machine 107 and the application server 160 a third communication link 165 is established. In the embodiment, that connection can occur via an internal communication network of the machine manufacturer which can be the same as the communication network of the second communication link 109 . Via the third communication link 165 a connection between the virtual machine 107 and the application server 160 is established via the Remote-Desktop-Protocol in such a way that via the virtual machine 107 the application software installed on the application server can be operated. Further, the input/output operations are forwarded to the application server 160 and the peripheral devices connected to the application server 160 via RDP to the virtual machine in such a way that the resources of the application server 160 are incorporated in the guest system of the virtual machine 107 , comparable with own resources. Thus, the application software installed on the application server 160 can be accessed via the virtual machine 107 . In particular, the application software 161 , 162 , 163 , 164 installed on the application server 160 can access local resources of the virtual machine 107 as if it is installed on the virtual machine 107 locally. Local resources are, for example, network connections, data storage media, and/or connected hardware or resources of the machine controller 103 locally embedded in the virtual machine 107 via RDP, e.g., network connections and data storage media of the machine controller or sensors, actuators and other hardware of the machine 104 which can be accessed from the machine controller 103 .
[0030] Between the virtual machine 107 and the service computer 102 a second communication link 109 is established. In the embodiment that connection can occur via an internal communication network of the machine manufacturer. The second communication link 109 can also be established via the Internet and protected via a VPN-tunnel.
[0031] Via the second communication link by means of the Remote-Desktop-Protocol a connection with the virtual machine 107 is established in that way that, via the service computer 102 , the application software installed on the virtual machine, in particular the application software for using a foreign-desktop-protocol, can be operated. It is possible to access the application software which is installed on the application server 160 and to operate the software as it is installed on the service computer 102 from the service computer 102 via the second communication link 109 , the virtual machine 107 and the third communication link 165 .
[0032] Further, it is possible to access the application software installed on the application server 160 from the machine controller 103 via the first communication link 108 , the virtual machine 107 and the third communication link 165 as if it is installed locally on the machine controller 103 . In particular, the application software 161 , 162 , 163 , 164 installed on the application server 160 has access to local resources of the machine controller 103 in that way as if they are installed on the machine controller 103 locally. Local resources are, for example, network links and data storage media of the machine controller 103 , or sensors, actuators and other hardware of the machine 104 which can be accessed from the machine controller 103 .
[0033] The structure of the first embodiment has the benefit that the computing work load can be removed from the central computer 105 to the application server 160 and thereby less demands are made on the resources of the central computer 105 . Further, the application software is installed only once on the application server 160 and available in the different virtual machine templates 107 ′ and virtual machines 107 via foreign-desktop-protocols. That means that this software no longer has to be installed and provided in each virtual machine template 107 ; wherefore the software installation has to be maintained and updated only once at central position and no longer in each virtual machine template 107 ′.
[0034] In FIG. 3 a second embodiment of the system 101 is shown. The second embodiment differs from the first embodiment only by that the application server 160 is no separate electronic data processing device, but it is executable itself as a virtual machine 160 ′ on the hypervisor of the central computer. The third communication link 165 ′ it not an internal communication network of the machine manufacturer, but a virtual connection between the virtual machine 107 and the virtual machine 160 ′ of the application server.
[0035] The system of the second embodiment has the benefit that the system is simplified at the site of the device by omitting a separate device for the application server 160 . Further, the system of the second embodiment has the benefits of the first embodiment regarding to simplify the maintainability of the virtual machine templates 107 ′ and the virtual machine 107 .
[0036] FIG. 4 shows a method for remote communication for machine maintenance. In a first link establishing step S 1 , there is established a link between the machine controller 103 and the virtual machine 107 . For that, first of all a copy of a suitable virtual machine template 107 ′ is created on the central computer 105 and, on the basis of the copy, the virtual machine 107 is started. Hereupon, the first communication link 108 is established via the Internet between the virtual machine 107 and the machine controller 103 . The first communication link can be protected via a VPN-tunnel.
[0037] In a second link establishing step S 2 , the second communication link between the virtual machine 107 and the service computer 102 is established. Especially when the virtual machine 107 and the service computer 102 are not in the same protected network, that communication link can be protected via a VPN-tunnel. The second communication link may occur via both, an Ethernet based internal communication network of the machine manufacturer or the Internet as well. When establishing the second communication link, the protocol RDP can be used. The second communication link 109 is configured in that way, that application software installed on the application server 160 , 160 ′ or the virtual machine 107 is integrable into the service computer 102 .
[0038] In a link establishing step S 3 , the third communication link between the virtual machine 107 and the application server 160 , 160 ′ is established. The third communication link 165 , 165 ′ may occur via both, an Ethernet based internal communication network of the machine manufacturer, or a virtual connection inside of the service computer 105 as well. When establishing the third communication link, the protocol RDP is used. The third communication link 165 is configured so that application software installed on the application server 160 , 160 ′ is integrable into the virtual machine.
[0039] If the connection is established in the method, the application software installed on the application server 160 for maintaining or operating the machine 104 can be used via the service computer 102 .
[0040] In a modified step S 1 , the first link is established by means of RDP as well, so that the application software installed on the application server 160 for machine maintenance and operation is used by the machine controller 103 as well. Especially the application software installed on the application server 160 accesses local resources of the machine controller 103 in such a way as if it is installed locally. Local resources are, e.g., network links and data storage media of the machine controller 103 , or sensors, actuators and other hardware of the machine 104 which can be accessed by the machine controller 103 .
[0041] This has the benefit that the requirements of the software for processing performance in not settled on the machine controller 103 which is typically in use for many years and therefore possibly does not offer sufficient resources any more for running a still up-to-date application software for machine maintenance and machine operating.
[0042] Further, depending on implementation, as an additional or alternative benefit, the installation of software updates on the machine controller 103 is avoided, which is especially expensive, since the operating system of the machine controller 103 is typically hardened by, e.g., shutting down of services or locking of interfaces for preventing undesired or damaging changes of the system. However, these arrangements typically resulting in a removal of functionality are complicating desired software updates as well.
[0043] Further, depending on implementation, additional or alternative benefits of application software, which is no longer installed direct on the machine controller 103 , consist in that duplicating of unlicensed application software is impeded and that a machine operator is no longer executing application software for machine maintaining and machine operating on his own, by which it is, e.g., possible to disable functions relevant for safety or to damage the machine 104 in case of incorrect usage. Rather, the access on application software executed on the application server 160 can, e.g., be restricted so that the software is only able to access resources of the machine controller 103 when service personnel supervise the execution of the application or decides the execution of the application by means of logging in on the central computer 105 with the service computer 102 .
[0044] In a finishing step S 4 , the first communication link 108 , the second communication link 109 and the third communication link 165 are disconnected and the virtual machine 107 is erased. The erasing of the virtual machine 107 can occur automatically in case of that neither the first communication link 108 , the second communication link 109 nor the third communication link 165 are active, or one of the three communication links is not active for an adjustable period of time.
[0045] The embodiments shown and described ought not to be understood as a conclusive enumeration, but have rather exemplary nature for explaining the invention. Thus, in the embodiment, the central computer is connected to the communication network of the machine manufacturer. But the central computer can also be accommodated and operated at an external service provider. The same applies for the application server.
[0046] In the embodiment the transmission protocol RDP is used as an example. Alternatively to that, other foreign-desktop-protocols can be used. The sentential connectives “and”, “or” and “either . . . or” are used in the meaning which leans on the logical conjunction, the logical inclusive disjunctions (often “and/or”), and the logical exclusive disjunctions, respectively.
[0047] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
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Methods, devices and systems for machine maintenance using a service computer, particularly using different maintenance applications feature at least one machine controller configured to control an associated machine and a computing system defining at least one virtual machine and comprising at least one application server on which is installed application software for at least one of the machine controller or the associated machine. The machine controller is connectable with the virtual machine via a first communication link so as to enable remote communication between the virtual machine of the computer and the machine controller. The virtual machine is connectable with the application server via a further communication link by a remote-desktop-protocol, such that at least one of the application server and the application software installed on the application server is operable via the virtual machine.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method and an apparatus for mixing a biological sample such as blood with a predetermined reagent and conducting a biochemical analysis, and to a cartridge for the biochemical analysis.
BACKGROUND OF THE INVENTION
[0002] As a conventional biochemical analysis apparatus of this kind, a discrete type apparatus such as shown in FIG. 8 is well known.
[0003] This discrete-type biochemical analysis apparatus 1 is generally comprised of a biological sample container retaining part 3 for holding biological sample containers 2 , a reaction container retaining part 5 for holding reaction container s 4 , a biological sample pipetter 6 , a diluent solution bottle 7 for containing a diluent solution, a reagent pipetter 8 , a reagent bottle 9 for containing a reagent, a photometer 10 , and a washing/drying device (not shown).
[0004] In analyzing the biological sample in this arrangement, firstly, the diluent solution within the diluent solution bottle 7 is sucked by the biological sample pipetter 6 and mixed with the biological sample within the biological sample container 2 to dilute the biological sample and then this diluted biological sample is transferred into the reaction container 4 . Secondly, the reagent within the reagent bottle 9 is dispensed in to the reaction container 4 by the reagent pipetter 8 and mixed with the biological sample to measure and analyze the absorbance of the biological sample by the photometer 10 . Then, after completion of the analysis, the biological sample within the reaction container 4 is discarded and the reaction container 4 is washed and dried by the washing/drying device. Subsequently, the analysis is conducted in turn in the same manner for other biological samples.
[0005] However, the conventional biochemical analysis method and the apparatus used therein as described above has required the pipetters 6 , 8 for diluting the biological sample or adding the reagent into the biological sample, and the washing/drying device for washing and drying the reaction container 4 after completion of the analysis. Thus, there has been a problem in that the operation of biochemical analysis is troublesome and the biochemical analysis apparatus becomes complex and large.
[0006] Further, since only the biological sample is made to be discarded after completion of the analysis, the biological sample needs to be chemically treated for discharging as a wastewater, which has caused a problem of increasing the cost of wastewater treatment.
[0007] The present invention is made to solve these problems and provides a biochemical analysis method and an apparatus used therein as well as a cartridge for biochemical analysis, which enable a lower cost, a smaller equipment size, and a simplified operation for analysis.
SUMMARY OF THE INVENTION
[0008] The present invention comprises the steps of tilting a container containing a biological sample and ejecting the biological sample within the container onto the central portion of a cartridge mounted on a turntable; rotating the turntable, exerting a centrifugal force upon the biological sample on the cartridge, and guiding the biological sample evenly into a plurality of reagent containing parts arranged radially in the cartridge; and analyzing the biological sample after it is guided into each of the reagent containing parts and mixed with a reagent therein.
[0009] Preferably, the present invention further comprises the step of guiding the biological sample, which is ejected onto the cartridge having a plurality of pairs of first reagent containing part and second reagent containing part separated vertically by means of a pair of films, into each first reagent containing part to mix with a first reagent and, after analyzing the biological sample, pressing the cartridge from above, rupturing the pair of films by a cutter provided between the first reagent containing part and the second reagent containing part while coupling the first reagent containing part and the second reagent containing part, mixing the biological sample with a second reagent, and analyzing the biological sample.
[0010] Also, the present invention further comprises the step of removing the analyzed cartridge from the turntable and mounting another cartridge to be analyzed next on the turntable.
[0011] Further, the present invention comprises the step of moving a container retaining part, which holds a predetermined number of the containers, along the tangential direction of the turntable and stopping the container retaining part when the container containing the biological sample to be analyzed next comes to confront the turntable.
[0012] Furthermore, the present invention comprises the step of injecting air into the tilted container and ejecting the biological sample within the container onto the cartridge.
[0013] Further, the present invention comprises the step of moving the container retaining part, which holds the predetermined number of the containers, along the tangential direction of the turntable and discarding the container emptied by ejection of the biological sample into a container disposal unit.
[0014] Also, the present invention comprises a turntable capable of mounting a cartridge thereon, the cartridge having a predetermined number of reagent containing parts arranged radially therein each containing a reagent; a biological sample ejecting mechanism part that tilts a container and ejects a biochemical sample within the container onto the central portion of the cartridge; a turntable control part that rotates the turntable, exerts a centrifugal force upon the biological sample on the cartridge, and guides the biological sample evenly into each of the reagent containing parts; and a measuring unit that mixes the biological sample with the reagent within each of the reagent containing parts and performs analysis on predetermined items.
[0015] Preferably, the present invention further comprises a container retaining part provided movably along the tangential direction of the turntable and capable of retaining a predetermined number of containers each containing the biological sample.
[0016] Also, the present invention further comprises a pressurizing part that presses the cartridge from above, wherein each of the reagent containing parts of the cartridge is separated vertically into a first reagent containing part and a second reagent containing part by means of a pair of films, the first reagent containing part and the second reagent containing part containing a first reagent and a second reagent respectively, a coupling part is provided between the first reagent containing part and the second reagent containing part, the coupling part having a cutter, and after the biological sample ejected onto the cartridge is guided into the first reagent containing part, mixed with the first reagent, and analyzed, the pair of films are ruptured by the cutter when the cartridge is pressed from above by the pressurizing part, while the first reagent containing part and the second reagent containing part are coupled by the coupling part and the biological sample is mixed with the second reagent and analyzed.
[0017] Further, the present invention is constructed such that the cartridge has an annular protruded part formed between the central portion thereof and the reagent containing parts, the protruded part having a plurality of cutting parts formed therein to communicate the central portion with the reagent containing parts, and the biological sample ejected onto the central portion is guided through the cutting parts into the reagent containing parts.
[0018] Furthermore, the present invention comprises a cartridge storing unit capable of storing a predetermined number of the cartridges and a cartridge disposal unit capable of containing analyzed ones of the cartridges, wherein the analyzed cartridge is removed from the turntable and discarded into the cartridge disposal unit, and another cartridge to be analyzed next is mounted onto the turntable from the cartridge storing unit.
[0019] Also, the biological sample ejecting mechanism part comprises an air gun that injects air into the tilted container.
[0020] Further, the present invention comprises a biological sample ejecting region provided in the central portion of the cartridge, and a plurality of reagent containing parts provided in the periphery of the biological sample ejecting region and communicating with the biological sample ejecting region; wherein the reagent containing part is separated vertically into a first reagent containing part and a second reagent containing part by means of a pair of films, the first reagent containing part and the second reagent containing part containing a first reagent and a second reagent respectively, a coupling part is provided between the first reagent containing part and the second reagent containing part, the coupling part having a cutter, and when pressed from above, the pair of films are ruptured by the cutter while the first reagent containing part and the second reagent containing part are coupled by the coupling part.
[0021] Preferably, the present invention comprises an annular protruded part formed between the biological sample ejecting region and the reagent containing parts, the protruded part having a plurality of cutting parts formed therein to communicate the biological sample ejecting region with the reagent containing parts.
[0022] Also, the protruded part is formed in two protruded parts, and the cutting parts for each of the protruded parts are arranged evenly such that the cutting parts of one protruded part are not aligned in a same radial direction with the cutting parts of the other protruded part.
[0023] Then, the construction of the present invention described above enables to provide for a simplified analysis operation and a smaller analysis apparatus, as well as reduction of the disposal cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a plan view of a biochemical analysis apparatus according to an embodiment of the present invention;
[0025] [0025]FIG. 2 is a front view of the biochemical analysis apparatus according to the embodiment of the present invention;
[0026] [0026]FIG. 3 is a side view of the biochemical analysis apparatus according to the embodiment of the present invention;
[0027] [0027]FIG. 4 is a schematic explanatory view illustrating the construction of a cartridge storing unit in the embodiment of the present invention;
[0028] [0028]FIG. 5 is the plan view of a cartridge in the embodiment of the present invention;
[0029] [0029]FIG. 6 is a cross-sectional view of a cartridge in the embodiment of the present invention;
[0030] [0030]FIG. 7 is the cross-sectional view of FIG. 6 taken along the line B-B; and
[0031] [0031]FIG. 8 is a schematic constructional view of a conventional example.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] An embodiment of the present invention will now be described with reference to the drawings.
[0033] FIGS. 1 - 7 illustrate a biochemical analysis apparatus 20 according to an embodiment of the present invention, which will be described below for an exemplary case where a serum is used as a biological sample.
[0034] The biochemical analysis apparatus 20 comprises a turntable 21 , a container retaining part 22 provided to be lineally movable along the tangential direction of the turntable 21 , a barcode reading part 23 arranged in the opposite side of the turntable 21 across the container retaining part 22 , an air gun 24 arranged in the opposite side of the container retaining part 22 across the turntable 21 , a cartridge storing unit 25 provided in proximity to the side of the turntable 21 , a cartridge disposal unit 26 arranged in the opposite side of the cartridge storing unit 25 across the turntable 21 , a container disposal unit 27 arranged beside the cartridge disposal unit 26 , a measuring unit 28 arranged in proximity to the turntable 21 , and a pressurizing part (not shown) provided above the turntable 21 , wherein rotation of the turntable is controlled by a turntable control part (not shown).
[0035] The container retaining part 22 forms a shape of laterally elongated box and is configured to be capable of retaining a predetermined number of containers 29 in an erected condition ( 10 containers in FIG. 1 and FIG. 2), wherein the outer surface of the container 29 has a barcode 30 attached thereto. Preferably, a cylindrical body for containing serum s separated by a biological sample separating apparatus according to a co-pending Japanese Patent Application No. 2002-74616 by the present inventor is used for the container 29 . In that case, since the serums within the cylindrical body are diluted beforehand by a diluent solution, there is no need for the biochemical analysis apparatus 20 to be provided with a mechanism for adding the diluent solution into the serums, thereby enabling a simpler and smaller apparatus to be provided. Also, since the cylindrical body can be placed directly in the container retaining part 22 , there is no need for the diluted serums within the cylindrical body to be transferred into another container, thereby enabling an improvement in working efficiency and reduction of the blood to be collected to a minute amount. Further, enabling the reduction of the blood to be collected to the minute amount also allows the blood collection to be conducted by a patient himself instead of an expert such as a doctor.
[0036] As best shown in FIG. 4, the cartridge storing unit 25 forms a shape of longitudinally elongated cylindrical box and contains cold-reserving equipment 31 in a lower part thereof, wherein a predetermined number of cartridges 33 ( 10 cartridges in FIG. 4) are stacked above the cold-reserving equipment 31 via a cartridge lifting equipment 32 . The cartridge storing unit 25 also has an opening at the upper side surface thereof as a cartridge output port 34 .
[0037] As best shown in FIGS. 5 - 7 , the cartridge 33 has a generally circular plane and is adapted to be stored in alignment within the cartridge storing unit 25 by a pair of recesses 35 formed on a circumferential side surface thereof. Also, the top surface of the cartridge 33 has a raised part 36 formed in the central portion thereof, and a first and a second annular protruded parts 37 , 38 respectively are formed concentrically around the raised part 36 . The first and second protruded parts 37 , 38 have a predetermined number of a first and a second cutting parts 39 , 40 respectively formed radially therein (3 cutting parts in the first protruded part 37 and 6 in the second protruded part 38 in FIG. 6) by which the raised part 36 is communicated with the outer periphery of the second protruded part 38 , and the first cutting part 39 and the second cutting part 40 are evenly arranged such that they are not aligned in a same radial direction.
[0038] Further, the cartridge 33 has a predetermined number of reagent containing parts 41 (12 containing pats in FIG. 6) disposed radially around the second protruded part 38 , and the reagent containing part 41 is divided vertically into a first reagent containing part 43 for containing a first reagent 42 and a second reagent containing part 45 for containing a second reagent 44 . Then, the bottom surface of the first reagent containing part 43 and the top surface of the second reagent containing part 45 are formed of a first and a second films 46 , 47 respectively, and a coupling part 48 is provided between the first and the second films 46 , 47 . The coupling part 48 comprises a cutter 49 , a pair of mating grooves 50 formed respectively on each side of the cutter 49 , and a pair of passage holes 54 perforated respectively between the cutter 49 and each of the mating grooves 50 , wherein the first reagent containing part 43 and the second reagent containing 44 are adapted to be coupled by side walls 51 , 52 of the first and second reagent containing parts 43 , 45 respectively being fitted into the pair of mating grooves 50 . In addition, a film 53 is attached on the top surface of the cartridge 33 excluding the raised part 36 .
[0039] The operation of the biochemical analysis apparatus 20 will now be described.
[0040] The container retaining part 22 holding 10 pieces of the container 29 that contains the diluted serums is moved laterally (rightward in FIG. 1 and FIG. 2) until the first container 29 (the rightmost container in FIG. 1 and FIG. 2) comes to confront the turntable 21 where the container retaining part 22 is stopped. After the barcode reading part 23 reads the barcode 30 of the container 29 , the container 29 is tilted toward the turntable 21 while the cartridge 33 is moved from the cartridge storing unit 25 to the turntable 21 and locked thereon. When the container 29 is tilted by 90 degrees or more, the air gun 24 injects air toward the inside of the container 29 so that the serums within the container 29 is ejected onto the raised part 36 of the cartridge 33 by the injection pressure.
[0041] Once the serums are ejected onto the raised part 36 , the turntable 21 rotates at a high speed under the control of the turntable control part (not shown) and the centrifugal force acting on the serums moves them along the top surface of the turntable 21 toward the outer periphery thereof. Subsequently, the serums pass through the first cutting part 39 , between the first protruded part 37 and the second protruded part 38 , and through the second cutting part 40 in turn, until the serums are guided into each of the first reagent containing part 43 to mix with the first reagent 42 . At this moment, since the first and second cutting parts 39 , 40 are arranged evenly such that they are not aligned in a same radial direction, the serums are evenly delivered to each of the first reagent containing parts 43 . Then, the turntable 21 is rotated by a predetermined angle (30 degrees in this case) at a time by the turntable control part and the measuring unit 28 performs the analysis on the predetermined items (12 items in this case). Once the analysis on the serums within the first reagent containing part 43 is completed, the cartridge 33 is pressed from above by the pressurizing part (not shown) so that the first and second films 46 , 47 are ruptured by the cutter 49 while the side walls 51 , 52 are fitted into the mating grooves 50 to couple the first reagent containing part 43 and the second reagent containing part 45 . This allows the serums to be received into the second reagent containing part 45 through the passage holes 54 and mixed with the second reagent 44 . Then, the turntable 21 is rotated again by 30 degrees at a time, and the measuring unit 28 performs the analysis on the 12 items for the serums within each of the second reagent containing parts 45 .
[0042] Once all the analyses on the serums contained in each of the second reagent containing parts 45 are completed, the cartridge 33 is removed from the turntable 21 to be discarded and stored in the cartridge disposal unit 26 . Also, the container 29 that has been emptied by ejection of the serums is moved, after it is returned to the previous erected condition, by the container retaining part 22 to the position where it confronts the container disposal unit 27 and where it is discarded and stored in the container disposal unit 27 .
[0043] Subsequently, the serums contained in other containers 29 are analyzed similarly and, once the analyses on the serums within all containers 29 (10 containers in this case) are completed, another set of containers 29 containing new serums are placed in the container retaining part 22 while a new set of cartridges 33 are placed in the cartridge storing unit 25 , and the analyses are conducted according to the same procedure as described above.
[0044] It is noted that, although in the above embodiment the case of using the serum as the biological sample has been described, the present invention is also applicable to other biological samples than the serum, such as urine, feces, pleural effusion, ascites, saliva, and the like, and adaptable to not only an infectious disease but also a special examination by altering the type of the reagent within the reagent containing part 41 of the cartridge 33 .
[0045] According to the present invention as described above, the mechanism for adding the reagent is not required since the reagent is contained beforehand in the cartridge, and also a washing/drying device for the container is not required since the container for containing the biological sample is disposable. Thus, the present invention enables a simplified analysis operation and a smaller analysis apparatus to be provided.
[0046] Furthermore, since the cartridge is adapted to be discarded with the analyzed biological sample and reagent remaining within the cartridge, it becomes possible for the cartridge to be burnt out, which can provide for reduction of the disposal cost.
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The present invention enables a lower cost, a smaller equipment size, and a simplified operation for analysis. The invention comprises the steps of tilting a container 29 containing a biological sample and ejecting the biological sample within the container 29 onto the central portion of a cartridge 33 mounted on a turntable 21; rotating the turntable 21, exerting a centrifugal force upon the biological sample on the cartridge 33, and guiding the biological sample evenly into a plurality of reagent containing parts 41 arranged radially in the cartridge 33; and analyzing the biological sample after it is guided into each of the reagent containing parts 41 and mixed with a reagent 42, 44 within each of the reagent containing parts 41.
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[0001] Continuation application of U.S. Ser. No. 09/693,079 filed on Oct. 20, 2000
CO-PENDING APPLICATIONS
[0002] Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications filed by the applicant or assignee of the present invention on May 23, 2000:
09/575,197, 09/575,195, 09/575,159, 09/575,132, 09/575,123, 09/575,148, 09/575,130, 09/575,165, 09/575,153, 09/575,118, 09/575,131, 09/575,116, 09/575,144, 09/575,139, 09/575,186, 09/575,185, 09/575,191, 09/575,145, 09/575,192, 09/575,181, 09/575,193, 09/575,156, 09/575,183, 09/575,160, 09/575,150, 09/575,169, 09/575,184, 09/575,128, 09/575,180, 09/575,149, 09/575,179, 09/575,187, 09/575,155 09/575,133, 09/575,143, 09/575,196, 09/575,198 09/575,178, 09/575,164, 09/575,146, 09/575,174, 09/575,163, 09/575,168, 09/575,154, 09/575,129 09/575,124, 09/575,188, 09/575,189, 09/575,162, 09/575,172, 09/575,170, 09/575,171, 09/575,161, 09/575,141, 09/575,125, 09/575,142, 09/575,140, 09/575,190, 09/575,138, 09/575,126, 09/575,127, 09/575,158, 09/575,117, 09/575,147, 09/575,152, 09/575,176, 09/575,151 09/575,177, 09/575,175 09/575,115, 09/575,114, 09/575,113, 09/575,112, 09/575,111, 09/575,108, 09/575,109, 09/575,110, 09/575,182, 09/575,173, 09/575,194, 09/575,136, 09/575,119, 09/575,135, 09/575,157, 09/575,166, 09/575,134, 09/575,121, 09/575,137, 09/575,167, 09/575,120, 09/575,122
[0003] The disclosures of these co-pending applications are incorporated herein by cross-reference.
FIELD OF THE INVENTION
[0004] The present invention relates to materials potentially suitable for use as the expansive element in thermoelastic design and to methods for ranking the potential relative suitabilities of those materials.
[0005] The invention as developed originally as a means of identifying and ranking a range of materials that potentially may exhibit superior properties for use in the manufacture of microscopic thermal bend actuators for use in micro-electro mechanical systems (MEMS), and will be described hereinafter with reference to this field. However, it will be appreciated that the invention is not limited to this particular use and is equally applicable to macroscopic design even though the overall design considerations are vastly different and certainly less complex.
BACKGROUND OF THE INVENTION
[0006] It is important to clarify that thermoelastic actuation is characterized using force, deflection and temperature as opposed to switching, which is characterized using deflection and temperature rise alone. Macroscopic thermoelastic actuators are typically used as switches that activate other more energy efficient actuation systems, however, microscopic thermoelastic actuators are an attractive actuation mechanism for a number of reasons. This includes the down scaling of certain physical phenomena. For example, it is possible to fabricate very thin films that decrease the thermal mass and minimize efficiency losses. Opposing gravitational and inertial forces become negligible on the microscopic scale. Other advantages include ease of fabrication (although more complex than simple electrostatic actuators) and the possibility of low voltage operation. Disadvantages include a low operational bandwidth determined by the thermal conductivities of substrate materials—this is more of an advantage for the current application allowing for rapid firing.
[0007] A relatively diverse range of output force and deflection values can be obtained by altering actuator geometry. However, the fundamental operation of actuation is directly related to the mechanical and thermal properties of the component materials. Correct material selection in association with effective design can result in either a smaller or a more efficient actuator. Such an actuator increases wafer yield and is thus more commercially viable. A more efficient actuator may be battery powered increasing operation simplicity and negating the requirement for expensive voltage transformers. An increase in thermal efficiency improves the operational firing frequency, and decreases the possibility of thermal crosstalk. This is especially relevant for arrays of thermal actuators in a micro-cilia device.
[0008] However, material selection for MEMS application is not straightforward. Firstly, published thin film properties can vary greatly due to different fabrication methods and difficulties associated with experimentally quantifying material properties on the microscopic scale. Secondly, certain thin films can only be fabricated with certain layer thicknesses because inherent stress can shatter or curl the substrate wafer. Thirdly, only certain materials can be used in the fabrication process at most fabs as the introduction of a new material can contaminate machinery.
[0009] Progress to Date
[0010] Until recently, the only materials regularly used or considered for use in such applications were polysilicon, single crystal silicon. However, the applicant just previously made the surprising discovery that titanium nitride and titanium boride/diboride exhibited excellent properties relevant to this application.
[0011] Realizing the breakthrough this surprising discovery signified, the applicant sought to try and identify possible alternatives in order to provide designers of thermoelastic systems with more choice and flexibility. However, given the lack of available data on their film properties for various materials and the fact that empirical testing with MEMS would be prohibitively expensive, there was clearly a need, or it was at least highly desirable to be able to determine a method of evaluating materials for this use based solely on the commonly available macro material properties.
SUMMARY OF THE INVENTION
[0012] It is therefore an ultimate object of one aspect of this invention to identify a range of alternative materials that will potentially exhibit superior properties for use in thermoelastic design and of another aspect to provide a means of ranking the potential suitability of a given range of materials for this same use.
[0013] According to a first aspect of the invention there is provided a method of selecting a material for use as the expansive element in a thermoelastic design by deriving an indicator of the material's potential effectiveness for that use, said method including the step of calculating a dimensionless constant εγ for that material in accordance with the formula:
ɛ γ = E γ 2 T ρ C
[0014] wherein E is the Young's modulus of the material; γ is the coefficient of thermal expansion; T is the maximum operating temperature, ρ is the density and C is the specific heat capacity.
[0015] In accordance with a second aspect the invention, in another broad form, also provides a method of manufacturing a thermoelastic element that includes at least one expansive element, the method including:
[0016] selecting a material for use as the expansive element in the thermoelastic design by deriving an indicator of the material's potential effectiveness for that use, said method including the step of calculating a dimensionless constant εγ for that material in accordance with the formula:
ɛ γ = E γ 2 T ρ C
[0017] wherein E is the Young's modulus of the material; γ is the coefficient of thermal expansion; T is the maximum operating temperature, ρ is the density and C is the specific heat capacity and selecting the material on the basis of ε, and
[0018] manufacturing the thermoelastic element with the at least one expansive element formed of the selected material.
[0019] Preferably, the method of selection includes the step of normalizing the dimensionless constant relative to that of silicon to a value ε which is achieved by deriving the value εγ for the material of interest at the relevant temperature value and dividing this by the value of ε obtained for silicon at that same temperature.
[0020] The relevant maximum operating temperature will depend upon the surrounding materials and their function but is most commonly the oxidizing temperature or the melting point temperature.
[0021] Desirably, the selection method includes the step of eliminating certain materials by requiring a pre-determined resistivity range. In one preferred form this resistivity range is between 0.1 μΩm and 10.0 μΩm.
[0022] In accordance with a third aspect of the invention there is provided an expansive element in a thermoelastic design that is made from any functionally suitable material or combinations of materials selected from a group including:
[0023] silicides and carbides of titanium.
[0024] In accordance with a fourth aspect of the invention there is provided an expansive element in a thermoelastic design that is made from any functionally suitable material or combinations of materials selected from a group including:
[0025] borides, silicides, carbides and nitrides of tantalum, molybdenum, niobium, chromium, tungsten, vanadium, and zirconium.
[0026] In accordance with a fifth aspect of the invention there is provided an expansive element in a thermoelastic design that is made from any functionally suitable alloy material or combinations of alloy materials selected from the group including:
[0027] borides, silicides, carbides and nitrides of titanium, tantalum, molybdenum, niobium, chromium, tungsten, vanadium, and zirconium.
[0028] Preferably the expansive element in a thermoelastic design in accordance with the third, fourth or fifth aspect of the invention also includes one or more of the following properties:
[0029] (a) a resistivity between 0.1 μΩm and 10.0 μΩm;
[0030] (b) chemically inert in air;
[0031] (c) chemically inert in the chosen ink; and
[0032] (d) depositable by CVD, sputtering or other thin film deposition technique.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Derivation of the dimensionless constant ε of the first aspect of the invention, together with sample applications and examples of derived values of this constant and other properties for a range of materials, will now be described in detail with reference to the accompanying drawings in which:
[0034] [0034]FIG. 1 shows a schematic representation of a thermoelastic actuator;
[0035] [0035]FIG. 2 shows a plot of longitudinal work versus heat energy for single material clamped/free titanium beam (length 20 μm, thickness 1 μm, width 5 μm);
[0036] [0036]FIG. 3 shows a plot derived from FIG. 2 of expansion efficiency versus temperature efficiency for a clamped/free titanium beam; and
[0037] [0037]FIG. 4 shows a comparison of mechanical work versus the heat energy of thermoelastic actuator fabricated from Titanium and Silicon.
DETAILED DESCRIPTION
[0038] A non-dimensionalized material actuation efficiency is presented that assesses the potential application of a material to thermoelastic design. The method is based on the material thermal and mechanical properties and assists in a structured approach of material selection for effective design.
[0039] The Material Actuation Efficiency
[0040] Actuators are characterized by a combination of deflection, force and operation temperature in contrast to switches that are characterized by operation temperature and deflection alone. Fundamental thermoelastic design is characterized by the differential longitudinal expansion of two bonded layers. Thus, the expansion of isolated unbonded layers directly relates to global behavior. A single material beam is used here to illustrate the material actuation efficiency. The approach is straightforward and relates to general thermoelastic design. The derivation assumes that material properties are constant across the thermal range.
[0041] Equations 1 to 3 are fundamental thermomechanical equations describing the behavior of simple single material beam subjected to a quantity of heat, Q as illustrated in FIG. 1. Equation 1 describes the extension, δL, of a free/free beam and equation 2 describes the reaction force, F, of a clamped/clamped beam.
δ L=γL 0 T (EQ 1)
[0042] Where: δL=extension of beam, L 0 =original length of beam, T=operation temperature (temperature rise), and γ=coefficient of thermal expansion of beam.
F=AEγT (EQ2)
[0043] F=force exerted by beam expansion, A=cross sectional area of beam, E=Young's Modulus.
Q=VρCt (EQ3)
[0044] Where: Q=heat energy input, V=volume of beam, ρ=density, and C=specific heat capacity of beam.
[0045] Potential mechanical work is given by equation 4 and is defined as the product of the clamped beam force, F, and free beam deflection, δL. The quadratic relationship between the heat input and output mechanical work for the simple monolithic beam is shown in FIG. 18.
W=FδL (EQ4)
[0046] Where: W=mechanical work
[0047] Equation 5 describes the non-dimensional thermoelastic actuation efficiency and is formulated as the quotient of the mechanical work and heat energy as described by equations 3 and 4. The efficiency is independent of geometry and is a primary indication of a material's potential application to thermoelastic design. The linear relationship between the actuation efficiency and material temperature for the simple beam is shown in FIG. 3. The graph indicates that high temperature operation is desirable for maximum efficiency. The plot is limited by the applicable operation temperature and therefore, different material plots are of different lengths. The assumption used in this text is that the operation temperature is the material melting point because it is indicative of the operable thermal range. Thus, the material actuation efficiency, ε, is defined as the actuation efficiency at the maximum operable temperature, T, of that material. The slope of the efficiency curve is a constant, m ε and is defined in equation 6. The combination of ε and m ε fully characterize a materials actuation characteristics non graphically.
ɛ = Output Mechanical Work Heat Energy Input = E γ 2 T ρ C [ ( N / m 2 ) ( 1 / ° C . 2 ) ( °C . ) ( kg / m 3 ) ( Nm / kg °C . ) ] ( EQ 5 ) m ɛ = ɛ T = E γ 2 ρ C [ N / m 2 1 / °C 2 kg / m 3 Nm / kg °C . ] ( EQ 6 )
[0048] Material Selection
[0049] Different thin film materials including materials with extreme properties (PTFE—high g, Diamond—high E) and compounds from all the major CVD groups including borides, silicides, nitrides and carbides is shown in Table 2. The efficiency values are scaled according to silicon efficiency values because the inclusion of scaled values greatly simplifies design equations described in the following text. The scaling or comparison of a material with respect to a reference material is an integral step in the material selection process. In addition, scaling also results in a more readable index as illustrated by the following comparisons. Silicon is chosen as the reference material because of its predominance in lithographic fabrication.
[0050] Preliminary candidates for thermoelastic actuation can be selected according to efficiencies and slopes, however, it is important to note that two materials that have identical ε but differing m ε will output different amounts of work for any constant geometry (see Comparison 1 below, different amounts of heat energy are also required). Three important design parameters are defined here as heat input, work output and volume. A design matrix can be constructed by varying each parameter and can then be used to select suitable materials. The following comparisons are used to assemble the design matrix.
TABLE 2 Material Properties. g E r C m e /m r,e O.T M.P. MN MN KXX R Material 10 −6 /° C. GPa kg/m 3 J/kg ° C. ° C. −1 ° C. ° C. O.T. M.P. W/m.K mWm Aluminum 23.1 68.9 2700 897 17.12 657 7.98 231 0.027 Boron Carbide 4.5 454 2520 955 4.31 2450 7.49 35 5e4 Chromium diBoride 11.1 540 5600 690 19.42 1000 2150 13.78 29.62 32 0.18 Chromium diSilicide 5.9 5600 1150 1560 0.8 Chromium Carbide 9.9 385 6680 530 12.02 1100 1895 9.38 16.16 19 0.75 Chromium Oxide 9.0 102 5210 730 2.45 1000 2603 1.74 4.52 30 13 Copper 16.5 110 8940 386 9.79 1085 7.53 398 0.017 Gold 14.2 80 19300 129 7.31 1064 5.52 315 0.023 Hafnium Carbide 6.3 410 12670 190 7.63 600 3930 3.24 21.25 13 0.4-0.6 Hafnium diBoride 7.6 11200 300 1500 3250 51 0.1 Hafnium diSilicide 8030 1100 1700 Hafnium Monocarbide 6.5 424 11940 3890 8 0.5 Hafnium Nitride 6.5 13,940 500 3300 17 32 Molybdenum 4.8 343 10200 251 3.48 2623 6.48 138 Molybdenum Boride 5 685 7480 530 4.87 1000 2140 3.46 7.40 27 0.18 Molybdenum Carbide 6.7 530 9120 315 9.34 500 2500 3.31 16.56 22 0.57 Molybdenum diSilicide 8.4 450 6240 550 10.44 1700 2050 12.58 15.17 49 0.7 Nickel 13.4 200 8900 444 10.25 1455 10.58 90.7 Niobium diBoride 8.6 650 7210 420 17.91 850 3000 10.80 38.10 0.12 17 Niobium diSilicide 8.5 5690 900 2050 0.5 Niobium Carbide 7.4 450 7820 290 12.26 650 3500 5.65 30.42 14 0.19 PTFE 220 1.3 2130 1024 32.54 200 4.62 140 10e22 Silicon 3.0 162 2330 705 1.00 1410 1410 1 1 149 2300 Silicon Carbide 4.7 304 3440 669 3.29 2700 6.30 90 0.5 Tantalum Carbide 6.7 510 14500 190 9.37 650 3900 4.32 25.93 23 0.35 Tantalum diBoride 8.5 250 12600 250 6.47 850 3090 3.90 14.17 16 0.14 Tantalum diSilicide 9.5 9080 360 800 2670 0.46 Titanium Carbide 7.4 462 4920 480 12.08 700 3160 6.00 27.08 17.2 1.55 Titanium difloride 8.2 575 4450 632 15.51 1400 3253 15.40 35.78 26.4 0.13 Titanium diSilicide 10.7 270 4100 480 17.72 1300 1540 16.34 19.35 46 0.145 Titanium Nitride 9.4 600 5450 636 17.25 500 2950 6.12 36.10 30 1.35 Tungsten Boride 5.0 790 13100 460 3.70 1000 2365 2.62 6.20 52 0.19 Tungsten Carbide 5.2 690 15800 200 6.66 500 2780 2.36 13.13 29 0.2 Tungsten diSilicide 7.0 300 9750 330 5.15 1200 2165 4.39 7.91 48 33e10 Vanadium diBoride 7.6 260 5100 670 4.96 600 2430 2.11 8.54 42 0.13 Vanadium Carbide 6.7 420 5480 530 7.32 600 2730 3.12 14.18 10 0.59 Vanadium diSilicide 11.2 5100 1000 1700 25 0.66 Vanadium Nitride 8.1 460 6080 630 8.89 450 2170 2.84 13.68 5.2 0.85 Zirconium Carbide 6.3 410 6560 250 11.19 600 3440 4.76 27.31 22 0.42 Zirconium diBoride 5.9 340 6170 1300 3245 58 0.15 Zirconium diSilicide 8.7 270 4900 1150 1600 15 0.76 Zirconium Nitride 5.9 500 7350 400 6.68 500 2950 2.37 13.97 10 0.2-0.3
[0051] Comparison 1
[0052] The mechanical work and heat input between a material and silicon for a constant beam volume is compared. Thus, Comparison 1 calculates the maximum possible relative work and associated relative heat input required due to a direct material substitution. Details of the comparison for different materials are included in Table 3 which shows that CVD ceramics are far superior actuator materials than silicon (Table 3 is formulated using melting point and Table 4 is formulated using oxidation temperature). Titanium nitride can output 159.3 times more the amount of mechanical work than silicon with only 4.41 times the amount of heat input. The factor in equation 8 and the scaled material efficiency ratio (as included in Table 2) repeatedly occur in the following comparisons illustrating the versatility of the method.
W c W r = ɛ c Q c ɛ r Q r = ɛ c ɛ r ( ρ c C c T c ρ r C r T r ) ( EQ 7 )
[0053] The r subscript denotes the reference material which is silicon in this case. The c subscript denotes the compared material.
Q c Q r = ( ρ c C c T c ρ r C r T r ) ( EQ 8 )
[0054] Comparison 2
[0055] Different materials increase in temperature by different amounts when subjected to the same quantity of heat energy for a constant volume. The material volume is scaled relative to the silicon volume according to the constraints that the same amount of silicon heat energy is input to both actuators and the compared material attains its operational temperature. Thus, the actuation efficiency value remains unchanged because it is not a function of volume and the operable temperature is reached (as equation 5 shows). Comparison 2 represents the design case where heat and volume are critical factors.
[0056] The scaled volume and output mechanical work are calculated using equations 9 and 10. The volume change is typically implemented by modifying one geometric dimension, i.e. length, width or thickness. Titanium nitride is capable of 36.1 times the amount of work that silicon is capable with the same heat energy input but with only 0.23 times the volume. Equation 9 is the inverse of equation 8 and equation 10 is simply the scaled efficiency number as included in Table 2.
Q r = V r ρ r C r T r = Q c = V c ρ c C c T c ⇒ V ( c , Qr ) V r = ρ r C r T r ρ c C c T c ( EQ 9 )
[0057] The first entry of the bracketed subscript in these equations refers to the material that the beam is constructed from. The second entry refers to the constraining variable for the described parameter. For example—W (c,Vc) =Mechanical work output from beam constructed of compared material with a volume of V c .
W ( c , Vc ) W ( r , Vr ) = ɛ c Q r ɛ r Q r = ɛ c ɛ r ( EQ 10 )
[0058] Comparison 3
[0059] The output mechanical work resulting from silicon heat energy for constant volume beams is compared. The operation temperature and efficiency value for the compared material changes. However, the new efficiency is easily calculated using a multiplicative ratio of the new and old operation temperatures because of the linear relationship between temperature and efficiency (as shown in FIG. 3). The new operation temperature and work are given by equations 11 and 12. This comparison represents the design case where heat is a critical parameter.
[0060] PTFE will melt when subjected to the input silicon heat value. Titanium disilicide outperforms titanium nitride mainly because of the higher computed operating temperature (Table 3).
Q r = V r ρ r C r T r = Q c = V c ρ c C c T ( c , Qr ) ⇒ T ( c , Qr ) = T r ( ρ r C r ρ c C c ) ( EQ 11 )
[0061] Comparison 4
W ( c , Qr ) W ( r , Qr ) = ɛ ( c , Qr ) Q r ɛ r Q r = T ( c , Qr ) ɛ 2 T c ɛ r = ( ρ r C r T r ρ c C c T c ) ɛ c ɛ r ( EQ 12 )
[0062] The material volume is scaled with respect to the silicon volume according to the constraint that the compared material operation temperature and silicon work are maintained. Thus, if the silicon work value is less then the original work then the volume is scaled down. Otherwise the volume is increased as is the case for PTFE or amorphous Silicon Dioxide. The material actuation efficiency reoccurs in the calculations as an inverse as shown in equation 14
[0063] Titanium nitride can output the same amount of work as silicon but with a volume that is less than two orders of magnitude smaller with an input heat energy that is less than an order smaller.
W r = V r E r γ r 2 T r 2 = W c = V c E c γ c 2 T c 2 ⇒ V ( c , Wr ) V r = E r γ r 2 T r 2 E c γ c 2 T c 2 ( EQ 13 ) Q ( c , Vc ) Q ( r , Vr ) = ɛ r W r ɛ c W r = ɛ r ɛ c ( EQ 14 )
[0064] Comparison 5
[0065] The input heat energy required to output silicon mechanical work for constant volume beams is compared. The operation temperature and thus efficiency value for the compared material changes. The new efficiency can be calculated in an identical fashion to that described in comparison 3. The operational temperature and heat input values are calculated using equations 15 and 16.
[0066] The table shows that titanium disilicide slightly outperforms titanium nitride whereas both PTFE and silicon dioxide will melt. The CVD ceramics are again shown to have the best performance.
W r = V r E r γ r 2 T r 2 = W c = V c E c γ c 2 T c 2 ⇒ T ( c , Wr ) = ( γ r γ c ) E r E c ( EQ 15 ) Q ( c , Wr ) Q ( r , Wr ) = ɛ r W r ɛ ( c , Qr ) W r = ɛ r T c ɛ c T ( c , Qr ) = ɛ r T c γ c ɛ c T r γ r E c E r ( EQ 16 )
TABLE 3 Design comparisons for materials included in Table 2. Comparisons are done using melting point temperature Comparison 1 Comparison 2 Comparison 3 Comparison 4 Comparison 5 Constant V Q V,Q W V,W V (c,Qr) / W (c,Vc) / W (c,Wr) / V (c,Wr) / Q (c,Vc) / Q (c,Wr) / Q c /Q r W c /W r V (r,Qr) W (r,Vr) T (c,Qr) W (r,Qr) V (r,Vr) Q (r,Vr) T (c,Wr) Q (r,Wr) Aluminum 0.69 5.48 1.46 7.98 >Tmelt 0.183 0.125 280.79 0.29 Boron Carbide 2.55 19.06 0.39 7.49 962.41 2.94 0.053 0.133 561.51 0.58 Chromium diBoride 3.59 106.23 0.28 29.62 599.41 8.26 0.009 0.0330 208.73 0.35 Chromium Carbide 2.90 46.80 0.35 16.16 654.20 5.58 0.021 0.062 277.16 0.42 Chromium Oxide 4.27 19.34 0.23 4.52 608.98 1.06 0.052 0.221 592.32 0.97 Copper 1.62 12.18 0.62 7.53 671.18 4.66 0.082 0.132 311.11 0.46 Gold 1.14 6.31 0.87 5.52 930.29 4.82 0.159 0.181 423.90 0.46 Hafnium Carbide 4.08 86.81 0.24 21.25 962.13 5.20 0.012 0.047 422.05 0.44 Molybdenum 2.90 18.78 0.34 6.48 904.67 2.23 0.053 0.154 605.63 0.67 Molybdenum Boride 3.66 27.09 0.27 7.40 584.23 2.02 0.037 0.135 411.42 0.70 Molybdenum Carbide 3.10 51.36 0.32 16.56 806.23 5.34 0.019 0.061 349.05 0.43 Molybdenum diSilicide 3.04 46.09 0.33 15.17 674.86 4.99 0.022 0.066 302.14 0.45 Nickel 2.48 26.26 0.40 10.58 586.13 4.26 0.038 0.095 284.10 0.48 Niobium diBoride 3.92 149.44 0.25 38.10 764.86 9.71 0.007 0.026 245.55 0.32 Niobium Carbide 3.43 104.26 0.29 30.42 1021.31 8.88 0.010 0.032 342.97 0.34 PTFE 0.19 0.87 5.31 4.62 >Tmelt 1.152 0.216 >Tmelt Silicon 1.00 1.00 1.00 1 1410.00 1.00 1.000 1 1410.00 1.00 Silicon Carbide 2.68 16.91 0.37 6.30 1006.42 2.35 0.059 0.158 657.00 0.65 Tantalum Carbide 4.64 120.27 0.22 25.93 840.70 5.59 0.008 0.038 355.83 0.42 Tantalum diBoride 4.20 59.57 0.24 14.17 735.28 3.37 0.017 0.071 400.60 0.54 Titanium 1.70 7.27 0.59 4.28 984.12 2.52 0.138 0.234 619.87 0.63 Titanium diBoride 3.95 141.32 0.25 35.78 823.54 9.06 0.007 0.028 273.81 0.33 Titanium diSilicide 1.31 25.32 0.76 19.35 1176.90 14.79 0.040 0.0517 306.22 0.26 Titanium Nitride 4.41 159.36 0.23 36.10 668.21 8.18 0.006 0.0277 233.83 0.35 Tungsten Boride 6.15 38.16 0.16 6.20 384.36 1.01 0.026 0.161 383.10 1.00 Tungsten Carbide 3.79 49.80 0.26 13.13 732.95 3.46 0.020 0.076 394.10 0.54 Tungsten diSilicide 3.01 23.80 0.33 7.91 719.86 2.63 0.042 0.126 444.06 0.62 Vanadium diBoride 3.58 30.63 0.28 8.54 677.83 2.38 0.033 0.117 439.34 0.65 Vanadium Carbide 3.42 48.53 0.29 14.18 797.46 4.14 0.021 0.071 392.10 0.49 Vanadium Nitride 3.59 49.09 0.28 13.68 604.67 3.81 0.020 0.0731 309.91 0.51 Zirconium Carbide 2.44 66.51 0.41 27.31 1412.28 11.21 0.015 0.0366 422.05 0.30 Zirconium Nitride 3.74 52.32 0.27 13.97 787.80 3.73 0.019 0.0716 408.09 0.52
[0067] [0067] TABLE 4 Design comparisons for material included in Table 2. Comparisons are done using oxidation temperature Comparison 1 Comparison 2 Comparison 3 Comparison 4 Comparison 5 Constant V Q V,Q W V,W V (c,Qr) / W (c,Vc) / W (c,Qr) / V (c,Wr) / Q (c,Vc) / Q (c,Wr) / Q c /Q r W c /W r V (r,Qr) W (r,Vr) T (c,Qr) W (r,Qr) V (r,Vr) Q (r,Vr) R (c,Wr) Q (r,Wr) Vanadium diBoride 0.885 1.864 1.13 2.10 >T oxid. 0.326 0.475 439.337 0.648 Vanadium Carbide 0.752 2.341 1.33 3.11 >T oxid. 0.26 0.32 392.1 0.49 Vanadium Nitride 0.74 2.1 1.34 2.83 >T oxid. 0.289 0.353 309.9 0.513 Zirconium Carbide 0.425 2.02 2.35 4.75 >T oxid. 0.301 0.21 422.05 0.299 Zirconium Nitride 0.64 1.5 1.57 2.36 >T oxid. 0.405 0.423 408.1 0.518
[0068] A Thermoelastic Actuator
[0069] A hot arm/cold arm actuator is presented in FIG. 1 to illustrate the results contained in Table 3. Only the steady state solution for a quantity of heat input to the heater is analyzed. The device comprises two identical material layers separated by air and connected to each other at the ends by a thermally non-conductive block. The force/deflection characteristics of the output mechanical power can be tuned by altering the separation between the two layers. A greater separation increases the transverse force but decreases deflection.
[0070] Two actuators constructed from titanium and silicon are compared using graphed energy results in FIG. 4. Five design comparisons for Titanium are plotted according to the results contained in Table 3. The relationship between volumes, mechanical work and heat energy are identical to those included in Table 3. Titanium volumes are scaled using length for Comparisons 2 and 4.
[0071] Discussion
[0072] The combination of five separate material properties is important in assessing a material's potential for thermoelastic design and materials with one predominant property have been shown to not necessarily be the best candidate. This is evident in both Table 3 for PTFE (high g) and diamond (high E). Both gold and copper have high g values but are hindered as good candidates by low E and high r values. Silicon is very inefficient compared to certain other materials, however, amorphous silicon dioxide is possibly the most inefficient material of all.
[0073] Output mechanical work, input heat energy and actuator volume are three essential characterizing parameters for thermoelastic design. The design method described incorporates these parameters using only material properties and provides a structured approach for material selection. The method is versatile because the approach assesses the potential of a material using easily calculated comparison ratios. It is important to note that the approach is a measure of a materials potential and must be used as a tool in conjunction with other appropriate design criteria. For example, criteria such as force/deflection characteristics of the output work, material resistivity, environmental ruggedness and material availability may be important. The operable temperature range is assumed to be from 0 degrees to the melting point on the Centigrade scale because it is indicative of the material thermal range. However, the maximum operable temperature could be different due to oxidation of the material or other thermal design constraints. Titanium nitride has close to the highest actuation efficiency value when melting point is used as a criteria. However, Titanium diSilicide is potentially a better candidate for use when oxidation temperature is used. Titanium nitride is a practical candidate because it is well established as a CMOS barrier material. The oxidation temperature of TiN can be raised from 500° C. to 900° C. by alloying with aluminum. The alloyed material has a symbol (Ti,Al)N.
[0074] The actuation efficiency of a simple thermoelastic titanium beam is low compared to other actuation mechanisms (less than 1 percent). It is theoretically possible to get a thermoelastic actuation efficiency of about 4.5 percent for a simple titanium nitride beam, however, this value typically decreases when the material is implemented in a MEMS device due to associated operational losses (for example—thermal conduction into the substrate).
[0075] The invention has been described herein by way of example only. Skilled workers in this field will readily recognize many variations and modifications which do depart from the spirit and scope of the broad inventive concept.
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The invention concerns thermoelastic designs incorporating and expansive element formed from material selected in accordance a procedure involving the derivation of an indicator of the material's potential effectiveness for each application.
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FIELD OF THE INVENTION
[0001] The present invention relates to better performing carpets for automotive flooring. In particular, the present invention relates to improved durability in carpets for automotive flooring. More particularly, the present invention relates to durable needle-punched carpets capable of being molded to conform to the shape of the automotive floor.
PRIOR ART
[0002] Automotive carpeting is made primarily by two methods. In a common method, solution-dyed extruded polyester fiber is “needle-punched.” In another common method, a colored extruded bulk continuous filament (BCF) nylon fiber is more thickly “tufted” on a fabric backing material. Tufted automotive carpets typically are more expensive than needle-punched. Alternatively, tufted auto carpets may be made with uncolored nylon and later dyed.
a. Tufted Carpets
[0003] The use of molded carpet modules for carpeting motor vehicle interiors is an old and well-established practice. U.S. Pat. Nos. 5,474,829 and 5,605,108 recite the teachings of U.S. Pat. Nos. 3,953,632 and 4,579,764, which latter patents are concerned with backing materials and molding features forming the modules. Also, recited are U.S. Pat. Nos. 4,871,602 and 5,109,784, which patents are directed to floor mats for use in automobiles that have strips in which more pile yarn is tufted into the backing fabric to form an area more resistant to wear.
[0004] The '829 and '108 patents themselves are directed, respectively, to a variable density motor vehicle carpet and a method of forming same. The method includes tufting in such a manner that selected areas have pile tufts arranged at lower densities than the selected high density areas, with the areas of high density having a greater resistance to wear that the areas of low density.
[0005] U.S. Pat. No. 4,016,318 discloses a method of making a moldable automobile mat formed of a tufted carpet having a stiff, heat-moldable thin layer urethane resin layer bonded to the back of the carpet to secure the tufts to the carpet and having a thick layer of a flexible, cross-linked, thermoset, elastomeric urethane resin secured to the stiff thermoplastic urethane resin layer.
b. Needle-Punched Carpets
[0006] Needled textile fabrics are normally composed of synthetic organic textile fibers, such as polyester or polypropylene fibers, needled together into a consolidated mat. Such fabrics may also be made of natural organic fibers capable of being formed into a non-woven fabric of substantial properties by the more traditional process, such as felting, and as such, are not usually needled to form a non-woven fabric.
[0007] Thus, most needled fabrics, being composed generally of synthetic organic fibers, find a variety of applications where relatively high physical properties are required, e.g. high strengths, with substantially uniform physical properties in both the longitudinal and widthwise direction, and particularly in those applications where economics dictate the use of materials less expensive than tufted fabrics or where the applications require more uniform thickness direction properties than tufted fabrics. Fabrics are generally restricted to synthetic organic fibers, but the application of using polypropylene fiber needled fabrics has been substantially limited when higher temperatures are involved. Thus, the normal polypropylene fiber needled fabrics suffer from considerable disadvantages in these regards. (U.S. Pat. No. 5,547,731 teaches “Needled Carpet and a Process for Producing It.”)
[0008] The art has attempted to overcome these disadvantages by use of a number of different approaches. Blends using polypropylene were used, but without significant improvement in wear performance.
[0009] The European and US car manufacturers have very different standards for the wear performance of flooring carpets. In the US, until a few years ago all the automotive flooring products were tufted and had to meet a performance of from about 2,000 to about 3,000 cycles on the Tabor Abrader test, requiring more expensive tufted carpeting. In Europe, however, the standard is about 300 cycles on the Tabor Abrader test, permitting use of less expensive needle-punched carpeting. The reason for this difference in performance standards is that in Europe most manufacturers sell their vehicles with separate additional floor mats. Because of the mats, they do not need their flooring to perform to a higher standard. In the US, on the other hand, the big three auto manufacturers sell most of their cars without separate floor mats; therefore, they needed a better performing base flooring product. In the last few years, at least Ford and GM have specified one needle-punched product for one of their vehicles. In both cases, they had to lower their standards for the Tabor Abrader test to about 1,000 cycles to “qualify” a needle-punched carpet product. Both companies have expressed their interest in a needle-punched product that would give them better performance. This desire to introduce a needle-punched product into their flooring systems, on a broader basis, comes from a drive to lower costs, with minimum loss of quality.
[0010] Needle-punched carpets made of the polypropylene fiber alone typically performs better than needle-punched carpets made solely of polyester in the Tabor Abrader test. However, a needle-punched carpet formed of polypropylene fiber alone is not moldable; whereas a needle-punched carpet formed of polyester fiber alone is moldable. (All flooring systems for US cars are molded.) So, there exists a need in the industry for a less expensive, durable, moldable auto carpet.
SUMMARY OF THE INVENTION
[0011] By combining a critical proportion of polypropylene and polyester fibers, a process was developed to produce an improved moldable, needle-punched automotive carpet. The improved carpet comprises a blend of fibers with specific properties that, when used to manufacture the needle-punched auto carpet, exhibits improved the wear and produces a moldable carpet, heretofore achieved only with more expensive tufted carpets. In addition to the critical blend of specific fibers, it was discovered that the addition of a binder fiber enhances the wear performance of carpets made from this critical fiber blend. As an optional last process step, it was further discovered that a unique finish material additionally improved the wear performance of carpets made from the blend of fibers disclosed herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Known needled-punched carpets typically have a backing of film or latex. After being needled, the tightly integrated fibers are impregnated with a binder, like latex or molten polyester or other like material. This way, the fibers in the top of the carpet are reinforced and anchored fast, so they cannot be pulled out as the carpet is used.
[0013] In U.S. Pat. No. 4,389,443, a cut pile fabric is taught. The cut pile fabric includes a needled non-woven batt of staple fibers that has an integral carrier member formed by fusing a face surface of the needled batt. A texturized surface is formed on the batt using a texturized needle loom, which punches through the batt from the one surface (called the back surface) of the batt so that texturized loops project from the carrier member. The non-texturized back surface of the batt typically has a backing applied as by latexing, fusing, or the like, with the texturized loops being tigered by a tigering roll to break, fracture or cut a high percentage of the loops. The tigered pile is typically polished by a polishing roll to remove the crimps in the fibers and to orient the fibers in a direction transverse to the plane of the batt prior to being sheared in a shear. A dense, plush, lightweight cut pile fabric is produced having stability and strength. The patent examples employed polyethylene fibers only, and the resultant stable, strong pile fabric was not molded.
[0014] It is understood that the invention moldable, needle-punched automotive carpet with improved wear performance may be prepared by methods generally known in the art. The invention improvement lies in the materials employed, as specified and claimed herein.
Needle-Punch Process
[0015] State-of-the-art computerized production lines for the manufacture of needle-punched carpets typically start with the provision of a raw material resin in the form of pellets from rail hopper cars and transferred, for storage until fed into the production line, in silos.
[0016] The first step in the production process is extrusion and spinning. (In the case of polyester, the resin material is crystallized and dried before extrusion.) The resin is usually blended uniformly, in molten state, with color pigments and other additives. The molten blend is extruded and flows under pressure through spinnerettes. (The denier and shape of the fiber is determined at this point.)
[0017] The next step involves drawing and annealing the fiber. During drawing, individual filaments are mellowed with heat, stretched, and annealed to achieve the elongation characteristics and strength required. In a subsequent step after drawing, the fiber is crimped to a “Z” shape for fiber cohesion, heat set, and cut to the desired length. Cut fibers are baled and, if necessary, are blended in certain proportions with other fibers appropriate for a specific fabric in production.
[0018] These bales of prepared fibers can then be opened and broken into clumps of fiber in hoppers designed to achieve a uniform fiber dispersion. The needle-punch operation begins with a carding operation, where fibers in the dispersion are combed by saw-toothed wire cylinders into a uniform web in which the orientation of alignment of individual fibers is closely controlled. Rollers then move the web of aligned fibers through cross-lapping equipment that operates to build up layers of fiber webs to achieve the desired weight and to improve uniformity of properties across the width of the web. Finally, the process gets its name by passing the layed-up (or cross-lapped) web through a needle loom where repetitive penetration by barbed needles binds the web into a tight fabric by mechanical entanglement of the fibers. The finished fabric leaving the needle loom is then taken up on rolls.
The Materials
[0019] Polypropylene is a very versatile polymer. It serves double duty, both as a plastic and as a fiber. As a fiber, polypropylene is used to make durable carpeting, such as indoor-outdoor, as well as automobile carpets. It works well for outdoor carpet because it is easy to make colored polypropylene, and because polypropylene doesn't absorb water, like nylon does. These are also reasons it performs well for auto carpets. The polypropylene preferred in the present invention is round and exhibits a denier of from 10 to 25, preferably 16-20, and most preferably 18. The preferred polypropylene also exhibits a tenacity of from 2.2 to 6 g/denier, preferably from 3 to 5 g/denier, and most preferably 4 g/denier.
[0020] The polyester preferred for use in the present invention is another versatile fiber. It is used for needle-punched carpets, trunk liners, and auto headliners, among other uses. Preferably, the polyester is also recyclable. The polyester fiber of the invention is round and exhibits D tex value from 10 to 25, preferably 18±1.5, a tenacity value of 2.5-4.6 g/denier, preferably 3.5±1.5 g/denier and an elongation at break of 70%±35%.
[0021] The invention wear improvement in a moldable, needle-punched auto carpet is preferably achieved by inclusion of a binder fiber. The binder fiber should exhibit a relatively low softening temperature that may include a polycaprolactone, a polyethylene, and a polyester. The preferred binder fiber for inclusion in the invention is a polyester that is a melt activated thermobonding fiber that exhibits a D tex value from 2 to 16, preferably 4±1.0, and an activation temperature range of 100-185° C., preferably 110-180° C.
[0022] The invention wear improvement in a moldable, needle-punched auto carpet is also preferably achieved by inclusion of a lubricant. The preferred lubricant for inclusion in the invention is a non-yellowing yarn lubricant is a homogenous blend of polymers and surfactants that is dispersible in cold and hot water, is nonionic or mildly amphoteric, exhibits a pH from 5.0-7.0 and has a density 6-10 lbs/gal, preferably 7-8 lbs/gal, and most preferably 8.3 lbs/gal.
[0023] Fiber loss and wear criteria for acceptability in auto carpet flooring are primarily determined by passing established minimum standards. Specimens tested for fiber loss cannot exceed 10% weight loss. Specimens tested for wear must achieve a satisfactory rating after 1400 taber wear cycles, 600 cycles for fiber loss plus an additional 800 cycles for wear. The taber wear test involves exposing a carpet specimen to repetitive rotations of the taber abrader. To achieve a rating of satisfactory, there shall be no backing scrim visible for tufted carpets and no complete holes for nonwoven carpets.
EXAMPLE 1
[0024] Fiber loss was measured in auto floor system samples of various compositions of polypropylene and/or polyester fibers. The following data show the least percent weight loss for the improved wear moldable, needle-punched carpet samples.
[0025] Data was collected from samples prepared as follows:
[0026] All samples tested were prepared in the manner of needle-punched carpet preparation disclosed above. “A” designated samples were prepared of 100% polyester with latex backing. “B” designated samples were prepared of 100% polypropylene with latex backing. “C” and “D” designated samples were prepared of 70:30 polyester/polypropylene with latex backing. “E” and “F” designated samples were prepared of 65% polyester, 28% polypropylene with 7% binder fiber with latex backing. “G” and “H” designated samples were prepared of 65% polyester, 28% polypropylene fused with 7% binder fiber. “J” through “M” designated samples were prepared of 65% polyester, 28% polypropylene fused with 7% binder fiber. “N” and “P” designated samples were prepared of 100% polyester fiber, and represent the current auto carpet product being marketed to at least one major U.S. auto manufacturer. “Q” through “T” designated samples were prepared of 18 denier 65% polyester, 28% polypropylene blends with 7% binder fiber with latex backing.
[0027] For the purposes of these examples, the polypropylene fiber used was standard automotive grade fiber manufactured by Drake Extrusion Inc. The polyester fiber employed in the samples containing same was FOSSFIBRE® Solution Dyed PET, available from Foss Manufacturing Co., Inc. The fiber binder employed in the samples was FOSSFIBRE® TYPE 410 PETG, from Foss Manufacturing Co., Inc. The lubricant employed in the samples for examples was FLUFTONE® APS manufactured by Apollo Chemical Corporation.
TABLE I Floor System Samples 1000 cycles 1400 cycles 2000 cycles 2500 cycles A1 4.90% A2 4.71% A3 4.75% A4 4.75% B1 3.07% B2 2.96% B3 3.12% B4 3.09% C1 2.72% C2 2.50% D1 2.57% D2 2.83% E1 3.02% E2 2.77% F1 3.03% G1 2.92% G2 3.26% HI 3.44% H2 3.54% J1 2.02% J2 2.20% K1 2.38% K2 2.64% LI 2.48% L2 2.32% M1 2.23% N1 3.72% N2 4.11% P1 3.59% P2 3.29% Q1 1.63% R1 1.63% SI 1.29% T1 1.95%
[0028] Comparisons between samples “A” and “B” show the reduced fiber loss using polypropylene versus polyester fibers. Comparisons between samples “C” and “D” show only a minor increase in fiber loss at 1400 cycles (2.70% ave.) versus 1000 cycles (2.61% ave.). Similarly, comparisons between latex-backed, fiber blended samples “E” and “F” show only a minor increase in fiber loss at 1400 cycles (3.03%) versus 1000 cycles (2.88%). At both 1000 cycles (3.09% ave.) and 1400 cycles (3.49% ave.), fused, fiber blended samples “G” and “H” experienced greater fiber loss than same fiber based “E” and “F.” Yet, molded, fiber blended samples “J” through “M” showed significant reductions in fiber loss over earlier fiber-blended samples at 1000 cycles (2.11% ave.), 1400 cycles (2.51% ave.), 2000 cycles (2.4% ave.) and 2500 cycles (2.23%). Current product samples (100% polyester) showed poor fiber loss performance at the lower cycle ranges (3.91% ave. at 1000 cycles and 3.44% ave. at 1400 cycles). Finally, by far the best fiber loss reductions were achieved by the invention fiber blend samples at each cycle count tested.
[0029] Thus, Table I shows the improvement (i.e., reduction) in percent fiber loss in the disclosed invention wear improved carpet employing the disclosed and claimed composition of fibers over carpet manufactured employing prior art materials.
EXAMPLE 2
[0030] The tabor abrader test (ASTM D3884-92), as discussed above, indicating standards for pass/fail determinations for floor carpeting were conducted on samples of the same carpet compositions of Example 1. The tabor abrader pass/fail determinations are shown in Table II below.
TABLE II Sample Results A1 Fail A2 Fail A3 Fail A4 Fail B1 Fail B2 Fail B3 Fail B4 Fail C1 Pass C2 Pass D1 Fail D2 Pass E1 Fail E2 Fail F1 Fail G1 Pass G2 Pass HI Pass H2 Pass J1 Pass J2 Pass K1 Pass K2 Pass L1 Pass L2 Pass M1 Fail N1 Pass N2 Pass P1 Fail P2 Fail Q1 Pass R1 Pass S1 Pass T1 Pass
[0031] As might be expected, reduced wear generally corresponded with the fiber loss values as shown in Table I. Thus, improved wear reduction was observed with the invention fiber blend compositions than was observed with the conventional carpet constructions.
[0032] It is to be understood that the present invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments, and of being practiced or carried out in various ways within the scope of the claims. Also it is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.
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An improved moldable, needle-punched automotive carpet of improved wear is disclosed by the invention process of combining a critical proportion of polypropylene and polyester fibers having optimal physical properties. A preferred embodiment of the invention additionally includes a binder fiber. The improved carpet comprises a blend of fibers with specific properties that, when used to manufacture the needle-punched auto carpet, produces a moldable carpet that exhibits improved wear, heretofore achieved only with more expensive tufted carpets.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a conductive gasket for improving electrical grounding between adjacent conductive parts, and, more particularly, to a gasket for improving electrical grounding within a computing system between a slotted panel through which connectors of circuit cards extend for the attachment of external cables and brackets mounting such circuit cards.
2. Background Information
FIGS. 1 and 2 are fragmentary elevations of a conventional computing system 8 including a mother board 10 and a conventional circuit card 12 having a tab 14 inserted within a card edge connector 16 of the mother board 10 . FIG. 1 is a fragmentary vertical cross-sectional elevation of the computing system 8 , while FIG. 2 is a fragmentary rear elevation thereof.
The rear end 18 of the circuit card 12 includes a card bracket 20 attached to a slotted panel 22 , forming part of the computing system, by means of a screw 24 . An individual slot 26 within the slotted panel 22 provides a space through which an I/O connector 28 extends for attachment to an external cable (not shown). Thus the card 12 is rigidly held in place by the screw 24 near its top edge 30 and by the engagement of its tab 14 with the card edge connector 16 near its lower edge 32 . The mother board 10 may be a relatively large system (or planar) board extending inwardly adjacent a cover 36 of the computing system. Alternately, the mother board 10 may be a riser board extending perpendicularly from the system (or planer) board to provide for the attachment of one or more circuit cards 12 . Typically, the computing system 8 includes a number of card edge connectors 16 and a number of slots 26 , each of which is located in a standard way relative to a connector 16 to provide for the installation of a standard type of circuit card 12 . While each circuit card 12 has a card bracket 20 , not all cards 12 have I/O connectors 28 . Cards 12 without I/O connectors, which are not configured for attachment to external cables, include brackets 20 which are used to close an associated slot 26 within the slotted panel 22 . When a circuit card 12 is not placed in one of the card edge connectors 16 , the associated slot 26 is closed by a filler bracket 38 , which is not attached to a circuit card 12 . Like the card brackets 20 , each filler bracket 38 is fastened in place using a screw 24 .
Electrical contact between the card bracket 20 and the slotted panel 22 is typically used to provide for electrical grounding of circuits within the circuit card 12 and within an external cable (not shown) connected to the I/O connector 28 . This contact may form a portion of multiple grounding points. Electrical contact between the card bracket 20 and the slotted panel 22 is also used to close a slot through which radio-frequency electromagnetic noise could otherwise be radiated to interfere with electronic communications.
A problem with this conventional approach arises from the uncertain nature of the electrical contact established between the card bracket 20 and the slotted panel 22 . While specific contact pressure between the card bracket 20 and the slotted panel 22 is established adjacent the head of screw 24 , the contact pressure at other locations between these parts depends on the slightly variable dimensions of parts, including their flatness.
A card bracket formed from a thin metal sheet, having a number of individual formed cantilevers to provide specific points for contact with a slotted panel, has been used in a number of circuit cards developed particularly for use with the IBM MICRO CHANNEL architecture. An example of this type of card bracket, configured particularly for use with a daughter card attached to the circuit card, is shown in U.S. Pat. No. 5,980,275. However, this type of card bracket must be used with a much different type of slotted panel having wide edges along which the contact cantilevers slide, and with cards not having formed brackets of the standard types used with the Industry Standard Architecture (ISA) and the Peripheral Card Interconnect (PCI) architecture. What is needed is a gasket providing specific contact locations which may be used with cards having such standard brackets, since such cards are widely available.
A number of conductive gaskets for various applications, other than the grounding of card brackets of slotted panels, are also formed to include a number of cantilevers providing specific points of contact. Such gaskets have a disadvantage of nesting together when they are shipped or otherwise handled in quantities, with the cantilevers of different gaskets interlocking so that the gaskets cannot easily be separated without damage. What is needed is a gasket configuration producing parts which can be handled and shipped together without this kind of nesting. Furthermore, such gaskets are often easily damaged during the handling and installation of associated parts, since the easily-twisted cantilevers may become snagged on other surfaces.
Conductive gaskets formed of fine-diameter woven conductive fibers or conductive fibers compressed into a matted, felt-like material have also been used for various applications other than the grounding of such card brackets. Gaskets formed in this way have disadvantages of a difficult fabrication process and of attendant relatively high costs.
U.S. Pat. No. 5,825,634 describes the use of an undulating or serpentine spring gasket in an assembly including a shielding cover fastened in place to extend along a portion of a surface of a circuit board. The spring extends between a peripheral edge of the cover and an electrical contact extending along the surface of the circuit board adjacent the peripheral edge. The relatively long and gentle undulations of the spring material produce alternating high and low areas. While a spring of this type can undergo relatively large deflections to provide a mechanically flexible interface between the mating parts, the resulting deflections of the spring, which cause each leg of the spring to lengthen as the spring is compressed between mating parts make it difficult to control the overall dimensions of the spring gasket in use. In the application of the present invention, i.e. in the grounding of card brackets to a slotted panel, overall dimensions must be carefully controlled, since a number of parts have to fit together in a small area.
SUMMARY OF THE INVENTION
Accordingly, it is a first objective of the present invention to provide a spring gasket causing electrical contact to be made at particular locations between a card bracket in a computing system and a slotted panel providing access to a circuit card I/O connector for external cables.
It is a second objective of the present invention to provide a spring gasket which is flexible, allowing electrical contact to occur despite variations in the dimensional configurations of adjacent parts.
It is a third objective of the present invention to provide a spring gasket in which the length of various legs within the gasket does not substantially change as the spring gasket is compressed.
It is a fourth objective of the present invention to provide a spring gasket which does not nest with other similar parts during storage or shipment.
It is a fifth objective of the present invention to provide a spring gasket which is not easily damaged by contact with adjacent parts during installation and handling.
According to a first aspect of the present invention, a conductive gasket for providing electrical conductivity between adjacent first and second conductive members separated in a first direction is provided. The conductive gasket includes a central web, a first plurality of contact bumps extending from the central web in the first direction; and a second plurality of contact bumps extending from the central web opposite the first direction, wherein contact bumps in the first and second pluralities of contact bumps are arranged in alternating patterns along the central web to include contact bumps in the first plurality of contact bumps adjacent contact bumps in the second plurality of contact bumps.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary cross-sectional end elevation of a computing system including a mother board and a conventional circuit card having a tab inserted within a card edge connector of the mother board;
FIG. 2 is a fragmentary rear elevation of the computing system of FIG. 1, showing a slotted panel and circuit card brackets;
FIG. 3 is a fragmentary plan view of the computing system of FIG. 1, showing a spring gasket installed therein in accordance with the present invention;
FIG. 4 is a fragmentary cross-sectional elevation of the computing system of FIG. 1, including the spring gasket of FIG. 3, taken as indicated by section lines IV—IV in FIG. 3 .
FIG. 5 is a fragmentary cross-sectional plan view of the slotted panel and circuit card brackets of FIG. 2, together with the spring gasket of FIG. 3, taken as indicated by section lines V—V in FIG. 4;
FIG. 6 is a fragmentary cross-sectional plan view of the slotted panel and circuit card brackets of FIG. 2, together with the spring gasket of FIG. 3, taken as indicated by section lines VI—VI in FIG. 4;
FIG. 6A is a fragmentary vertical cross-sectional elevation of the slotted panel of FIG. 2, together with the spring bracket of FIG. 3, taken as indicated by section lines VIA—VIA in FIG. 4;
FIG. 7 is a fragmentary vertical cross-sectional elevation of the slotted panel of FIG. 2, together with the spring gasket of FIG. 3, taken as indicated by section lines VII—VII in FIG. 4;
FIG. 8 is a front elevation of a spring gasket built in accordance with a first alternative version of the present invention; and
FIG. 9 is a front elevation of a spring gasket built in accordance with a second alternative version of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While FIGS. 1 and 2 have been described as showing the prior art, continued reference will be made to these figures, and reference numerals originally used in reference to these figures will continue to be used, as devices configured in accordance with the present invention are used with the prior art devices of FIGS. 1 and 2.
FIG. 3 is a fragmentary top view of the computer system 8 , having installed therein a spring gasket 40 configured in accordance with the present invention, together with a pair of filler brackets 38 . The remaining positions in which filler brackets 38 and card brackets 20 can be installed are shown with such brackets not being installed in order to reveal the structure of the spring gasket 40 .
FIG. 4 is a fragmentary cross-sectional front elevation of the computer system 8 , having installed therein the spring gasket 40 . This cross-section view is taken in the direction indicated by section lines IV—IV in FIG. 3 to show a portion of the interior surface 42 of the rear wall 44 of the computer. In the example of this figure, the slotted panel 22 includes seven slots 26 , each of which is to be internally covered by either a card bracket 20 or a filter bracket 38 (as shown in FIG. 2 ). However, in FIG. 3, these brackets 20 , 26 and the various circuit cards 12 are not shown as installed, in order that the details of the spring gasket 40 , which is shown as installed, may be easily seen.
Referring to FIGS. 3 and 4, the spring gasket 40 is installed inside the slotted panel 22 to provide for electrical contact between the slotted panel 22 and any combination of card brackets 20 (shown in FIG. 2) and filler brackets 38 which may be fastened in place with screws 24 extending through holes 46 along a ledge 48 of the slotted panel 22 . The spring gasket 40 includes a slot 50 aligned with each of the slots 26 in the slotted panel 22 , so that each I/O connector 28 extending outward from a card bracket 20 , as shown in FIG. 1, can extend through a slot 50 in the in the spring gasket 40 as well as a slot 26 in the slotted panel 22 . The spring gasket 40 also includes an upper ledge 52 , which is fastened in place to extend along the ledge 48 of the slotted panel 22 . This upper ledge 52 includes a number of clearance holes 54 , which are brought into alignment with the holes 46 extending along the ledge 48 of the slotted panel 22 . When a combination of circuit cards 12 , having card brackets 20 , and filler brackets 38 is installed using screws 24 extending through the clearance holes 54 into the holes 46 , the spring gasket 40 is clamped between the slotted panel 22 and the brackets 20 , 38 .
FIGS. 5, 6 , and 6 A are fragmentay cross-sectional view of the computer system 8 , taken in the direction indicated by section lines V—V, VI—VI, and VIA—VIA, respectively, in FIG. 3, to show contact conditions occuring among the slotted panel 22 , the spring gasket 40 , and a pair of brackets, each of which may be either a card bracket 20 or a blank bracket 38 . These brackets 20 or 38 are shown as installed in FIGS. 5 and 6 but not in FIGS. 3 and 6A.
Referring to FIGS. 4-6, the portion of the spring gasket 40 extending downward, in the direction of arrow 56 , between the slotted panel 22 and the brackets 20 , 38 , includes a central web 58 , a first plurality of contact bumps 60 extending inward, in the direction of arrow 62 , from the central web 58 , and a second plurality of contact bumps 64 extending outward, opposite the direction of arrow 62 , from the central web 58 . Preferably, the spring gasket is stamped and formed from a spring metal sheet, such as a 0.1 mm (0.004 in.) thick sheet of half-hard stainless steel, with the contact bumps 60 , 64 extending 0.75 mm (0.03 in.) from the center of the central web 58 . Each of the contact bumps 60 , 64 preferably extends to an edge 66 of the spring gasket 40 .
Unlike the cantilevers of various gaskets and brackets described in the prior art, the contact bumps 60 , 64 are not defined by slots extending into the web 58 , but are rather formed such that the perimeter of the bump is continuous with the central web 58 . Therefore, the contact bumps 60 , 64 provide a number of contact surfaces which are not easily twisted or otherwise damaged during handling and installation of the spring gasket 40 , or during a subsequent installation of a circuit card 12 having a bracket 20 which is slid along the spring gasket 40 during the installation of the card 12 . Furthermore, this lack of slots extending into the web 58 prevents a number of spring gaskets 40 which are stored or shipped together from nesting in a way preventing the easy separation of the parts without damage. In this way, another advantage over prior-art devices having cantilevers is achieved.
The complex curvature 68 forming the contact bumps 60 , 64 limits the flexibility of each of these bumps 60 , 64 , causing most of the deflection occurring with the compression of the spring gasket 40 between the slotted panel 22 and the brackets 20 , 38 to occur within the central web 58 . Preferably, the outward-extending contact bumps 60 and inward-extending contact bumps 64 are arranged in alternating positions, with the outward extending contact bumps 60 being formed at points of a first rectangular array, and with the inward-extending contact bumps 64 being formed at points of a second rectangular array. These arrays extend in the vertical direction indicated by arrow 56 and in the horizontal direction indicated by arrow 70 . In the example of FIG. 4, both the first and second rectangular arrays are divided by intervening slots 50 , having sides also extending in the vertical and horizontal directions indicated by arrows 56 and 70 , respectively. Adjacent outward-extending contact bumps 60 are separated by individual inward-extending contact bumps 64 , and adjacent inward extending contact bumps 64 are separated by individual outward-extending contact bumps 60 , so that compression of the spring gasket 40 results in twisting of the central web 58 .
FIG. 7 is a fragmentary vertical cross-sectional view of the spring gasket 40 installed on the slotted panel 22 , taken as indicated by section lines VII—VII in FIG. 4 to show the lower edge of a slot 50 , which is formed by a tab 71 extending outward to prevent the lower end 72 of a card bracket 20 (shown in FIG. 2) from catching on a sharp edge of the spring gasket 40 as a card 12 (shown in FIG. 1) is installed against the spring gasket by sliding dowmward.
In accordance with a preferred version of the present invention, the spring gasket 40 and the slotted panel 22 have equal numbers of slots, with the slots 50 of the spring gasket 40 being in alignment with the slots 26 of the slotted panel 22 . To this end, the spring gasket may be formed in a number of different configurations having different numbers of slots 50 . For example, FIG. 8 is a front elevation of a spring gasket 74 having two slots 50 , and FIG. 9 is a front elevation of a spring gasket 76 having only one slot 50 . Alternately, a spring gasket may be placed to ground the bracket 20 of only one card, or of several cards among many, where such grounding is particularly important.
While the invention has been described in its preferred forms or embodiments with some degree of particularity, it is understood that this description has been given only by way of example, and that numerous changes in details of construction, fabrication, and use, including changes in the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.
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A computing system includes a number of circuit cards fastened by brackets to a slotted panel, which has slots allowing the attachment of external cables to the circuit cards. Electrical grounding between the slotted panel and the brackets is achieved through the use of a conductive gasket extending along an inner surface of the slotted panel. The conductive gasket includes a central web, a number of contact bumps extending from the central web to the slotted panel, and a number of contact bumps extending from the central web to the brackets. Contact bumps thus extending in opposite directions are placed in alternating positions along the central web, so that the central web is deflected as the contact gasket is compressed.
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This is a Continuation-in-Part application of international application PCT/DE96/02501 filed Dec. 21, 1996 and claiming the priority of German patent application 196 00 218.4 filed Jan. 5, 1996.
BACKGROUND OF THE INVENTION
The invention relates to a perovskite of the ABO 3 type provided with a surface layer. The perovskites are for example, SrTiO 3 , BaTiO 3 or KNbO 3 . The invention also relates to a method of manufacturing such perovskites.
It is known to utilize perovskites as substrates for single crystal layer growth or as a material for high temperature fuel cells.
Perovskites have at their surfaces depressions or projections of a size corresponding about to their lattice parameter C=4 Å. These deviations from a smooth surface detrimentally affect single crystal layer growth on the perovskites.
In addition, the life of a perovskite used in a high temperature fuel cell is limited because of the chemically aggressive environment.
It is the object of the present invention to provide a perovskite which is chemically more stable and is more suitable as a substrate for single crystal layer growth and to provide a method of manufacturing such perovskites.
SUMMARY OF THE INVENTION
In accordance with the invention, a perovskite of the type ABO 3 is provided with a surface layer of AO*(ABO 3 ) n produced at high temperatures in an oxidizing atmosphere. AO*(ABO 3 ) n is known as Ruddlesden-Popper phase. The layer is built up in the form of terraces, that is, it has at its surface delimited areas which are separated from each other by steps. The height of the steps corresponds to the lattice parameters of the Ruddlesden-Popper phase with a predetermined n in c--direction of the standard cell c*=(2n+1)c represents the lattice parameter of the Ruddlesden-Popper phase. C is the lattice parameter of the original Perovskite. The surface areas are free of projections or depressions of a size in the area of 4 Å which occurs with the perovskites as mentioned earlier. From the layer as claimed, strip-like or island-like areas of an AO*(ABO 3 ) n phase are to be distinguished as will be described below.
The terrace-like arrangement of the AO*(ABO 3 ) n layer is chemically more stable than a simple perovskite of the type ABO 3 . Consequently, this new material is suitable, in an improved way, for use in a chemically oxidizing atmosphere that is for example in an atmosphere which causes strong segregations of components of perovskite. Such an atmosphere is present especially in high temperature fuel cells particularly at the cathode side. To prevent aging processes from occurring, perovskites with AO*(ABO 3 ) n surface layers are preferably used in high temperature fuel cells, for example, in the form of electrodes.
If a perovskite is provided with a AO*(ABO 3 ) n surface layer, n-1 terrace-like structures are formed on the surface. It is then possible in a way which is better than it has been possible in the past, to grow on such a layer for example, a single crystal YBa 2 Cu 3 O 7 . The improvement is possible because the lattice constant of YBa 2 Cu 3 O 7 is about 11.6-11.7 Å and is therefore comparable to the step height of the terrace structures.
The occurrence of new phases such as Sr n+1 Ti n O 3n+1 at the perovskite SrTiO 3 is known, for example, from Surface Science Letters 285 (1993) L510-L516. This phase was obtained under reducing conditions; it grows normal to the surface. It occurs in stripes. It is therefore not a layer. In addition, there is no Ruddlesden-Popper phase.
The occurrence and the manufacture of Ruddlesden-Popper phases as terrace-like layers which extend over the whole surface of a perovskite and have controllable step heights (2n+1)c is not known.
It is also not known to use AO*(ABO 3 ) n phases as protective layers or as means for the improvement of single crystal growth.
Layer structures consisting of a perovskite of the type ABO 3 with a AO*(ABO 3 ) n surface layer as a substrate and with a single crystal layer on the AO*(ABO 3 ) n layer have a higher quality as well as a smaller number of staple defects by adaptation of the c-lattice constant (=lattice parameter of the Ruddlesden-Popper phase) to the lattice constant of the single crystal layer. The better the respective lattice constants are adapted, the higher is the layer quality.
DESCRIPTION OF PREFERRED EMBODIMENTS
The AO*(ABO 3 ) n layers for the perovskites SrTiO 3 , BaTiO 3 , PbTiO 3 or KnbO 3 were made by exposing these perovskites to an oxidizing environment (particularly, an O 2 environment at pressures of 1-200 mbar) and a temperature of 800 to 950° C. Under these conditions, the AO*(ABO 3 ) n phase is formed in a growth pattern parallel to the (100) surface. Dependent on the selected temperature and the selected oxygen pressure, uniform AO*(ABO 3 ) n layers of a terrace-like structure are formed on the perovskite surface (Ruddlesden-Popper phase) and with a defined n. n=1 was the thermodynamically most stable phase under oxidizing conditions when compared with perovskites of the type mentioned initially as well as when compared with Ruddlesden-Popper phases with a higher n.
At low pressures of for example 1 mbar, Ruddlesden-Popper phases with higher n of for example n=4, 5 or 6 were obtained.
Starting at 500° C., the growth of Ruddlesden-Popper phases occurred island-like. In order to obtain layers, it was necessary to use higher temperatures. In order to obtain a homogeneous coating, it is necessary with SrTiO 3 for example, to use a minimum temperature of about 750° C. At pressures of 100 to 200 mbar and temperatures of 800 to 950° C. Ruddlesden-Popper phases with n=1 were obtained after one to two hours. In this way layers of 200 to 300 Å thickness were obtained.
On an AO*(ABO 3 ) n surface of a perovskite of the type ABO 3 a terrace-like structure with steps is formed, whose height is 12 Å.
Also, YBa 2 Cu 3 O 7 layers were produced on the Sr 2 TiO 4 surface (c*≈11.8 Å) of a SrTiO 3 substrate and on the Pb 2 TiO 4 surface (c*≈11.91 Å) of a Pb 2 TiO 3 substrate. The layer thicknesses of Sr 2 TiO 4 and of Pb 2 TiO 4 were about 200 to 300 Å.
|
On the (100) surface of a perovskite of the type ABO 3 , a Ruddlerden-Popper AO*(ABO 3 ) n layer is generated by exposing the perovskite to an oxidizing atmosphere at temperatures above 750° C.
| 2
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This is a continuation application of U.S. application Ser. No. 08/398,304, filed Feb. 27, 1995, now abandoned.
FIELD OF THE INVENTION
The present invention relates to differentiation therapy and chemoprevention of cancer, and in particular to novel helper inducers which act on abnormal methylation enzymes of cancer cells.
BACKGROUND OF THE INVENTION
Abbreviations used are:
AdoHcy: s-adenosyl homocysteine
AdoMet: s-adenosyl methionine
MAT: methionine adenosyltransferase
MT: methyltransferase
NBT: nitroblue tetrazolium
RA: retinoic acid
SAHH: s-adenosyl homocysteine hydrolase
Differentiation therapy of cancer
Differentiation therapy may be the most ideal therapy for cancers if target cancer cells have ample receptors for inducers to initiate biological responses. The therapeutic efficacy is excellent and adverse side effects are minimal. Interferon and retinoic acid have produced remarkable results in the treatment of hairy cell leukemia (1), and acute promyelocytic leukemia (2,3), respectively, that these differentiation inducers are considered to be the drugs of choice for the treatment of these cancers. The success of differentiation therapy is, however, rather limited. After all differentiation therapy is just on the horizon. Many problems associated with this therapy still remain to be solved. At the moment, the immediate difficulties are that cancers responding well to interferon therapy are only a few, and the remission resulting from retinoic acid therapy is very short. Besides, mechanisms of differentiation therapy are not yet well established.
Role of methylation enzymes in the regulation of cell proliferation and differentiation
The expression of genes related to differentiation function is the most critical event in cell differentiation. These genes are in the repressed state in stem cells. Evidence has accumulated to indicate that DNA methylation plays a major role in the repression of certain genes (4-6). DNA methylation is taking place on the cytosine residues as 5mC, which occur exclusively in the CG sequence on the symmetric sites of DNA duplex. It takes two cell cycles of DNA hypomethylation for the removal of methylated sites and the expression of genes so affected (7-9).
DNA methylation is the most important biological methylation related to cell proliferation and differentiation, because of its apparent involvement in the regulation of gene expression. However, rRNA methylation also plays an important role in this respect. Most rRNA methylation is taking place on the 2'-o- ribose moieties. Such methylation is essential to protect rRNA sequences during biogenesis of ribosomes (10). rRNA's are synthesized first as a large 45 S precursor, which is processed in the nucleus to yield two ribosomal subunits. All of the methylated nucleosides are confined to the ribosomal RNA sequences. If these rRNA sequences do not have full compliment of methylated nucleosides, these sequences will also be degraded as those non-conserved sequences. Thus, the production of ribosomes depends greatly on the methylation of pre-rRNA.
Production of ribosomes is necessary to prepare the cells to enter S phase. It is essential that proteins needed for the replication of chromosomes are available prior to the engagement of DNA synthesis. If the production of ribosomes is selectively prohibited after growth stimulation by employing actinomycin D (11), which is a selective inhibitor of rRNA synthesis, or by shifting to the non-permissive temperature of a temperature sensitive mutant (12), DNA synthesis will also be aborted, and the cells terminate at G1 phase. These experiments clearly show that ribosome production is an absolute prerequisite to commit the cells to replication.
Role of abnormal methylation enzymes in malignant growth
With nucleic acid methylations demonstrated to play such important roles as the regulation of gene expression and ribosome production, a very important role must be ascribed to methylation enzymes. Methylation enzymes are a ternary enzyme complex consisting of MAT-MT-SAHH. There are a wide variety of MTs. Each individual MT is a very specific enzyme, and has its own unique function. But by virtue of association with the same pair of MAT and SAHH, MTs become a family of enzymes regulated by a common mechanism. Methylation enzymes are normally regulated by an activating effector such as steroid hormone in case of a steroid hormone target tissue (13). In the absence of such an activating effector. the ternary enzyme complex dissociates into individual enzymes which are quickly destroyed by endogenous proteolytic enzymes. It appears that the ternary enzyme complex is the stable and functional entity of methylation enzymes. Evidently normal methylation enzymes are totally dependent on an exogenous activating effector. In non-steroid hormone target tissues, activating effectors of methylation enzymes can be produced in response to growth stimulation.
Methylation enzymes of cancer cells are different from these of normal cells. The difference is due to toe association of methylation enzymes with a cancer specific protein factor. These abnormal methylation enzymes were discovered by Liau et al.(14-16) who presented evidence to show that cancer methylation isozymes displayed kinetic properties distinctly different from their normal counterparts. The Km values for the normal isozyme pairs which are designated with a sur-L, are 3 μM methionine and 0.35 μM adenosine for MAT L and SAHH L , respectively. Those for the cancer isozymes, which are designated with a sur-LT, are 20 μM methionine and 2.2 μM adenosine for MATL T and SAHH LT , respectively. The existence of an altered cancer MAT isozyme was confirmed by Surfrin and Lombarini (17) and by Kappler et al.(18). The cancer specific protein factor not only enhances enzyme activity and alters kinetic properties, but also changes the stability and regulation of ternary methylation enzymes. This factor acts like an activating effector of normal methylation enzymes to keep cancer methylation enzymes in extremely stable and active forms. Instead of relying on an exogenous activating effector, cancer cells generate an endogenous protein factor to ensure an efficient methylation system responsible for streamline production of functional RNAs needed for cell proliferation, and the reproduction of DNA methylation pattern to maintain malignant phenotype. Thus, abnormal methylation enzymes are clearly the most critical problem of cancer.
The altered cancer MAT LT was shown to be present in primary and transplantable rat hepatomas (15), and human cancers xenografted into athymic nude mice which included melanomas, sarcomas, a lymphoma, and adenocarcinomas of the colon, lung, breast, liver, ovary, uterus and nasopharynx (19). A surgical cancer tissue and HL-60 leukemia cells in culture also showed the same abnormality. Whereas enzyme levels of MAT LT were invariably elevated in cancer tissues, there existed a good correlation between levels of enzyme and growth rates of xenografted human cancers (19). Abnormal methylation enzymes were, however, never detected in normal tissues, including rapidly proliferating tissues such as regenerating liver, fetal tissues, bone marrow cells, and intestinal mucosa. Therefore, abnormal methylation enzymes are a specific abnormality associated with cancer. Since abnormal methylation enzymes play an important role in the promotion of malignant growth, they offer an opportunity for therapeutic intervention. The association with a cancer specific protein makes abnormal cancer methylation enzymes to respond differently to regulatory effectors in comparison with normal methylation enzymes. Our studies indicated that cancer RNA methylation enzymes responded markedly to inhibitory effectors such as oligonucleotides and intercalating agents, but only marginally to stimulatory effectors such as ATP and polyphosphate (10,20). In stark contrast, normal RNA methylation enzymes responded markedly to stimulatory effectors, but not at all to inhibitory effectors. So obviously abnormal cancer methylation enzymes are the selective targets for cancer intervention.
Abnormal methylation enzymes as selective targets for differentiation therapy of cancer
As above described, abnormal methylation enzymes are the roots of cancer problems, which effectively block cancer cells from entering differentiation pathways. It follows that the elimination of abnormal methylation enzymes should enable cancer cells to undergo terminal differentiation. As a matter of fact, our earlier experiments showed that this assumption was correct. The treatment of Novikoff ascites hepatoma resulted in the conversion of abnormal methylation enzymes into normal methylation enzymes (16), a delayed inhibition of macromolecular synthesis, and the termination of cell growth (21). The effect of poly (I)(C) most likely is an indirect effects since poly (I)(C) is unable to get inside the cell. It has been demonstrated that poly (I)(C) was capable of inducing oligoisoadenylate synthetase like interferon (22). The product of this induced enzyme, oligoisoadenylate which is a trinucleotide, may be the inhibitory effector responsible for the elimination of abnormal methylation enzymes. We have previously demonstrated that cancer rRNA methylation enzymes were sensitive to the inhibition by oligonucleotides, particularly trinucleotides (10). Oligonucleotides are the products of differentiated cells. Natural products which have similar function as oligortucleotides include conjugated oligopeptides and organic acids (23, 24). Such natural products possessing selective antitumor effect have been named antineoplastons by Burzynski (25). Antineoplastons are low molecular weight metabolites. In the kidney low molecular weight metabolites get back to the blood stream after glomerular filtration by reabsorption. Reabsorption is often incomplete. Thus s a normal person excretes a small amount of antineoplastons constantly. However S a healthy person is able to maintain a balance S so that there are always enough antineoplastons circulating to suppress malignant evolution. Liau et al. called such a natural chemical defense mechanism chemo-surveillance (26).
The active component of antineoplastons have been purified which showed pronounced activity in the induction of terminal differentiation of HL-60 cells (23) and in the inhibition of colony formation of HBL-100 cells (24). One active preparation contains primarily acidic peptides conjugated with pigment, and the other preparation contains primarily organic acids Both have similar biological activities e despite different chemical forms. When tested on partially purified MAT isozymes, these active preparations were shown to inhibit the abnormal cancer isozyme and convert it into the normal isozyme. It appears that the active components of antineoplastons selectively antagonize the cancer specific protein factor of MAT LT , and eliminate the influence of this factor on the methylation enzymes. The antitumor mechanism is mediated through the modulation of abnormal methylation enzymes, resulting in hypomethylation of DNA and pre- rRNA (9). As a consequence, cancer cells are induced to undergo terminal differentiation. The effect is selective on cancer cells, since normal cells do not have that cancer specific protein factor for these active components to interact.
From enzymatic point of view, the conversion of abnormal methylation enzymes into normal methylation enzymes is the critical mechanism to trigger terminal differentiation. Analyses of intracellular pool sizes of AdoMet and AdoHcy strongly support the conclusion above reached. It has been shown by De La Rosa et al. (27) that the pool size of AdoMet of cancer cells was constitutively elevated. This finding is consistent with the higher Km of the cancer MAT isozyme. Studies conducted by Chiba et al. (28) indicated that when HL-60 cells became terminally differentiated, both pool sizes of AdoMet and AdoHcy shrunk, reflecting precisely the conversion of higher Km abnormal cancer methylation enzymes into lower Km normal enzymes. It appears that studies from different point of views have come to the same conclusion that abnormal methylation enzymes are responsible for denying cancer cells to undergo terminal differentiation.
Natural chemo-surveillance and the evolution of cancer
If human bodies are equipped with antineoplastons to suppress the evolution of cancer, why people get cancer? It is the same question as asking why people get sick when immune-surveillance is operating? Obviously surveillance mechanisms break down, so people get sick. Our studies indicated that cancer patients were deprived of chemo-surveillance because of excessive excretion of low molecular weight metabolites (26, 29). Excessive excretion results in the depletion of endogenous antineoplastons, thus creating conditions favorable for the multiplication of cancer cells. In addition, the growth of cancer cells causes even greater loss of endogenous antineoplastons. Eventually chemo-surveillance is totally non-functional in terminal stage cancer patients. Although abnormal methylation enzymes are the most important cause of cancer problems, the destruction of chemo-surveillance is another important factor which has a pivotal influence on the pathogenesis of cancer. If a therapy can deal with both contributing factors of cancer, namely can eliminate abnormal methylation enzymes and restore chemo-surveillance, the therapy will have a greater chance to succeed.
Antineoplaston preparations purified from urine appears to take care of both contributing factors of cancer very well. On one hand abnormal methylation enzymes were corrected to become normal enzymes, and on the other hand the excessive urinary excretion of peptides was quickly reversed (23, 29). The efficacy of antineoplaston therapy was indeed remarkable (30).
The reason why cancer patients excrete large amounts of low molecular weight metabolites is probably attributable to inflammation. Inflammation causes macrophages to release cachectin, and cachectin is responsible for the symptom known as cachexia which is characterized by excessive excretion of metabolites, increased catabolism including lipid movilization, and anorexia (31-33). Acute inflammation lasts only a short while. Therefore it does not have much effect on the evolution of cancer. Chronic inflammation because of long lasting effect is definitely a contributing factor on cancer. For example, quite a number of patients suffering from AIDS or hepatitis B become cancer patients. Cancer cells are themselves sources of chronic inflammation because of expression of genes not normally expressed in wealthy cells. The more the growth of cancer cells, the worse the cachexia becomes. An effective means to control cachexia will be beneficial in cancer therapy. Cachexia, however, is totally neglected by conventional cancer therapists. We have previously shown that cytotoxic drugs induced excessive excretion of peptides (26). Thus, cytotoxic drugs contribute to the destruction of chemo-surveillance. The body eventually become defenseless after long term application of cytotoxic drugs. If there are surviving cancer cells not responding to cytotoxic therapy, these cells are going to multiply very well. The therapeutic efficacy of cytotoxic drugs depends on the total elimination of cancer cells, a task not easily attainable. In contrast, antineoplaston therapy quickly restores chemo-surveillance, and this natural defense mechanism is capable of taking care of the residual cancer cells. There is no need to wipe out a whole population of cancer cells.
Phenylacetyl glutamine, a component of antineoplaston preparations, is capable of reversing excessive excretion of peptides normally associated with cancer patients. This compound is inactive by itself on the growth of malignant cells in culture. Nevertheless, it is producing encouraging results on the therapy of early stage cancers (26), and on the prevention of chemical carcinogenesis (34-36). Its therapeutic and chemopreventive effect are likely attributable to its ability to restore and to protect chemo-surveillance. It has been demonstrated that induction of cancer was much easier to take place in cultured cells than in intact animals (37, 38). This is because chemo-surveillance is operating in intact animals, and it takes time for this chemical protection mechanism to break down in order for the symptom to show up. Inflammatory agents such as proton oil serve as promoters to enhance carcinogenesis, and agents such as phenylacetyl glutamine which have the ability to keep chemo-surveillance intact can serve as chemopreventive agents. In summary, chemo-surveillance if utilize properly can be very useful to assist cancer therapy or prevention.
Role of helper inducers in differentiation therapy
Inducers of differentiation can directly or indirectly convert abnormal methylation enzymes into normal enzymes. Antineoplastons are direct inducers, and retinoic acid, interferon and poly(I)(c) (polyinosinic acid:cytidylic acid) are indirect inducers (9, 16, 39). The effectiveness of indirect inducers relies totally on the availability of receptors. Because of this limitation, responding cancers are only limited to a few. Recently Liau et al. reported a group of chemicals, although devoid of differentiation inducing activity, could nevertheless greatly potentiate the activity of inducers (40). Chemicals as such were accordingly named helper inducers. Helper inducers are mostly inhibitors of component enzymes of ternary methylation enzymes, such as competitive inhibitors of MAT herein described. Butyric acid is the most effective helper inducer among competitive inhibitors of MAT, but phenylacetic acid is also active (40). Helper inducers of this group are relatively nontoxic (41-43). From therapeutical point of view, helper inducers are valuable because they can greatly increase the scope of responding cancers, particularly toward indirect inducers. From economical point of view, helper inducers are also valuable because they can greatly reduce the burden of patients. These chemicals are cheap and abundant. In some special cases, helper inducers can be used alone to achieve cancer therapy. Brain is a special compartment shielded by a blood-brain barrier. Exogenous chemicals are not easy to get in, and endogenous products are also not easy to get out. The loss of endogenous antineoplastons in brain compartment is not as great as that of other compartments. Therefore, the employment of helper inducers alone can achieve effective therapy of brain cancers, particularly astrocytoma. Astrocytoma is not responding to any cytotoxic drugs. Thus so far, phenylacetic acid is the only drug astrocytoma responds well. By the same token, helper inducers can be used for the treatment of cancer at early stage, and for the prevention of cancer.
SUMMARY OF THE INVENTION
We recognize the important contribution of helper inducers in the differentiation therapy and the chemoprevention of cancer, a systemic study was conducted to explore helper inducers. We screened effective helper inducers on one hand, and on the other hand, modified chemical forms to improve their effectiveness and applicability. We have come to the conclusion that the following chemicals are excellent helper inducers: methyl and ethyl phenylacetamides, ethyl phenylacetate, 2,4-dichlorophenylacetic acid, and indole acetic acid. Methyl and ethyl phenylacetamides, ethyl phenylacetate, 2,4-dichlorophenylacetic acid, and indole acetic acid are competitive inhibitors of MAT.
The present invention provide a pharmaceutical composition for differentiation therapy and prevention of cancer, preferably brain and prostatic cancer, comprises one or more than one compounds as help inducers selected from the group consisting of methyl phenylacetamide, ethyl phenylacetamide, ethyl phenylacetate, 2,4-dichlorophenyl acetic acid, and indole acetic acid.
Preferably, the pharmaceutical composition has a form suitable to be administered orally, parenterally, or topically.
Preferably, the pharmaceutical composition further comprises an active compound as an differentiation inducer for differentiation therapy of cancer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot which shows potentiation of RA-induced terminal differentiation by ethidium bromide, wherein the concentrations of ethidium bromide used are 0.0 μM (∇), 1.0 μM () and 2.0 μM (◯), respectively.
FIG. 2 is a plot which shows effectiveness of acetic acid (◯), butyric acid (□), hexanoic acid (), and phenylacetic acid (∇) as helper inducers.
FIG. 3 is a plot which shows helper inducer activity of and cell inhibitory effect by methyl phenylacetamide.
FIG. 4 is a plot which shows helper inducer activity of and cell inhibitory effect by ethyl phenylacetamide.
FIG. 5 is a plot which shows helper inducer activity of and cell inhibitory effect by ethyl phenylacetate.
FIG. 6 is a plot which shows helper inducer activity of and cell inhibitory effect by 2,4-dichlorophenyl acetic acid.
FIG. 7 is a plot which shows helper inducer activity of and cell inhibitory effect by indole acetic acid.
FIG. 8 is a plot which shows indole acetic acid as inducer of terminal differentiation.
DETAILED DESCRIPTION OF THE INVENTION
Although named as helper inducers, their application in the differentiation therapy of cancer is beyond helping role to potentiate the therapeutic efficacy of differentiation inducers. Helper inducers are actually essential components to achieve differentiation therapy. We have noticed that differentiation induced in the presence of helper inducers could reach greater extent of completion as compared to inducers alone (40). With inducers alone, NBT+ cells rarely exceeded 85%. There was always a small fraction of uninduced cells. This small fraction of uninduced cells is the reason why the remission resulting from RA therapy is so short (44). Differentiation is a long process which must go through two cell cycles of uninterrupted DNA hypomethylation (45-47). If cells are damaged during this process, DNA synthesis can not progress to completion. These damaged cells if repaired are likely to revert back to the original malignant state. And the symptom reappears. Malignant cells have elevated levels of methylation enzymes. These enzymes are dependent upon cancer specific protein factor to maintain stability as ternary enzyme complexes. Once that cancer specific protein factor is antagonized by antineoplastons or antineoplaston-like factors induced by differentiation inducers, ternary methylation complexes will dissociate to give rise to individual component enzymes. Some of methyltransferases in monomeric forms may become nucleases, better known as latent nucleases, to cause cell damage (10), resulting in the disruption of differentiation. The employment of helper inducers is designed to control the damage attributable to latent nucleases so that differentiation can reach completion. It is clear that helper inducers are also indispensable components of differentiation therapy. Helper inducers can facilitate differentiation and reduce the chance of recurrence.
I. Preparation of derivatives of phenylacetic acid
The establishment of phenylacetic acid as helper inducer (40) and the effectiveness of phenylacetic acid in the treatment of astrocytoma (30, 43) have been well documented. It is, however, not a good helper inducer. It requires a few mM quantities to show biological activity as helper inducer. Besides, the odor is offensive. There are rooms for improvement. We have discovered that following derivatives of phenylacetic acid were much better on the basis of activity and the odor they generated.
I-1. Preparation of N-substituted phenylacetamides
N-substituted phenylacetamides are all known compounds listed in reference 51. However, we have designed a procedure shown in scheme 1 to prepare these derivatives. ##STR1##
Phenylacetyl chloride was reacted with methylamine or ethylamine in benzene. The products were purified by column chromatography and recrystallization.
EXAMPLE I-1-1.
phenylacetamide (3-1)
Dissolved 15 g (0.1 mol) of phenylacetyl chloride in 100 ml of benzene. While stirring on a magnetic stirrer, introduced ammonia gas into the benzene solution at 20°-30° C. After reaction, the solid was collected by filtration, washed with water, and dried. The filtrate was washed in a separators funnel with water, and dehydrated with anhydrous magnesium sulfate. The solution was evaporated to dryness in a rotary evaporator. The residue together with the solid above obtained was purified by column chromatography employing silica gel-chloroform system, and recrystallization with chloroform to yield white crystal as compound 3-1. Yield, 11 g (80%).
mp.: 153°-155° C.; IR(KBr)v max : 3300, 3120(NH), 1670(C═O)cm -1 ; 1 H-NMR (CDCl 3 3.58(s,2H,--CH 2 ), 5.60(br,2H,--NH 2 ), 7.24-7.30(m, 5H,--C 6 H 5 ), MS, m/z: 135(M + ); element analysis: C 8 H 9 NO, calculated value: C:71.09, H:6.71, N: 10.36, found value: C: 17.15, H: 6.93, N: 10.26
EXAMPLE I-1-2
N-Methyl phenylacetamide (3-2)
Dissolved 15 g(0.1 mol) of phenylacetyl chloride in 100 ml of benzene. While stirring on a magnetic stirrer, introduced methylamine into the benzene solution at 20°-30° C. Followed the procedure of compound 3-1 for the purification of the product to yield N-methyl phenylacetamide as light yellowish crystal. Yield, 12 g (80%).
mp.: 56°-59° C.; IR(KBr)v max : 3340(NH), 1630(C═O)cm -1 ; 1 H-NMR(CDCl 3 )δ:2.75(s,3H,--CH 3 ), 3.59(s,2H,--CH 2 ), 5.59(br,1H,--NH ), 7.28-7.31(m,5H,--C 6 H 5 ); MS, m/z: 149(M + ); element analysis: C 9 H 11 NO, calculated value: C:70.04, H: 8.08, N: 10.21, found value: C: 70.18, H: 8.05, N: 10.07
EXAMPLE I-1-3:
N-Ethyl phenylacetamide (3-3)
Dissolved 15 g (0.1 mol) of phenylacetyl chloride in 100 ml of benzene. While stirring on a magnetic stirrer, added 25 g of ethylamine (0.5 mol) into the benzene solution at 20°-30° C. After reaction, the solution was washed with water, dehydrated with anhydrous magnesium sulfate. The solvent was removed by rotary evaporator and the residue was purified by column chromatography as compound 3-1 to yield N-ethyl phenylacetamide as yellowish crystal. Yield, 14 g (85%).
mp.: 72°14 74° C.; IR(KBr)v max : 3360(NH), 1630(C═O)cm -1 ; 1 H-NMR(CDCl 3 )δ: 1.02(t,3H,--CH 3 ), 3.25(m,2H,--N--CH 2 ), 3.50(s,2H,--CH 2 --CO--), 7.20-7.33(m,5H,--C 6 H 5 ); MS, m/z: 163(M + ); element analysis: C 10 H 13 NO, calculated value: C:73.59, H: 8.03, N: 8.58, found value: C: 73.67, H: 8.00, N: 8.41
l-2. Preparation of alkyl phenylacetates:
Esters of phenylacetic acid are listed in references 52 and 53. We prepared these derivatives according to the standard procedure shown in scheme 2. ##STR2##
In the presence of Lewis acid, phenylacetic acid was allowed to react with alcohol to yield respective ester.
EXAMPLE I-2-1
Methyl phenylacetate (5-1)
Dissolved 13 g (0.1 mol) of phenylacetic acid in 500 ml of anhydrous methanol. Introduced HC1 gas, while refluxing for 3 hours. The solvent was then removed by evaporation. Dissolved the ester in benzene, which was successively washed with water and 10% NaOH. The organic layer was dehydrated with anhydrous magnesium sulfate. The solvent was again removed by evaporation. Methyl phenylacetate was finally purified by column chromatography employing silica gel chloroform system. The solvent was removed by evaporation to yield yellowish liquid. Yield, 6 g (40% ).
bp.: 218° C.; IR(KBr)v max : 1700(C═O)cm -1 ; 1 H-NMR(CDCl 3 )δ: 3.62(s,2H,--CH 2 ), 3.70(s,3H,--CH 3 ), 7.30-7.32(m,5H,--C 6 H 5 ); MS, m/z: 150(M + )
EXAMPLE I-2-2
Ethyl phenylacetate (5-2)
Dissolved 13 g (0.1 mol) of phenylacetic acid in 500 ml of anhydrous ethanol. The reaction and purification of the product were as those described for methyl phenylacetate. Ethyl phenylacetate was a yellowish liquid. Yield, 6.5 g (40% ).
bp.: 227° C.; IR(KBr)v max : 1700(C═O)cm -1 ; 1 H-NMR(CDCl 3 )δ: 1.24(s,3H,--CH 3 ),3.61(s,2H,--CH 2 --CO--), 4.15(s,2H,--OCH 2 ), 7.29-7.32(m,5H,--C 6 H 5 ); MS, m/z: 164(M + )
I-3. Other helper inducers we have so for discovered such as 2,4-dichlorophenyl acetic acid, and indole-3-acetic acid were obtained from Sigma Chemical Company.
Experimental materials herein described such as all trans-retinoic acid, phenylacetic acid, phenylacetyl chloride, butyric acid, and hexanoic acid were obtained from E. Merck Darmstadt.
II. Determination of the activity of helper inducers
The procedure developed by Liau et al. (40) was employed for the determination of the activity of helper inducers. The procedure was based on the NBT assay of the induced differentiation of HL-60 cells. HL-60 cells were subcultured at an initial concentration of 1.5×10 5 cells/ml. Each flask contained 10 ml. Flasks were divided into several sets of 5 flasks containing RA from 0 to 0.125 μM. RA was dissolved in methanol. The volume of methanol added was limited to 2% so that the growth and differentiation of HL-60 cells were not appreciably affected. One set served as control, while helper inducers of the indicated amounts were added to other sets. After 96 hours cell number was counted, and NBT assay was conducted as previously described (40). NBT+ cells of the control without any addition were always below 4%. In the presence of helper inducers alone, the control numbers were in general below 10%. The respective control value was subtracted from each experimental value. ED 50 values which are defined as effective dosages to cause induction of 50% NBT+ cells, can be obtained from plots of NBT+values versus concentrations of RA in the absence and presence of helper inducers. As shown in FIG. 1 ED 50 of RA is 0.12 μM. In the presence of 1 μM or 2 μM ethidium bromide as helper inducer, this value is reduced to 0.056 μM or 0.03 μM, respectively. The reductive index is defined as ED 50 in the presence of helper inducer divided by ED 50 in the absence of helper inducer. This value bears an inverse relationship with the effectiveness of the helper inducer.
The biological activity of helper inducers is greatly influenced by the chemical structure. As shown in FIG. 2, butyric is the most active helper inducer among competitive inhibitors of MAT. Acetic acid is completely ineffective. The addition of a phenyl group to acetic acid restores some activity. Hexanoic acid is much less active compared to butyric acid. Although butyric acid is a very active helper inducer, it is not a suitable therapeutic drug because it is quickly metabolized. In addition, the odor is very offensive. Phenylacetic acid is a stable chemical metabolically, but the activity is not that good. The odor of phenylacetic acid is offensive too. Through a systemic search, we have discovered the following compounds to serve as excellent helper inducers.
II-1. N-Methyl phenylacetamide
N-Methyl phenylacetamide was dissolved in methanol for the determination of its activity as helper inducer. As shown in FIG. 3, it takes 0.65 mM to reach a reductive index of 0.5. The corresponding concentration of phenylacetic acid is 4 mM. Therefore, it is a good improvement. The growt of HL-60 was not affected by this compound below 2 mM. It does not have offensive odor. It is a great improvement in this respect too. The only disadvantage is that it is not soluble in water. It can not be formulated as a parenteral preparation. It is perfectly all right to be formulated as oral preparations.
II-2. Ethyl phenylacetamide
Ethyl phenylacetamide is very much alike methyl phenylacetamide with respect to chemical properties and biological activity. It is slightly less active, requiring 0.87 mM to reach a reductive index of 0.5 as shown in FIG. 4.
II-3. Ethyl phenylacetate
This is a yellowish liquid with pleasant smell. It was dissolved in methanol for the determination of its activity as helper inducer. As shown in FIG. 5, it is a very active helper inducer. The activity is 10-fold greater than phenylacetic acid, requiring 0.4 mM to reach a reductive index of 0.5. It is very easily hydrolyzed in contact with acid. Therefore, the soft gel preparation must have an enteric coating to avoid acid hydrolysis.
II-4. 2,4-Dichlorophenylacetic acid
This is a colorless crystal with pleasant smell. It was dissolved as sodium salt for the determination of its activity as helper inducer. As shown in FIG. 6 it is also a very active helper inducer, requiring 0.3 mM to reach a reductive index of 0.5. Because of a chlorine-substituted derivative, its toxicity must be checked in order to consider it for clinical application. It certainly can be considered for short-term application of terminal cancer patients.
II-5. Indole acetic acid
Replacement of phenol group with indole group greatly increases the activity as shown in FIG. 7, it takes 0.25 mM to reach a reductive index of 0.5. A very active help inducer often by itself is also a formidable inducer. It is not surprising that indole acetic acid is active as inducer at concentration above 0.5 mM as shown in FIG. 8.
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(11). Epifanova, O. I., Abuladze, M. K., and Zoniovska, A. I., Effect of low concentrations of actinomycin D on the initiation of DNA synthesis in rapidly proliferating and stimulated cell cultures. Exp. Cell Res.,92:25-30.1975.
(12) Toniola, D., Weiss, H. K., and Basilio, C. A., Temperature sensitive mutation affecting 28S ribosomal RNA production in mammalian cells. Proc. Acad. Sci. USA, 70: 1273-1277, 1973.
(13). Liau, M. C., Chang, C. F., Saunders, G. P., and Tsai, Y. H., S-adenosylmethionine hydrolases as the primary target enzymes in androgen reculation of methylation complexes. Arch. Biochem. Biophys., 208:261-272,1981.
(14). Liau, M. C., Lin, G. W., and Hurlbert, R. B., Partial purification and characterization of tumor and liver S-adenosylmethionine synthetases. Cancer Res., 37:427-435, 1977a.
(15). Liau, M. C., Chang, C. F., and Becker, F. F., Alteration of S-adenosylmethionine synthetases during chemical hepatocarcinogenesis and in resulting carcinomas. Cancer Res., 39: 2113-2119. 1979.
(16). Liau, M. C., and Burzynski, S. R., Altered methylation complex isozymes as selective targets for cancer chemotherapy. Drugs Exptl. Clin. Res., 12(Suppl.1): 61-70, 1986.
(17). Sufrin, J. R., and Lombardini, J. B., Differences in the active site region of tumor versus normal isozymes of mammalian ATP: L-methionine S-adenosyltransferase. Mol. Pharmacol., 22: 752-759, 1982.
(18). Kappler, F., Hai, T. T., and Hampton, A., Isozyme-spectific enzyme inhibtor, 10 adenosine 5 -triphosphate derivatives as substrates or inhibtors of methionine adenosyltransferases of rat normal and hepatoma tissues. J. Med. Chem.,29: 318-322,1986.
(19). Liau, M. C., Chang, C. F.,and Giovanella, B. D., Demonstration of an altered S-adenosylmethionine synthetase in human malignant tumors xenografted into athymic nude mice. J. NatI. Cancer Inst., 64: 1071-1075,1980.
(20). Liau, M. C., Lin, G. W., Knight, C. A., and Hurlbert, R. B., Inhibition of RNA methylation by intercalating agents. Cancer Res., 37: 4202-4210, 1977b.
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(22). Chapekar, M. S., and Glazer, R. I., Effects of fibroblast and recombinant leukocyte interferons and double stranded RNA on ppp(2'-5')A synthesis and cell proliferation in human colon carcinoma cells in vitro. Cancer Res., 43 :2683,1983.
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(24). Liau, M. C., and Burzynski, S. R., Separation of active anticancer components of antineoplaston A2, A3 and A5. Intl. J. Tiss. React., 12(Suppl.): 1-18, 1990a.
(25). Burzynski, S. R., Antineoplastons:Biochemical defense against cancer. Physiol. Chem.Phys.,8:275-279,1976.
(26). Liau, M. C., Szopa, M., Burzynski, B., and Burzynski S. R., Chemosurveillance: A novel concept of the natural defense mechanism against cancer. Drugs Exptl. Clin. Res., 12(Suppl. 1): 71-76, 1987b.
(27). De La Rosa, J.,Geller, A. M., Legros, H. L., and Kotb,M., Induction of interleukin 2 production but not methionine adenosyltransferase activity or S- adenosylmethionine turnover in Jukat T-cell. Cancer Res.,52: 3361-3363,1992.
(28). Chiba,P.,Wallner, L., and Kaiser, E., S-Adneosylmethionine metabolism in HL-60 cells: effects of cell cycle and differentiation. Biochem. Biophys. Acta, 971:38-45,1988.
(29). Liau, M. C., Szopa, M., Burzynski, B., Burzynski, S. R., Quantitative assay of plasma and urinary peptides as an aid for the evaluation of cancer patients undergoing antineoplaston therapy. Drugs Exptl. Clin Res. 12(Suppl. I):61-70, 1987a.
(30). Burzynski, S. R., and Kubove, E., Initial clinical study with antiplaston A2 injections in cancer patients with five years follow-up. Drugs Exptl. Clin. Res., 13(Suppl. 1): 1-11,1987a.
(31). Clark, P. M. S., Kricka, L. J., and Whitehead, T. P.,Pattern of urinary proteins and peptides with rheumatoid arthritis investigated with the iso-dalt technique. Clin. Chem.,26:201,1980.
(32). Borek, E., et al. Altered excretion of modified nucleosides and βaminoisobutyric acid in subjects with acquired immunodeficiency syndrome or at risk for acquired immunodeficiency syndrome. Cancer Res.,46:2557,1986.
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(34). Kampalath, B. N., Liau, M. C.,Burzynski,B.and Burzynski, S. R. M., Chemoprevention by antineopalstons A10 of benzo (a) pyrene-induced pulmonary neoplasia. Drugs Exptl.Clin. Res.,13(Suppl.):51-56,1987.
(35). Kampalath, B. N., Liau, M. C.,Burzynski,B.and Burzynski, S. R., Protective effect of antineoplaston A10 in hepatocarcinogenensis induced by aflatoxin B1. Intl. J. Tiss. React., 12 (Suppl.):43-50,1990.
(36). Muldoon, T. G., Copland, J. A. and Hendry, L. B., Antineoplaston A10 activity on carcinogen-induced rat mammary tumors. Intl. J. Tiss. React., 12(SupppI.):51-56, 1990. (37). Rubin, H., and Colby, C., Early release of growth inhibition in cells infected with Rous sarcoma virus. Proc. Natl. Acad. Sci. USA, 60: 752-759, 1982.
(38). Parod, S. and Brambilla, G., Relationship between mutation and transformation frequencies in mammlian cells treated in vitro with chemical carcinogens. Mutat. Res., 47:53. 1977.
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(40). Liau, M. C., Liau, C. P., and Burzynski, S. R., Potentiation of induced terminal differentiation by phenylacetic acid and related chemicals. Intl. J.
Exptl. Clin. Chemother. 5: 9-17, 1992.
(41). Burzynski, S. R., Mohabbat, M. O., ,Lee S. S., Preclinical studies in Antineoplaston AS2-1 and Antineoplaston AS2-5. Drugs Exptl. Clin.Res. 12(Suppl.I): 11-16, 1986a.
(42). Burzynski, S. R., Burzynski, B., Mohabbat, M. O., Toxicology studies in antineoplaston AS2-1injections in cancer patients. Drugs Exptl. Clin. Res., 12(Suppl. I): 25-36, 1986b.
(43). Ram, Z., Samid, D., Walbriddge, S., Oshiro, E. M., Viola, J. J., Tao-Cheng, J. H. Shack, S., Thibault, A., Myers, C. E., Oldfield E. H. Growth inhibition, tumor maturation, and extended survival in experimental brain tumors in rats treated with phenylacetate. Cancer Res., 54: 2923-2927, 1994.
(44). Adamson, P. C., Boylan, B. F., Balis, F. M., Murfy, R. F., Godwin, K. A.Gudas, L. T., and Poplack,D. G., Time course of induction of metabolism of all-trans retinoic acid and the up-regulation of cellular retinoic acid binding protein Cancer Res.,53:472-476,1993.
(45). Yen, A., Reese, S. L. and Albright, K. L., Dependence of HL-60 myeloid cell differentiation on continuous and split retinoic acid exposure: precommitment memory associated with altered nuclear structure. J. Cell Physiol., 118:277-286, 1984.
(46). Yen, A., Reese, S. L., and Albright, K. L., Control of cell differentiation during proliferation. II. Mycloid differentiation and cell cycle arrest of HL-60 promyelocytes preceded by nuclear structural changes. Leuk. Res., 9: 51-71, 1985a.
(47). Yen, A., Control of HL-60 myeloid differentiation: Evidence of uncoupled growth and differentiation, S-phase specificity, and two step regulation. Exp.
Cell Res., 156: 198-212, 1985b.
(48). Burzynski, S. R., and Kubove, E., Phase I clincial studies of antineoplastons A3 injections. Drugs Exptl. Clin. Res., 13 (Suppl.1):13-30,1987b.
(49). Burzynski, S. R., Kubove, E. and Burzynski, B., Phase I clinical studies of antineoplaston A5 injections. Drug Exptl. Clin. Res., 13(Suppl.1):33-44,1987c.
(50). Burzynski, S. R., Treatment of malignant brain tumors with antineoplastons. Adv. Exp.Clin.Chemother.6/88:45-46,1988.
(51). Slobodan D., Petrovic, Nada D., Stojanovic, Ostoja K., Stojanovic, Nestor L. Kobilarox, J. Serb. Chem. Soc., 51, 395-405, 1986.
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(53). El-Chahawi, Moustafa; Richtzenhain, Hermann, Ger. Offen. 2,240,399(CI. C 07c), 28 Feb. 1974, Appl. P22 40 399.2, 17 Aug. 1972.
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Cancer cells are blocked from entering differentiation pathways because of abnormal methylation enzymes, which are responsible for keeping cancer cells in cycling state. Effective differentiation inducers are those capable of acting directly or indirectly to convert abnormal methylation enzymes into normal enzymes, thereby enabling cancer cells to undergo terminal differentiation. Differentiation employing inducer alone often can not reach completion because of the damage created by the inducer. Such damage can be prevented if differentiation is induced in the presence of helper inducers, which are basically inhibitors of the component enzymes of methylation. Thus, differentiation induced in the presence of helper inducers is more likely to reach completion. Therefore, helper inducers are essential components of differentiation therapy, not just merely to potentiate the activity of differentiation inducers. The present inventors discover that alkyl phenylacetamides, alkyl phenylacetate, 2,4-dichlorophenylacetate, and indole acetate are potent helper inducers.
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BACKGROUND OF THE INVENTION
The present invention relates to a wheel and brake device for a means of transportation, preferably a transport trolley, where at least one wheel is pivotally supported and where the brake device includes at least one brake activating means at the front and/or rear end of the means of transportation, the activating means being activatable and deactivatable by activating in one direction only, a cam mechanism defining two fixed resting positions for an activated brake and for a deactivated brake, respectively, and at least one brake lever connecting the brake activating means to a brake block intended for engagement with teeth on at least one wheel.
Such devices are known from various means of transportation, especially transport trolleys used in aircraft cabins. In such transportation trolleys at least the pairs of wheels at one end of the trolley are pivotally supported for the sake of trolley manoeuvrability. Such trolleys are provided with a brake device which should be able to brake the wheels even when the trolleys are heavily loaded and when the floor in the aircraft cabin is sloping, e.g., during take-off. Normally, the brake is activated by means of foot pedals located at each end of the trolley and which enables the establishment of an engagement between the brake block and the wheels.
U.S. Pat. No. 3,571,842 discloses a brake device of the type mentioned above. However, this device is associated with the disadvantage that the brake and the brake activating means are directly connected to a wheel. If the wheel can pivot, it becomes difficult to operate the brake activating means as in certain circumstances it may have moved underneath the means of transportation. Furthermore, its use is very troublesome as a brake activating means is required for each wheel to be braked. According to this patent, a friction engagement is established between the brake block and the wheel. This is disadvantageous as wear of the friction surfaces of the wheels and the brake block neccesitate a relatively frequent inspection and adjustment. This problem is solved by a brake device according to DE-A-3,130,100 wherein a mechanical engagement between the brake block and the teeth on the wheel of the trolley is illustrated. However, this device is complicated and demands a precise adjustment of the engagement portion of the brake block and the teeth.
Transportation trolleys are also known which at one and/or other end have a brake activating means acting on several wheels However, the brake device on the known trolleys is complex as, at each end, they comprise two foot pedals which by a downwardly orientated pressure both activate and deactivate the brake. Alternatively, one brake pedal only may be provided at each end which is activated and deactivated by a downwardly orientated pressure and an upwardly orientated pressure, respectively. However, this construction would be harmful to the shoes of the staff when they apply the upwardly directed pressure with the upper side of their shoe. In the known trolleys, an activating and a deactivating operation of the brake is effected from one end of the trolley. If a deactivation has to be effected from the opposite end of the trolley to the end where the activation is effected, a complex construction with doubling of several elements is required.
Even though the drawbacks associated with the known trolleys of the type mentioned above is explained with a view to transportation trolleys utilized in aircraft cabins, it is obvious that other means of transportation of a similar type as, e.g., fodder trucks for use in stables, waste containers, hospital beds, etc., suffer from the same or corresponding drawbacks. Therefore, the invention may advantageously be used in connection with various means of transportation.
It is the object of the present invention to remedy the above-mentioned drawbacks and to provide a device of the type mentioned in the preamble of the specification which is easy to operate and which requires little maintenance and adjustment and which also permits safe braking.
SUMMARY OF THE INVENTION
This object is achieved with a wheel and brake device which is characterized in that device comprises only one brake activating means at the one and/or at the other end of the means of transportation, that the brake lever is arranged so that the brake activating means is connected to the brake block on all the wheels to be braked, that the cam mechanism comprises a cam track and a cam follower of which one of the elements of the cam mechanism is firmly connected to the means of transportation while the other element is connected to the brake lever, that the wheels are constituted of twin wheels with teeth arranged on the opposing wheel rims, and that the brake block comprises two mutually independent resilient compliant tabs intended for engagement with each their respective set of teeth.
Hereby a device is achieved where the brake activating means by activation in one direction only, advantageously by depressing a foot pedal, alternately provides an activation and a deactivation of the brake on all of the wheels to be braked as the one resting position of the cam follower is so provided that the brake lever connected thereto sets the brake block of each wheel in an active position while the other resting position of the cam follower defines an inactive position for the brake block of each wheel. Thus the device is very easy to operate as the user needs only to apply a pressure on one brake activating means and only in one direction irrespective of a braking or a releasing operation of all the wheels to be braked is to be performed. Besides, an engagement between the brake block and the teeth of the wheels will establish a safe mechanical engagement as, due to their resilience, the tabs are urged into engagement with the teeth. Furthermore, in case of a break in one of the tabs there will be established a braking of the wheel by means of the other tab.
It should be noted that the brake block and the teeth can be formed in any convenient manner which makes it possible to establish a safe engagement, e.g., by tapering the elements intended for engagement with each other.
Furthermore, it is to be observed that activation of the brake activating means may be carried out using a manually-operated handle by electrical activation or in another way.
The described device may be used both for means of transportation where a braking of the wheels is established at one end only and in connection with means of transportation where a braking of the wheels is established at both ends. Furthermore, a suitable design of the brake lever will make it possible to activate and/or deactivate the brake from both the front and the rear ends of the means of transportation. Thus an alternate function is always achieved irrespective of a preceding operation of the brake having taken place from the opposite end. It is also possible to position the brake activating means at the sides of the means of transportation.
Furthermore, the brake block may optionally be arranged for connection to a fixed wheel or a pivotally supported wheel as the brake block is arranged in a fixed mutual position in relation to the teeth in order for it always to be able to engage with these.
The invention will now be described in further detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exploded perspective view of a wheel and brake device according to the invention,
FIGS. 2-4 illustrate a cam track according to the invention,
FIG. 5 illustrates a swinglebar connecting the brake lever to the cam follower,
FIGS. 6 and 7 illustrate partial sections through pivotal wheels according to the invention,
FIGS. 8-11 shows a foot-operated two-piece brake pedal according to the invention, and
FIG. 12 is a view of a lever arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a support framework 1 for transportation trolley (not shown) for use in aircraft cabins. The support framework 1 is provided with four pivotal twin wheels 2. The wheels 2 are respectively positioned substantially in each corner of the support framework 1. The transportation trolley is arranged to be braked by means of a foot-operated brake pedal 3. The trolley may be operated from one end or the other end as a brake pedal 3 is arranged at both ends of the support frame-work. The brake pedal 3 is formed of two separate parts 3A, 3B which will be explained below. The brake pedal 3 is connected via a brake lever 4 to a swinglebar 5. The swinglebar 5 is connected to a further brake lever 4' in order to establish an interconnection between the brake pedals 3 at both ends of the trolley. The swinglebar 5 is pivotally connected to a cam follower 6 running in a cam track means 7 mounted on the underside of the support framework 1 to secure the correct function by activation of one of the brake pedals 3. The cam follower 6 is elaborated as a lever which at one end has a member which engages with the cam track and at the other end is pivotally connected with the swinglebar 5. As will be explained below, the brake pedals 3 operate exclusively by a downwardly directed pressure activation, both when an activation of the brake and when a deactivation of the brake is to be effected. The entire arrangement comprising the cam track means 7, cam follower 6 and the swinglebar 5 is covered by a protection plate 8 which is mounted to the support framework and which is provided with recesses to ensure a correct mutual positioning of the swinglebar, the brake levers, springs and which on one hand prevents mechanical damage and on the other hand prevents soiling. Thus the cam track means 7 is secured by a recess in the protection plate and a recess 7' in the support framework 1. Furthermore the swinglebar is pivotally supported about a pin which is integral with the protection plate.
The two elements 3A, 3B of the brake pedals 3 are mutally pivotally connected about a shaft 9 mounted in two brackets 10 secured between two wheels 2 at opposite ends of the support framework. The two-component brake pedal is hinged about the shaft 9 with the centre of gravity so placed that it always reverts to be free of the floor to avoid damage. The elements 3B of the brake pedals are connected to the swinglebar 5 via the brake levers 4,4'. Furthermore, the element 3B abuts one end of a lever arm 11. The other end of the lever arm 11 abuts a brake block 12 located substantially coaxially about the swivel axis 13 of the pivotal wheel. The brake block 12 is arranged to engage with teeth 2' positioned on opposing sides of the twin wheels. The brake arrangement makes it possible to brake all four wheels irrespective of which brake pedal 3 is activated. It is also possible to release all four wheels by activating any of the two brake pedals 3.
FIGS. 2, 3 and 4 illustrate the cam track means 7 having a cam track 14. The cam track 14 comprises an inclined surface 15 and an inclined surface 16, which surfaces as seen in the direction of the passage of the cam follower along the cam track, are both upwardly orientated, and which surfaces connect substantially plane parts of the bottom of the cam track at one resting position 17 and another resting position 18 in such a way that this will ensure an evenly rising course of the cam track bottom on to a breast which is located between the resting position 18 and the resting position 17 as seen in the direction of the passage of the cam follower along the cam track. A higher degree of security for the correct passage of the cam follower 6 along the cam track 2 is hereby achieved. Thus the cam track 14 provides two resting positions 17 and 18 for the cam follower 6. By activation of the brake pedal, the cam follower 6 starts its passage from the resting position 17 where the brake is deactivated, along the cam track across the inclined surface 15 and when the user lifts his/her foot from the brake pedal, the brake is led into its resting position 18 where the brake is activated. The sidewise-displacement of the cam follower 6 from the first rectilinear section of the cam track 14 into the following section positioned substantially perpendicularly to the first section is ensured by means of a spring 19 (see FIG. 1) secured in a recess 20 in the cam follower means. As clearly shown in FIG. 1, this displacement from the resting position 17 to the resting position 18 is performed by depression of one of the brake pedals 3. By a following depression of one of the brake pedals, the cam follower will be displaced upwardly due to the action of the spring 19, as shown in FIG. 4 and when the brake pedal is released the cam follower will continue its passage along the cam track 14 across the inclined surface 16 whereupon the cam follower 6 moves past the breast and downwards into the first section of the cam track and is returned to the first resting position where the brake is again deactivated. The cam track means 7 is fixed in relation to the support framework 1 by means of a tack which is integral with the protection plate and is mounted through an opening 21. The spring 19 is secured in the cam track means 7 using a tack 22 (see FIG. 1) mounted in an opening 23. To ensure that the cam follower 6 maintains correct engagement with the bottom of the cam track 14, a spring 24 is provided which is fixed in relation to the cam track means 7 using a tack which is integral with the protection plate and which is mounted in an opening 25.
FIG. 5 shows a plane view of a swinglebar intended for connecting the brake levers 4,4' to the cam follower 6. The swinglebar 5 is mounted pivotally about an axis 26. The two branches 27 of the swinglebar 5 are provided with several openings 28, in which the ends of the brake levers 4,4' and the cam follower 6, respectively, can be mounted. The choice of openings depends on the support framework length of the trolley. Thus it is possible to use the system in connection with support framework of trolleys 1 of varying lengths. It will also be possible to use the brake arrangement in connection with a very short trolley support framework (not shown) where a braking of the wheels is utilized at one end of the trolley only corresponding to the wheels 2 shown on the right hand side of FIG. 1.
FIGS. 6 and 7 illustrate two partial sections through the pivotal twin wheels. The wheels are mounted about an axle-shaft bolt 29 through bearings 30. The axle-shaft bolt 29 is mounted in a pivotally supported fork bracket 31. By means of a bearing 32, the fork bracket 31 is mounted pivotally about an axis 35 in relation to a bracket 33 which is firmly connected to the support framework 1. The bearing 32 is cast into the fork bracket 31 in order to achieve maximum strength of the construction. By use of a sealed bearing a substantially maintenance free and closed construction is achieved.
FIGS. 6 and 7 also show the brake block 12. The brake block 12 is constituted by a cranked element of which a first cylindrical part 34 extends concentrically about the substantially vertical axis 35 about which the wheels are pivotally supported. The other part 36 of the cranked element extends in a substantially vertical plane passing through the rotation axis 37 of the wheels. As clearly illustrated in FIG. 7, the vertical axis 35 is offset in relation to a vertical plane comprising the axis of rotation 37 of the wheels which is necessary in order to obtain good functioning of the pivotal wheels 2. The other part 36 of the brake block is constituted by two resilient compliant tabs 38 intended for engagement with the teeth 2' on the twin wheels.
The brake block 12 is set into position by the lever arm 11 where the tabs 38 are brought into engagement with the teeth 2' to define the brake condition. A spring 39 ensures that the tabs 38 are brought out of engagement with the teeth 2' when the action of the lever arm 11 on the first part 34 of the brake block 12 stops. Hereby a condition without braking of the wheels is achieved. Thus, with the illustrated embodiment of the brake block it becomes possible to bring the tabs 38 safely into engagement with the teeth 2' through a translatory displacement of the brake block. However, it should be noted that the brake block may also be constructed with tabs extending from the first part 34 of the brake block if the wheels are not pivotal as the axis of rotation 37 of the wheels may then be situated directly under the axis 35 of the first cylindrical part 34.
FIGS. 8-11 show that the brake pedal 3 is a two-component construction. Thus it comprises a first part 3A and a second part 3B. The part 3A is used only in a foot-operated brake pedal while the part 3B is always to be used. The part 3A comprises a recess 40 aligned with openings 41 in the part of 3B. Hereafter the two elements are connected by means of the shaft 9 mounted in the brackets 10 (not shown in FIG. 8-11). The part 3A comprises a corrugated portion 42 which the user depressed when activating or deactivating the brake. By this activation, the surface 43 of the part 3B will act on a substantially spherical portion 44 (see FIG. 12) of the lever arm 11. Thus the lever arm may be located in two different positions by tipping about an edge 45 which abuts the bottom of a recess 48 in which the lever arm 11 is positioned. In this one position the substantially spherical portion 44 will be moved upwards by the surface 43 and the other end 46 of the lever arm 11 will activate the brake block 12 in this position so as to be in the position where the tabs 38 are in engagement with the teeth 2'. In its other position, the other end 46 of the lever arm 11 will be moved upwardly due to the effect from the spring 39 and the tabs 38 are then brought out of engagement with the teeth 2' and due to the tipping about the edge 45 the spherical portion 44 is moved downwards. The other part 3B of the brake pedal is swung to its deactivated position due to the action of a tension spring 5'(see FIG. 1) which is mounted between a fixed position on the support framework and the swinglebar 5 and which pulls the swinglebar 5 which, via the brake levers 4,4', swings the other part 3B of the brake pedal to the deactivated position, whereby the spring 39 can displace the end 46 of the lever arm 11 upwards. The part 3B of the pedal is provided with an opening 47 to which the brake levers 4,4' can be attached in order to provide the interconnection between the brake pedals 3.
Each lever arm 11 is located as shown in FIG. 1 and, as mentioned above, in the recess 48 in the support framework 1. The recess 48 extends from a position overlapped by the brake pedal to a point in the immediate continuation of the vertical axis 35 passing through the cylindrical section 34 of the brake block 12. Thus the lever arms 11 are relatively simple to mount as they are simply placed loosely in their respective recesses 48 whereupon the brackets 33 are mounted on the support framework 1.
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In a wheel and brake device for a transportation vehicle with pivotal wheels, a particularly simple brake operation may be achieved by placing a brake activating structure at each end of the vehicle and connecting it to a brake lever. The device comprises only one pedal at opposite ends. The pedals are arranged to be activated in only one direction irrespective of whether a braking or a releasing operation is to be performed. Each pedal is connected to a swinglebar by brake levers, the swinglebar also being connected to a cam follower. The cam follower runs along a cam track defining two fixed resting positions for the cam follower. In one of the resting positions, tabs on a brake block will engage with teeth firmly connected to the wheels.
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BACKGROUND OF THE INVENTION
The present invention relates to the transmission of data, and more particularly to the transmission of data unobtrusively embedded in a video signal representing a television program in order to transmit additional information to a receiver of the television program, or to identify the originator of the television program.
A television program is generally broadcast live, or recorded for subsequent broadcasting or distribution to affiliates, licensees or the public on media such as video cassettes. These programs are usually copyrighted or otherwise proprietary to the originator. Unauthorized sale or broadcasting of these programs is difficult to prevent. It is frequently impractical to determine the source of the program that may have been used without permission. Additionally it may be desirable to transmit additional information along with the television program for use by affiliates and licensees.
In either event it would be beneficial to be able to include additional data in the video signal of the television program without interfering with the displayed picture as seen by a viewer. Methods to add information to a video signal without interfering with the viewable picture have concentrated on lines in the vertical interval. However, only a small number of lines are available for this purpose. Also these lines are removed by many pieces of video equipment and replaced with newly generated waveforms containing only synchronizing information. If the purpose of the information is to identify the source of the program, the lines containing additional information could intentionally be replaced so that the source could not be determined.
What is desired is an unobtrusive means for embedding data within the active video portion of a video signal.
SUMMARY OF THE INVENTION
Accordingly the present invention provides for unobtrusively embedding data in a video signal by adding a low level waveform to the video signal during the active video portion of the video signal. The low level waveform may be selected from a plurality of unique waveforms, such as a set of random noise waveforms that are unlikely to occur in a normal video signal, each of which represents a unique digital data word. The low level waveform to be embedded in the video signal has levels significantly below the noise level of the video signal. The low level waveform is detected by correlating the video signal with all of the unique waveforms, or with a desired one of the unique waveforms if a particular data word is sought. The video signal is multiplied by each waveform, or with the desired waveform, and the result is compared with a threshold value to determine a correlation coefficient for each waveform. The correlation coefficient that exceeds the threshold identifies the low level waveform embedded in the video signal. The detected low level waveform may then be converted into a digital word or identifier.
The objects, advantages and other novel features of the present invention are apparent from the following detailed description when read in conjunction with the appended claims and attached drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an encoder according to the present invention.
FIG. 2 is a block diagram of a decoder according to the present invention for detecting one specific low level waveform in a video signal.
FIGS. 3A and 3B are a block diagram of a decoder according to the present invention for detecting one of a plurality of low level waveforms in a video signal.
FIG. 4 is a block diagram of an alternate embodiment of the decoder according to the present invention for detecting one specific low level waveform in a video signal.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 an encoder has a video signal, Vin, input to a sync separator 10 and a combiner circuit 12. Horizontal, H, and vertical, V, sync pulses are extracted from the input video signal by the sync separator 10. The H pulses repeat at the video line rate and the V pulses repeat at the video field rate. The H pulses are input to a phase lock loop 14 that synchronizes a sampling frequency to the horizontal sync rate. A phase detector 16 receives the H pulses for comparison with derived H pulses to generate an error signal. The error signal is input via a low pass filter 18 to a voltage controlled oscillator (VCO) 20 having a nominal frequency equal to the sampling frequency. The error signal adjusts the sampling frequency to maintain synchronization with the H pulses from the input video signal.
The sampling frequency from the VCO 20 is input to a blanking counter 22 and an address counter 24. The blanking counter 22 outputs the derived H pulses that are fed back to the phase detector 16 to complete the phase lock loop 14. The blanking counter 22 also provides a blanking signal that is input to the address counter 24. The sampling frequency from the VCO 20 generates addresses from the address counter 24 that are input to a waveform generator 26 and to a terminal count detector 28. The waveform generator 26 has a waveform memory 30 that is addressed sequentially by the addresses from the address counter 24. The data in the memory 30, representing a low level waveform or a plurality of low level waveforms, may be loaded conventionally by a memory load system 34.
The blanking signal from the blanking counter 22 inhibits the address counter 24 from counting the sampling frequency during the inactive portion of the video material, i.e., during the horizontal retrace interval, so that the data is addressed from the memory 30 only during the active line intervals. To prevent fixed-pattern noise that may be detectable by an observer of the resulting television picture even when the waveform level is as low as one-sixth times the noise level of the input video signal, the length of the waveform is chosen so that the period of time before a portion of the waveform appears at or near a location where it previously appeared corresponds to many video frames.
The output from the address counter 24 is input to the terminal count detector 28 for comparison with a predetermined maximum count. The output of the terminal count detector 28 goes low when the terminal count is reached. The terminal signal from the terminal count detector 28 is input to an AND gate 35. Also input to the AND gate 35 is a signal that is output from a vertical sync counter 36. The vertical sync counter 36 is driven by the V pulses from the sync separator 10, and the output of this counter goes low after every n fields of the input video signal. The output of the AND gate 35 resets the address counter 24 after every complete waveform memory cycle and after every n video fields.
Where the purpose of the encoder is to merely add a specified low level waveform as an originator identifier to the input video signal, only one waveform exists within the waveform memory 30. However where information data is to be added to the input video signal, such data, Din, is input to a first-in/first-out (FIFO) buffer 38. Each data word is loaded as a low level waveform into the FIFO buffer 38 in response to an independent input clock signal. The output from the FIFO buffer 38 is input to some of the address lines of the waveform memory 30 as a block or waveform select address. The terminal signal from the terminal count detector 28 serves as an output clock for the FIFO buffer 38 so that the new data word from the buffer addresses the waveform memory 30 each time the terminal count is detected. The output from the address counter 24 provides the addresses to the waveform memory 30 for the selected block or low level waveform as described above. The waveform memory 30 contains in this case all the low level waveforms that may be added to the input video signal. The output from the FIFO buffer 38 determines which low level waveform is added to the input video signal during a data period, and the output from the address counter 24 determines which low level waveform sample is added at any instant in time during the data period. The output from the waveform memory 30 is converted to an analog signal having a level below the noise level of the input video signal by a digital-to-analog convertor 32 for addition to the input video signal by the combiner circuit 12.
To decode the data added to the input video signal a correlation technique is used. The input video signal, f v (t), is multiplied by each waveform, f i (t), where i is an integer from one to a predetermined maximum number of waveforms, N. The resulting products are integrated over a time interval, T, equal to the data period to determine a correlation coefficient, CE, for each low level waveform. One correlation coefficient equation that might be implemented is: ##EQU1## If a low level waveform is present and identical to f i (t), then it correlates well and the correlation coefficient CE i for that waveform is high. Since only one low level waveform is sent at a time, the correlation coefficients for all the other waveforms are low.
An alternative correlation coefficient equation is: ##EQU2##
In the detector circuit of FIG. 2 the video signal with the added data, or originator identifier, is input to an analog-to-digital convertor 42 and a sync separator 44. The output of the sync separator 44 is input to a phase lock loop 46 identical to that in the encoder of FIG. 1, having a phase detector 48, a low pass filter 50, a voltage controlled oscillator (VCO) 52 and a blanking counter 54. The VCO 52 provides the sampling frequency for the A/D convertor 42. Likewise the outputs of the VCO 52 and the blanking counter 54 are input to an address counter 56 that addresses a waveform memory 58 having the desired low level waveform loaded by a memory loader system 60 that corresponds to the originator identifier pattern in the pattern memory 30 of the encoder. The output of the address counter 56 also is input to a terminal count detector 62, the output of which is input to an AND gate 64 together with the output of a divider 66 clocked by the V pulses from the sync separator 44.
The outputs of the analog-to-digital converter 42 and the waveform memory 58 correspond to the two multiplicands of the above equations, and are multiplied together by a digital multiplier 68. The output of the multiplier 68 is input to an integrator 70 for integration over the specified time interval T. The resulting correlation coefficient is input to a comparator 72 together with a threshold correlation value. If the output of the comparator 72 is high, then the originator identifier low level waveform is contained in the video signal. Otherwise the specific identifier is not present.
Referring now to FIGS. 3A and 3B a decoder for decoding information data from the video signal is shown. As in the single identifier decoder of FIG. 2 the input video signal with added data is input to both an A/D convertor 42 and a sync separator 44. The H pulses from the sync separator 44 are input to the phase lock loop 46 that provides the sampling frequency for the A/D convertor 42 and for the address counter 56 from the VCO 52. The addresses from the address counter are input to the memory 58, loaded by the memory load system 60 with all the low level waveforms, and the terminal count detector 62. Now however there are N outputs from the memory 58, one for each stored waveform.
The individual waveforms from the memory 58 are input to the multiplier 68 having N individual multipliers 74, one for each pattern. The digitized input video from the A/D converter 42 is input to each of the individual multipliers 74 for combination with each of the waveforms. The outputs of the multipliers 74 are input to the integrator 70 having a channel for each waveform to produce an integrated output for each waveform/video combination. The outputs from the integrator 70 are input to the comparator 72 having a plurality of N individual comparators 80 for each waveform channel, and the outputs of the individual comparators are input to an encoder 82 that converts the N output lines from the comparator 72 into an m-bit digital word corresponding to the particular waveform detected in the video signal during that data period.
As shown in FIG. 3B each integrator 70 may be implemented by an accumulator 76 and a latch 78 connected in series. The outputs of the multipliers 68 are accumulated over a period of time T by the respective accumulators 76. The output of the accumulators 76 are stored in the respective latches 78 at the end of the period of time. The outputs of the latches 78 are then compared by the comparators 72 with the threshold correlation value. The terminal count signal from the terminal count detector 62 serves as a reset signal for the accumulators 76 and as a clock pulse to latch the outputs of the accumulators into the latches 78. The terminal count signal also is applied to the address counter 56 via an AND gate 88 to reset the address counter for the detection of the next data word in the video signal.
A field one synchronizer 84 receives the V pulses from the sync separator 44 and a field one signal from a field one detector 86, where the field one signal is one of the digital data words corresponding to one of the low level waveforms. The field one detector 86 has as an input the output of the N-line to m-line encoder 82 so that, when a field one identifier word is detected, the field one signal is generated. The field one signal is generated periodically during the generation of data, such as once every fifteen frames. If a field one signal is not detected when expected for a given number of intervals, then loss of data sync is determined by the field one synchronizer 84. The synchronizer 84 then provides a reset pulse to AND gate 88 for each V pulse, i.e., at the beginning of each video field, until a field one identifier is found and the field one signal generated. Once the field one signal is generated, the address counter 56 is reset by the terminal count detector 62, and the pulses from the field one detector 86 are redundant unless loss of sync is detected again.
For information data transmission the detector of FIGS. 3A and 3B detects data by testing for the presence of each low level waveform in every data period. For 256 possible distinguishable low level waveforms an eight-bit data word defines which waveform is detected. The duration of the data period is such that a low level waveform does not appear at or near the same place in the picture of the input video signal for several frames by selecting a duration that is not equal to an integral number of lines and by selecting the duration so an integral number of data periods is not equal to a small number of fields. For an input NTSC video signal the VCO sampling frequency may be twice the subcarrier frequency, 2f sc , with 376 samples per active video line producing 7050 samples per data period equal to 18.75 video lines. If there are 485 active lines in a frame, the address counters 24 and 56 are reset at a fixed location in the raster once every fifteen frames since fifteen frames contain 7275 active lines and 7275 is the smallest integer that is divisible by 18.75 and 485. Since one of 256 possible waveforms is transmitted in a data period, eight bits of input data are transmitted per waveform and 3104 bits are transmitted in fifteen frames equivalent to an approximately six kbaud data rate. The waveform is added well below the noise level of the video signal, such as one-third to one-half times the noise level, so that it is not visible to an observer of the displayed video signal.
FIG. 4 represents an alternative embodiment for a decoder implementing the second of the two equations for determining the correlation coefficient for an identifier waveform. Again the detector generates the same low level identifier waveform as that of the encoder of FIG. 1 in the same manner. The identifier waveform from the waveform memory 58 is converted to analog by digital-to-analog converter 90, and then mixed with the input video signal by multiplier 92. The output of the multiplier 92 is input to a low pass filter 94, the output of which indicates whether the identifier waveform is present in the input video signal. The time constant of the low pass filter 94 is equal to several frames of the video input signal.
Thus the present invention provides an unobtrusive method of embedding data in a video signal by adding a unique waveform, corresponding to a digital word or originator identifier, having a level below the noise level of the video signal. The waveform is detected using a correlation technique by which the video signal with the added data is multiplied by each possible waveform, the output digital word or originator identifier corresponding to the waveform having a high correlation coefficient.
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Data is embedded in a video signal by adding a low level wavefrom to the video signal, the low level wave form having a level below the noise level of the video signal and corresponding to the data. To detect the data embedded in the video signal the video signal is correlated with the low level waveform corresponding to the data to produce a correlation coefficient. A high correlation coefficient indicates the presence of a low level waveform which is converted into the data. The low level waveform extends over many video lines such that it does not occur at or near the same location within a video frame for many video frames to avoid fixed-pattern noise anomalies that may be detected by a viewer of the television picture.
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This invention relates to an electrical cable and more particularly, to a cable for use in an extremely adverse environment, such as those encountered in oil wells.
BACKGROUND OF THE INVENTION
Electrical cables which are used in oil wells must be able to survive and perform satisfactorily under extremely adverse conditions of heat and mechanical stress. Ambient temperatures in wells are often high and the I 2 R losses in the cable itself add to the ambient heat. The service life of a cable is known to be inversely related to the temperature at which it operates. Thus, it is important to be able to remove heat from the cable while it is in its operating environment.
Cables are subjected to mechanical stresses in several ways. It is common practice to attach cables to oil pump pipes to be lowered into a well using bands which can, and do, crush the cables, seriously degrading the effectiveness of the cable insulation and strength. The cables are also subjected to axial tension and lateral impact during use.
It is therefore conventional to provide such cables with external metal armor and to enclose the individual conductors within layers of materials chosen to enhance the insulation and strength characteristics of the cable, but such measures are sometimes not adequate to provide the necessary protection.
An additional problem arises as a result of down-hole pressures, which can be in the hundreds or thousands of pounds per square inch, to which the cables are subjected. Typically, the insulation surrounding the conductors in a cable contains micropores into which gas is forced at these high pressures over a period of time. Then, when the cable is rather quickly extracted from the wall, there is not sufficient time for the intrapore pressure to bleed off. As a result, the insulation tends to expand like a balloon and can rupture, rendering the cable useless thereafter.
In U.S. Pat. No. 4,409,431 in which the assignee is the same as the assignee of the instant invention, there is described a cable structure which is particularly suitable for use in such extremely adverse environments. The structure protects the cable against compressive forces and provides for the dissipation of heat from the cable which is an important feature in high temperature operating environments, for reasons discussed therein.
As described in said copending application, the cable protective structure includes one or more elongated support members which conform to, and extend parallel and adjacent an insulated conductor comprising the cable. The members are rigid in cross-section to resist compressive forces which would otherwise be borne by the cable conductors. For applications requiring the cable to undergo long-radius bends in service, the elongated support may be formed with a row of spaced-apart slots which extend perpendicularly from the one edge of the support member into its body to reduce the cross-sectional rigidity of the member in the slotted areas so as to provide flexibility in the support to large-radius bending about its longitudinal axis.
For certain service applications, it may be preferred that the electrical insulating jacket on a cable conductor not be in direct contact with the slot openings. This is because the slot openings in the support member may allow highly corrosive materials to gain access to the jacket composition by flowing inwardly through the slots. In addition, the corners formed by the slots may cut into or abrade the underlying cable jacket upon repeated bending of the cable.
BRIEF DESCRIPTION OF THE INVENTION
An object of the present invention is to provide a cable protective structure which includes an elongated, bendable support member for protecting an underlying layer of conductor insulation from compressive forces and abrasion caused by bending of the member.
Another object of this invention is to provide an elongated cable protective structure which is a composite of an outer bendable portion formed of a plurality of interconnected sections of rigid cross-section for protecting an underlying conductor from compressive forces and an inner element for protecting the conductor against abrading contact with the compression-resisting sections.
Still another object of this invention is to provide an elongated, bendable cable protective structure which is comprised of a composite of two parts; an outer channel of rigid cross-section for protecting internal cable conductors against transversely-applied compressive forces and adapted to bend about its longitudinal axis, and an inner liner which is bendable with the outer channel for protecting the insulation on the conductors from abrasion and/or adverse chemicals or environments.
Yet another object is to provide a composite cable protective structure in accordance with the foregoing objects, for use in down-hole oil wells which is made thermally conductive to dissipate heat received by the cable in such environments.
Still yet another object of this invention is to provide an electrical cable protective structure housed within the protective jacket of the cable which is made of an assemblage of two components to simplify the manufacture of the protective structure.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a partial perspective sectional view of a length of cable constructed in accordance with this invention, illustrating an end portion with its outer protective jacket removed.
FIG. 2 is a side elevational view of the one end portion of the cable of FIG. 1 as viewed in the direction of arrow 2 of FIG. 1.
FIG. 3 is a sectional end view of a compression-resisting channel member for use in the instant cable, taken along section line 3--3 of FIG. 2.
FIG. 4 is a sectional end view of a liner component for the interior of the compression-resisting member of FIG. 3.
FIG. 5 is an end sectional view of a composite compression-resisting member mounted on an insulated cable conductor taken along section line 5--5 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates one embodiment of a cable constructed in accordance with the present invention which is particularly suitable for down-hole or oil well applications. The cable 10 illustrated therein includes an exterior metal protective jacket 11 which surrounds and encloses a plurality of individually insulated conductors 12, 13 and 14. For down-hole applications, the conductors are arranged so that the central axes of the conductors lie parallel and in essentially the same plane providing the cable with a preferred flat shape.
The jacket 11 is typically formed of metal corrugations wrapped about the conductors 12, 13 and 14 in helical fashion. The juxtaposed conductors are of considerable length, as needed, it being understood that only a very short length of the cable is illustrated in FIG. 1. Interposed between the insulated conductors are four support members 15, 16, 17 and 18, each of the support members being elongated and extending parallel to the conductors.
The support members 15, 16, 17 and 18 are made of a material which is substantially rigid in cross-section and which is selected to have good thermal conductivity properties; specifically, a thermal conductivity which is at least greater than the thermal conductivity of the conductor insulation. Fiber-filled carbon compositions are suitable for this purpose, and also exhibit good compression resistance. Metals such as steel and aluminum are also suitable for this purpose, as are metal-filled curable polymeric materials.
A channel 20 for each of the support members 15, 16, 17 and 18 may be punched from a single, continuous strip of U-shape channel material and hence, each length of channel 20 will be of substantially identical cross-sectional size and shape. Such being the case, a description of the channel 20 for one support member, namely member 15, will suffice to also describe its nature and usage in counterpart support members 16, 17 and 18.
The channel 20 is essentially of U cross-sectional shape formed by upper and lower legs 21 and 22, respectively, which are substantially flat, parallel and horizontal as viewed in FIG. 2 so that they conform to the respective upper and lower flat surfaces of the metallic jacket 11. The lateral legs of the support members are joined by a rigid, vertical leg 23 which is slightly longer than the overall diameter of the conductor and its covering layer or layers of insulation. As will be seen, the cross-sectional shape of the support is that of a substantially U-shaped channel with the legs 21 and 22 extending approximately to the center of the adjacent conductor which faces the U of the channel. Hence, the legs 21 and 22 extend from the joining leg 23 to each side of this conductor a distance which is about equal to the maximum radius of the conductor plus its insulation covering. Crushing forces applied to the cable jacket 11, especially in directions perpendicular to the longitudinal axis of the cable 10, will be resisted by the channels 20 which are rigid in cross-section and damage to the conductor insulation by such forces will thereby be prevented or at least minimized. Thus, when the cable is attached to an element such as a well pipe or oil recovery motor by bands or straps, a situation which often causes crushing of a cable, the band engages the outside of jacket 11 and the rigid support members 15, 16, 17 and 18 prevent damage from being done.
The channels 20 for the support members 15, 16, 17 and 18, while quite rigid and resistive to compression in directions perpendicular to the longitudinal axis of the cable 10, should also have a degree of bidirectional flexibility and resilience which can permit the cable to undergo long-radius bends as necessary when installing the cable in a service location. This can be provided by a first row of slots 30 extending inwardly through each of the channel legs 21 and perpendicularly through the joining leg 23 and terminating approximately at the bend where the leg 23 joins the opposite leg 22. The slots 30 are substantially uniformly spaced apart in the longitudinal direction of the channel and thereby divide the channel 20 into a succession of individual, flexibly interconnected channel segments. Longitudinally and alternately spaced between slots 30 is a second and opposite row of slots 31 which extend perpendicularly into the body of each channel 20 from leg 22 to the bend where the leg 21 meets the leg 23. Slots 31 are also substantially uniformly apart in the longitudinal direction, and lie approximately midway between slots 30. Thus, the slots 30 and 31 extend inwardly alternately from the legs 21 and 22, respectively, and impart greater bidirectional flexibility in the channels 20 in the major plane of cable bending; that is, in a plane perpendicular to the plane passing through the centers of the juxtaposed cable conductors 12, 13 and 14. When installed in a cable, the resulting channel structure 20 of alternately, flexibly interconnected channel segments would be similar in appearance to that shown in FIG. 1.
Although the slots provide channel flexibility, the sharp edges formed in the channels 20 by the slots might abrade the electrical insulation on the cable conductors 12, 13 and 14 which are at least partially surrounded by the channels 20 of the support members 15, 16, 17 and 18 with repeated bending of these members. As best seen in FIGS. 1 and 5, each of the conductors 12, 13 and 14, which may be stranded or solid metallic conductors, are covered by one or more concentric layers or coatings of suitable electrical insulation; two such layers being shown and designated 34 and 35, respectively. These insulating coatings typically are composed of plastic or rubber components which are relatively soft and therefore may have the surfaces thereof cut or abraded by rubbing or other direct contact with harder surfaces. Any such cutting or abrasion of the conductor insulation may seriously degrade its coating and insulating characteristics.
The slots 30 and 31 cut into the channels 20 may result in sharp edges, burrs and corners being formed on the inside of the channels 20 which might abrade the softer insulating layer 35 placed in immediate contact with a channel 20, especially if the channel is formed from steel or aluminum stock.
To prevent such abrasion, an elongated liner is inserted into the U formed by channel 20. The liners, one of which is designated by the numeral 40 in FIGS. 4 and 5, have substantially flat, opposite surfaces 43 and 44, respectively, abutting and coextensive with the inner surfaces of legs 21 and 23, FIGS. 1 and 5. A semi-circular edge surface 45 is formed on the liner to conform to the cylindrical, outermost insulating layer 35. Each liner 40 is made sufficiently continuous to bridge the inner corners and edges formed by the slots 30 and 31, thereby spacing these edges from direct contact with the insulation on the underlying conductor core.
The protective liners 40 are preferably somewhat flexible so as to bend through arcs simultaneously with its overlying channel 20 in directions substantially perpendicular to the major bending plane or longitudinal axis of the cable 10. For oil well applications, the liners 40 are preferably composed of a material having good thermal conductivity to dissipate the heat applied to the cable 10 in such environments. The liner material should be relatively smooth to slide on the outermost insulating jacket 35, especially during bending of the latter. A suitable metallic material for the liners is lead, which has a smooth surface for facilitating sliding upon resilient layers of insulation and yet provides good thermal conductivity. Other suitable metallic or nonmetallic materials may also be used for the liners. The liners also afford a measure of protection to the insulation of the conductors against contact with, and possible attack by, insulation-degrading and corrosive chemicals. The central cable conductor 13, FIG. 1, is especially protected by oppositely facing, and the nearly adjoining edges of the concave surfaces 45 of the two liners which are respectively embodied in a pair of oppositely facing support members 16 and 17.
By forming each of the support members 15, 16, 17 and 18 as a composite of a channel 20 and a liner component 40 which can be inserted into the channel 20, the manufacture of the composite support members is facilitated. As is the case with the channels 20, the individual liners 40 can be manufactured by cutting the requisite lengths from a longer, continuous length of suitably sized and shaped strip of liner material.
The liners 40 may be fixedly mounted in their respective channels 20 by merely dimpling, semi-piercing or coining inwardly small surface areas on the opposite legs 21 and 22 of the channels 20 to form inwardly projecting protuberances or barbs 46. The opposing protuberances 46 cooperate to grip therebetween the upper and lower surfaces 43 and 44 of the liners 40 forcibly pressed into associated channel members with their concave surfaces 45 facing the same direction as that of the interior of the channel U.
While one advantageous embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
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Disclosed is a flat, electrical cable for use in extremely adverse environments, such as found in oil wells, comprising a plurality of conductors individually sheathed in insulation. The cable includes an elongated, compression-resisting member positioned adjacent an insulated conductor, the member being slotted laterally to impart a degree of bending thereto. A bendable liner is mounted between the member and the insulation sheath of the adjacent conductor to bridge the slots and thereby protect adjacent insulation from abrasion by edges formed on the member by the slots during bending.
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TECHNICAL FIELD
The technical field of this invention is methods for cleaning and maintaining electrodes used in electroplating apparatus used in the electroplating of metals onto semiconductor workpieces.
BACKGROUND OF THE INVENTION
In the production of semiconductor wafers and other semiconductor articles it is necessary to plate metals onto the semiconductor surface to provide conductive areas which transfer electrical current. There are two primary types of plating layers formed on the wafer or other semiconductor workpiece. One is a blanket layer used to provide a metallic layer which covers large areas of the wafer. The other is a patterned layer which is discontinuous and provides various localized areas that form electrically conductive paths within the layer and to adjacent layers of the wafer or other device being formed.
The plating of copper onto semiconductor articles has in particular proven to be a great technical challenge and at this time has not achieved commercial reality due to practical problems of forming copper layers on semiconductor devices in a reliable and cost efficient manner.
In the electroplating of copper, aluminum, tin, nickel, and other metals there is a reoccurring problem of buildup of the metal being plated on the electrodes. In typical processes the anode is present in the plating bath and the cathode is connected to the wafer or other semiconductor article being plated. Deposits of the plating metal occur not only on the wafer but also at the cathodes. When these deposits of plating metal become substantial, then they must be removed. Removal is needed to prevent unintended attachment of the electrodes to the wafer being plated, and to prevent small particles of plating metal from breaking free and lodging on the wafer in a local which results in a defect.
Under prior knowledge it has been it has been necessary to remove the deposits from the cathodes on a frequent basis using a manual maintenance procedure. The prior techniques have required manual removal of the cathodes from the processing equipment with associated cleaning and reinstallation back into the processing equipment. Such maintenance requirements have a very derogatory effect on production throughput because the machine is shut down and service is then performed. Even if the maintenance allows installation of new or substitute electrodes, the down-time is substantial and a significant economic loss for the semiconductor device manufacturer.
Thus, there is a need in the art for improved techniques, apparatus, and maintenance procedures for removing accumulated plating deposits from the electrodes of semiconductor plating systems.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described below with reference to the accompanying drawings, which are briefly described below.
FIG. 1 is an environmental view of the semiconductor processing head of the present invention showing two processing heads in a processing station, one in a deployed, “closed” or “processing” position, and one in an “open” or “receive wafer” position.
FIG. 2 is an isometric view of the semiconductor processing head of the present invention.
FIG. 3 is a side elevation view of the processing head of the present invention showing the head in a “receive wafer” position.
FIG. 4 is a side elevation view of the processing head of FIG. 3 showing the head in a rotated position ready to lower the wafer into the processing station.
FIG. 5 is a side elevation view of the processing head of FIG. 3 showing the head operator pivoted to deploy the processing head and wafer into the bowl of the processing station.
FIG. 6 is a schematic front elevation view of the processing head indicating the portions detailed in FIGS. 7 and 8.
FIG. 7 is a front elevation sectional view of the left half of the processing head of the apparatus of the present invention also showing a first embodiment of the wafer holding fingers.
FIG. 8 is a front elevation sectional view of the left half of the processing head of the apparatus of the present invention also showing a first embodiment of the wafer holding fingers.
FIG. 9 is an isometric view of the operator base and operator arm of the apparatus of the present invention with the protective cover removed.
FIG. 10 is a right side elevation view of the operator arm of the present invention showing the processing head pivot drive mechanism.
FIG. 11 is a left side elevation view of the operator arm of the present invention showing the operator arm drive mechanism.
FIG. 12 is schematic plan view of the operator arm indicating the portions detailed in FIGS. 13 and 14.
FIG. 13 is a partial sectional plan view of the right side of the operator arm showing the processing head drive mechanism.
FIG. 14 is a partial sectional plan view of the left side of the operator arm showing the operator arm drive mechanism.
FIG. 15 is a side elevational view of a semiconductor workpiece holder constructed according to a preferred aspect of the invention.
FIG. 16 is a front sectional view of the FIG. 1 semiconductor workpiece holder.
FIG. 17 is a top plan view of a rotor which is constructed in accordance with a preferred aspect of this invention, and which is taken along line 3 — 3 in FIG. 16 .
FIG. 18 is an isolated side sectional view of a finger assembly constructed in accordance with a preferred aspect of the invention and which is configured for mounting upon the FIG. 17 rotor.
FIG. 19 is a side elevational view of the finger assembly of FIG. 18 .
FIG. 20 is a fragmentary cross-sectional enlarged view of a finger assembly and associated rotor structure.
FIG. 21 is a view taken along line 7 — 7 in FIG. 4 and shows a portion of the preferred finger assembly moving between an engaged and disengaged position.
FIG. 22 is a view of a finger tip of the preferred finger assembly and shows an electrode tip in a retracted or disengaged position (solid lines) and an engaged position (phantom lines) against a semiconductor workpiece.
FIG. 23 is a sectional view showing a second embodiment semiconductor processing station having a workpiece support assembly and a plating station bowl assembly.
FIG. 24 is an enlarged sectional view similar to FIG. 23 showing only portions of the workpiece support.
FIG. 25 is an exploded perspective view of portions of the workpiece support shown in FIG. 24 .
FIG. 26 is an exploded perspective view of portions of a rotor assembly forming part of the workpiece support shown in FIG. 24 .
FIG. 27 is a perspective view showing an interior face of the rotor assembly.
FIG. 28 is a perspective view showing the interior face of the rotor assembly with a wafer supported thereon.
FIG. 29 is an enlarged perspective view showing an actuator transmission which mounts on the rotor assembly and controls motion of workpiece-engaging fingers.
FIG. 30 is an exploded perspective assembly view of the actuator transmission shown in FIG. 29 .
FIG. 31 is a longitudinal sectional view of the actuator transmission shown in FIG. 29 .
FIG. 32 is a longitudinal sectional view of one preferred form of electrode assembly which can be used in the second embodiment processing system.
FIG. 33 is a longitudinal sectional view of one preferred form of electrode assembly which can be used in the second embodiment processing system.
FIG. 34 is a longitudinal sectional view of one preferred form of electrode assembly which can be used in the second embodiment processing system.
FIG. 35 is a longitudinal sectional view of one preferred form of electrode assembly which can be used in the second embodiment processing system.
FIG. 36 is a longitudinal sectional view of one preferred form of electrode assembly which can be used in the second embodiment processing system.
FIG. 37 is a sectional view showing an enlarged distal tip portion of a further electrode before being pre-conditioned in accordance with another aspect of the invention.
FIG. 38 is a sectional view showing the enlarge distal tip portion of the previous figure after being pre-conditioned.
FIG. 39 is a longitudinal sectional view of one preferred form of electrode assembly which can be used in the second embodiment processing system.
FIG. 40 is a sectional view showing the electrode assembly of FIG. 39 in position ready to engage a semiconductor workpiece.
FIG. 41 is a sectional view showing the electrode assembly of FIG. 39 in an engaged position with a semiconductor workpiece.
FIG. 42 is a longitudinal sectional view showing the plating station bowl shown in FIG. 23 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
TABLE 1
Listing of Subsections of Detailed Description and
Pertinent Items with Reference Numerals and Page Numbers
Workpiece Support
11
semiconductor processing machine 400
11
workpiece supports 401
11
Workpiece support 402
11
Workpiece support 403
11
semiconductor manufacturing chamber 404
11
beam emitter 81
11
operator base 405
12
processing head 406
12
operator arm 407
12
wafer holder 408
12
fingers 409
12
Workpiece holder 408
12
workpiece spin axis 410
12
process pivot axis 411
12
operator pivot axis 412
12
workpiece W
12
fingertips 414
12
processing bowl 417
13
left and right forks 418 and 419
14
Operator Base
14
operator base back portion 420
14
operator base left yoke arm 421
14
operator base right yoke arm 422
14
yoke arm fasteners 423
14
operator arm bearings 424
15
operator arm 425
15
Operator Arm
15
process arm rear cavity 426
15
lift motor 452
15
rotate motor 428
15
processing head left pivot shaft 429
16
processing head right pivot shaft 430
16
Operator Arm-Processing Head Rotate
Mechanism
16
Processing head rotate mechanism 431
16
rotate shaft 432
16
securing collar 433
16
rotate motor support 434
17
rotate encoder 435
17
rotate pulley inboard bearing 436
17
rotate belt 437
18
processing head pulley 438
18
rotate belt tensioner 439
18
tensioner hub 468
19
processing head shaft bearing 440
19
processing head rotate bearing 469
19
processing head shaft bearing 441
19
cable brackets 442 and 443
19
rotate overtravel protect 444
20
rotate flag 447
20
Rotate optical switches 445 and 446
20
Operator Arm-Lift Mechanism
21
operator arm lift mechanism 448
21
lift motor shaft 454
21
lift gear drive 453
22
lift drive shaft 456
22
lift bushing 449
22
anchor plate 458
22
anchor fasteners 457
22
Lift bearing 450
22
lift bearing support 460
22
operator arm frame 461
22
lift anchor 451
22
lift overtravel protect 462
23
lift optical switch low 463
23
lift optical switch high 464
23
lift flag 465
23
lift motor encoder 455
24
lift motor 452
24
slotted lift flag mounting slots 467
24
lift flag fasteners 466
24
Processing Head
24
processing head housing 470
24
circumferential grooves 471
25
rotate shaft openings 474 and 475
25
left and right processing head mounts 472
25
processing head door 476
25
processing head void 477
25
Processing Head Spin Motor
26
workpiece holder 478
26
spin axis 479
26
spin motor 480
26
top motor housing 481
26
spin motor shaft 483
27
workpiece holder rotor 484
27
rotor hub 485
27
rotor hub recess 486
27
workpiece shaft snap-ring 488
27
rotor recess groove 489
27
spin encoder 498
28
optical tachometer 499
28
Processing Head Finger Actuators
30
Pneumatic piston 502
30
actuator spring 505
30
cavity end cap 507
30
retaining ring 508
31
pneumatic inlet 503
31
pneumatic supply line 504
31
actuator plate 509
31
actuator plate connect screw 510
31
Wave springs 529
31
bushing 512
31
pneumatic piston recess 511
31
finger actuator contacts 513
32
Processing Head Workpiece Holder
32
finger actuator lever 514
32
finger stem 515
32
finger diaphragm 519
32
workpiece holder rotor 484
32
finger opening 521
32
rotor diaphragm lip 523
33
finger spring 520
33
finger actuator tab 522
33
finger collar or nut 517
33
shoulder 518
33
finger actuator mechanism 500
33
cavity 501
34
Semiconductor Workpiece Holder -
34
Electroplating Embodiment
semiconductor workpiece holder 810
34
bottom half or bowl 811
34
Processing Head and Processing Head
35
Operator
workpiece support 812
35
spin head assembly 814
35
lift/rotate assembly 816
35
motor 818
36
rotor 820
36
rotor spin axis 822
36
finger assembly 824
36
actuator 825
36
rotor center piece 826
37
spokes 828
37
rotor perimeter piece 830
37
Finger Assembly
38
finger assembly frame 832
38
angled slot 832a
39
flnger assembly frame outer flange 834
39
inner drive plate portion 836
39
Finger Assembly Drive System
39
bearing 838
39
collet 840
39
bearing receptacle 839
39
spring 842
40
spring seat 844
40
Finger Assembly Electrical System
40
pin connector 846
40
finger 848
40
nut 850
41
anti-rotation pin 852
41
finger tip 854
41
electrode contact 858
41
Finger Assembly Drive System Interface
42
finger actuator
42
actuation ring 863
42
first movement path axis 864
43
secondary linkage 865
43
link arm 867
43
actuator torque ring 869
43
pneumatic operator 871
43
Engaged and Disengaged Positions
44
arrow A
44
workpiece standoff 865
45
bend 866
45
Finger Assembly Seal
46
seal 868
46
rim portion 870
46
Methods and Operation
47
Second Embodiment Processing Station -
53
Generally
second semiconductor processing station 900
53
workpiece support assembly 901
53
processing bowl 917
53
processing or manufacturing chamber 904
54
Workpiece Support Generally
54
rotor assembly 984
54
Workpiece Support Head Operator
54
processing head 906
54
head operator 907
54
upper portion 908
54
head connection shaft 909
54
horizontal pivot axis 910
54
Workpiece Support Main Part
55
processing head housing 970
55
processing head frame 982
55
door plate 983
55
door ring member 984
55
frame-pivot shaft connection 985
55
pivot shaft connection base 935
55
first housing part 971
56
housing cap 972
56
main part mechanism chamber 973
56
peripheral groove 986
56
inflatable door seal 987
56
annular rotor receiving groove 988
56
Workpiece Support Rotor Drive
57
workpiece spin motor 980
57
stator armatures 916
57
motor shaft 918
57
bottom motor bearing 921
57
bottom motor housing 922
57
top motor housing 923
57
top motor bearing 927
57
fasteners 924
57
frame extensions 925
57
top frame piece 926
58
Workpiece Support Rotor Assembly
58
rotor assembly 930
58
rotor shaft 931
58
rotor shaft hub 932
58
shaft hub receptacle 933
58
inner rotor part 934
58
inner rotor part hub 935
58
peripheral band 936
58
snap-ring 937
58
transmission receptacles 937
58
fasteners 941
59
rotor face panel 943
59
apertures 787
59
support standoffs 721
59
workpiece peripheral guide pins 722
59
reinforcing ribs 942
59
side wall 944
59
finger passageways 949
60
rotor shaft mounting nut 888
60
angular position encoder 498
60
Workpiece Detection Subsystem
61
mounting 738
61
detector 739
61
workpiece detector windows 741
62
Workpiece Support Finger Actuator
63
finger pivot axes 953
64
workpiece standoff supports 721
64
finger actuator transmission 960
65
finger head mounting receptacle 954
65
locking pin groove 955
65
finger mounting pin 956
65
transmission base 961
65
mounting cutout 962
65
transmission shaft 963
65
shaft channel or groove 964
66
shaft camming control member 965
66
ball 966
66
ball support fastener 967
66
interior shaft passageway 968
66
spring retainer 969
66
finger mounting spring 938
66
set screw 939
66
transmission head 656
66
bearing 657
66
head pieces 658 and 659
67
head fasteners 660
67
head guide rods 661
67
two guide passageways 662
67
head bias springs 664
67
shaft seal 667
67
transmission head depression ring 683
67
operator output connection ring 684
67
pneumatic actuator engines 691
67
pneumatic manifolds 692
67
Electrode Fingers With Submerged
68
Conductive Current Transfer Areas
finger assembly 631
68
finger shaft 632
68
finger head 633
68
locking pin 956
68
dielectric sheathing 634 and 635
68
contact head 636
68
contact face 637
68
submersion line 639
69
first electrically conductive segment 642
69
second electrically conductive segment 643
69
third electrically conductive segment 644
69
third dielectric segment 653
70
third dielectric sheath 654
70
distal contact insert part 655
70
insert receptacle 616
70
contact face 617
70
electrode finger 979
71
dielectric sheath 621
71
Electrode Fingers With Dielectric Sheaths
72
Covering Submerged Areas
electrode finger 681
72
dielectric sheath 682
72
contact insert side walls 619
72
insert contact part or tip 655
73
Pre-Conditioning of Electrode Contact Faces
74
electrode 614
74
distal exposed surface 615
74
dielectric sheath 616
74
Methods Using Workpiece-Engaging
76
Electrode Assembly With Sealing Boot
electrode finger 583
76
electrode shaft 584
76
head 633
76
cover or boot 585
76
distal contact lip 586
76
contact insert part 655
76
skirt portion 587
76
electrode shaft distal end surface 588
76
contact face 617
76
substrate or other subjacent layer 561
77
thin metallic seed layer 562
77
via or other opening 563
77
photoresist layer 564
77
Plating Bowl Assembly
80
electroplating bowl assembly 303
80
process bowl or plating vessel 316
80
outer bowl side wall 617
80
bowl bottom 319
80
bowl rim assembly 314
80
cup assembly 320
80
fluid cup portion 321
80
cup side 322
80
cup bottom 323
80
flutes 372
80
cup main joint 387
80
riser tube 361
80
fitting 362
81
fluid inlet line 325
81
bowl bottom opening 327
81
cup fluid inlet openings 324
81
overflow chamber 345
81
level detectors 351 and 352
81
diffuser height adjustment mechanisms 386
82
mounting fasteners 389
82
Plating Anode Shield
82
anode shield 393
82
anode shield fasteners 394
82
Workpiece Support
Turning now to FIG. 1, a semiconductor processing machine 400 having two workpiece supports 401 is shown. Workpiece support 402 is shown in a “open” or “receive wafer” position in order to receive a workpiece or semiconductor wafer for further processing. Workpiece support 403 is shown in a “closed” or “deployed” position wherein the semiconductor wafer has been received by the workpiece support and is being exposed to the semiconductor manufacturing process in the semiconductor manufacturing chamber 404 . FIG. 1 also shows an optional beam emitter 81 for emitting a laser beam detected by robotic wafer conveyors to indicate position of the unit.
Turning now to FIG. 2, an enlarged view of the workpiece support 401 is shown. Workpiece support 401 advantageously includes operator base 405 , a processing head 406 , and an operator arm 407 . Processing head 406 preferably includes workpiece holder or wafer holder 408 and which further includes fingers 409 for securely holding the workpiece during further process and manufacturing steps. Workpiece holder 408 more preferably spins about workpiece spin axis 410 .
The processing head is advantageously rotatable about processing head pivot axis or, more briefly termed, process pivot axis 411 . In this manner, a workpiece (not shown) may be disposed between and grasped by the fingers 409 , at which point the processing head is preferably rotated about process head pivot axis 411 to place the workpiece in a position to be exposed to the manufacturing process.
In the preferred embodiment, operator arm 407 may be pivoted about operator pivot axis 412 . In this manner, the workpiece is advantageously lowered into the process bowl (not shown) to accomplish a step in the manufacture of the semiconductor wafer.
Turning now to FIGS. 3-5, the sequence of placing a workpiece on the workpiece support and exposing the workpiece to the semiconductor manufacturing process is shown. In FIG. 3, a workpiece W is shown as being held in place by fingertips 414 of fingers 409 . Workpiece W is grasped by fingertips 414 after being placed in position by robot or other means.
Once the workpiece W has been securely engaged by fingertips 414 , processing head 406 can be rotated about process head pivot axis 411 as shown in FIG. 4 . Process head 406 is preferably rotated about axis 411 until workpiece W is at a desired angle, such as approximately horizontal. The operator arm 407 is pivoted about operator arm pivot axis 412 in a manner so as to coordinate the angular position of processing head 406 . In the closed position, the processing head is placed against the rim of bowl 416 and the workpiece W is essentially in a horizontal plane. Once the workpiece W has been secured in this position, any of a series of various semiconductor manufacturing process steps may be applied to the workpiece as it is exposed in the processing bowl 417 .
Since the processing head 406 is engaged by the operator arm 407 on the left and right side by the preferably horizontal axis 411 connecting the pivot points of processing head 406 , a high degree of stability about the horizontal plane is obtained. Further, since the operator arm 407 is likewise connected to the operator base 405 at left and right sides along the essentially horizontal line 412 connecting the pivot points of the operator arm, the workpiece support forms a structure having high rigidity in the horizontal plane parallel to and defined by axes 411 and 412 . Finally, since operator base 405 is securely attached to the semiconductor process machine 400 , rigidity about the spin axis 410 is also achieved.
Similarly, since processing head 406 is nested within the fork or yoke shaped operator arm 407 having left and right forks 418 and 419 , respectively, as shown in FIG. 2, motion due to cantilevering of the processing head is reduced as a result of the reduced moment arm defined by the line connecting pivot axes 411 and 412 .
In a typical semiconductor manufacturing process, the workpiece holder 408 will rotate the workpiece, having the process head 406 secured at two points, that is, at the left and right forks 418 and 419 , respectively, the vibration induced by the rotation of the workpiece holder 408 will be significantly reduced along the axis 411 .
A more complete description of the components of the present invention and their operation and interrelation follows.
Operator Base
Turning now to FIG. 9, operator base 405 is shown. The present invention advantageously includes an operator base 405 which forms an essentially yoke-shaped base having an operator base back portion 420 , an operator base left yoke arm 421 , and an operator base right yoke arm 422 . Yoke arms 421 and 422 are securely connected to the base of the yoke 420 . In the preferred embodiment, the yoke arms are secured to the yoke base by the yoke arm fasteners 423 . The yoke arm base in turn is advantageously connected to the semiconductor process machine 400 as shown in FIG. 1 .
The upper portions of the yoke arm advantageously include receptacles for housing the operator arm bearings 424 which are used to support the pivot shafts of the operator arm 425 , described more fully below.
Operator Arm
Still viewing FIG. 9, the present invention advantageously includes an operator arm 407 . As described previously, operator arm 407 preferably pivots about the operator arm pivot axis 412 which connects the center line defined by the centers of operator arm pivot bearings 424 .
Operator arm or pivot arm 407 is advantageously constructed in such a manner to reduce mass cantilevered about operator arm pivot axis 412 . This allows for quicker and more accurate positioning of the pivot arm as it is moved about pivot arm axis 412 .
The left fork of the pivot arm 418 , shown more clearly in FIG. 11, houses the mechanism for causing the pivot arm to lift or rotate about pivot arm pivot axis 412 . Pivot arm right fork 419 , shown more clearly in FIG. 10, houses the mechanism for causing the processing head 406 (not shown) to rotate about the process head pivot axis 411 .
The process arm rear cavity 426 , shown in FIG. 9, houses the lift motor 452 for causing the operator arm 407 to rotate about pivot arm axis 412 . Process arm rear cavity 426 also houses rotate motor 428 which is used to cause the processing head 406 to rotate about the processing head pivot axis 411 . The rotate motor 428 may more generally be described as a processing head pivot or rotate drive. Processing head 406 is mounted to operator arm 407 at processing head left pivot shaft 429 and processing head right pivot shaft 430 .
Operator arm 407 is securely attached to left yoke arm 421 and right yoke arm 422 by operator arm pivot shafts 425 and operator arm pivot bearings 424 , the right of which such bearing shaft and bearings are shown in FIG. 9 .
Operator Arm-Processing Head Rotate Mechanism
Turning now to FIG. 13, a sectional plan view of the right rear corner of operator arm 407 is shown. The right rear section of operator arm 407 advantageously contains the rotate mechanism which is used to rotate processing head 406 about processing head pivot shafts 430 and 429 . Processing head rotate mechanism 431 preferably consists of rotate motor 428 which drives rotate shaft 432 , more generally described as a processing head drive shaft. Rotate shaft 432 is inserted within rotate pulley 425 which also functions as the operator arm pivot shaft. As described previously, the operator arm pivot shaft/lift pulley is supported in operator arm pivot bearings 424 , which are themselves supported in operator base yoke arm 422 . Rotate shaft 432 is secured within left pulley 424 by securing collar 433 . Securing collar 433 secures rotate pulley 425 to rotate shaft 432 in a secure manner so as to assure a positive connection between rotate motor 428 and rotate pulley 425 . An inner cover 584 is also provided.
Rotate motor 428 is disposed within process arm rear cavity 426 and is supported by rotate motor support 434 . Rotate motor 428 preferably is a servo allowing for accurate control of speed and acceleration of the motor. Servo motor 428 is advantageously connected to rotate encoder 435 which is positioned on one end of rotate motor 428 . Rotate encoder 435 , more generally described as a processing head encoder, allows for accurate measurement of the number of rotations of rotate motor 428 , as well as the position, speed, and acceleration of the rotate shaft 432 . The information from the rotate encoder may be used in a rotate circuit which may then be used to control the rotate motor when the rotate motor is a servo. This information is useful in obtaining the position and rate of travel of the processing head, as well as controlling the final end point positions of the processing head as it is rotated about process head rotate axis 411 .
The relationship between the rotate motor rotations, as measured by rotate encoder 435 , may easily be determined once the diameters of the rotate pulley 425 and the processing head pulley 438 are known. These diameters can be used to determine the ratio of rotate motor relations to processing head rotations. This may be accomplished by a microprocessor, as well as other means.
Rotate pulley 425 is further supported within operator arm 407 by rotate pulley inboard bearing 436 which is disposed about an extended flange on the rotate pulley 425 . Rotate pulley inboard bearing 436 is secured by the body of the operator arm 407 , as shown in FIG. 13 .
Rotate pulley 425 advantageously drives rotate belt 437 , more generally described as a flexible power transmission coupling. Referring now to FIG. 10, rotate belt 437 is shown in the side view of the right arm 419 of the operator arm 407 . Rotate belt 437 is preferably a toothed timing belt to ensure positive engagement with the processing head drive wheel, more particularly described herein as the processing head pulley 438 , (not shown in this view). In order to accommodate the toothed timing belt 437 , both the rotate pulley 425 and the processing head pulley 438 are advantageously provided with gear teeth to match the tooth pattern of the timing belt to assure positive engagement of the pulleys with the rotate belt.
Rotate mechanism 431 is preferably provided with rotate belt tensioner 439 , useful for adjusting the belt to take up slack as the belt may stretch during use, and to allow for adjustment of the belt to assure positive engagement with both the rotate pulley and the processing head pulley. Rotate belt tensioner 439 adjusts the tension of rotate belt 437 by increasing the length of the belt path between rotate pulley 425 and processing head pulley 438 , thereby accommodating any excess length in the belt. Inversely, the length of the belt path may also be shortened by adjusting rotate belt tensioner 439 so as to create a more linear path in the upper portion of rotate belt 437 . The tensioner 439 is adjusted by rotating it about tensioner hub 468 and securing it in a new position.
Turning now to FIG. 13, processing head pulley 438 is mounted to processing head rotate shaft 430 in a secured manner so that rotation of processing head pulley 438 will cause processing head rotate shaft 430 to rotate. Processing head shaft 430 is mounted to operator arm right fork 419 by processing head shaft bearing 440 , which in turn is secured in the frame of the right fork 419 by processing head rotate bearing 469 . In a like manner, processing head shaft 429 is mounted in operator arm left fork 418 by processing head shaft bearing 441 , as shown in FIG. 9 .
Processing head pivot shafts 430 and 429 are advantageously hollow shafts. This feature is useful in allowing electrical, optical, pneumatic, and other signal and supply services to be provided to the processing head. Service lines such as those just described which are routed through the hollow portions of processing head pivot shafts 429 and 430 are held in place in the operator arms by cable brackets 442 and 443 . Cable brackets 442 and 443 serve a dual purpose. First, routing the service lines away from operating components within the operator arm left and right forks. Second, cable brackets 442 and 443 serve a useful function in isolating forces imparted to the service cables by the rotating action of processing head 406 as it rotates about processing head pivot shafts 429 and 430 . This rotating of the processing head 406 has the consequence that the service cables are twisted within the pivot shafts as a result of the rotation, thereby imparting forces to the cables. These forces are preferably isolated to a particular area so as to minimize the effects of the forces on the cables. The cable brackets 442 and 443 achieve this isolating effect.
The process head rotate mechanism 431 , shown in FIG. 13, is also advantageously provided with a rotate overtravel protect 444 , which functions as a rotate switch. Rotate overtravel protect 444 preferably acts as a secondary system to the rotate encoder 435 should the control system fail for some reason to stop servo 428 in accordance with a predetermined position, as would be established by rotate encoder 435 . Turning to FIG. 13, the rotate overtravel protect 444 is shown in plan view. The rotate overtravel protect preferably consists of rotate optical switches 445 and 446 , which are configured to correspond to the extreme (beginning and end point) portions of the processing head, as well as the primary switch component which preferably is a rotate flag 447 . Rotate flag 447 is securely attached to processing head pulley 438 such that when processing head shaft 430 (and consequently processing head 406 ) are rotated by virtue of drive forces imparted to the processing head pulley 425 by the rotate belt 437 , the rotate flag 447 will rotate thereby tracking the rotate motion of processing head 406 . Rotate optical switches 445 and 446 are positioned such that rotate flag 447 may pass within the optical path generated by each optical switch, thereby generating a switch signal. The switch signal is used to control an event such as stopping rotate motor 428 . Rotate optical switch 445 will guard against overtravel of processing head 406 in one direction, while rotate optical switch 446 will provide against overtravel of the processing head 406 in the opposite direction.
Operator Arm-Lift Mechanism
Operator arm 407 is also advantageously provided with an operator arm lift mechanism 448 which is useful for causing the operator arm to lift, that is, to pivot or rotate about operator arm pivot axis 412 . Turning to FIG. 14, the operator arm lift mechanism 448 is shown in the sectional plan view of the right rear corner of operator arm 407 .
Operator arm lift mechanism 448 is advantageously driven by lift motor 452 . Lift motor 452 may be more generally described as an operator arm drive or operator arm pivot drive. Lift motor 452 is preferably a servo motor and is more preferably provided with an operator encoder, more specifically described as lift motor encoder 456 . When lift motor 452 is a servo motor coupled with lift encoder 456 , information regarding the speed and absolute rotational position of the lift motor shaft 454 may be known from the lift encoder signal. Additionally, by virtue of being a servo mechanism, the angular speed and acceleration of lift motor 452 may be easily controlled by use of the lift signal by an electrical circuit. Such a lift circuit may be configured to generate desired lift characteristics (speed, angle, acceleration, etc.). FIG. 14 shows that the lift operator may also include a brake 455 which is used to safely stop the arm if power fails.
Lift motor 452 drives lift motor shaft 454 which in turn drives lift gear drive 453 . Lift gear drive 453 is a gear reduction drive to produce a reduced number of revolutions at lift drive shaft 456 as the function of input revolutions from lift motor shaft 454 .
Lift drive gear shaft 456 is secured to lift anchor 451 which is more clearly shown in FIG. 11 . Lift anchor 451 is preferably shaped to have at least one flat side for positively engaging lift bushing 449 . Lift anchor 451 is secured to lift drive shaft 456 by anchor plate 458 and anchor fasteners 457 . In this manner, when lift drive shaft 456 is rotated, it will positively engage lift bushing 449 . Returning to FIG. 14, it is seen that lift bushing 449 is mounted in operator left yoke arm 421 , and is thus fixed with respect to operator base 405 . Lift bearing 450 is disposed about the lift bushing shank and is supported in operator arm 407 by lift bearing support 460 which is a bushing configured to receive lift bearing 450 on a first end and to support lift gear drive 453 on a second end. Lift bearing support 460 is further supported within operator arm 407 by operator arm frame 461 . The lift arm is thus free to pivot about lift bushing 449 by virtue of lift bearing 450 .
In operation, as lift motor 452 causes lift gear drive 453 to produce rotations at gear drive shaft 456 , lift anchor 451 is forced against lift bushing 449 which is securely positioned within right operator yoke arm 421 . The reactive force against the lift anchor 451 will cause lift bearing support 460 to rotate relative to lift bushing 449 . Since lift bushing 449 is fixed in operator base 405 , and since operator base 405 is fixed to processing machine 400 , rotation of lift bearing support 460 will cause lift arm 407 to pivot about operator arm pivot axis 412 , thereby moving the processing head 406 . It is advantageous to consider the gear drive shaft (or “operator arm shaft”) as being, fixed with respect to operator base 405 when envisioning the operation of the lift mechanism.
Operator lift mechanism 448 is also advantageously provided with a lift overtravel protect 462 or lift switch. The lift rotate protect operates in a manner similar to that described for the rotate overtravel protect 444 described above. Turning now to FIG. 11, a left side view of the operator arm 407 is shown which shows the lift overtravel protect in detail.
The lift overtravel protect preferably includes a lift optical switch low 463 and a lift optical switch high 464 . Other types of limit switches can also be used. The switch high 464 and switch low 463 correspond to beginning and endpoint travel of lift arm 407 . The primary lift switch component is lift flag 465 , which is firmly attached to left operator base yoke arm 421 . The lift optical switches are preferably mounted to the movable operator arm 407 . As operator arm 407 travels in an upward direction in pivoting about operator arm pivot axis 412 , lift optical switch high 464 will approach the lift flag 465 . Should the lift motor encoder 455 fail to stop the lift motor 454 as desired, the lift flag 465 will break the optical path of the lift optical switch high 464 thus producing a signal which can be used to stop the lift motor. In like manner, when the operator arm 407 is being lowered by rotating it in a clockwise direction about the operator arm pivot axis 412 , as shown in FIG. 11, overtravel of operator arm 407 will cause lift optical switch low 463 to have its optical path interrupted by lift flag 465 , thus producing a signal which may be used to stop lift motor 452 . As is shown in FIG. 11, lift flag 465 is mounted, to left operator base yoke arm 421 with slotted lift flag mounting slots 467 and removable lift flag fasteners 466 . Such an arrangement allows for the lift flag to be adjusted so that the lift overtravel protect system only becomes active after the lift arm 407 has traveled beyond a preferred point.
Processing Head
Turning now to FIG. 6, a front elevation schematic view of the processing head 406 is shown. Processing head 406 is described in more detail in FIGS. 7 and 8. Turning now to FIG. 7, a sectional view of the left front side of processing head 406 is shown. Processing head 406 advantageously includes a processing head housing 470 and frame 582 . Processing head 406 is preferably round in shape in plan view allowing it to easily pivot about process head pivot axis 411 ,with no interference from operator arm 407 , as demonstrated in FIGS. 3-5. Returning to FIG. 7, processing head housing 470 more preferably has circumferential grooves 471 which are formed into the side of process head housing 470 . Circumferential grooves 471 have a functional benefit of increasing heat dissipation from processing head 406 .
The sides of processing head housing 470 are advantageously provided with rotate shaft openings 474 and 475 for receiving respectively left and right processing head pivot shafts 429 and 430 . Processing head pivot shafts 429 and 430 are secured to the processing head 406 by respective left and right processing head mounts, 472 and 473 . Processing head mounts 472 and 473 are affirmative connected to processing head frame 582 which also supports processing head door 476 which is itself securely fastened to processing head housing 470 . Consequently, processing head pivot shafts 429 and 430 are fixed with respect to processing head 407 and may therefore rotate or pivot with respect to operator arm 407 . The details of how processing head pivot shafts 429 and 430 are received within operator arm 407 were discussed supra.
Processing head housing 470 forms a processing head void 477 which is used to house additional processing head components such as the spin motor, the pneumatic finger actuators, and service lines, all discussed more fully below.
The processing head also advantageously includes a workpiece holder and fingers for holding a workpiece, as is also more fully described below.
Processing Head Spin Motor
In a large number of semiconductor manufacturing processes, is desirable to spin the semiconductor wafer or workpiece during the process, for example to assure even distribution of applied process fluids across the face of the semiconductor wafer, or to aid drying of the wafer after a wet chemistry process. It is therefore desirable to be able to rotate the semiconductor workpiece while it is held by the processing head.
The semiconductor workpiece is held during the process by workpiece holder 478 described more fully below. In order to spin workpiece holder 478 relative to processing head 406 about spin axis 479 , an electric, pneumatic, or other type of spin motor or workpiece spin drive is advantageously provided.
Turning to FIG. 8, spin motor 480 has armatures 526 which drive spin motor shaft 483 in rotational movement to spin workpiece holder 478 . Spin motor 480 is supported by bottom motor bearing 492 in bottom motor housing 482 . Bottom motor housing 482 is secured to processing head 406 by door 476 . Spin motor 480 is thus free to rotate relative to processing head housing 470 and door 476 . Spin motor 480 is preferably additionally held in place by top motor housing 481 which rests on processing head door 476 . Spin motor 480 is rotationally isolated from top motor housing 481 by top motor bearing 493 , which is disposed between the spin motor shaft 483 and top motor housing 481 .
The spin motor is preferably an electric motor which is provided with an electrical supply source through pivot shaft 429 and/or 430 . Spin motor 480 will drive spin motor shaft 483 about spin axis 479 .
To secure workpiece holder rotor 484 to spin motor shaft 483 , workpiece holder rotor 484 is preferably provided with a rotor hub 485 . Rotor hub 485 defines a rotor hub recess 486 which receives a flared end of workpiece holder shaft 491 . The flared end 487 of workpiece holder shaft 491 is secured within the rotor hub recess 486 by workpiece shaft snap-ring 488 which fits within rotor recess groove 489 above the flared portion 487 of workpiece holder shaft 491 .
The workpiece holder shaft 491 is fitted inside of spin motor shaft 483 and protrudes from the top of the spin motor shaft. The top of workpiece holder shaft 491 is threaded to receive thin nut 527 (see FIG. 7 ). Thin nut 527 is tightened against optical tachometer 499 (describe more fully below). Optical tachometer 499 is securely attached to spin motor shaft 483 such that as the spin motor 480 rotationally drives the spin motor shaft 483 , the workpiece holder shaft 491 is also driven.
Workpiece holders may be easily changed out to accommodate various configurations which may be required for the various processes encountered in manufacturing of the semiconductors. This is accomplished by removing spin encoder 498 (described below), and then thin nut 527 . Once the thin nut has been removed the workpiece holder 478 will drop away from the processing head 406 .
The processing head is also advantageously provided with a spin encoder 498 , more generally described as a workpiece holder encoder, and an optical tachometer 499 . As shown in FIG. 7, spin encoder 498 is mounted to top motor housing 481 by encoder support 528 so as to remain stationary with respect to the processing head 406 . Optical tachometer 499 is mounted on spin motor shaft 483 so as to rotate with the motor 480 . When operated in conjunction, the spin encoder 498 and optical tachometer 499 allow the speed, acceleration, and precise rotational position of the spin motor shaft (and therefore the workpiece holder 478 ) to be known. In this manner, and when spin motor 480 is provided as a servo motor, a high degree of control over the spin rate, acceleration, and rotational angular position of the workpiece with respect to the process head 407 may be obtained.
In one application of the present invention the workpiece support is used to support a semiconductor workpiece in an electroplating process. To accomplish the electroplating an electric current is provided to the workpiece through an alternate embodiment of the fingers (described more fully below). To provide electric current to the finger, conductive wires are run from the tops of the fingers inside of the workpiece holder 478 through the electrode wire holes 525 in the flared lower part of workpiece holder shaft 491 . The electrode wires are provided electric current from electrical lines run through processing pivot shaft 429 and/or 430 .
The electrical line run through pivot shaft 430 / 429 will by nature be stationary with respect to processing head housing 470 . However, since the workpiece holder rotor is intended to be capable of rotation during the electroplating process, the wires passing into workpiece support shaft 491 through electrode wire holes 525 may rotate with respect to processing head housing 470 . Since the rotating electrode wires within workpiece shaft 491 and the stationary electrical supply lines run through pivot shaft 430 / 429 must be in electrical communication, the rotational/stationary problem must be overcome. In the preferred embodiment, this is accomplished by use of electrical slip ring 494 .
Electrical slip ring 494 , shown in FIG. 7, has a lower wire junction 529 for receiving the conductive ends of the electrical wires passing into workpiece holder shaft 491 by electrode wire holes 525 . Lower wire junction 529 is held in place within workpiece holder shaft 491 by insulating cylindrical collar 497 and thus rotates with spin motor shaft 483 . The electrode wires terminate in a single electrical contact 531 at the top of the lower wire junction 529 . Electrical slip ring 494 further has a contact pad 530 which is suspended within the top of workpiece holder shaft 491 . Contact pad 530 is mechanically fastened to spin encoder 498 , which, as described previously, remains stationary with respect to processing head housing 470 . The stationary-to-rotational transition is made at the tip of contact pad 530 , which is in contact with the rotating electrical contact 531 . Contact pad 530 is electrically conductive and is in electrical communication with electrical contact 531 . In the preferred embodiment, contact pad 530 is made of copper-beryllium. A wire 585 carries current to finger assemblies when current supply is needed, such as on the alternative embodiment described below.
Processing Head Finger Actuators
Workpiece holder 478 , described more fully below, advantageously includes fingers for holding the workpiece W in the workpiece holder, as shown in FIGS. 7 and 8. Since the workpiece holder 478 may be removed as described above, it is possible to replace one style of workpiece holder with another. Since a variety of workpiece holders with a variety of fingers for holding the workpiece is possible, it is desirable to have a finger actuator mechanism disposed within processing head 407 which is compatible with any given finger arrangement. The invention is therefore advantageously provided with a finger actuator mechanism.
Turning to FIG. 7, a finger actuator mechanism 500 is shown. Finger actuator mechanism 500 is preferably a pneumatically operated mechanism. A pneumatic cylinder is formed by a cavity 501 within top motor housing 481 . Pneumatic piston 502 is disposed within cavity 501 . Pneumatic piston 502 is biased in an upward position within cavity 501 by actuator spring 505 . Actuator spring 505 is confined within cavity 501 by cavity end cap 507 , which is itself constrained by retaining ring 508 . Pneumatic fluid is provided to the top of pneumatic piston 502 via pneumatic inlet 503 . Pneumatic fluid is provided to pneumatic inlet 503 by pneumatic supply line 504 which is routed through processing head pivot shaft 429 and hence through the left fork 418 of the operator arm 407 . Turning to FIG. 8, it can be seen that a second pneumatic cylinder which is identical to the pneumatic cylinder just described is also provided.
Pneumatic piston 502 is attached to actuator plate 509 by actuator plate connect screw 510 . Wave springs 529 provide flexibility to the connecting at screws 510 . Actuator plate 509 is preferably an annular plate concentric with the spin motor 580 and disposed about the bottom motor housing 482 , and is symmetrical about spin axis 479 . Actuator plate 509 is secured against pneumatic piston 502 by bushing 512 which is disposed in pneumatic piston recess 511 about pneumatic piston 502 . Bushing 512 acts as a support for wave springs 529 to allow a slight tilting of the actuator plate 509 . Such an arrangement is beneficial for providing equal action against the finger actuator contracts 513 about the entire actuator plate or ring 509 .
When pneumatic fluid is provided to the space above the pneumatic piston 502 , the pneumatic piston 502 travels in a downward direction compressing actuator spring 505 . As pneumatic piston 502 travels downward, actuator plate 509 is likewise pushed downward by flexible bushing 512 . Actuator plate 509 will contact finger, actuator contacts 513 causing the fingers to operate as more fully described below.
Actuator seals 506 are provided to prevent pneumatic gas from bypassing the top of the pneumatic piston 502 and entering the area occupied by actuator spring 505 .
Processing Head Workpiece Holder
Workpiece holder 478 is used to hold the workpiece W, which is typically a semiconductor wafer, in position during the semiconductor manufacturing process.
Turning now to FIG. 8, a finger 409 is shown in cross section. Finger 409 advantageously includes a finger actuator contact 513 which is contacted by actuator plate 509 , as described above. Finger actuator contact 513 is connected to finger actuator lever 514 (more generally, “finger extension”) which is cantilevered from and connected to the finger stem 515 . Finger stem 515 is inserted into finger actuator lever 514 . Disposed about the portion of the finger actuator lever which encompasses and secures finger stem 515 is finger diaphragm 519 . Finger diaphragm 519 is preferably made of a flexible material such <as Tetrafluoroethylene, also known as Teflon® (registered trademark of E. I. DuPont de Nemours Company). Finger 409 is mounted to workpiece holder rotor 484 using finger diaphragm 519 . Finger diaphragm 519 is inserted into the finger opening 521 in rotor 484 . The finger diaphragm 519 is inserted into the rotor from the side opposite that to which the workpiece will be presented. Finger diaphragm 519 is secured to rotor 484 against rotor diaphragm lip 523 . Forces are intentionally imparted as a result of contact between the actuator plate 509 and the finger actuator contact 513 when the finger actuator mechanism 500 is actuated.
Finger actuator lever 514 is advantageously biased in a horizontal position by finger spring 520 which acts on finger actuator tab 522 which in turn is connected to finger actuator lever 514 . Finger spring 520 is preferably a torsion spring secured to the workpiece holder rotor 484 .
Finger stem 515 is also preferably provided with finger collar or nut 517 which holds the finger stem 515 against shoulder 518 . Finger collar 517 threads or otherwise securely fits over the lower end of finger actuator lever 514 . Below the finger collar 517 , finger stem 515 extends for a short distance and terminates in fingertip 414 . Fingertip 414 contains a slight groove or notch which is beneficially shaped to receive the edge of the workpiece W.
In actuation, finger actuator plate 509 is pushed downward by finger actuator mechanism 500 . Finger actuator plate 509 continues its downward travel contacting finger actuator contacts 513 . As actuator plate 509 continues its downward travel, finger actuator contacts are pushed in a downward direction. As a result of the downward direction, the finger actuator levers 514 are caused to pivot.
In the preferred embodiment, a plurality of fingers are used to hold the workpiece. In one example, six fingers were used. Once the actuator plate 509 has traveled its full extent, the finger stems 515 will be tilted away from the spin axis 479 . The circumference described by the fingertips in this spread-apart position should be greater than the circumference of the workpiece W. Once a workpiece W has been positioned proximate to the fingertips, the pneumatic pressure is relieved on the finger actuator and the actuator spring 505 causes the pneumatic piston 502 to return to the top of the cavity 501 . In so doing, the actuator plate 509 is retracted and the finger actuator levers are returned to their initial position by virtue of finger springs 520 .
Semiconductor Workpiece Holder—Electroplating Embodiment
FIG. 15 is a side elevational view of a semiconductor workpiece holder 810 constructed according to a preferred aspect of the invention.
Workpiece holder 810 is used for processing a semiconductor workpiece such as a semiconductor wafer shown in phantom at W. One preferred type of processing undertaken with workpiece holder 810 is a workpiece electroplating process in which a semiconductor workpiece is held by workpiece holder 810 and an electrical potential is applied to the workpiece to enable plating material to be plated thereon. Such can be, and preferably is accomplished utilizing a processing enclosure or chamber which includes a bottom half or bowl 811 shown in phantom lines in FIG. 1 . Bottom half 811 together with workpiece holder 810 forms a sealed, protected chamber for semiconductor workpiece processing. Accordingly, preferred reactants can be introduced into the chamber for further processing. Another preferred aspect of workpiece holder 810 is that such moves, rotates or otherwise spins the held workpiece during processing as will be described in more detail below.
Processing Head and Processing Head Operator
Turning now to FIG. 15, semiconductor workpiece holder 810 includes a workpiece support 812 . Workpiece support 812 advantageously supports a workpiece during processing. Workpiece support 812 includes a processing head or spin head assembly 814 . Workpiece support 812 also includes a head operator or lift/rotate assembly 816 . Spin head assembly 814 is operatively coupled with lift/rotate assembly 816 . Spin head assembly 814 advantageously enables a held workpiece to be spun or moved about a defined axis during processing. Such enhances conformal coverage of the preferred plating material over the held workpiece. Lift/rotate assembly 816 advantageously lifts spin head assembly 814 out of engagement with the bottom half 811 of the enclosure in which the preferred processing takes place. Such lifting is preferably about an axis x 1 . Once so lifted, lift/rotate assembly 816 also rotates the spin head and held workpiece about an axis x 2 so that the workpiece can be presented face-up and easily removed from workpiece support 812 . In the illustrated and preferred embodiment, such rotation is about 180° from the disposition shown in FIG. 15 . Advantageously, a new workpiece can be fixed or otherwise attached to the workpiece holder for further processing as described in detail below.
The workpiece can be removed from or fixed to workpiece holder 810 automatically by means of a robotically controlled arm. Alternatively, the workpiece can be manually removed from or fixed to workpiece holder 810 . Additionally, more than one workpiece holder can be provided to support processing of multiple semiconductor workpieces. Other means of removing and fixing a semiconductor workpiece are possible.
FIG. 16 is a front sectional view of the FIG. 15 semiconductor workpiece holder. As shown, workpiece support 812 includes a motor 818 which is operatively coupled with a rotor 820 . Rotor 820 is advantageously mounted for rotation about a rotor spin axis 822 and serves as a staging platform upon which at least one finger assembly 824 is mounted. Preferably, more than one finger assembly is mounted on rotor 820 , and even more preferably, four or more such finger assemblies are mounted thereon and described in detail below although only two are shown in FIG. 16 . The preferred finger, assemblies are instrumental in fixing or otherwise holding a semiconductor workpiece on semiconductor workpiece holder 810 . Each finger assembly is advantageously operatively connected or associated with a actuator 825 . The actuator is preferably a pneumatic linkage which serves to assist in moving the finger assemblies between a disengaged position, in which a workpiece may be removed from or added to the workpiece holding, and an engaged position in which the workpiece is fixed upon the workpiece holder for processing. Such is described in more detail below.
FIG. 17 is a top or plan view of rotor 820 which is effectively taken along line 3 — 3 in FIG. 16 . FIG. 16 shows the preferred four finger assemblies 824 . As shown, rotor 820 is generally circular and resembles from the top a spoked wheel with a nearly continuous bottom surface. Rotor 820 includes a rotor center piece 826 at the center of which lies rotor axis 822 . A plurality of struts or spokes 828 are joined or connected to rotor center 826 and extend outwardly to join with and support a rotor perimeter piece 830 . Advantageously, four, of spokes 828 support respective preferred finger assemblies 824 . Finger assemblies 824 are advantageously positioned to engage a semiconductor workpiece, such as a wafer W which is shown in phantom lines in the position such would occupy during processing. When a workpiece is so engaged, it is fixedly held in place relative to the rotor so that processing can be effected. Such processing can include exposing the workpiece to processing conditions which are effective to form a layer of material on one or more surfaces or potions of a wafer or other workpiece. Such processing can also include moving the workpiece within a processing environment to enhance or improve conformal coverage of a layering material. Such processing can, and preferably does include exposing the workpiece to processing conditions which are effective to form an electroplated layer on or over the workpiece.
Finger Assembly
Referring now to FIGS. 18-20, various views of a preferred finger assembly are shown. The preferred individual finger assemblies are constructed in accordance with the description below FIG. 18 is an isolated side sectional view of a finger assembly constructed in accordance with a preferred aspect of the invention. FIG. 19 is a side elevational view of the finger assembly turned 90° from the view of FIG. 18 . FIG. 20 is a fragmentary cross-sectional enlarged view of a finger assembly and associated rotor structure. The finger assembly as set forth in FIGS. 18 and 19 is shown in the relative position such as it would occupy when processing head or spin head assembly 814 (FIGS. 15 and 16) is moved or rotated by head operator or lift/rotate assembly 816 into a position for receiving a semiconductor workpiece. The finger assembly is shown in FIGS. 18 and 20 in an orientation of about 180° from the position shown in FIG. 20 . This typically varies because spin head assembly 814 is rotated 180° from the position shown in° FIGS. 15 and 16 in order to receive a semiconductor workpiece. Accordingly, finger assemblies 824 would be so rotated. Lesser degrees of rotation are possible.
Finger assembly 824 includes a finger assembly frame 832 . Preferably, finger assembly frame 832 is provided in the form of a sealed contact sleeve which includes an angled slot 832 a , only a portion of which is shown in FIG. 19 . Angled slot 832 a advantageously enables the finger assembly to be moved, preferably pneumatically, both longitudinally and rotationally as will be explained below. Such preferred movement enables a semiconductor workpiece to be engaged, electrically contacted, and processed in accordance with the invention.
Finger assembly frame 832 includes a finger assembly frame outer flange 834 which, as shown in FIG. 20, engages an inner drive plate portion 836 of rotor 820 . Such engagement advantageously fixes or seats finger assembly frame 832 relative to rotor 820 . Such, in turn, enables the finger assembly, or a portion thereof, to be moved relative to the rotor for engaging the semiconductor workpiece.
Finger Assembly Drive System
Referring to FIGS. 16 and 18 - 20 , the finger assembly includes a finger assembly drive system which is utilized to move the finger assembly between engaged and disengaged positions. The finger assembly drive system includes a bearing 838 and a collet 840 operatively adjacent the bearing. Bearing 838 includes a bearing receptacle 839 for receiving a pneumatically driven source, a fragmented portion of which is shown directly above the receptacle in FIG. 20 . The pneumatically driven source serves to longitudinally reciprocate and rotate collet 840 , and hence a preferred portion of finger assembly 824 . A preferred pneumatically driven source is described below in more detail in connection with the preferred longitudinal and rotational movement effectuated thereby. Such longitudinal reciprocation is affected by a biasing mechanism in the form of a spring 842 which is operatively mounted between finger assembly frame 832 and, a spring seat 844 . The construction develop a bias between finger assembly frame 832 and spring seat 844 to bias the finger into engagement against a wafer. Advantageously, the cooperation between the above mentioned pneumatically driven source as affected by the biasing mechanism of the finger assembly drive system, enable collet 840 to be longitudinally reciprocated in both extending and retracting modes of movement. As such, finger assembly 824 includes a biased portion which is biased toward a first position and which is movable to a second position away from the first position. Other manners of longitudinally reciprocating the finger assembly are possible.
Finger Assembly Electrical System
Referring to FIGS. 16 and 19, the finger assembly preferably includes a finger assembly electrical system which is utilized to effectuate an electrical bias to a held workpiece and supply electrical current relative thereto. The finger assembly electrical system includes a pin connector 846 and a finger 848 . Pin connect or 846 advantageously provides an electrical connection to a power source (not shown) via wire 585 and associate slip ring mechanism, described above in connection with FIG. 7 and other FIGS. This is for delivering an electrical bias and current to an electrode which is described below. Pin connector 846 al so rides within angled slot 832 a thereby mechanically defining the limits to which the finger assembly may be both longitudinally and rotationally moved.
Finger 848 is advantageously fixed or secured to or within collet 840 by a nut 850 which threadably engages a distal end portion of collet 840 as shown best in FIG. 18 . An anti-rotation pin 852 advantageously secures finger 848 within collet 840 and prevents relative rotation therebetween. Electrical current is conducted from connector 846 through collet 840 to finger 860 , all of which are conductive, such as from stainless steel. The finger and collet can be coated with a suitable dielectric coating 856 , such as TEFLON or others. The collet 840 and finger member 860 are in one form of the invention made hollow and tubular to conduct a purge gas therethrough.
Finger assembly 824 may also optionally include a distal tip or finger tip 854 . Tip 854 may also have a purge gas passage formed therethrough. Finger tip 854 advantageously engages against, a semiconductor workpiece (see FIG. 20) and assists in holding or fixing the position of the workpiece relative to workpiece holder 810 . Finger tip 854 also assists in providing an operative electrical connection between the finger assembly and a workpiece to which an electrical biased is to be applied and through which current can move. Finger tip 85 can include an electrode contact 858 for electrically contacting a surface of a semiconductor workpiece once such workpiece is secured as describe below.
Finger Assembly Drive System Interface
A finger assembly drive system interface is operatively coupled with the finger assembly drive system to effectuate movement of the finger assembly between the engaged and disengaged positions. A preferred finger assembly drive system interface is described with reference to FIGS. 16 and 20. One component of the finger assembly drive system interface is a finger actuator 862 . Fingers actuator 862 is advantageously provided for moving the finger assembly between the engaged and disengaged position. Finger actuator 862 acts by engaging bearing receptacle 839 and moving finger assembly 824 between an engaged position and a disengaged position. In the engaged position, finger tip 854 is engaged against a semiconductor workpiece. In the disengaged position finger tip 854 is moved away from the workpiece.
The finger assembly drive system interface includes pneumatic actuator 825 (FIG. 16 ). Pneumatic actuators 825 are operatively connected to an actuation ring 863 and operates thereupon causing the drive plate to move reciprocally in the vertical direction as viewed in FIG. 16 . Finger actuator 862 is operatively connected to actuation ring 863 in a manner which, upon pneumatic actuation, moves the finger actuator into engagement with bearing receptacle 839 along the dashed line in FIG. 20 . Such allows or enables the finger assembly to be moved longitudinally along a first movement path axis 864 .
Pneumatic actuator linkage 825 also includes a secondary linkage 865 . Secondary linkage 865 is pneumatic as well and includes a link arm 867 . Link arm 867 is connected or joined to an actuator torque ring 869 . Preferably, torque ring 869 is concentric with rotor 820 (FIG. 17) and circuitously links each of the finger actuators together. A pneumatic operator 871 is advantageously linked with the secondary linkage 865 for applying force and operating the linkage by angularly displacing torque ring 869 . This in turn rotates the finger assemblies into and away from the engaged position.
Preferably finger actuator engagement bits 862 , under the influence of pneumatic linkage 825 , moves the finger assembly, and more specifically collet 840 and finger 848 along a first axial movement path along axis 864 . The finger actuator engagement bits 862 , then under the influence of pneumatic operator 871 are turned about the axes of each bit like a screwdriver. This moves collet 840 and finger 848 in a second angular movement. Such second movement turns the fingers sufficiently to produce the angular displacement shown in FIG. 21 . According to a preferred aspect of this invention, such movement of the finger assemblies between the engaged and disengaged positions takes place when spin head assembly 814 has been moved 180° from its FIG. 15 disposition into a face-up condition.
The engagement bits 862 can be provided with a purge gas passage therethrough. Gas is supplied via tube 893 and is passed through the finger assemblies.
Engaged and Disengaged Positions
FIG. 21 is a view of a portion of a finger assembly, taken along line 7 — 7 in FIG. 18 . Such shows in more detail the above-described engaged and disengaged positions and movement therebetween relative to a workpiece W In the disengaged position, finger 848 is positioned adjacent the semiconductor workpiece and the finger tip and electrode contact do not overlap with workpiece W. In the engaged position, the finger tip overlaps with the workpiece and the electrode is brought to bear against the workpiece. From the disengaged position, finger assembly 824 , upon the preferred actuation, is moved in a first direction away from the disengaged position. Preferably, such first direction is longitudinal and along first movement path axis 864 . Such longitudinal movement is linear and in the direction of arrow A as shown in FIGS. 18 and 19. The movement moves the finger assembly to the position shown in dashed lines in FIG. 18 . Such movement is effectuated by pneumatic operator 825 which operates upon actuation ring 863 (FIG. 16 ). This in turn, causes finger actuator 862 to engage with finger assembly 824 . Such linear movement is limited by angled slot 832 a . Thereafter, the finger assembly is preferably moved in a second direction which is different from the first direction and preferably rotational about the first movement path axis 864 . Such is illustrated in FIG. 21 where the second direction defines a generally actuate path between the engaged and disengaged positions. Such rotational movement is effectuated by secondary linkage 865 which pneumatically engages the finger actuator to effect rotation thereof. As so moved, the finger assembly swings into a ready position in which a semiconductor workpiece is ready to be engaged and held for processing. Once the finger assembly is moved or swung into place overlapping a workpiece, the preferred finger actuator is spring biased and released to bear against the workpiece. An engaged workpiece is shown in FIG. 20 after the workpiece has been engaged by finger tip 854 against a workpiece standoff 865 , and spin head assembly 814 has been rotated back into the position shown in FIG. 15 . Such preferred pneumatically assisted engagement takes place preferably along movement path axis 864 and in a direction which is into the plane of the page upon which FIG. 21 appears.
As shown in FIG. 18, finger 848 extends away from collet 840 and preferably includes a bend 866 between collet 840 and finger tip 854 . The preferred bend is a reverse bend of around 1800 which serves to point finger tip 854 toward workpiece W when the finger assembly is moved toward or into the engaged position (FIG. 21 ). Advantageously, the collet 840 and hence finger 848 are longitudinally reciprocally movable into and out of the engaged position.
Finger Assembly Seal
The finger assembly preferably includes a finger assembly seal 868 which is effectuated between finger 848 and a desired workpiece when the finger assembly is moved into the engaged position. Preferably, adjacent finger tip 854 . A seal 868 is mounted adjacent electrode contact 858 and effectively seals the electrode contact therewithin when finger assembly 824 is moved to engage a workpiece. The seal can be made of a suitable flexible, preferably elastomeric material, such as VITON.
More specifically, and referring to FIG. 22, seal 868 can include a rim portion 870 which engages workpiece surface W and forms a sealing contact therebetween when the finger assembly is moved to the engaged position. Such seal advantageously isolates finger electrode 860 from the processing environment and materials which may plate out or otherwise be encountered therein. Seal 868 can be provided with an optional bellows wall structure 894 (FIG. 22 ), that allows more axial flexibility of the seal.
FIG. 22 shows, in solid lines, seal 868 in a disengaged position in which rim portion 870 is not engaged with workpiece W. FIG. 22 also shows, in phantom lines, an engaged position in which rim portion 870 is engaged with and forms a seal relative to workpiece W. Preferably and advantageously, electrode contact 858 is maintained in a generally retracted position within seal 868 when the finger assembly is in the disengaged position. However, when the finger assembly is moved into the engaged position, seal 868 and rim portion 870 thereof splay outwardly or otherwise yieldably deform to effectively enable the electrode and hence electrode contact 858 to move into the engaged position against the workpiece. One factor which assists in forming the preferred seal between the rim portion and the workpiece is the force which is developed by spring 842 which advantageously urges collet 840 and hence finger 860 and finger tip 858 in the direction of and against the captured workpiece. Such developed force assists in maintaining the integrity of the seal which is developed in the engaged position. Another factor which assists in forming the preferred seal is the yieldability or deformability of the finger tip when it is brought into contact with the workpiece. Such factors effectively create a continuous seal about the periphery of electrode contact 858 thereby protecting it from any materials, such as the preferred plating materials which are used during electroplate processing.
Methods and Operation
In accordance with a preferred processing aspect of the present invention, and in connection with the above-described semiconductor workpiece holder, a sheathed electrode, such as electrode 860 , is positioned against a semiconductor workpiece surface in a manner which permits the electrode to impart a voltage bias and current flow to the workpiece to effectuate preferred electroplating processing of the workpiece. Such positioning not only allows a desired electrical bias to be imparted to a held workpiece, but also allows the workpiece itself to be mechanically held or fixed relative to the workpiece holder. That is, finger assembly 824 provides an electrical/mechanical connection between a workpiece and the workpiece holder as is discussed in more detail below.
Electrode 856 includes an electrode tip or electrode contact 858 which engages the workpiece surface. A seal is thus formed about the periphery of the electrode tip or contact 858 so that a desired electrical bias may be imparted to the workpiece to enable plating material to be plated thereon. According to a preferred aspect of the processing method, the electrode is moved in a first direction, preferably longitudinally along a movement axis, away from a disengaged position in which the workpiece surface is not engaged by the electrode tip or contact 858 . Subsequently, the electrode is rotated about the same movement axis and toward an engaged position in which the electrode tip may engage, so as to fix, and thereafter bias the workpiece surface.
Such preferred movement is effectuated by pneumatic linkage 825 and pneumatic operator 871 as described above.
According to a preferred aspect of the invention, the seal which is effectuated between the electrode member and the workpiece is formed by utilizing a yieldable, deformable seal member 868 which includes a rim portion 870 . The rim portion 870 serves by contacting the workpiece surface to form a continuous seal as shown in FIG. 8 . The preferred electrode tip is brought into engagement with the workpiece surface by advancing the electrode tip from a retracted position within the seal or other sheath to an unretracted position in which the workpiece surface is engaged thereby. Such movement of the electrode tip between the retracted and unretracted positions is advantageously accommodated by the yieldable features of the seal 868 .
In addition to providing the preferred electrical contact between the workpiece and the electrode tip, the finger assembly also forms a mechanical contact or connection between the assembly and the workpiece which effectively fixes the workpiece relative to the workpiece holder. Such is advantageous because one aspect of the preferred processing method includes rotating the workpiece about rotor axis 822 while the workpiece is exposed to the preferred plating material. Such not only ensures that the electrical connection and hence the electrical bias relative to the workpiece is maintained during processing, but that the mechanical fixation of the workpiece on the workpiece holder is maintained as well.
The above described pneumatically effectuated movement of the preferred finger assemblies between the engaged and disengaged positions is but one manner of effectuating such movement. Other manners of effectuating such movement are possible.
The invention also includes novel methods for presenting a workpiece to a semiconductor process. In such methods, a workpiece is first secured to a workpiece holder. The methods work equally well for workpiece holders known in the art and for the novel workpiece holders disclosed herein.
In the next step in the sequence, the workpiece holder is rotated about a horizontal axis from an initial or first position where the workpiece holder was provided with the workpiece to a second position. The second position will be at an angle to the horizontal. The angle of the workpiece holder to the horizontal is defined by the angle between the plane of the workpiece and the horizontal. In the method, the workpiece holder is advantageously suspended about a second horizontal axis which is parallel to the first horizontal axis of the workpiece holder. At this point in the method, the angle between the first and second horizontal axes and a horizontal plane corresponds to the angle between the workpiece holder and the horizontal. The workpiece holder is then pivoted about the second horizontal axis to move the workpiece and the workpiece holder from its initial location to a final location in a horizontal plane. Advantageously, when the workpiece holder is pivoted about the second horizontal axis, the first horizontal axis also pivots about the second horizontal axis.
Preferably, during the step of rotating the workpiece holder about the first horizontal axis, the angle of the workpiece holder with respect to some known point, which is fixed with respect to the workpiece holder during the rotation process, is continually monitored. Monitoring allows for precise positioning of the workpiece holder with respect to the horizontal surface.
Likewise, during pivoting of the workpiece holder about the second horizontal axis, it is preferable that the angle defined by the line connecting the first and second horizontal axes and the horizontal plane be continually monitored. In this manner, the absolute position of the workpiece holder (and hence the workpiece itself) will be known with respect to the horizontal plane. This is important since the horizontal plane typically will contain the process to which the workpiece will be exposed.
It should be noted that in the above and following description, while the workpiece is described as being presented to a horizontal plane, it is possible that the workpiece may also be presented to a vertical plane or a plane at any angle between the vertical and the horizontal. Typically, the processing plane will be a horizontal plane due to the desire to avoid gravitational effects on process fluids to which the workpiece is exposed. In one embodiment after the workpiece has been presented to the processing plane, the workpiece holder is rotated about a spin axis to cause the workpiece to spin in the horizontal plane. Although not required in all semiconductor manufacturing processes, this is a common step which may be added in the appropriate circumstance.
The next advantageous step in the method consists of pivoting the workpiece holder about the second horizontal axis back along the path that the workpiece holder was initially pivoted along when presenting the workpiece to the horizontal process plane. There is no requirement that the workpiece holder be pivoted back to the same position whence it began, although doing so may have certain advantages as more fully described below.
The method advantageously further consists of the step of rotating the workpiece holder about the first horizontal axis to return the workpiece to the position when it was initially presented to and engaged by the workpiece holder. It is advantageous to rotate the workpiece holder about the first axis in a direction opposite from the initial rotation of the workpiece holder.
The advantage of having the workpiece holder terminate at an end position which corresponds to the initial position when the workpiece was loaded into the workpiece holder is efficiency. That is, additional machine movements are not required to position the workpiece holder to receive a new workpiece.
The method more preferably includes the step of rotating the workpiece holder about the first horizontal axis at least two support points along the first horizontal axis. This beneficially provides support and stability to the workpiece holder during the rotation process and subsequent movement of the apparatus.
The method also more preferably includes the step of pivoting the workpiece holder along with the first horizontal axis about the second horizontal axis at least two support points along the second horizontal axis. This beneficially provides additional support for the workpiece holder while allowing the workpiece holder to be moved in a vertical “Z-axis” direction.
Importantly, the only motion described in the above method is rotational motion about several axes. In the method described, there is no translational motion of the workpiece holder in a X-, Y-, or Z-axis without corresponding movement in another axisz as a result of rotating through an arc.
Second Embodiment Processing Station—Generally
FIG. 23 shows principal components of a second semiconductor processing station 900 incorporating features of the invention. Processing station 900 as shown is specifically adapted and constructed to serve as an electroplating station similar to electroplating station 400 described hereinabove. To reduce unnecessary replication, only the principal parts showing differences and features of the invention are shown and described. Other aspects of the invention are as described above or can be done in a variety of constructions.
The two principal parts of processing station 900 are the workpiece support assembly 901 and the processing bowl 917 . The workpiece support 401 will be considered first and the processing bowl and its features will be described in further detail later in this description. As FIG. 23 indicates, portions of the workpiece support 401 mate with the processing bowl to provide a substantially closed processing vessel which encloses a substantially enclosed processing or manufacturing chamber 904 .
Workpiece Support Generally
The workpiece support processing head holds a wafer W for rotation within the processing chamber 904 . A rotor assembly 984 has a plurality of workpiece-engaging fingers 979 that hold the wafer against features of the rotor. Fingers 979 are also preferably adapted to conduct current between the wafer and a plating electrical power supply (not shown).
Workpiece Support Head Operator
The workpiece support assembly 901 includes a processing head 906 which is supported by an head operator 907 . Head operator 907 includes an upper portion 908 which is adjustable in elevation to allow height adjustment of the processing head. Head operator 907 also has a head connection shaft 909 which is operable to pivot about a horizontal pivot axis 910 . Pivotal action of the processing head using operator 907 allows the processing head to be placed in an open or face-up position (not shown) for loading and unloading wafer W. FIG. 23 shows the processing head pivoted into a face-down position in preparation for processing.
A variety of suitable head operators which provide both elevational and horizontal pivoting action are possible for use in this system. The preferred operators are also fitted with positional encoders (not shown) which indicate both the elevation of the processing head and its angular position as pivoted about horizontal head pivot axis 910 .
Workpiece Support Main Part
FIGS. 24 and 25 show additional details of the preferred construction of processing head 906 . The processing head includes a main part which moves with and is relatively stationary with respect to the pivot shaft 909 . The main part supports a rotating assembly which will be described in greater detail below.
The main part includes a processing head housing 970 and processing head frame 982 . The processing head frame 982 includes a door plate 983 . A door ring member 984 is joined to plate 983 using suitable fasteners to provide a door assembly which serve as the principal parts covering the upper opening of the processing bowl when the processing head is mated with the bowl.
The processing head frame also includes a frame-pivot shaft connection 985 which includes two mounting rings which receive and securely connect with the processing head pivot shaft 909 . FIG. 25 shows that the pivot shaft connection mounting rings are made in two parts and secured by fasteners (not shown). The pivot shaft connection base 935 is secured to the door plate 983 using fasteners.
Processing head 906 is generally round in shape when viewed in plan view. The processing head main part includes a housing 970 which has a first housing part 971 and a second housing part or housing cap 972 . The processing head housing 970 encloses a main part enclosure which surrounds a processing head main part mechanism chamber 973 . Chamber 973 is used to house additional processing head components, such as the spin motor, the finger actuators, and related service lines, such as discussed more fully below.
The upper surface of the door ring member 984 is provided with a groove which receives the lower edge of the first housing piece 971 . The outer periphery of the door ring member also advantageously includes a peripheral groove 986 which mounts an inflatable door seal 987 . Seal 987 seals with portions of the processing bowl to form a more fluid-tight processing chamber therewithin.
The lower surface of the door ring member 984 is preferably provided with an annular rotor receiving groove 988 which receives top peripheral portions of the rotor therein in close proximity. This construction allows a gas purge (not shown) to be applied between the door and rotor to help prevent processing vapors from migrating behind the rotor and into to the various mechanisms present in the main part of the processing head. The periphery of the door ring member is further provided with a chamfered lower edge to facilitate mating with the processing bowl.
The processing head also advantageously includes a moving assembly in the form of a workpiece holder 978 . The workpiece holder includes fingers 979 for holding a semiconductor workpiece. These features will be more fully described below.
Workpiece Support Rotor Drive
The processing head main part also includes a workpiece holder drive which moves the workpiece holder relative to the main part of the processing head. The preferred action is for the workpiece holder drive to be in the form of a rotor drive which rotates the workpiece holder. The rotor drive can be an electric motor, pneumatic motor or other suitable drive. As shown, the processing head includes an electric workpiece spin motor 980 .
The drive motor 980 has stator armatures 916 which drive motor shaft 918 in rotational movement. Drive motor 980 is supported by bottom motor bearing 921 in bottom motor housing 922 . Bottom motor housing 922 is secured to the main part of the processing head at a central opening in the door plate 983 . Motor 980 is also held in place by a top motor housing 923 . Drive motor 980 is rotationally isolated from top motor housing 923 by a top motor bearing 927 , which is disposed between the spin motor shaft 918 and the top motor housing. Both motor housings are secured to the processing head frame 982 using fasteners 924 which extend down through the motor housings and into the door plate 983 . The fasteners 924 also extend upwardly through frame extensions 925 . Frame extensions 925 support a top frame piece 926 . Cap 972 is screwed onto piece 926 at mating threads along the lower interior portion of the cap.
The drive motor is preferably an electric motor provided with a supply of electricity via wiring run through pivot shaft 909 or otherwise extending to the processing head.
Workpiece Support Rotor Assembly
The hollow shaft 918 of the drive motor receives portion of a rotor assembly therein. The rotor assembly is secured to the motor shaft and is rotated therewith. FIG. 26 shows major portions of the rotor assembly in exploded detail. The rotor assembly 930 includes a rotor shaft 931 . Rotor shaft 931 has a rotor shaft hub 932 which is held within a shaft hub receptacle 933 formed in an inner rotor part 934 . The inner or first rotor part 934 , also called an inner rotor drive plate, has a plurality of spokes which extend from the inner rotor part hub 935 outwardly to connect with a peripheral band 936 . The shaft hub, 932 is held in the hub receptacle 933 using a snap-ring 937 .
The inner rotor part 934 also includes a plurality of receptacles 937 . Receptacles 937 are used to mount a plurality of actuator transmission assemblies 960 . The transmission receptacles 937 receive lower portions of the transmission assemblies. The receptacles have bottom openings through which the finger assemblies 979 (see. FIG. 24) extend and are mounted in the transmission assemblies. Additional description is provided below in connection with the finger assembly actuators.
FIG. 26 also shows that the rotor assembly 930 preferably includes a second or outer rotor part 940 . The inner and outer rotor parts are secured together by fasteners 941 (see FIG. 24 ). The outer rotor part 940 includes a rotor face panel 943 which extends across the disk-shaped rotor part to form a barrier to processing fluids.
The front or exposed side of the outer rotor part is provided with apertures 787 through which finger actuator transmission shafts 963 extend in supporting relationship for the fingers 979 . Workpiece support standoffs 721 are mounted upon the face of the rotor to support the back side of the workpieces in opposition to the forces exerted by the fingers 979 . The face of the rotor can also advantageously be provided with workpiece peripheral guide pins 722 to facilitate proper location of a wafer upon installation upon the face of the rotor.
Along the back side of the outer rotor part are reinforcing ribs 942 which align with the spokes of the inner rotor part 934 . The reinforcing ribs 942 receive fasteners 941 and connect the two rotor parts together. At the periphery of the outer rotor part is a side wall 944 . The upper or back edge of the peripheral side wall 944 is in close fitting relationship with the door ring 984 at annular groove 988 to resist migration of processing fluids to the back side of the rotor assembly.
The outer rotor part 940 also has an array of bosses 948 at the peripheral end of the reinforcing ribs 942 . Within bosses 948 are finger passageways 949 which allow the finger assemblies 979 to mount in the finger actuator transmission assemblies 960 . The rotor assembly also includes the transmission assemblies and finger assemblies. Additional details of these components as well as additional parts of the finger actuation mechanisms is described in greater detail below.
The rotor shaft 931 fits inside of motor shaft 918 and protrudes from the top of the shaft and is held by a rotor shaft mounting nut 888 . Also mounted near the top of the rotor shaft is an optical tachometer 499 . Optical tachometer 499 is securely attached to motor shaft 918 and features, such as notches, formed on the tachometer are optically detected to provide a precise measurement of rotor angular velocity. The optical emitter-detector couplet used with tachometer 499 are not shown, but are mounted on either sides of the wheel to allow selective passage of light therethrough.
The rotor assembly is also advantageously provided with a angular position encoder 498 . As shown, encoder 498 is mounted to the top motor housing 923 so as to remain stationary with respect to the main part of the processing head. The angular position encoder 498 and optical tachometer 499 allow the speed, acceleration, and precise rotational position of the motor shaft 918 and rotor assembly to be known and controlled.
In one application of the present invention the workpiece support is used to support a semiconductor workpiece in an electroplating process. To accomplish the electroplating an electric current is provided to the workpiece through an alternate embodiment of the fingers (described more fully below). To provide electric current to the electrode fingers 979 , conductive wires (not shown) are run from the transmissions 960 toward the hub of the rotor. Current is supplied to the electrode fingers 979 through the hollow rotor shaft using wires (not shown) connected to a slip ring electrical connector 687 mounted near the upper end of shafts 918 and 931 .
Workpiece Detection Subsystem
The processing head also preferably includes a wafer or workpiece detection subsystem. This subsystem allows the processing head to through its control system to determine whether there is a workpiece held in the rotor or not. This is of particular significance if the system experiences a power interruption or otherwise is being started in any situation where workpieces may be present in the machine. Operational safeguards can then be included in the control system to prevent mishandling of wafers or processing stations which may have a workpiece held therein.
As shown in FIG. 25, the processing head frame part 983 is provided with a mounting 738 which is an appropriately shaped recess used to mount a detector 739 . Detector 739 is preferably an optical emitter-detector unit which emits a beam which passes downwardly as oriented in FIG. 25 . The emitted beam passes through workpiece detector windows 741 (see FIG. 26) formed in the face panel of the outer rotor part. The windows can be discrete inserts, or more preferably, they are thinly dimensioned panel portions of the rotor face panel 943 . The rotor face panel is advantageously made of a material which is transmissive of the detector beam being used. For example, the panel can be made from polyvinylidene fluoride polymer which is thinned to a suitably thin dimension, such as in the approximate range from about 1-5 millimeters.
A suitable detector 739 is a Sunx brand model RX-LS200, and other commercially available detectors. The preferred detector uses an infrared beam emitter (not individually shown) which is detected by a pair of beam detectors (not individually shown). The beam emitter and beam detectors are preferably part of the same unit which serves as the workpiece detector. The workpiece detector preferably operated in a trigonometric mode. In the trigonometric mode, the angle of the reflected beam is an important discriminating parameter. Thus any portion of the beam reflected by the detector window 741 is incident upon the pair of detectors at a reflection angle which is outside of the normal detection angel range. Such portions of the beam reflected by the window 741 are thus minimized and the detector is not triggered by such reflectance. Instead, the pair of beam detectors are adjusted to sense a reflected beam which is incident at a reflected angle associated with the wafer or other workpiece surface which is more distant than the window. When there is no workpiece held in the workpiece holder, then the detector senses the absence and this is used by the control system as an indication that there is no wafer present in the wafer support.
In general the emitted infrared beam used in the preferred workpiece detector subsystem is sufficient to detect the presence of a wafer or other semiconductor workpiece held in a stationary position with the rotor positioned so that one of the windows 741 is in position aligned to allow the emitted beam to pass therethrough and be reflected by the workpiece back through the window for detection. The detection system described herein is not sufficient to allow detection during rotation of the rotor and any workpiece held thereon. The invention may also be practiced in a situation where sensing can be accomplished while the rotor rotates.
The workpiece detector arrangement shown has the distinct benefit of being mounted wholly behind the rotor face panel without provision of any openings which might allow processing fluids to enter the space behind the rotor. This reduces maintenance, improves reliability, and simplifies construction costs.
Workpiece Support Finger Actuator
The preferred wafer support also includes a plurality of wafer-engaging fingers 979 positioned about the periphery of the wafer or other workpiece. FIG. 27 shows the front face of the outer rotor part 940 in a face-up orientation with fingers 979 extending therefrom. The preferred fingers are J-shaped and mounted for pivotal action about a finger pivot axes 953 . The pivotal action preferably ranges between an outboard position and an inboard position. In the outboard position the J-shaped fingers are positioned outwardly and clear of the wafer peripheral edge. A preferred outboard position is illustrated in FIG. 27 . In the outboard position the hooked portions of the J-shaped fingers are oriented at approximately 15 angular degrees outward from a line drawn tangent to the periphery of the wafer adjacent to the finger. In the inboard position the fingers are positioned inwardly to engage the wafer, as shown in FIG. 28 . In the inboard position the hooked portions of the J-shaped fingers are oriented at approximately 45 angular degrees inward from a line drawn tangent to the periphery of the wafer adjacent to the finger.
The face of the rotor assembly is provided with workpiece standoff supports 721 which are in complementary position to the engagement ends of the fingers when the fingers are in a retracted position to hold the wafer. This construction securely captures the wafer or other workpiece between the fingers and the standoffs.
In addition to the pivotal action of the engagement fingers, the fingers are also move axially toward and away from the face of the rotor. In the inboard position the fingers are retracted toward the wafer to engage the exposed, front face of the wafer along a marginal band adjacent to the periphery of the wafer. In the outboard position the fingers are extended away from the face of the wafer to prevent rubbing action as the fingers pivot away from the wafer. This compound action including both a pivot component and an axial component is accomplished using a finger actuator transmission 960 shown in perspective relationship to the rotor in FIG. 26 . Transmissions 960 are mounted within the transmission receptacles 937 of the inner rotor part 934 . The transmissions are further mounted by transmission retainers 951 which are secured by fasteners to inner rotor part 934 .
FIG. 29 shows the finger actuator transmission 960 in greater detail. The lower end of transmission 960 includes a finger head mounting receptacle 954 . Receptacle 954 is advantageously provided with a locking feature included to secure the fingers in the receptacles. As shown, the receptacle includes a convoluted, bayonet-type, locking pin groove 955 . Locking pin groove 955 receives a transversely mounted finger mounting pin 956 (see FIG. 32) which is a rolled or other suitable pin secured in the head of the finger assembly.
FIGS. 29, 30 , and 31 detail the preferred construction of the actuator transmissions 960 . The transmissions include a transmission base 961 which is provided with a mounting cutout 962 which is borne upon by the retainers 951 when installed in the rotor. The base also includes a central passageway within which is received a transmission shaft 963 . Shaft 963 can both pivot and move axially within the central passageway. The shaft and base 961 are constructed to interact in a manner which controls the relative motion of the shaft. This is done to provide the compound pivotal and axial movement of the shaft and a finger 979 which is held therein. As shown, the inactive mechanism is provided in the form of a shaft channel or groove 964 which is engaged by a shaft camming control member 965 . The camming action of the groove is provide by a helical advance over a pivotal movement range of approximately 60 degrees of rotation. The associate axial travel is in the range of approximately 5-20 millimeters, more preferably about 10-15 millimeters.
The camming control member 965 is advantageously in the form of a ball 966 held into the groove 964 using a ball support fastener 967 . Fastener 967 has a ball socket which receives portions of the ball. Fastener 967 also serves as a convenient electrical contact terminal when electricity is supplied to the fingers 979 .
The shaft 963 is provided with an interior shaft passageway 968 which receives a spring retainer 969 . Spring retainer 969 has an engagement head which mechanically engages with a finger mounting spring 938 . The spring 938 serves to bias a finger assembly into a locked position using the locking pin 956 held in biased relationship by groove 955 . Spring retainer 969 is secured in the passageway by a set screw 939 .
FIG. 31 also shows that the transmission 960 preferably includes a transmission head 656 . Transmission head 656 is connected to the upper end of shaft 963 using a bearing 657 which allows the shaft to pivot relative to the head pieces 658 and 659 . Head pieces 658 and 659 capture the bearing between them, and are joined by head fasteners 660 . The head fasteners 660 thread into a pair of head guide rods 661 . Head guide rods 661 are slidably received by two guide passageways 662 formed in the transmission base 961 . The head assembly is biased upwardly by two head bias springs 664 . Engagement between ball 966 and groove 964 limits the upward movement of the head assembly under action by springs 664 .
The lower end of shaft 963 is sealed to the base 961 using a shaft seal 667 which helps to keep any abraded metal within the transmission and prevent contamination toward the fingers 979 . Shaft 963 , also has a transverse hole 665 which is used as an electrical connection feature that receives a wire (not shown) run from the slip ring down the rotor shaft. The wire is secured in hole 665 by a set screw (not shown).
The transmissions 960 are activated by a transmission head depression ring 683 (see FIG. 24 ). Depression ring 683 , is connected to an operator output connection ring 684 (see FIG. 25 ). The operator output connection ring is secured by fasteners to the output shafts of pneumatic actuator engines 691 . FIG. 25 also shows pneumatic manifolds 692 used to supply the actuator engines. The preferred construction shows three actuator engines 691 which have outputs which move upwardly and downwardly to depress the transmission heads 658 and operate the fingers in the compound axial and pivotal motion already described. The actuator engine outputs are extended to depress rings 683 and 684 , and to depress the transmission heads 658 thus causing the fingers 979 to move from the inboard retracted positions of FIG. 28 to the outboard extended positions of FIG. 27 .
Electrode Fingers With Submerged Conductive Current Transfer Areas
FIGS. 32-39 show a number of different electrode finger constructions. The different constructions shown have particular application to differing applications. FIG. 32 shows a finger assembly 631 having intended application for contacting a semiconductor wafer during blanket plating of copper. Finger assembly 631 includes a finger shaft 632 which is formed in a J-shape and made from an electrically conductive material, such as stainless steel or tungsten. The finger assembly also preferably includes an integral finger head 633 which is received into the receptacle 954 of the actuator transmission 960 . The head has a pin aperture which receives the locking pin 956 therein for engagement with the locking groove 955 formed in the receptacle of the actuator transmission.
Finger assembly 631 also preferably includes dielectric sheathing 634 and 635 . Dielectric sheathing 634 and 635 is advantageously made from a polyvinylidene fluoride coating or layer applied to the shaft of the finger. The dielectric sheathing is preferably provided upon only limited portions of the electrode shaft and adjacent the contact head 636 . The contact head has a contact face 637 which directly bears upon the wafer to pass electrical current between the electrode and wafer. The contact face 637 is approximately equal to a fluid submersion boundary 639 . The submersion boundary indicates the approximate level of the plating liquid during processing.
The limited coverage of the dielectric sheathing is for the purpose of improving the uniformity of plating performed upon semiconductor workpieces held in the wafer support. It is believed that the submersible surfaces of the electrode finger are best provided with dielectric sheathing segments which comprise between approximately 25 percent and 75 percent of the submersible area of the electrode. These amounts do not consider the contact face as part of the areas. FIG. 32 show two segments 634 and 635 which cover about 50 percent of the electrode finger shaft exterior surfaces from the submersion line 639 downward, as positioned in a plating liquid bath during processing. The first dielectric segment 634 is adjacent to the contact face 637 a first electrically conductive segment 642 exists between the dielectric segment 634 and the contact face 637 . A second electrically conductive segment 643 exists between first and second dielectric segments 634 and 635 . A third electrically conductive segment 644 exists between the second dielectric segment 635 and submersion line 639 . The electrically conductive segments 642 - 644 provide current transfer areas which cause plating current that is supplied through the finger head 633 to be directly passed to the plating liquid contained in a plating bath. This is believed to provide a more uniform current density and more uniform voltage profile across the surface of a wafer which is being blanket plated with copper or other plating metals.
FIG. 33 shows another plating system workpiece support electrode 651 having many of the same features as electrode 631 described immediately above. The same reference numerals have been used to designate similar parts. Differences between finger electrodes 651 and 631 will now be described. Electrode 651 has three current transfer areas 642 - 644 . The size and shape of areas 642 - 644 are somewhat different from the corresponding areas of electrode 631 . More specifically, the second and third current transfer areas 643 and 644 are elongated along the shaft. The second dielectric sheath segment 635 is shortened. A third dielectric segment 653 has been included. The third dielectric sheath 654 forms the submerged dielectric segment 653 and also extends above the submersion line 639 to head 633 . The area of the submerged current transfer segments is between 25 and 75 percent of the submerged surface area, more particularly, about 50 percent.
Electrode 651 is also provided with a distal contact insert part 655 . Insert part 655 is received within an insert receptacle 616 formed in the distal end of the electrode shaft. The insert contact tip 655 defines a contact face 617 which bears upon a wafer being held. The insert contact part is made from a conductive material which is preferably non-corrosive material, such as platinum or stainless steel.
FIG. 34 shows a further electrode finger construction in the form of electrode finger 979 . Similar parts to electrode fingers 631 and 651 are similarly numbered in this figure. The electrode shaft is covered by a dielectric sheath 621 which largely covers the electrode shaft and leaves only a first current conductive area 642 which is immediately adjacent to the contact face 637 . This construction is contrasted to the electrodes 631 and 651 because electrode finger 979 does not have current transfer areas which comprise 25 percent of the submerged portion of the electrode. It also does not have current transfer areas which are exposed in a manner which is separated by a dielectric segment interpositioned between the contact face 637 and the removed or remote current conductive segment.
FIG. 35 shows a further electrode finger 601 which has submerged current transfer areas 642 - 644 . It also has dielectric segments 634 and 635 . Dielectric segment 635 of this figure has a differing shape and coverage area as compared to the other electrodes discussed above. In this construction the dielectric sheath extends along the outer curvature of the electrode J-bend. Curved upper edges extend so as to provide an overlying web portion 603 which covers the inner curvature of the J-bend. Performance in terms of plating uniformity has been found to be superior in some processes which employed the electrode of this figure.
The electrodes 631 , 651 and 601 are preferably used in novel processes according to this invention. These processes include contacting a surface of the semiconductor article or workpiece with an electrode at a contact face thereof. The methods also include submersing a portion or portions of the electrode into a plating bath containing a plating liquid which is typically a solution and mixture have various components known in the art. The methods also preferably include wetting a processed surface of the semiconductor article with the plating bath. Further included is the step of moving or conducting electrical current through the electrode and plating bath to perform an electroplating action to occur upon at least the processed surface of the wafer or other article. The methods further advantageously include diverting a portion of the electrical current directly between the electrode and the plating bath along at least one electrically conductive segment of the electrode. The electrically conductive segment is preferably spaced from the contact face a substantial distance, such as greater than 5 millimeters, and preferably is spaced therefrom by an intervening dielectric sheath.
Electrode Fingers With Dielectric Sheaths Covering Submerged Areas
FIG. 36 shows another electrode finger 681 which is similar to electrode finger 651 . Finger 681 is similar to finger 651 except it includes a full dielectric sheath 682 which extends from above submersion line 639 to contact insert side walls 619 . This construction preferably uses a coating layer 682 , such as from polyvinylidene fluoride, which can be applied by dipping or otherwise forming the layer over the shaft of the electrode. This construction includes the dielectric layer over the distal end of the electrode shaft and into sealing relationship with the side walls of the insert contact part or tip 655 . The dielectric coating or other layer 682 excludes corrosive processing fluids. Since the contact tip is preferably made from a non-corrosive material, such as platinum, the only material of the electrode which is exposed to direct corrosive action is the non-corrosive tip which is able to maintain good service despite the difficult operating environment.
Additionally, the construction of electrode 681 is particularly advantageous because the joint formed between the inserted contact tip 655 and receptacle 616 is covered and protected from direct exposure to the corrosive plating liquid and fumes present in the processing chamber.
The invention further includes methods for plating metals onto the surface of a semiconductor workpiece using electrode finger 681 . The methods include contacting a surface of the workpiece with an electrode assembly using a contact face, such as face 617 , on a contact part, such as contact insert part 655 . The contact insert is mounted on the distal end of the electrode shaft. It is further preferably provided with a dielectric layer formed about the distal end in sealing relationship against the contact part. The methods further preferably include submersing or otherwise wetting a processed surface of the workpiece, such as in a plating bath liquid used to plate the workpiece with a plating material. The methods also preferably include excluding the plating bath liquefied from the contact part joint, such as the joint formed between the contact part 655 and receptacle 616 . The methods further include electroplating the workpiece with plating material by passing electrical current through the contact part and between the semiconductor workpiece and electrode assembly. The contact face plating layer is more preferably formed from the plating material as is described below in additional detail. The method is most preferably used to plate copper onto the surface of semiconductor materials, such as silicon or oxides thereof.
Pre-Conditioning of Electrode Contact Faces
FIGS. 37 and 38 illustrates a further electrode construction in accordance with further inventive aspects of the workpiece support systems and methods described herein. FIG. 37 shows distal end portions of an electrode 614 . Electrode 614 is otherwise similar to electrode 681 described above. At the distal end of electrode finger 614 is a distal exposed surface 615 is made from a suitable material, such as stainless steel or tungsten. A dielectric sheath 616 is advantageously provided along the exterior portions of the electrode adjacent to the distal exposed surface 615 .
FIG. 38 shows the electrode 614 with a deposited contact face plating layer 618 formed thereon. The layer 618 is preferably a layer made from the same or a very similar material as is being plated onto the semiconductor workpieces with which electrode 614 is to be used. For example, if copper is being plated onto the semiconductor device, then the layer 618 is a layer plated from the same plating, bath or from a plating bath which will provide a layer 618 which is the same or very similar to the constituency of the copper deposited onto the semiconductor device being plated. In a preferred manner of carrying out this invention, the exposed distal surfaces 615 are placed into a plating bath and electrical current is conducted through the bath and distal end of the electrode 614 . This causes a plating action to occur which deposits the layer 618 . The resulting layer is preferably at least 1 micron in thickness, more preferably in the approximate range of 1-100 microns thick.
This method and resulting construction results in a pre-conditioned electrode contact surface which is of the same or very similar material as plated onto the semiconductor device during the later plating operation. The use of the same or similar materials prevents galvanic or other types of chemical reactions from developing due to dissimilarity of the metals involved.
The invention further includes additional methods for plating metals onto the surface of a semiconductor workpiece. The preferred methods include contacting a surface of the semiconductor workpiece with an electrode at a contact face forming a part of the electrode. The contact face is covered or substantially covered by a contact face plating layer. The contact face plating layer is formed from a contact face plating material which is the same or chemically similar to thee plating material which is to be plated onto the semiconductor workpiece during processing. The methods also preferably include submersing or otherwise wetting a processed surface of the workpiece into a plating bath or using a plating liquid or fluid. Other means for depositing the plating material as a contact face layer may alternatively be used. The methods further include electroplating workpiece plating material onto the semiconductor workpiece by passing electrical current between the workpiece and the electrode having such contact face plating layer. The methods are of particular advantage in the plating of copper onto semiconductors using a copper contact face plating layer.
Methods Using Workpiece-Engaging Electrode Assembly With Sealing Boot
FIG. 39 shows a further electrode finger 583 which has features similar to 651 and such similar features are identified with the same reference numbers. Electrode finger 583 differs from finger 651 in that the electrode shaft 584 is covered between the head 633 to the distal end of the electrode shaft with a cover or boot 585 . Boot 585 is preferably made in a manner which provides a continuous cover from near the electrode head 633 to a distal contact lip 586 . The boot includes additional features adjacent the contact insert part 655 . More specifically, the boot includes a skirt portion 587 which extends above the electrode shaft distal end surface 588 . The contact face 617 of (the insert part 655 is preferably about even with the distal contact lip 586 which is formed upon the end of the skirt portion 587 . The skirt portion serves as a deformable seal which comes into contact with a surface of a wafer or other semiconductor workpiece being contacted.
FIGS. 40 and 41 illustrate novel methods which advantageously utilize the improved features of electrode finger 583 . The methods involve plating metals onto the surface of semiconductor workpieces, specifically onto a semiconductor wafer W which has a substrate or other subjacent layer 561 which has been previously provided with a thin metallic seed layer 562 which is shown by a heavy black line in that figure. A via or other opening 563 exists in a photoresist layer 564 which overlies the substrate and seed layers.
FIG. 40 shows the electrode 583 poised in a disengaged position in preparation for contact with the surface. FIG. 41 shows the electrode 583 retracted against the surface of the workpiece. In the engaged position the contact face 617 is extended through the opening 563 and into direct electrical contact with exposed areas of the seed layer 562 which are not covered by the layer of photoresist or other covering layer. A seal is formed by depressing the skirt 587 and attached lip 586 against the outer surface of the photoresist layer 564 .
The novel methods include selecting an electrode assembly having desired features, such the features of electrode finger 583 . More specifically, the selecting step preferably includes selecting an electrode assembly having an electrode contact which is surrounded by an electrode boot or other sealing member. The methods also include engaging coated surface portions, such as photoresist layer 564 , with the sealing member or boot. The sealing can occur about a continuous peripheral sealing line, such as defined by the engagement of lip 586 against the photoresist surface. It is important to engage the lip against the photoresist surface and not against the seed layer 562 because sealing against the seed layer can cause erosive or corrosive effects to occur at or near the line or area of engagement of the boot with the seed layer. Such erosive or corrosive actions can cause the seed layer to become discontinuous or even totally isolated. A discontinuous or isolated contact region will lead to electroplating failure because the needed current will not be communicated in an even manner to the areas adjacent to the electrode which need current to accomplish plating. The engagement of the seal against the coating causes a sealed space to be enclosed within the seal by the electrode boot and the processed surface of the workpiece.
The novel methods further include enclosing a via or other opening within the seal. The via is present on the processed surface and has associated exposed seed layer portions therein for allowing electrical contact to be made. The via is needed to allow direct contact between the contact face of the electrode finger assembly and the seed layer which is used to communicate electrical current across the wafer for electroplating a metal thereonto. Thus, the methods further include contacting the seed layer through the via with the electrode contact to form an electrically conductive connection between the electrode assembly and the seed layer. This contacting step is advantageously performed using a contact face which bears upon the seed layer and is enclosed with the sealed space. Other desirable attributes explained hereinabove in connection with other electrodes can also be utilized to advantage in performing this process.
The methods still further include wetting the processed surface of the workpiece with a plating or other processing liquid. This is typically done by lowering the wafer holder into position to bring the outer, processed surface of the wafer into direct contact with a plating liquid held in a plating bath, such as described elsewhere herein in additional detail.
The methods also preferably include passing electrical current through the electrode and plating bath to cause electroplating to occur upon exposed seed layer areas of the processed surface. Such exposed seed layer areas may be trenches, vias or other features where the photoresist layer 564 is not present to cover the seed layer 562 . The electrical current causes electroplating to occur on such exposed seed layer areas.
Still further, the methods preferably include excluding plating or other processing liquid from the sealed space to substantially reduce or eliminate plating or other action in the area immediate adjacent to the contact with the electrode.
The methods described above are of particular relevance to plating copper onto semiconductors.
Plating Bowl Assembly
FIG. 42 shows an electroplating bowl assembly 303 . The process bowl assembly consists of a process bowl or plating vessel 316 having an outer bowl side wall 317 , bowl bottom 319 , and bowl rim assembly 314 . The process bowl is preferably circular in horizontal cross-section and generally cylindrical in shape although other shapes of process bowl may be possible.
The invention further advantageously includes a cup assembly 320 which is disposed within process bowl vessel 316 . Cup assembly 320 includes a fluid cup portion 321 having a cup side 322 and a cup bottom 323 . As with the outer process bowl, the fluid cup 321 is preferably circular in horizontal cross-section and cylindrical in shape. The cup assembly also has a depending skirt 371 which extends below the cup bottom 323 and has flutes 372 open therethrough for fluid communication and release of any gas that might collect as the chamber below fills with liquid. The cup assembly can be made using upper and lower portions which couple together at a cup main joint 387 . The cup is preferably made from polypropylene or other suitable material, which is advantageously dielectric.
The lower opening in the cup bottom wall is connected to a riser tube 361 which is adjustable in height relative thereto by a threaded connection. The riser tube seals between the bottom wall 319 of the process bowl and the cup bottom 323 . The riser tube is preferably made from polypropylene or other suitable dielectric material. A fitting 362 connects the riser tube 361 and the fluid inlet line 325 to allow adjustment of the anode vertical position. The fitting 362 can accommodate height adjustment of both the riser tube and inlet line 325 . The inlet line is made from a conductive material, such as titanium and is used to conduct electrical current to the anode 334 , as well as supply fluid to the cup.
Process fluid is provided to the cup through fluid inlet line 325 . The fluid inlet line rises through riser tube 361 and bowl bottom opening 327 and through cup fluid inlet openings 324 . Plating fluid fills the cup portion 321 through opening 324 as supplied by a plating fluid pump (not shown) or other suitable supply which provides the fluid under at least some pressure for delivery.
The upper edge of the cup side wall 322 forms a weir which determines the level of plating liquid within the cup. Excess fluid pours over this top edge surface into the overflow chamber 345 . The fluid held in the overflow chamber 345 is sensed by two level detectors 351 and 352 . One level detector is used to sense a desired high level and the other is used to sense an overfull condition. The level of liquid is preferably maintained within a desired range, for stability of operation. This can be done using several different outflow configurations. A preferred configuration is to sense the high level using detector 351 and then drain fluid through a drain line as controlled by a control valve. It is also possible to use a standpipe arrangement (not illustrate), and such is used as a final, overflow protection device in the preferred plating station 303 . More complex level controls are also possible.
The outflow liquid from chamber 345 is preferably returned to a suitable reservoir. The liquid can then be treated with additional plating chemicals or other constituents of the plating or other process liquid and used again.
The plating bowl assembly 303 further includes an anode 334 . In the preferred uses according to this invention, the anode is a consumable anode used in connection with the plating of copper or other metals onto semiconductor materials. The specific anode will vary depending upon the metal being plated and other specifics of the plating liquid being used. A number of different consumable anodes which are commercially available may be used as anode 334 .
FIG. 42 also shows a diffusion plate 375 provide above the anode 334 for rendering the fluid plating bath above the diffusion plate with less turbulence. Fluid passages are provided over all or a portion of the diffusion plate to allow fluid communication therethrough. The height of the diffusion plate is adjustable using three diffuser height adjustment mechanisms 386 and secured by three mounting fasteners 389 .
Plating Anode Shield
The invention also includes an anode shield 393 which can be secured to the consumable anode 334 using anode shield fasteners 394 . The anode shield and anode shield fasteners are preferably made from a dielectric material, such as polyvinylidene fluoride or polypropylene. The anode shield is advantageously about 2-5 millimeters thick, more preferably about 3 millimeters thick.
The anode shield serves to electrically isolate and physically protect the back side of the anode. It also reduces the consumption of organic plating liquid additives consumed. Although the exact mechanism may not be known at this time, the anode shield is believed to prevent disruption of certain materials which develop over time on the back side of the anode. If the anode is left unshielded the organic chemical plating additives are consumed at a significantly greater rate. With the shield in place these additive are consumed less. The shield is preferably positioned on the anode so as to shield it from direct impingement by the incoming plating liquid.
The invention thus also include methods for plating which include other method steps described herein in combination with shielding a consumable anode from direct flow of plating liquids using a dielectric anode shield.
As illustrated and described above, the electrodes used to conduct plating power to the workpiece may develop deposits. This is particularly true in those instances in which the electrodes are directly exposed to the electrolyte during electroplating. Accordingly, the reactor may be operated to execute at least two operational cycles: a normal cycle and a cleaning cycle. More particularly, the reactor is operated during the normal cycle to electroplate at least one metal on a surface of one or more semiconductor workpieces. The reactor is then operated during a cleaning cycle to clean the electrodes that were used to electroplate the metal by removing metal that was deposited on the electrodes during the normal operating cycle. The cleaning cycle is executed as an operational step that is separate from the normal cycle in which the workpieces are electroplated. The cleaning cycle takes place “in-situ” in that the cleaning of the electrodes takes place at the site of the reactor.
In accordance with one specific embodiment of the method, the electroplating and in-situ cleaning processes are performed in an operational sequence that begins by establishing electrical contact between at least one surface of the workpiece and the electrode. At least one surface of the workpiece is then brought into electrical contact with an electrolyte within the reactor base after which a current is passed through the electrode and the at least one surface of the semiconductor workpiece using an electrical power supply. This application of power results in the electroplating of a metal from the electrolyte onto the surface of the workpiece. The workpiece is then removed from electrical contact with the electrode and the electrode is placed into the electrolyte within the reactor base without a workpiece. With the electrode in contact with the electrolyte, a further current is generated by the electrical power supply for flow between the electrode and the electrolyte in a direction opposite to the direction of current flow during electroplating. The voltage potential used to generate this current may be in the range of about 0.1 to 100 volts, with a range of 1 to 10 volts being suitable. The voltage used may be selected so that it is dependent on the number of workpieces that are processed during the normal cycle of operation. Further, this potential may be generated between the electrode and the anode or, alternatively, between the electrode and an auxiliary electrode. Application of this reversed power causes metal previously plated onto the electrode to electrochemically disperse into the electrolyte and leaves the electrode clean for subsequent use in the electroplating of a further set of workpieces.
To enhance cleaning of the electrodes, the reactor head may be rotated in the electrolyte during the cleaning cycle. For example, the reactor head may be rotated at an angular velocity of about 1 to 300 revolutions per minute, with a smaller range of 10 to 100 revolutions per minute also being suitable. The rotation may take place concurrently with the application of the reverse current and may occasionally reverse direction. For example, the rotation may be reversed every 10 seconds to about every one minute.
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Methods and apparatuses for in-situ cleaning of semiconductor electroplating electrodes to remove plating metal without requiring !the manual removal of the electrodes from the semiconductor plating equipment. The electrode is placed into the plating liquid and, an electrical current having reverse polarity is passed between the electrode and plating liquid. Plating deposits which have accumulated on the electrode are electrochemically dissolved and removed from the electrode.
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BACKGROUND OF THE INVENTION
This invention relates to energy-absorbing tear webbing, and more particularly to such webbing which has woven pile or tear yarn which is designed primarily for parachute harnesses and the like, but it is understood that the invention can be used for any purposes for which it is found applicable.
The use of strap webbing for absorbing shock has been proposed in the parachute art and wherever straps are employed in an environment to absorb shock, such as a window-washer harnesses.
One example of a parachute harness is illustrated in U.S. Pat. No. 2,352,036 where the several straps are temporarily attached together by thread stitching. When a force is applied between the straps, the stitching therebetween is gradually parted to absorb the shock. The intervals between the rows of stitches can be irregular to vary the shock-absorbing characteristics.
Experience has revealed that the backing straps may be physically damaged by the needle during the stitching process, and for this and other reasons it has been proposed to replace the breakable stitching with a pile yarn which is woven in and between the backing straps during the weaving process of fabricating the straps. Such a technique is illustrated by the U.S. Pat. Nos. 3,463,202 and 3,612,110. In these two patents, the pile or binder yarn passes over a group of several weft picks in one strap before transferring to the other strap, etc., except where provision is made for a buckle where the pile yarn extends unwoven along the straps for a predetermined distance.
Test have shown that such prior art webbing straps perform satisfactorily at low speeds, i.e., under 200 f.p.s. However, tearing out through the backing strap is minimized by making the straps much stronger than would otherwise be necessary. Failure of the straps to peel apart at high speeds has prevented the use of such straps in those applications where velocity of separation exceed 300 f.p.s.
SUMMARY OF THE INVENTION
An improved energy absorbing webbing of the type formed of at least two woven straps or tapes interconnected by a woven pile yarn is achieved by uniquely arranging disposition of the pile ends so as to gradually increase the resistance to tearing. In other words, there is a gradual increase in the density of the pile ends along a given length of the webbing which causes a correspondingly gradual increase in shock absorption. A second aspect of the improved webbing is the increased resistance of the straps to tearing out instead of peeling, which result is attained by employing a so called W-shaped weave to snub the pile yarn around each and every weft end, rather than by gross over-design of the straps as is found necessary in prior-art webbings.
OBJECTS OF THE INVENTION
A principal object of this invention is to provide an energy absorbing tear webbing which will function at high speed separations to achieve the desired result.
A further principal object of this invention is to provide an energy absorbing tear webbing which will provide a gradual and progressively increase in the resistance by the tear elements in such webbing.
Another important object is to provide webbing straps having an increased resistance to tearing out of the backing straps especially to high speed velocities, without the necessity of their being over-strengthened.
A still further object is to provide a webbing having an arrangement of a pile yarn which will snub or bind each and every weft end of the webbing straps.
Still another object is to provide a webbing which is more versatile and which can be tailored for use in a variety of different applications.
Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a sample webbing fabricated from two woven backing straps normally connected together in back-to-back contiguous relation by three pile yarn woven in and between the straps. The straps being shown in an expanded condition for purposes of clarity.
FIG. 2 is a reduced sized diagrammatic top view of the type of webbing in FIG. 1 showing by solid lines the location along the length of the webbing where plurality of pile yarns are gradually first introduced in the webbing as pile ends.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings where like reference numerals refer to similar parts throughout the figures there is shown in FIG. 1 a sample tear webbing 10 constructed according to the teaching of the present invention. Webbing 10 is fabricated of two woven webbing straps 12 and 14 which straps may be of conventional design and identical to each other. Straps 12 and 14 are woven as separate systems with longitudinally extending warp yarn sets 16, 18, respectively, and transversely extending filler or weft yarn sets 20, 22, respectively. Straps 12 and 14 are woven preferably by separate shuttles to provide independent straps, connected together in the unique manner presently to be described.
Straps 12 and 14 are detachably connected together in contiguous, face-to-face relation, as shown in FIG. 1 by pile yarns 24, 26, and 28, only three pile yarns being shown for clarity of illustration. For example, in FIG. 2 fifteen different pile yarns are illustrated, the details of which will be hereinafter described. Accordingly, the precise manner, as well as the disposition of the pile yarns, used in any particular piece of webbing will depend on the desired amount of energy to be absorbed, which in turn depend on specific application to which the webbing is to be employed.
As is well known in the webbing art, the function of the pile or tear yarn is to absorb energy by tearing when the two straps are pulled apart laterally, for example by the force illustrated by arrows 30. The details of how webbing 10 is incorporated in any specific parachute harness or other equipment and the manner of applying the force 30 forms no part of the present invention.
One of the significant novel features of the present invention is the unique arrangement of detachably connecting the two webbings together to provide for better shock absorption characteristics.
According to the teaching of the aforementioned prior art patent, i.e., U.S. Pat. No. 3,612,110, the pile yarn is woven between the straps uniformly along the length of the webbing, or in other words, the pile yarn woven in a non-graduated or uniform manner. As has been described, this prior art construction generally has been satisfactory when used in low speed separations by constructing the webbing straps stronger than would otherwise be necessary to prevent the tearing-out of the webbing straps.
According to the present invention, the various pile yarns are introduced as pile ends between the webbing straps in a non-uniform or in a graduated manner. Gradually increasing the density of the pile ends along the given length of the webbing, correspondingly will increase gradually the resistance by the pile ends to, and absorption of, the tearing force in any selected increment that is determined by the designer to be optimum for the specific application.
For example, in FIG. 1 pile yarn 24 illustrated by the dotted line, one of the three illustrated pile yarns, initially is woven in webbing strap 12 (progressing from left to right in the drawing) like any warp yarn. Pile yarn 24 progresses along webbing strap 12 and initially becomes a pile end at station A along the length of the webbing at cross-over point 30, between the webbing straps. Thereafter, pile yarn 24 follows a repeated W woven pattern alternately in the two webbing straps. The significance of the W pattern will be hereinafter described.
The second pile yarn 26, illustrated by the heavy solid line, is continuously woven in webbing strap 14 like any warp yarn, and initially becomes a pile end at station B at cross-over point 32. Thus, at station B pile yarn 26 supplements pile yarn 24, and the two yarns provide an increased resistance to the tearing force 30.
Likewise, third pile yarn 28, illustrated in FIG. 1 by a light solid line, is continuously woven in strap 12 as a warp yarn until station C where it initially becomes a pile end at cross-over point 34. Pile yarn 28 is then woven in a W formation in strap 14, and then alternates with a similar pattern between the webbing straps 12 and 14, in a similar manner described for pile yarns 24 and 26.
It should be noted that after station C, webbing 10 thereafter contains a uniform or non-graduated number of pile ends, for the three pile yarn example of webbing shown in FIG. 1. That is, the pile ends of the three different pile yarns consecutively cross over from one webbing strap to the other.
Thus, it can be seen with the three-pile yarn webbing as illustrated in FIG. 1, that the portion of the webbing commencing from the left, as viewed in the drawing, and extending to and including station C represents a graduated pile end webbing section which provides a gradually increasing resistance to the tearing force 30. Conversely, the remaining length of the webbing to the right of station C is a non-graduated pile end webbing section providing a uniform resistance to the tearing force.
Webbing 10 can be woven with only graduated pile ends, namely stations A, B and C or integrated together as shown in FIG. 1, depending on the design requirements.
FIG. 2 is a reduced top view of a webbing 36 of the type illustrated in FIG. 1 showing diagrammatically where along the length of the webbing a plurality of the different pile yarns are initially introduced as pile ends in the webbing. For example, a central pile yarn 38 is initially crossed over between the webbing straps at station E at the beginning of the length of the webbing. Similarly, pile yarns 40 to 52, initially appear in the webbing as pile ends at stations F to G, respectively. Therefore, the gradually increasing number of density of pile ends, appearing in non-uniform section 54, as previously described, provides a correspondingly increasing resistance to the tearing force to which the webbing straps are subjected. The section 56 of the webbing 36 in FIG. 2 represents a uniform or non-graduation portion of the webbing which will offer a uniform resistance to the force.
In order to make the increase of resistance in such small steps as to be essentially continuous, the pile yarn can be fed from a creel of individual spools rather than from warps as presently done. The initial resistance to separation can be performed by a small number of pile ends (as few as one to five) and the remaining pile ends can be woven into the backing straps as additional warp ends. By means of a Jacquard machine, one or two additional ends can be added to the pile at intervals, which will, either linearly or logarithmically, depending on the tear webbing length available, include all available ends in the pile at one-half to three-quarters of the available tear length.
This unique so-called W weave configuration of the pile yarns woven in the respective webbing straps is another important feature of this invention. The W pattern should be readily discernible to the eye in FIG. 1. The function of the W weave is to bind or snub the respective pile yarns to each and every filler ends 20 and 22, so that the pile ends will tear rather than slip. Slippage causes the pile yarn to reinforce each other which enables a build-up of forces that will either cause failure of the webbing straps or failure of the webbing to peel and separate. As previously stated this is one of the disadvantages of the prior art patents which requires an over-design in the strength of the backing straps.
As shown in FIG. 1, the W weave is formed by passing each of the pile yarns over one filler end and under the next adjacent filler end thereby achieving a snubbing action between the pile yarn and each of the filler ends, binding the pile yarn in place. To achieve this result, each pile yarn must pass over and under at least three adjacent filler yarns in each webbing strap as shown in FIG. 1, before becoming a pile end, thus forming in effect a W weave. However, if additional binding is found necessary in any particular application the extent of the pile yarn weave in each strap can be extended for additional filler picks in multiples of two, that is, five, seven, etc.
Although Jacquard and creel are the preferred machines for weaving, the above weaving can be accomplished substantially by the use of a Dobby loom with multiple harnesses and with the pile yarn fed either from a creel or from multiple warps.
According to the present invention an improved energy-absorbing tear webbing is proposed that eliminates two of the difficulties experienced with prior art webbings, namely, the tearing out through the backing straps which has caused complete webbing system failure; and secondly; the failure of the pile yarn to tear at high speeds which results in a failure of the webbing to provide energy absorption. The invention webbing system is particularly valuable in high-speed separations where the velocity of separations exceed 300 f.p.s. because the prior art systems are incapable of use for these applications.
Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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An improved tear webbing is fabricated of two woven straps offering graduy increasing resistance to tearing of the pile yarn woven between the straps to assure that sequential tearing of only the pile ends will occur; and by providing the technique of snubbing or binding the pile yarn in place around each adjacent weft picks of the webbing so that the pile yarn will tear and discourage slipping that may otherwise cause failure of the straps.
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FIELD OF THE INVENTION
The present invention relates to a composite material based on an electret-type polymer matrix and a piezoelectric material contained in the matrix. More specifically, the invention relates to the electret composite of the aforementioned type that has deep trapping centers on the boundaries between the phases. The composite material of the invention may find wide industrial application, e.g., in the manufacture of robots, acoustoelectric transducers, communication systems, information writing and storing systems, electrical measuring instruments, etc.
BACKGROUND OF THE INVENTION
An electret is a solid dielectric that exhibits persistent dielectric polarization. In particular, an electret is a solid dielectric with a quasi-permanent electric moment. Electrets may be classified as real-charge electrets and dipolar-charge electrets. Real-charge electrets are dielectrics with charges of one polarity at or near one side of the dielectric and charges of opposite polarity at or near the other side, while dipolar-charge electrets are dielectrics with aligned dipolar charges. Some dielectrics are capable of storing both real and dipolar charges.
U.S. Pat. No. 4,046,704 issued to I. Sumita in 1977 discloses a high polymer electret comprising one member of poly-3,3-bis(chloromethyl)oxacyclobutane, poly-3,3-bis-(fluoromethyl)oxacyclobutane and poly-3,3-bis(bromoethyl)oxacyclobutane group. It possesses stability. A disadvantage of this material is that stability of this material is unpredictable because of its multicomponent structure. Another drawback of this multicomponent material is strong dependence on properties of the components.
Also known in the art is a method of preparation of a polymer electret described in U.S. Pat. No. 4,291,245 issued T. Nowlin, et al., in 1981. The method comprises the following steps: (a) providing a parylene film having one side affixed to a metal layer and grounding said metal layer; (b) charging the free side of the film with a direct current corona, the charge being of sufficient magnitude to convert the film to an electret; (c) providing p-xylylene monomer vapor in sufficient amount to coat the charged film; and (d) introducing the vapor from step (c) and the electret into a deposition zone, said zone being under vacuum and at a temperature at which the vapor will condense, whereby the electret is conformally coated with parylene. Its disadvantages include complex technology and multistage preparing, as well as existing unstable low organic compounds in the composition that reduce the life of the electret.
Known in the art is another polymer electret described in U.S. Pat. No. 4,626,263 to N. Inoue, et al., in 1981. The electret comprises 60 to 99% of non-polar polymer, 0.5 to 39.5% of polar polymer, and 0.5 to 20% of at least one component selected from the group consisting of (A) a non-polar polymer modified with an unsaturated carboxylic acid or a derivative thereof, (B) a non-polar polymer modified with an unsaturated epoxy monomer and (C) a non-polar polymer modified with a silane monomer having an olefinically unsaturated bond. In this electret, a high charge density can be maintained stably over a long period, and this electret can be easily formed into a film. An air filter prepared from this electret has excellent dust collecting efficiency. Its disadvantages include complex compounds, limited temperature range of stability, and instability in a heterocharge relaxor state caused by orientation of the polar polymer component during electrothermopolarization.
U.S. Pat. No. 6,573,205 issued to D. Myers, et al., in 2003 describes a porous polymeric sheet having an electrostatic charge and comprising a zero-three composite of a polymeric matrix and a ferroelectric material dispersed therein. The polymeric component comprises a non-polar thermoplastic polymer, such as a polyolefin, and a second thermoplastic polymer having polar functional units, such as a telomer. The composite material is formed into a porous sheet and is electrically or corona poled to create an electret material which is well suited for use in various filtration, air-masking and dust wipe applications. Its disadvantages included using barium titanate, barium titanate strontium, lead titanate and solid solutions based on their ferroelectric phase; as well as having relatively low Curie temperature and unstable domain structure.
U.S. Patent Application Publication 20080249269 (published in 2008 and invented by H. Chin, et al.) describes a polymer electret with outstanding thermal and charge stability. The electret materials comprise a melt blend of a thermoplastic polymer and one or more compounds selected from the aromatic trisamides. The aromatic trisamides are for example of the formula. The melt blends are subjected to an electret treatment, for example a corona treatment. The electret materials are for example nonwoven polyolefin webs and are employed as filter materials, wipes, absorbent materials, filter masks, acoustic materials, printing substrates, measuring devices or contactless switches. The electret materials may also comprise an additive selected from a hindered amine light stabilizers and hydroxyphenylalkylphosphonic esters or monoesters. Disadvantages of such electrets include complex manufacturing, use of low-molecular-weight aromatic materials, and unpredictability in formation of a system comprising homo- and heterocharges that define electret properties.
The known polymer electrets, however, possess a number of disadvantages such as low potential difference, relatively short lifespan, insufficient dielectric permeability and electric resistance, complexity of manufacture, and a multicomponent composition.
BRIEF SUMMARY OF THE INVENTION
An electret composite of the present invention is free of the disadvantages inherent in the known polymer electrets and is additionally characterized by having deep trapping centers on the interphase boundaries. The polymer electret composite of the invention comprises a matrix of high-density polyethylene or a fluorine-containing polymers and a piezoelectric material that may have various structures.
According to one aspect of the invention, an electret composite may comprise a high-density polyethylene matrix and a piezoelectric material having a tetragonal structure (PZT-8), where PZT-8 stands for piezoelectric ceramic material of the type PbTiO 3 —PbZrO 3 —PbNb 2/3 Zn 1/2 O 3 —PbNb 2/3 Mn 1/3 O 3 .
According to another aspect of the invention, an electret composite may comprise a high-density polyethylene matrix and a piezoelectric material having a rhombohedral structure (PZT-5A), where PZT-5A stands for a piezoelectric ceramic material of the type PbTiO 3 —PbZrO 3 —PbNb 2/3 Zn 1/3 O 3 —PbNb 2/3 Mg 1/3 O 3 —MnO 2 .
According to a third aspect of the invention, an electret composite may comprise a polyvinylidene fluoride matrix and a piezoelectric ceramic material with tetragonal structure (PZT-8).
According to a fourth aspect of the invention, an electret composite may comprise a polyvinylidene fluoride matrix and a piezoelectric ceramic with rhombohedral structure (PZT-5A).
According to a fifth aspect of the invention, an electret composite may comprise a polyvinylidene chloride matrix and a piezoelectric ceramic material with tetragonal structure (PZT-8).
According to a sixth aspect of the invention, an electret composite may comprise a matrix of copolymer vinylidene-chloride and tetrafluoroethylene and a piezoelectric ceramic with tetragonal structure (PZT-8), where tetrafluoroethylene is [—CH 2 —CF 2 —] n +[—CF 2 —CF 2 —] n , wherein “n” is a degree of polymerization ranging from 1000 to 10000.
According to a seventh aspect of the invention, an electret composite may comprise a matrix of copolymer vinylidene-chloride and tetrafluoroethylene and a piezoelectric ceramic with rhombohedral structure (PZT-8).
The polymer-piezoceramic type electret composite of the invention with deep trapping centers on the boundaries between the phases may have the following characteristics:
potential difference>500V; lifespan>10 years; dielectric permeability≧20; specific electric resistance≧10 14 Ohm·m; high electric capacity of electret material (due to dielectric permeability ∈ equal to or greater than 20); for example, electric capacity of the electret composite of the invention may have a value which is three times greater than electric capacity of polyvinylidene fluoride having the highest value of dielectric permeability (∈=10) among other known polymers; electric capacity C being determined by the following formula: C=∈ 0 ·∈·S/d, wherein S is an area, and d is a thickness of the electret composite provision of deep trapping centers on the interphase boundaries with activation energy in the range of 1 to 1.25 eV. stable electret charge with density of 6·10 −4 C/m 2 .
DETAILED DESCRIPTION
An electret polymer-piezoelectric composite of the invention with deep trapping centers on the interphase boundaries comprises a polymer matrix material, such as a high-density polyethylene or a fluorine-containing polymers and a piezoelectric material that may have various structures. The electret composite of the invention possesses a number of advantages as compared to known electret composites, such as 1) high potential difference, 2) high relaxation time (lifespan); 3) relatively high dielectric permeability; 4) high specific electric resistance; 5) simplicity of manufacturing technique, 6) fewer number of ingredients; 7) use of piezoelectric materials as ferroelectric phase with stable domain structure and high Curie temperature.
According to one aspect of the invention, an electret composite may comprise a high-density polyethylene matrix and a piezoelectric material having a tetragonal structure (PZT-8), where PZT-8 stands for piezoelectric ceramic material of the type PbTiO 3 —PbZrO 3 —PbNb 2/3 Zn 1/2 O 3 —PbNb 2/3 Mn 1/3 O 3 .
According to another aspect of the invention, an electret composite may comprise a high-density polyethylene matrix and a piezoelectric material having a rhombohedral structure (PZT-5A); where PZT-5A stands for a piezoelectric ceramic material of the type PbTiO 3 —PbZrO 3 —PbNb 2/3 Zn 1/3 O 3 —PbNb 2/3 Mg 1/3 O 3 —MnO 2 .
According to a third aspect of the invention, an electret composite may comprise a polyvinylidene fluoride matrix and a piezoelectric ceramic material with tetragonal structure (PZT-8).
According to a fourth aspect of the invention, an electret composite may comprise a polyvinylidene fluoride matrix and a piezoelectric ceramic with rhombohedral structure (PZT-5A).
According to a fifth aspect of the invention, an electret composite may comprise a polyvinylidene chloride matrix and a piezoelectric ceramic material with tetragonal structure (PZT-8).
According to a sixth aspect of the invention, an electret composite may comprise a matrix of copolymer vinylidene-chloride and tetrafluoroethylene and a piezoelectric ceramic with tetragonal structure (PZT-8), where tetrafluoroethylene is [—CH 2 —CF 2 —] n +[—CF 2 —CF 2 —] n .
According to a seventh aspect of the invention, an electret composite may comprise a matrix of copolymer vinylidene-chloride and tetrafluoroethylene and a piezoelectric ceramic with rhombohedral structure (PZT-5A).
Stability of electret properties of the composite of the invention results from the formation of a quasi-neutral system on the interphase boundaries. The aforementioned system consists of electrons on the interphase boundary injected during electrothermopolarization and piezophase domains orientation under the effect of local field of the injected charge carriers.
The deep ionized trapping centers are obtained on the interphase boundaries by a method that comprises the following steps: crystallizing the electret composite under conditions of electric-charge plasma in air thus forming oxidizing centers in the polymer phase; locally ionizing the polymer matrix material at deep levels on the interphase boundaries by cycle electrothermopolarization; and neutralizing the polymer matrix at the local levels of low polymer-phase activation energy by thermal cleaning. What is meant here by the term “thermal cleaning” is a neutralization of shallow traps with activation energy less than 0.5 eV.
EXAMPLES
Example 1
A sample of each electret polymer-piezoelectric composite comprising high-density polyethylene and PZT-8 ceramic was prepared by hot pressing. Deep ionized trapping centers on the interphase boundaries of this composite were formed by subjecting the prepared sample to the effect of crystallization sample in condition of acting plasma of an electric discharge and subsequent electrothermal treatment. The treated sample was polarized, and spectra of thermostimulated depolarizing current were measured. The electret potential difference and density of electret charges were also measured, and relaxation time of the electret state was determined. In almost all cases, the potential difference produced by the electret material (hereinafter referred to as “potential difference”) remained practically the same during the lifespan of the electret state of the composite material and had a value exceeding 500 V. Polarization of electrets was carried out for 0.5 hours at an electric field intensity E f of 2.5 to 8 MV/m and in the temperature range T n of 373 to 413 K. The measured specific electric resistance was greater than 10 14 Ohm·m. Parameters of the given electret composites are shown in Table 1.
TABLE 1
Characteristics of electrets and modes of polarization
Modes of polarization
E f ,
Q, 10 −5
τ
Treatment
Composites
MV/m
T n , K
t n,hour
C/m 2
(years)
modes
high-density
8
373
0.5
2.2
6
—
polyethylene -
PZT-8
high-density
7.5
373
0.5
5
9
Plasma-
polyethylene -
crystallized
PZT-8
high-density
8
373
0.5
8.7
11-12
Plasma-
polyethylene -
crystallized
PZT-8
and electro-
thermally
treated
Q is a density of electret charge,
τ is a lifetime of the electret (years);
T n , is a polarization temperature (° K);
t n is polarization time (hours).
Example 2
A sample of an electret polymer-piezoelectric composite comprising high-density polyethylene and PZT-5A ceramic was prepared by hot pressing. Formation of deep ionized trapping centers on the interphase boundary of the composite was carried out under conditions of electric discharge plasma and electrothermal treatment. The obtained sample was polarized, and spectra of thermostimulated depolarizing current were measured. The electret potential difference and density of electret charges were also measured, and relaxation time of the electret state was determined. Polarization of electrets was carried out for 0.5 hours at electric field intensity E f of 2.5 to 10 MV/m and in the temperature range T n of 350 to 450 K. Parameters of given electret composites are shown in Table 2.
TABLE 2
Characteristics of electrets and modes of polarization
Modes of polarization
E n ,
Q, 10 −5
τ
Treatment
Composites
MV/m
T n , K
t n,hour
C/m 2
(years)
modes
high-density
8
373
0.5
2.8
6.5
—
polyethylene -
PZT-5A
high-density
8
373
0.5
5.7
8.5
Plasma-
polyethylene -
crystallized
PZT-5A
high-density
8
373
0.5
6.7
10-11
Plasma-
polyethylene -
crystallized
PZT-5A
and electro-
thermally
treated
Q is a density of electret charge,
τ is a lifetime of the electret (years);
T n , is a polarization temperature (° K);
t n is polarization time (hours).
Example 3
A sample of each electret polymer-piezoelectric composite comprising a polyvinylidene fluoride and PZT-8 ceramic was prepared by hot pressing. Formation of deep ionized trapping centers on the interphase boundary of the composite was carried out under conditions of condition of electric discharge plasma and by electrothermal treatment. The obtained sample was polarized, and spectra of thermostimulated depolarizing current were measured. The electret potential difference and density of electret charges were also measured, and relaxation time of the electret state was determined. Polarization of electrets was carried out for 0.5 hours at electric field intensity E f of 2.5 to 10 MV/m and in the temperature range T n of 350 to 450 K. Parameters of given electret composites are shown in Table 3.
TABLE 3
Characteristics of electrets and modes of polarization
Modes of polarization
Q,
E n ,
10 −5
τ
Treatment
Composites
MV/m
T n , K
t n,hour
C/m 2
(years)
modes
polyvinylidene
6
413
0.5
2.0
0.5
—
fluoride - PZT-8
polyvinylidene
6
413
0.5
7.5
9-10
Plasma-
fluoride - PZT-8
crystallized
polyvinylidene
6
413
0.5
8.0
11-13
Plasma-
fluoride - PZT-8
crystallized
and electro-
thermally
treated
Q is a density of electret charge,
τ is a lifetime of the electret (years);
T n , is a polarization temperature (° K);
t n is polarization time (hours).
Example 4
A sample of each electret polymer-piezoelectric composite comprising a polyvinylidene fluoride and PZT-5A ceramic was prepared by hot pressing. Formation of deep ionized trapping centers on the interphase boundary of the composite was carried out under conditions of electric discharge plasma and by electrothermal treatment. The obtained sample was polarized, and spectra of thermostimulated depolarizing current were measured. The electret potential difference and density of electret charges were also measured, and relaxation time of the electret state was determined. Polarization of electrets was carried out for 0.5 hours at electric field intensity E f of 2.5 to 10 MV/m and in the temperature range T n of 350 to 450 K. Parameters of the given electret composites are shown in Table 4.
TABLE 4
Characteristics of electrets and modes of polarization
Modes of polarization
Q,
E n ,
10 −5
τ,
Treatment
Composites
MV/m
T n , K
t n,hour
C/m 2
year
modes
polyvinylidene
6.5
413
0.5
2.0
2-3
—
fluoride - PZT-5A
polyvinylidene
6
413
0.5
5.6
9-10
Plasma-
fluoride - PZT-5A
crystallized
polyvinylidene
6
413
0.5
8.0
11-12
Plasma-
fluoride - PZT-5A
crystallized
and electro-
thermally
treated
Q is a density of electret charge,
τ is a lifetime of the electret (years);
T n , is a polarization temperature (° K);
t n is polarization time (hours).
Example 5
A sample of each electret polymer-piezoelectric composite comprising a polyvinylidene chloride and PZT-8 ceramic was prepared by hot pressing. Formation of deep ionized trapping centers on the interphase boundary of the composite was carried out under conditions of electric discharge plasma and electrothermal treatment. The obtained sample was polarized, and spectra of thermostimulated depolarizing current were measured. The electret potential difference and density of electret charges were also measured, and relaxation time of the electret state was determined. Polarization of electrets was carried out for 0.5 hours at electric field intensity E f of 2.5 to 10 MV/m and in the temperature range T n of 350 to 450 K. Parameters of the given electret composites are shown in Table 5.
TABLE 5
Characteristics of electrets and modes of polarization
Modes of polarization
Q,
E n ,
10 −5
τ,
Treatment
Composites
MV/m
T n , K
t n,hour
C/m 2
year
modes
polyvinylidene
5
413
0.5
2.2
0.8
—
chloride - PZT-8
polyvinylidene
5
413
0.5
7.8
10-11
Plasma-
chloride - PZT-8
crystallized
polyvinylidene
5
413
0.5
8.2
12-13
Plasma-
chloride - PZT-8
crystallized
and electro-
thermo-
treated
Q is a density of electret charge,
τ is a lifetime of the electret (years);
T n , is a polarization temperature (° K);
t n is polarization time (hours).
Example 6
A sample of each electret polymer-piezoelectric composite comprising a copolymer vinylidene-chloride and tetrafluoroethylene and PZT-8 ceramic was prepared by hot pressing. Formation of deep ionized trapping centers on the interphase boundary of the composite was carried out under conditions of electric discharge plasma and by electrothermal treatment. The obtained sample was polarized, and spectra of thermostimulated depolarizing current were measured. The electret potential difference and density of electret charges were also measured, and relaxation time of the electret state was determined. Polarization of electrets was carried out for 0.5 hours at electric field intensity E f of 2.5 to 10 MV/m and in the temperature range T n of 350 to 450 K. Parameters of given electret composites are shown in Table 6.
TABLE 6
Characteristics of electrets and modes of polarization
Modes of polarization
Q,
E n ,
10 −5
τ,
Treatment
Composites
MV/m
T n , K
t n, hour
C/m 2
year
modes
Copolymer of
6
433
0.5
3.0
2-4
—
vinylidene-
chloride and
tetrafluoro-
ethylene -
PZT-8
Copolymer of
6
433
0.5
5.6
6
Plasma-
vinylidene-
crystallized
chloride and
tetrafluoro-
ethylene -
- PZT-8
Copolymer of
6
433
0.5
8.0
11-13
Plasma-
vinylidene-
crystallized and
chloride and
electro-
tetrafluoro-
thermally
ethylene -
treated
- PZT-8
Q is a density of electret charge,
τ is a lifetime of the electret (years);
T n , is a polarization temperature (° K);
t n is polarization time (hours).
Example 7
A sample of each electret polymer-piezoelectric composite comprising a copolymer vinylidene-chloride and tetrafluoroethylene and PZT-5A ceramic was prepared by hot pressing. Formation of deep ionized trapping centers on the interphase boundary of the composite was carried out under conditions of electric discharge plasma and electrothermal treatment. The obtained sample was polarized, and spectra of thermostimulated depolarizing current were measured. The electret potential difference and density of electret charges were also measured, and relaxation time of the electret state was determined. Polarization of electrets was carried out for 0.5 hours at electric field intensity E f of 2.5 to 10 MV/m and in the temperature range T n of 350 to 450 K. Parameters of given electret composites are shown in table 7.
TABLE 7
Characteristics of electrets and modes of polarization
Modes of polarization
Q,
E n ,
10 −5
τ,
Treatment
Composites
MV/m
T n , K
t n,hour
C/m 2
year
modes
Copolymer of
6
433
0.5
2.0
3-4
—
vinylidene-
chloride and
tetrafluoro-
ethylene -
PZT-5a
Copolymer of
6
433
0.5
5.7
9
Plasma-
vinylidene-
crystallized
chloride and
tetrafluoro-
ethylene -
PZT-5a
Copolymer of
6
433
0.5
8.0
11-13
Plasma-
vinylidene-
crystallized and
chloride and
electro-
tetrafluoro-
thermally
ethylene -
treated
PZT-5a
Q is a density of electret charge,
τ is a lifetime of the electret (years);
T n , is a polarization temperature (° K);
t n is polarization time (hours).
Although the invention has been shown and described with reference to specific embodiments, it is understood that these embodiments should not be construed as limiting the areas of application of the invention and that any changes and modifications are possible provided that these changes and modifications do not depart from the scope of the attached patent claims.
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An electret composite comprising a polymer matrix material that contains particles of a piezoelectric material with deep trapping centers on the interphase boundaries between the matrix and particles of a piezoelectric material. The piezoelectric material may have a tetragonal or a rhombohedral structure, and the polymer matrix material may be selected from high-density polyethylene, polyvinylidene fluoride, and a copolymer of vinylidenechloride and tetrafluoroethylene. The composite has a potential difference>500V, lifespan>10 years, dielectric permeability≧20, specific electric resistance≧10 14 Ohm·m; provision of deep trapping centers on the interphase boundaries with activation energy in the range of 1 to 1.25 eV, and stable electret charge.
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SUMMARY OF THE INVENTION
The present invention relates to gladhands of the type used in tractor and/or trailer applications and has particular application to a gladhand structure which includes a shutoff valve.
A primary purpose of the invention is a combination gladhand and shutoff valve in which the shutoff valve is positioned within the gladhand body and moves toward and away from a coaxially positioned gladhand seal.
Another purpose is a simply constructed reliably operable combination gladhand and shutoff valve.
Another purpose is a combination structure of the type described in which an exterior handle mounted on the gladhand body, slidably moves a valve plug within the gladhand body toward and away from the conventional gladhand seal.
Another purpose is a combination gladhand and shutoff valve of the type described which may be arranged either with or without a spring return for the slidable valve plug.
Other purposes will appear in the ensuing specification, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated diagrammatically in the following drawings wherein:
FIG. 1 is a plan view of one form of combination gladhand and shutoff valve, with parts removed and parts in section,
FIG. 2 is a section along plane 2--2 of FIG. 1,
FIG. 3 is a section, similar to FIG. 2, but illustrating a modified form of gladhand and shutoff valve construction,
FIG. 4 is a section along plane 4--4 of FIG. 3,
FIG. 5 is a plan view of yet a further form of gladhand structure,
FIG. 6 is a section along plane 6--6 of FIG. 5,
FIG. 7 is a partial view along plane 7--7 of FIG. 5,
FIG. 8 is a top plan view of a further modified form of the invention,
FIG. 9 is a section along plane 9--9 of FIG. 8, and
FIG. 10 is a partial side view of the gladhand body illustrating the ramp controlling movement of the shutoff valve.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present application describes a combination gladhand and shutoff valve which finds particular application in over-the-road vehicles and has utility as a part of the air system connecting a tractor to a trailer and/or connecting one trailer to a following trailer. In the trade the following trailer is known as a full trailer, whereas the trailer mounted upon a tractor is known as a semi-trailer. The gladhand construction shown has application within the air system of such vehicles and although only a portion of the gladhand construction is illustrated, it is well known in the art that there is a further fitting required in a complete gladhand construction. But for simplicity in description, only a portion of the gladhand construction is shown and described herein.
Reference is made to the following U.S. patents which illustrate similar types of gladhand constructions: 4,109,673, 3,960,365 and 3,245,428.
In the construction of FIGS. 1 and 2, the gladhand includes a body 10 having an outwardly extending flange 12 with a cam surface 14. Surface 14 will cooperate with a similar gladhand structure which forms the other part of the overall gladhand construction. Thus, two elements, body 10 and the portion of the gladhand construction not shown, together form a coupling for two air hoses whereby the air supply on the tractor may be coupled to the semi-trailer or the semi-trailer may be coupled to the full trailer.
Body 10 has an air inlet passage 16 and an air outlet 18. A seal member 20 is positioned in air outlet 18 and takes the conventional form of seals used in gladhand constructions. Seal 20 may have a peripheral slot 22 within which is received a flange 26 of body 10. In some constructions there may be a second casting flange to more firmly hold the gladhand seal in position, thus eliminating the need for slot 22.
Inlet 16 communicates, through a passage 28, with a chamber 30 which in turn is in communication with air outlet 18. Positioned within chamber 30 is a drive member 32 and a movable valve plug 34. The plug and drive member have mating and cooperating cam surfaces, with the line defining these cam surfaces being indicated at 35. The cam surfaces form a ramp whereby rotation of drive member 32, as described hereinafter, will cause the valve plug to slidably move within chamber 30. Valve plug 34 is prevented from rotation by one or more key connections 36 each of which consists of a slot 37 formed in the side of chamber 30 and an outwardly extending projection 39 on the valve plug.
A handle 38 is positioned exteriorly of body 10 and has a shaft 40 attached thereto, which shaft extends through a closure element 42 into the interior of chamber 30. A seal 41 is positioned between shaft 40 and element 42 and a seal 43 is positioned between element 42 and body 10. Shaft 40 may carry a head or the like 44 which is used in holding the shaft to drive member 32. Thus, rotation of the handle will cause rotation of shaft 40 which in turn will rotate drive member 32 and thus cause slidable coaxial movement of valve plug 34 as described.
Positioned within chamber 30 is a coil spring 46 which, as shown, has one end bottomed against flange 26 and the other end positioned against a shoulder 48 on valve plug 34. The spring may be bottomed against any support within the chamber. Thus, coil spring 46 functions as a return spring and moves valve plug 34 away from seal member 20 when the handle 38 is turned to open the valve. In the structure shown in the drawings, coil spring 46 is directly within the path of air flow from passage 28 to air outlet 18. It may be otherwise. The spring may be positioned along the side of the valve plug in such a way as it is not within the path of flow and thus does not form a restriction to such flow.
Valve plug 34 may have an outwardly extending nose 50 which has a size and shape to permit it to penetrate an opening 52 in seal 20. The nose may be in sealing contact with the seal or it may be slightly undersize so as not to form a seal at this point, but only to serve as a positioning or partial closing element. In such event, valve plug 34 also includes a bead or peripherally or circumferentially extending rim 54 which is positioned for sealing contact, as indicated in dotted lines in FIG. 2, with a surface of seal 20 and generally in alignment with flange 26. Thus, the actual seal between the valve plug and seal member 20 may be by bead 54 rather than by nose 50. In the alternative, both elements may perform a sealing function. It is important for the area of seal contact between rim 54 and seal member 20 to be supported or backed up by flange 26 so that the closure of the valve plug upon the seal will not force the seal outwardly from air opening 18.
In operation, the open position of the combination gladhand and shutoff valve is illustrated in FIG. 2 in full lines. Upon rotation of handle 38 between stops 56 and 58, the mating cam surfaces between drive member 32 and valve plug 34 will cause the valve plug to slidably move toward the valve closed position indicated in dotted lines in FIG. 2. When handle 38 is rotated in the opposite direction, to open the valve, return spring 46 will cause the valve plug to move back to the full line open position of FIG. 2.
In the construction of FIGS. 3 and 4, the gladhand body is indicated at 60 and has an air inlet 62 and an air outlet 64. A seal 66 is positioned within air outlet 64, as described earlier. A handle 68 is attached to a shaft 70 which has a drive member portion 72 extending within chamber 74 formed in body 60. A valve plug 76 is positioned within chamber 74 and drive member 72 extends within the valve plug. Valve plug 76 has a key 77 extending outwardly into a keyway 61 formed on the inside of body 60. Drive member 72 may have a cross slot 78 carrying a projection or the like 80 which projection extends outwardly therefrom and into a diagonal slot 82 formed in valve member 76. Thus, rotation of handle 68 will rotate drive member 72 which, through the described pin and slot connection, will cause coaxial movement of valve plug 76. In the FIGS. 3 and 4 form of the invention there is no return spring, as the positive connection between the valve plug and the drive member functions to move the valve plug both toward and away from a valve closing position. Although not shown, it should be understood that FIG. 3 and all subsequent forms of the invention will include seal means similar to element 41 and 43 of FIGS. 1 and 2.
One version of the method by which the effect of misalignment between the seal member and valve plug is minimized is illustrated in the FIGS. 3 and 4 construction. At the end of valve plug 76 there is a projection which is in the form of a ball member 84 which extends into a cooperating socket or recess 86 in a nose member 88. The nose member actually forms the seal or provides the sealing contact with seal 66. A pin or the like 90 may be used to positively connect ball member 84 into the socket 86 of nose member 88.
Nose member 88 has an outwardly extending rim or lip 92 which may provide the sealing contact between the valve plug and seal 66, as described earlier. Again, the sealing contact or valve closing seal may be provided by both the seal rim and the nose or, in the alternative, by one or the other.
Of advantage in the construction of FIGS. 3 and 4 is that the valve plug is both self-centering and equalizing in that the sealing pressure provided by the plug, particularly through use of rim 92, is equally distributed about the area where the rim contacts the seal member.
In the construction of FIGS. 5, 6 and 7, a body is indicated at 100 and has an air inlet 102 and an air outlet 104 and a gladhand seal member 106 for use in closing the air outlet. A chamber 108 is formed within body 100 and is connected with air inlet 102 by a passage 110.
A valve plug 112 has a nose portion 114, which may be of the floating type, and an outwardly extending flange 116 which provides a sealing rim 118. Plug 112 is movable coaxially, as in the other forms of the invention, toward and away from the passage in the seal member, thereby performing a valve closing function. Valve plug 112 may have a first groove 120 containing a seal ring 122 which prevents air from within the gladhand from leaking outwardly. A wiping seal 124 may be positioned within a body groove 126 surrounding valve plug 112 to prevent dirt and other contaminants from reaching the interior of the gladhand. Similar seals may be used in the other embodiments disclosed herein. In the past, in some gladhand constructions, moisture has seeped in along the surface of mating metal parts causing corrosion and a freezing of the metal parts. The wiping seal is effective to prevent any moisture from reaching the interior mating metal surfaces of the gladhand and valve member.
Mounted exteriorly on body 100 is a handle 128 which is attached by a screw or the like 130 to the exterior of gladhand body 100. Handle 128 carries a diagonal or slanted cam or ramp surface 132 which extends into a groove 134 on valve plug 112. Groove 134 has a slanted or ramp or cam surface mating that of surface 132 whereby rotation of handle 128, through the cooperating cam surfaces on the valve plug and the handle, will cause the valve plug to coaxially move within the chamber in the gladhand body toward and away from valve closing and opening positions. Although a key and keyway construction between the valve plug and the gladhand housing or body are not illustrated in the FIGS. 5, 6 and 7 construction, such may be added, if desired. In general, the mating cam or ramp surfaces will cause longitudinal or coaxial movement of the valve plug in response to rotary movement of handle 128.
In the construction of FIGS. 8, 9 and 10, a body is indicated at 140 and has an air inlet 142 and an air outlet 144 and a gladhand seal member 146 for use in closing the air outlet. A chamber 148 is formed within body 140 and is connected with air inlet 142 by a passage 150.
A valve plug 152 has a nose portion 154, which again may be of the floating type, and an outwardly-extending flange 156 which may provide a sealing rim 158. Valve plug 152 is movable coaxially, as in the other forms of the invention, toward and away from the central and coaxially-arranged passage in the seal member, thereby performing a valve closing function.
A handle 160 is positioned outside of body 140 and is fixed to valve plug 152 by a fastener 162 which is engaged to a stem portion 164 of valve plug 152. A washer 166 may seat upon the exterior surface of body 140 and may be formed of a synthetic material such as Teflon or the like to provide a smooth bearing surface for rotation of handle 160 relative to the body. There is a collar 168 positioned within the opening of the body accomodating the outwardly-extending portion of the valve plug and the collar may seat an internal seal 170 and an external seal 172. Seal 170 seals to the exterior of plug 152 and seal 172 seals to the interior of the body. A small washer or seat member 174 may hold both of the seals in position and itself forms the seat for a coil spring 176, the opposite end of which is reduced in diameter and bears against a shoulder 178 of valve plug 152. Thus, as illustrated particularly in FIG. 9, spring 176 is effective to urge valve plug 152 to the closing position.
The external surface of body 140 adjacent the area where valve plug 152 extends outwardly therefrom has a ramp-like surface illustrated particularly in FIG. 10. The ramp is indicated at 180 and cooperates with a camming slot 182 in handle 160. Accordingly, when handle 160 is rotated in the direction of the arrow of FIG. 8, the handle will not only pivot about valve plug 152, but will be axially moved away from body 140 to thereby withdraw valve plug 152 from the closed position of FIG. 9 to an open position in which there is communication between the inlet 142 and the outlet 144. There is a notch 184 in the exterior surface of body 140 adjacent the ramp whereby the handle is rotated through a predetermined arc, after which its slot or groove 182 will fit within notch 184. This will hold the valve plug in an open position, which position will have handle 160 spaced outwardly from body 140. Handle 160 must initially be moved outwardly so as to release it from the notched and slot or groove arrangement described, after which spring 176 will return the valve plug and thus the handle to the original closed position of FIG. 9.
The invention is particularly useful in the tractor-trailer environment described, although it has applications in other transportation environments. The gladhand seals which are shown are conventional gladhand seals. The present invention is particularly important in that it uses the conventional glad-hand seal to also perform the valve closing function when a shut-off valve or shutoff cock is integrally formed with the gladhand.
Thus, a valve plug is movable coaxially toward and away from valve closing positions and movement of the plug may be provided by an exterior rotatable handle through the various mechanical constructions described. The valve plug may be an integral single member as shown in the FIGS. 1, 2, 5, 6, 7, 8, 9, and 10 constructions, or it may have a separate independently mounted nose member, as illustrated in FIG. 3. There may be a return spring or rotation of the handle may be effective to cause the valve plug to move both toward and away from the valve closing seal.
Whereas the preferred form of the invention has been shown and described herein, it should be realized that there may be many modifications, substitutions and alterations thereto.
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A combination gladhand and shutoff valve for use in tractor and/or trailer applications has a gladhand body with an air inlet and an air outlet. A seal member is positioned at the air outlet and there is a chamber within the body which connects the inlet and outlet. A valve plug is movable within the chamber toward and away from the seal member along a path coaxial with the outlet and the seal member. The valve plug has portions thereon which cooperate with the seal member to close the outlet. A handle is located outside of the gladhand body and is operatively associated with the valve plug for effecting movement thereof between open and closed positions.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to building materials, and is more particularly concerned with acoustical tile suitable for use in ceiling structures having good acoustical properties, good fire retardance, and being free of undesirable warping.
2. Prior Art
Acoustical tile for use in sound absorbing ceilings has found wide use in the industry. U.S. Patent No. 1,769,519 discloses such an acoustical tile which, according to its teachings, is formed of a mixture of granulated mineral wool, fillers, certain coloring materials, if needed, and a binder, particularly one of an amylaceous nature, such as thick boiling starch. This mixture or composition is placed upon suitable trays which have been previously covered with paper, such as newsprint, and then screeded to a suitable thickness with a reciprocating edge. A pleasing surface, including elongated fissures, resembling that of travertine stone is normally obtained. Alternatively, by screeding in a different manner the surface can be made without the fissures. The trays are then placed in an oven, and dried or cured. The dried sheets, called slabs, are removed from the mold, and dressed on both faces to provide smooth surfaces, to obtain the desired thickness and to prevent warping, and are then cut into tiles of a desired size.
Previous to this invention it had been assumed by those skilled in this art that for maximum drying speed the moisture should leave from both the bottom and the top surfaces of the drying slab and that covering the bottom surface with an impervious lamina would increase the drying time. Accordingly, the tray bottoms were made of foraminous material and covered with thin, relatively unsized layers of paper so as to facilitate the passage of water out of the back surface of the tile through the paper. Drying the composition under these conditions resulted in migration of the starch to both the bottom and top surfaces where it strengthened the surface areas. During the dressing operation, the face surface of the slab was normally sanded off to obtain a pleasant smooth surface, thereby removing a portion of the face area of high starch concentration. The resulting tiles were found to warp unless the corresponding back surface area of high starch content was also sanded off. Thus, the back surface of the slabs was dressed by sanding off the paper and a portion of the hardened composition to compensate for sanding of the other (face) side. Sanding the paper back on conventional tiles is also required to pass the E-84 flame spread test, and is at least as important as avoiding warping.
Removing the back surface of the slabs in the aforenoted process is not only a time-consuming and costly operation but also results in the loss of the paper and part of the cured composition, thereby necessitating the use and curing of extra material in initially forming the slabs.
In U.S. Pat. No. 3,307,651 there is disclosed an acoustical tile of the type described having an aluminum foil backing. Such a tile has improved fire-retardance properties and acoustical properties. Additionally, the aluminum backing serves to release the finished tiles from the trays in which they are formed. Additionally, this tile exhibits excellent sound attenuation properties, that is, it prevents to a high degree sound from passing through the tile. However, this tile has exhibited a significant adverse property. When the face surface of the tile is subsequently painted with a finishing material such as paint and the material dried, this causes the tile to warp, with the face of the tile becoming concave. This effect is also known as cupping or lipping. The undesirable feature of this condition is that when any kind of grazing light strikes the face of a tile having a concave surface, the edges of the tile are accentuated, and in the more aggravated condition the edges may actually form ridges in exaggerated form or even stand out from adjacent tiles. In the case of standard tile not having an aluminum foil backing, this condition is prevented by wetting the back surface with water simultaneously with the painting and drying operation. This completely eliminates the problem. However, such tiles have inferior acoustical sound attenuating properties.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an acoustical tile having good acoustical properties such as noise reduction coefficient and sound transmission coefficient.
It is another object of the invention to provide an acoustical tile having good fire-retardance.
It is still another object to provide an acoustical tile having an outer face which is not concave but which may be either flat or slightly convex.
It is still another object of the invention to provide a tile which may be readily released from the tray in which it is formed, and which does not require sanding off of a portion of the back thereof thereby suffering a loss in thickness of the tile.
Still further objects of the invention will appear from the description and drawing.
According to the invention, an acoustical tile is provided formed of a fibrous material such as mineral wool and a binder, and having a paper backing affixed thereto which has been treated with a fire-retardant composition. The paper backing improves the acoustical properties. improves fireretardance, and permits the back wetting of the tile when the face of the tile is coated with a decorative coating mterial, thereby preventing the tile from warping in a dried condition in which the face surface of the tile might become concave.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view showing an acoustical tile according to the invention;
FIG. 2 is a sectional view of the tile according to the prior art having an aluminum foil backing, showing in broken lines the direction of warping when a paint coating is applied to the face of the tile and permitted to dry, and
FIG. 3 is a cross-sectional view showing a tile according to the invention which has been treated with a protective coating on the face and wherein the back surface of the tile has been back wetted with water, and the two surfaces having been permitted to dry at the same time.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 3, an acoustical tile 10 is shown having a body 11 formed of mineral wool and a binder and other conventional fillers and additives, and having a face surface 12 and a back surface 13. The back surface 13 has a fire-retardant paper backing affixed thereto, and the face surface 12 has a protective coating 15 of a material such as paint applied thereto.
When the protective coating 15 is applied to the acoustical tile 10 shown in FIG. 1, and when the coating dries, it shrinks and causes warping of the tile so that the face surface having the paint coating becomes concave, an undesirable condition. Consequently, at the same time that the protective coating is applied to the face surface, the paper backing 14 of the back surface 13 is wet with water, and subsequently dried with heat, causing the paper backing to shrink, and to oppose the shrinking force of the paint, thereby resulting in a substantially flat face surface. Alternatively, if desired, the paper backing 14 may be back wet to a sufficient degree so that the paper shrinks to a greater degree than the painted surface, causing a slight convexity on the face surface 12a of FIG. 3.
FIG. 2 shows an acoustical tile 20 of the prior art having a mineral wool body 21, an aluminum foil backing 22 affixed to the back surface, and a protective coating 23 applied to the face surface. Although this type of tile has good fire-retardance properties and good acoustical properties, because the aluminum foil is impervious to water, it does not permit back wetting. Consequently, when a paint coating is applied to the face surface, it causes the tile to warp as shown in the broken lines, thereby causing an undesirable concave surface on the face of the tile.
The following examples are provided for illustrative purposes only and are not to be considered in any way limiting.
EXAMPLE 1
Acoustical tiles according to the invention are prepared by lining a plurality of trays with a sheet of fire-retardant paper, utilizing Mosinee PS 1724 paper for one group of trays, and Mead 3 PO 166 paper for another group. The paper is taken from rolls and spread evenly as continuous sheets over the lines of molds or trays.
An amylaceous binder-mineral fiber composition is formed by first preparing a starch binder from the following:
______________________________________Thick boiling starch, pounds 250Calcium sulfate hemihydrate, pounds 200Boric acid, pounds 15Paraffin wax, pounds 10Water, gallons 595______________________________________
The mixture is cooked at 180°-195° F. for 5 to 8 minutes and is then ready for use. Examples of presently available thick boiling starches are Corn Products Company's starch products 3123 and 3173 and A. E. Staley Manufacturing Company's starch product Sta-Thik.
Into a container are placed 135 gallons of the above starch binder and 250 pounds of granulated mineral wool, and mixed together for a total mixing time for the entire formulation of about 8 minutes to obtain an aqueous plastic mixture. The mixture is then placed in a feeder box and introduced into the trays in abutting end to end relationship, as the trays pass under the feeder box. The trays subsequently pass under a reciprocating screed bar driven by a motor which forms fissures on the face surface of the tiles. Subsequently a knife is passed between the trays to cut both the paper backing and mix. The trays then pass into an oven where the contents are dried and cured at temperatures of between 250° and 350° F. for 14 to 18 hours. The paper backing is now bonded to the tile composition.
The tiles are then removed from the trays to form into tiles of the desired size. The tiles are subsequently passed through a coating stage where they are sprayed with a protective coating such as a polyvinyl acetate latex paint, and simultaneously the paper backing is sprayed with water. The treated tiles are then dried, the shrinking of the paper coating counteracting the shrinking of the protective coated surface, and thereby preventing the face of the tile from acquiring a concave warp. If desired sufficient water may be applied to cause a slight convex warp on the face of the tile.
The fire retardant or resistant paper may be any of a large number known in the art. Generally such papers comprise cellulose fibers and a fire-retardant composition dispersed therein. The preferred paper is a kraft paper, although other forms of paper known in the art may be used. Among the fire-retardant fillers are those disclosed in U.S. Patent Nos. 2,416,447, 3,202,567, and 3,770,577, the disclosures of which are incorporated herein by reference. Among such fire-retardant fillers which may be used are one or more of the following: zinc borate, antimony oxide, various organic hallide compositions, chlorinated paraffin, titanium dioxide, polyvinyl chloride, polyvinylidene chloride, chlorinated polyethylene, chlorinated diphenyls, various phosphorus compounds, and chlorinated polyester compounds. Mosinee PS 1724 is produced by the Mosinee Paper Company, Mosinee, Wisconsin, and is formed of kraft paper having as a filler antimony oxide (Sb 2 O 3 ) and vinyl chloride. Mead 3 PO 166 paper is produced by the Mead Corporation, Chillichothe, Ohio, and is formed of kraft paper and believed to have a filler of antimony oxide.
The fire-retardant filler, in order to be useful for the present invention, in addition to being fire-retardant must also be non-water-leachable upon the application of water to paper. This may be accomplished by utilizing water-insoluble materials, or, where water-soluble materials are used, by coating the particles with a polymeric material such as an acrylic latex or a polyvinyl alcohol latex, and spray-drying the filler particles.
The fillers may be added during the formation of the fiber mix in the beater, or may be subsequently added as a sizing or coating material.
EXAMPLE 2
Fire hazard tests were conducted in accordance with UL Standard 723 (ASTM E-84). In preparation for the tests, acoustical tiles were prepared as described above in Example 1 utilizing for one test a tile having a paper backing of Mosinee PS 1724 fire-retardant paper, and in the second test a paper backing formed of Mead 3 PO 166, also known as fire-retardant kraft paper T-0166-A. In order to qualify under the existing Classification in Procedure R 3623, Vol. 1 or 2, Sec. 5, it is necessary that the tiles equal or better the fire hazard ratings of flame spread 15, fuel contributed 20, and smoke developed 0. Prior to the tests, the papers were cut down the middle of the tile with a razor blade and the paper surface exposed to the igniting flame. Results of the tests are shown below in Table I.
TABLE I______________________________________Paper Backing Flame Fuel Smoke Samples Spread Contributed Developed______________________________________Mosinee PS 1724 5.1 8.1 2.0Mead 3 PO 166 7.7 12.8 0______________________________________
As can be seen, acoustical tile according to the invention met or exceeded all requirements. The smoking of the Mosinee paper backing tile was subsequently corrected by substituting a different protective coating.
EXAMPLE 3
Tests were carried out to determine the acoustical properties of tiles according to the invention, as produced in Example 1 utilizing a tile having a backing of Mosinee PS 1724 paper, as compared with prior art tiles utilizing an aluminum foil backing. The test used was the standard Ceiling Sound Transmission Test by the two-room method in accordance with Acoustical Materials Association "Standardized Mountings for Ceiling Sound Transmission Tests by the Two-Room Method" of July, 1964. In carrying out the test two 10 feet × 14 feet suspended ceilings with communicating 30 inch-deep plenum over STC 61 partition were utilized. In each case the ceilings were formed of 3/4 inch × 12 inch × 12 inch tile, the tile of the invention having a fire-retardant paper backing according to Example 1, and the prior art tile having an aluminum foil backing. In each case the tiles were provided with a square edge, kerfed and rabbeted, and installed in AMA Standard Suspension No. ICF. The tests were carried out by measuring sound transmission to determine the Normalized Attenuation Factor (NAF) in decibels (dB) at frequencies in intervals of one-third octave according to the procedure designated as AMA-1-II-1967. In Table II, column A lists the results obtained from testing tiles according to the invention as prepared in Example 1, whereas the results shown in Column B are of tests carried out on prior art high grade aluminum foilbacked tile.
TABLE II______________________________________f(Hz) NAF______________________________________ A B125 32 31160 39 40200 38 36250 32 30315 33 30400 35 33500 37 34630 38 35800 39 371000 40 391250 43 421600 47 472000 53 532500 53 543150 56 574000 59 59______________________________________
From the data above the ceiling Sound Transmission Class (STC) was determined per ASTM Designation E413-70T as follows:
______________________________________Acoustical Tile STC______________________________________A 41B 39C 35______________________________________
The results of the tests as determined in the STC ratings show that both the paper backed tile of the invention (A) and the prior art aluminum foil backed tile (B) have excellent sound attenuation properties and place both of the tiles in the 40-44 STC classification, whereas the prior art tile (C) representing a tile in which the temporary paper backing was subsequently sanded off and which had been previously tested had an STC value of 35, placing it in the lower 35-39 STC classification.
The acoustical tile of the present invention with a fire-retardant paper backing has a number of advantages over prior art tiles. The presence of the paper backing acts as a mold release to permit the tiles to be removed from the trays in which they are formed. Because the paper backing is fire-retardant, it need not be removed by sanding the back surface, a step which is necessary when non-fire-retardant papers are used. Because this step is eliminated, the accompanying loss of material is avoided, and therefore less starting material need be used to form the tiles. The paper coating accomplishes a high degree of reduction in sound transmission, rendering the tile far superior to conventional tiles having a sanded backing surface, and exhibiting such acoustical properties equal to the acoustically excellent aluminum foil-backed acoustical tiles. The tiles of the present invention have an advantage over aluminum foil-backed acoustical tile in that they permit wet-backing of the tile during the application of a protective coating on the face surface, thereby preventing concave warping or "lipping" of the face surface of the tile, as generally occurs in the case of aluminum foil-backed tile. The present tiles are competitive with regard to cost and are readily fabricated by normal procedures and equipment.
It is to be understood that the invention is not to be limited to the exact details of operation or structure shown and described in the specification and drawing, since obvious modifications and equivalents will be readily apparent to one skilled in the art.
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An acoustical tile comprising a relatively thin, flat body of acoustical composition including fibrous material and a binder, and a paper backing affixed thereto having a fire-retardant material dispersed therein, the outer facing surface of the tile being either planar or slightly convex.
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FIELD OF THE INVENTION
The present invention relates to a translucent dressing which can be manufactured and offered to the consumer as a two-phase system. Upon shaking by hand, an emulsion is produced which remains stable for at least one week. Such a dressing is suitable for use on e.g. salad.
BACKGROUND OF THE INVENTION
Conventional dressings for use on salads, especially those in use in Mediterranean countries, are emulsions of an oil phase (e.g. 50-60%) in a water phase (containing vinegar), optionally further containing salt, herbs, and spices. As the size of the oil droplets in these dressings is around 0.2-5 mm it is easily visible by the eye that oil is present. Such dressings are conventionally prepared fresh by the housewife by shaking or stirring oil (40-70%), vinegar (60-30%) and optionally salt, herbs together, to give a translucent, emulsified but not very stable salad dressing. Such dressing will generally be used directly after mixing and before phase separation occurs. Similar formulations are also commercially available but give rise to phase separation and/or the formation of creamy, turbid layers.
As a convenient alternative, there are available ready-to-use salad dressings which are in the form of a stable fine emulsions of oil and water, having an opaque, milky appearance, with no oil visibly present (either as droplets or as a separate layer).
Yet other type emulsions (having more coarse oil droplets) are disclosed in GB 2 143 114. Herein, salad dressings containing 10-50% oil, 0.1-0.4% gum arabicum, 0.3-0.7% iota-carrageenan and water are described. Said composition is processed to form an emulsion using emulsifying apparatus. It is reported the so-prepared emulsion is stable for at least several months. In order for such emulsions to be stable, either high levels of emulsifiers and stabilisers need to be used or the amount of oil which can be emulsified in the water in a stable manner is restricted, e.g. to 50% or less. If low levels of emulsifiers or stabilisers are used or high levels of oil, phase separation is likely to occur. Although such dressings may be convenient in use, they are generally perceived by the customer as artificial, as no oil can readily be seen as a separate layer (the visible presence of oil is seen as a quality attribute in dressings).
SUMMARY OF THE INVENTION
Up till now, dressings suitable for application on salad either are stable emulsions that have no visible oil present, have a limited amount of oil, or are compositions that are not stable for more than a few minutes after applying shear or have a tendency to separate in creamy, turbid layers.
Although the stable emulsions as disclosed in GB 2 143 114 (which appears as a single phase system in which oil is not visible as a separate layer) are attractive to consumers in many countries, consumers in other countries (e.g. Spain) have a preference for salad dressings which are both easy to use (e.g. single pack purchase, easy to convert in an emulsion of reasonable stability) and which have, at least upon purchase, visibly present oil and water phases, preferably as separate layers. Such products would be seen as high quality, “artisanal” type products, resembling in appearance traditional home-made products (the visible oil layer which is initially present). After conversion into an emulsion, the droplet size of the oil droplets should preferably such that a majority of them can be seen by the eye.
Hence, there is a need for packed composition containing all ingredients needed for preparing a high quality dressing suitable for application on salad, which packed composition preferably appears as a two-phase system on purchase by the customer (an oil phase being visible by the eye, preferably as separate layers), but which composition may be transformed into a dressing by shaking the packed composition by hand by the customer prior to use. Preferably, the composition should be such that high levels of oil 50-70% (preferably 50-65%) are present.
It is preferred that a once formed emulsion is stable for at least a few hours, preferably days to weeks. Also, it is preferred that if chopped vegetables or herbs (particle size e.g. 0.5-5 mm) are present in the composition they neither settle at the bottom nor be floating on the water or oil layer.
It has now been found that the above objectives can be achieved by a container in which is present a composition comprising (based on the total composition):
a vegetable oil phase in an amount of 30-70 wt %
a water phase in an amount of 70-30 wt %,
a thickener capable of giving a yield stress when dissolved in water,
wherein at least the majority of the oil is present as a separate, visible and transparent layer and wherein the amount of thickener is such that composition gives upon shaking by hand an oil-in-water emulsion which is stable for at least one week.
To prepare the above composition the thickener is dissolved in the water phase (or a part thereof), whereafter all components are introduced in the container. In the absence of agitation or emulsifying action, a two-layer system will form, which can be distributed and sold as such, and which may be turned in a dressing by the end user by shaking the container by hand, thus closely resembling (both in appearance and processing by the consumer) traditional, home-made clear salad dressings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows stress shear as a function of shear rate for the water phases of examples 1, 3, 5 and 6.
DETAILED DESCRIPTION OF THE INVENTION
In the compositions according to the invention it is preferred (in order to achieve the desired stability) that the water phase comprising the thickener has a yield stress of at least 0.3 Pa. Preferably, the yield stress is larger than 0.5 Pa, more preferably larger than 0.7 Pa. Although the yield stress may be quite large, it should not be too large, as it will then cause difficulties to mix the oil phase with the water phase by hand force. Hence, the water phase in the composition preferably has a yield stress of less than 5 Pa, more preferably less than 2.5 Pa.
With the system as presented herein it is possible to offer compositions which contain all ingredients desired for a dressing for e.g. salads, which compositions may contain high levels of oil (e.g. 50-65% or even 50-70%, based on the total composition) and which compositions can still be stable for a period of at least a week.
A suitable thickener for obtaining the desired stability or yield stress according to the above is iota-carrageenan. Hence, the water phase should preferably containing such an amount of carrageenan that the yield stress is larger than 0.3 Pa (or preferably larger than 0.5 Pa, more preferably larger than 0.7 Pa). It was found that if iota-carrageenan is present in an amount of 0.2 or more and less than 0.65% by weight, based on the water phase, the desired stability could be obtained, depending upon e.g. the amount of oil and solids present, without the water phase becoming too viscous (too viscous in this respect is such that the dressing is no longer easy pourable). More preferably, the amount of iota-carrageenan present in the water phase is between 0.3 and 0.55% (or even 0.3-0.45%) by weight, based on the water phase.
The yield stress can be determined from a graph of shear stress vs shear rate. The above values of yield stress of the water phase relate to measurements when the shear stress as a function of the shear rate is measured using a Carrimed CSL 500 rheometer using a 6 cm 2 deg. cone, at a temperature of 20° C. Shear rate is to be increased from 0 to 50 (1/s) in 300 seconds, and the shear stress can be measured. From a graph of the shear stress (Pa) vs. shear rate (1/s) the yield stress can be found by extrapolating the curve to shear rate=0.
As the composition in the container according to the invention is intended to be used as a salad dressing (which is traditionally acidic), it is preferred that the water phase comprises an organic acid in such an amount that the pH of the water phase is between 2.0 and 4.5, preferably between 2.5 and 4.0. Such an organic acid can suitably be chosen from acetic acid (e.g. from vinegar), citric acid, lactic acid or mixtures thereof.
To impart a specific flavour to the salad to which the dressing herein disclosed is applied it may be preferred that the composition in the container further comprises salt, herbs, spices, chopped garlic, garlic oil, or mixtures thereof, in an amount of 0.1-10 wt % based on the total mixture. Other ingredients like chopped vegetables or olives may also be added. Preferably the above particulate material is dispersed in the water phase in a stable manner.
The amount of oil present in the composition in the container according to the invention may vary between 30-70 wt % based on the total composition, although minimum amounts of 40 wt % and maximum amounts of 65 wt % may be preferred as this are the amounts traditionally used in salad dressings.
The compositions as disclosed above are preferably packed in containers having a single space, such as ordinary flasks, bottles, jars, cans, etcetera. In order to make the particular properties of the present invention visible, such container is preferably at least partially transparent or translucent. Glass bottles are preferred in this respect.
The compositions as described above can suitably be prepared by first preparing a water phase containing all ingredients except for the oil. Such a water phase then contains the suitable thickener, the organic acid such as acetic acid, and optionally salts, herbs and spices. The water phase is preferably heated (e.g. to temperatures of 75-95° C.) for pasteurising purposes and/or for ensuring the thickener is adequately dissolved. After cooling (e.g. to below 30° C.), the water phase can be poured in the container the composition is ultimately sold (e.g. glass or plastic bottle). Thereafter the oil phase (generally only containing vegetable oil such as sunflower or olive oil) can be added by gently pouring it (e.g. via the wall of the bottle) on top of the water phase layer and closing the bottle. A suitable amount of headspace should be allowed to ensure mixing is possible by shaking the container by hand.
The invention is further exemplified by the following examples, which are to be understood as to be non-limiting.
EXAMPLE 1
A dressing composition having an oil content of 50% was prepared having the following composition:
ingredient
total %
% on water phase
sunflower oil
50.0
salt
2.0
4.0
vinegar (10%)
8.0
16.0
iota-carrageenan*
0.18
0.36
water
39.82
79.64
total
100
*iota-carrageenan used was Deltagel 552, ex Quest International, the Netherlands.
Preparation: all ingredients except for the oil were mixed to form the water phase, said waterphase was heated under stirring to 90° C. Thereafter, under continuous stirring the waterphase was cooled to 30° C. Glass bottles (250 ml) were filled with 115 ml of the water phase and gently, 115 ml of the oil was poured gently on the water phase.
The appearance was a clear/translucent water phase with on top of that a clear oil phase. Upon shaking, a coarse emulsion is obtained which remained stable for at least 6 weeks. (“stable” is herein to be understood as no oil or water separation and no formation of creamy, turbid layers between the oil and water phase.)
Of the water phase, the shear stress as a function of the shear rate was measured using a Carrimed CSL 500 rheometer using a 6 cm 2 deg. cone, at a temperature of 20° C. Shear rate was increased from 0 to 50 (1/s) in 300 seconds, and the shear stress was measured. From a graph of the shear stress (Pa) vs. shear rate (1/s) the yield stress was found by extrapolating the curve to shear rate=0.
EXAMPLE 2
A dressing composition having an oil content of 60% was prepared having the following composition:
ingredient
total %
% on water phase
sunflower oil
60.0
salt
2.0
5.0
vinegar (10%)
8.0
20.0
iota-carrageenan*
0.20
0.50
onion pieces
0.10
0.25
carrot pieces
0.10
0.25
water
29.6
74
total
100
*iota-carrageenan used was Deltagel 552, ex Quest International, the Netherlands.
Preparation: all ingredients except for the oil were mixed to form the water phase, said waterphase was heated under stirring to 90° C. Thereafter, under continuous stirring the waterphase was cooled to 30° C. Glass bottles (250ml) were filled with 92 ml of the water phase and gently, 138 ml of the oil was poured gently on the water phase.
The appearance was a clear/translucent water phase with the onion and carrot particles evenly distributed, and on top of the water layer a clear oil phase. Upon shaking, a coarse emulsion is obtained which remained stable for at least 6 weeks. (“stable” is herein to be understood as no oil or water separation and no formation of creamy, turbid layers between the oil and water phase.) The onion and carrot particles remained evenly distributed over the whole composition.
EXAMPLE 3
A dressing composition having an oil content of 70% was prepared having the following composition:
ingredient
total %
% on water phase
sunflower oil
70.0
salt
1.50
5.0
white wine
6.0
20.0
vinegar (10%)
garlic pieces
0.20
0.67
iota-carrageenan*
0.125
0.42
water
22.18
73.92
total
100
*iota-carrageenan used was Deltagel 552, ex Quest International, the Netherlands.
Preparation: all ingredients except for the oil were mixed to form the water phase, said waterphase was heated under stirring to 90° C. Thereafter, under continuous stirring the waterphase was cooled to 30° C. Glass bottles (250 ml) were filled with 66 ml of the water phase and gently, 154 ml of the oil was poured gently on the water phase.
The appearance was a clear/translucent water phase with on top of that a clear oil phase. Upon shaking, a coarse emulsion is obtained which remained stable for at least 6 weeks. (“stable” is herein to be understood as no unacceptable oil or water separation and no formation of creamy, turbid layers between the oil and water phase.)
EXAMPLE 4
(Control)
A dressing composition having an oil content of 50% was prepared having the following composition:
ingredient
total %
% on water phase
sunflower oil
50.0
salt
1.50
3.0
alcohol vinegar
6.0
12.0
(10%)
dried parsley
0.05
0.10
xanthan-gum*
0.35
0.70
water
42.10
84.20
total
100
*xanthan-gum used was Keltrol F, ex Kelco.
Preparation: all ingredients except for the oil were mixed to form the water phase, said waterphase was heated under stirring to 75° C. Thereafter, under continuous stirring the waterphase was cooled to 30° C. Glass bottles (250 ml) were filled with 110 ml of the water phase and gently, 110 ml of the oil was poured gently on the water phase.
The appearance was a clear/translucent water phase with on top of that a clear oil phase. Upon shaking, a coarse emulsion is obtained which did not remain stable. Within less than 6 weeks a visible oil layer at the top and a visible water layer at the bottom formed. Also, the parsley was not distributed evenly over the composition, but aggregated in the middle part of the composition.
EXAMPLE 5
(Control)
A dressing composition having an oil content of 50% was prepared having the following composition:
ingredient
total %
% on water phase
sunflower oil
50.0
salt
2.0
4.0
vinegar (10%)
8.0
16.0
iota/kappa-
0.18
0.36
carrageenan mixture*
water
39.82
79.64
total
100
*iota/kappa-carrageenan mixture used was Hamulsion DBV, ex Hahn & Co, the Netherlands.
Preparation: all ingredients except for the oil were mixed to form the water phase, said waterphase was heated under stirring to 90° C. Thereafter, under continuous stirring the waterphase was cooled to 30° C. Glass bottles (250ml) were filled with 110 ml of the water phase and gently, 110 ml of the oil was poured gently on the water phase.
The appearance was a clear/translucent water phase with on top of that a clear oil phase. Upon shaking, a coarse emulsion is obtained which did not remain stable. Within less than 6 weeks a visible oil layer at the top and a visible water layer at the bottom formed.
EXAMPLE 6
(Control)
A dressing composition having an oil content of 50% was prepared having the following composition:
ingredient
total %
% on water phase
sunflower oil
50.0
salt
1.50
3.0
alcohol vinegar
6.0
12.0
(10%)
dried parsley
0.05
0.10
xanthan-gum*
0.27
0.54
water
42.18
84.36
total
100
*xanthan-gum used was Keltrol F, ex Kelco.
Preparation: all ingredients except for the oil were mixed to form the water phase, said waterphase was heated under stirring to 75° C. Thereafter, under continuous stirring the waterphase was cooled to 30° C. Glass bottles (250ml) were filled with 110 ml of the water phase and gently, 110 ml of the oil was poured gently on the water phase.
The appearance was a clear/translucent water phase with on top of that a clear oil phase. Upon shaking, a coarse emulsion is obtained which did not remain stable. Within less than 6 weeks a visible oil layer at the top and a visible water layer at the bottom formed. Also, the parsley was not distributed evenly over the composition, but aggregated in the middle part of the composition.
Yield Stress
Shear stress as a function of the shear rate was measured for the water phases of examples 1, 3, 5, and 6. This was done using a Carrimed CSL 500 rheometer using a 6 cm 2 deg. cone, at a temperature of 20° C. Shear rate is to be increased from 0 to 50 (1/s) in 300 seconds, and the shear stress was measured. From a graph of the shear stress (Pa) vs. shear rate (1/s) the yield stress was found by extrapolating the curve to shear rate=0. The results are set out in FIG. 1 . Examples 1 and 3 showed a yield stress of approx. 0.8 and 1.6 Pa, respectively. Examples 5 and 6 showed little to no yield stress.
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The invention relates to a translucent dressing which can be manufactured and offered to the consumer as a two-phase system, having separate oil and water layers. Upon shaking by hand, an emulsion is produced which remains stable for at least one week. Such a dressing is suitable for use on e.g. salad.
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FIELD OF THE INVENTION
[0001] The present invention relates to the manufacture of magnetic disks and, more particularly, a modular configuration for linearly aligned chambers used in the manufacture of such disks.
BACKGROUND OF THE INVENTION
[0002] Hard disk drives are an efficient and cost effective solution for data storage. Depending upon the requirements of the particular application, a disk drive may include from one to multiple hard disks and data may be stored on one or both surfaces of each disk. While hard disk drives are traditionally thought of as a component of a personal computer or as a network server, usage has greatly expanded to include other storage and retrieval applications such as set top boxes for recording and time shifting of television programs, personal digital assistants, cameras, music players and many other consumer and industrial electronic devices, each having different information storage capacity requirements.
[0003] Typically, hard memory disks are produced with functional magnetic recording capabilities on one or both surfaces of the disk. In conventional practice, these hard disks are produced by subjecting one or both sides of a substrate disk, such as glass, ceramic, metal or metal alloy, typically an aluminum based alloy, or some other suitable material, to numerous manufacturing processes. Active materials are deposited on one or both sides of the substrate disk and one or both sides of the disk are subject to full processing such that one or both sides of the substrate disk may be referred to as active or functional from a memory storage stand point. The end result is that one or both sides of the finished disk have the necessary materials and characteristics required to effect magnetic recording and provide data storage.
[0004] The processing of both single-sided and double-sided hard memory disks involve a number of discrete process steps usually performed in a clean-room environment. Typically, twenty-five substrate disks are placed in a plastic cassette or carrier, axially aligned in a single row. Because the disk manufacturing processes are typically conducted at adjacent locations using different equipment, the cassettes are moved from process station to process station. For some processes, the substrate disks are individually removed from the cassette by automated equipment, one or both surfaces of each disk are subjected to the particular process, and the processed disk is returned to the cassette. Alternatively, in some processes, a plurality of disks are simultaneously processed. For example, in some instances one or more entire cassettes of disks may be simultaneously processed. Once the disks have been fully processed and returned to the cassette, the cassette is transferred to the next station for further processing of the disks.
[0005] More particularly, in a conventional disk manufacturing process, the substrate disks are initially subjected to data zone texturing. Texturing prepares the surfaces of the substrate disk to receive layers of materials which will provide the active or memory storage and retrieval capabilities on each disk surface. Texturing is typically accomplished by either fixed abrasive texturing or free abrasive texturing. Following texturing, the cassette is typically moved to an adjacent station for washing. Washing is a multi-stage process that usually includes scrubbing of the disk surfaces in the presence of cleaning liquids or water. The textured substrate disks are then subjected to a drying process. Drying is typically performed on all of the disks from an entire cassette at the same time.
[0006] Following the drying process, the disks are returned to the cassette and it is moved to the laser zone texturing station where a laser beam is focused on and interacts with discrete portions of the disk surface to create an array of bumps upon which the head and slider assembly will land on and take off. Laser zone texturing is typically performed one disk at a time. Again, the cassette is transported to succeeding stations for washing and drying process steps.
[0007] Following the last drying step, the disks are then subjected to a process which adds layers of materials to either one or both surfaces for purposes of creating data storage and retrieval capabilities. The disks may be processed individually or in groups. The deposition of material layers onto the substrate may be accomplished by sputtering or by other techniques known to persons of skill in the art. The sputtering process is typically conducted in a series of vacuum chambers. FIG. 1 depicts a row of linearly aligned and interconnected chambers 10 where disks 12 move from one chamber to the next, for example from chamber 10 a to 10 b to 10 c , etc. The disks 12 travel through the row of interconnected chambers 10 using automated means known to those of skill in the art. Conventional process chambers 10 are typically rectangular in configuration and adjacent process chambers, for example chambers 10 b and 10 c in FIG. 1 , and are typically connected to one another via their abutting sidewalls 14 .
[0008] Typically, the first one or two chambers, for example 10 a and 10 b , add a soft under layer, for example an iron cobalt alloy, to the substrate. The under layer facilitates the magnetic flux path during read and/or write operations. Several deposition chambers 10 c , 10 d and 10 e usually follow the initial chambers 10 a and 10 b. Two common types of deposition processes include vacuum deposition and magnetron sputtering. In a vacuum sputtering process, following the depositing of an underlayer, a magnetic recording layer and then an overcoat layer are added onto the surface or surfaces of each disk. Vacuum sputtering is accomplished by applying a voltage between the depositing material (the cathode) and the grounded chamber walls (the anode) in a vacuum chamber containing a sputtering gas such as argon. With magnetron sputtering a magnetic array is placed on the backside of a sputtering target. When a negative voltage is applied to the sputtering target the resulting negative field attracts positive ions to the sputtering target. When a positive ion collides with atoms at the surface of the sputtering target a surface atom becomes sputtered. Subsequent to the sputtering chambers the substrate disks are cooled in one or more cooling chambers, for example 10 e , etc.
[0009] Following the addition of sequentially deposited layers to one or both disk surfaces 16 , a lubricant layer typically is applied in a subsequent process. Typically, the lubrication process is accomplished by subjecting an entire cassette of disks to a liquid lubricant. After the lubrication process, the disks 12 are typically moved to the next station and subjected to surface burnishing to remove asperities, enhance bonding of the lubricant to the disk surface and otherwise provide a generally uniform finish to the disk surface 16 . Following burnishing, the substrate disks can also be subjected to various types of testing.
[0010] FIG. 2 illustrates the conventional manner of interconnecting and sealing adjacent chambers, for example, chambers 10 d and 10 e. Adjacent chamber sidewalls 14 d and 14 e must be sealed in order to maintain the necessary vacuum pressure. Typically, an o-ring 20 provides the means for sealing adjacent chamber sidewalls 14 d and 14 e together. As illustrated in FIGS. 2 , 3 and 4 , in a conventional chamber 10 , one sidewall 14 d is machined to provide a groove 22 to receive an o-ring 20 . An o-ring 20 is then positioned within the groove 22 . The groove 22 surrounds an opening 24 in the sidewalls of each chamber 10 through which the disks 12 are transported from one chamber to the next, for example from 10 d to 10 e. The abutting sidewall 14 e from the adjacent chamber 10 e is machined to provide a smooth surface to abut the o-ring 20 . The adjacent chambers 10 d and 10 e are sealed by compressing the o-ring 20 between the two adjacent chamber sidewalls 14 d and 14 e. FIG. 4 shows a cross-sectional view of two adjacent chamber sidewalls 14 d and 14 e compressing the o-ring 20 to provide effective sealing means between the process chambers 10 d and 10 e.
[0011] The adjacent chambers 10 d and 10 e are fastened together to compress the o-ring 20 and form a seal. As illustrated in FIG. 2 , alignment pins 26 are provided on the chamber sidewall 14 d to align adjacent chambers 10 d and 10 e for physical interconnection. Once the chambers 10 d and 10 e are proximally in place, each alignment pin 26 of one chamber sidewall 14 d is received by a cooperating opening or slot on the adjacent chamber sidewall 14 e (not shown). As further illustrated in FIG. 2 , cutouts or recesses 28 are provided adjacent to the four corners 30 of each sidewall 14 d and 14 e to allow access to the head of a bolt 18 and a complementary nut (not shown) for physically interconnecting the adjacent chambers 10 d and 10 e. In other embodiments, the chambers 14 may be physically interconnected by means of C-clamps spanning the complementary recesses 28 . The alignment pins 26 may be used to properly align the adjacent chambers 10 d and 10 e and then the C-clamps may be clamped onto the cutouts 28 . In yet other embodiments, a threaded bolt 18 may extend from one side wall 14 d and interconnect with a threaded bore in the sidewall 14 e of the adjacent chamber 10 e (not shown). Because the chambers 10 are frequently and repeatedly subjected to vacuum pressures and because disks are transferred between chambers it is important to ensure that adjacent chambers 10 d and 10 e are reliably and securely physically interconnected. Further still, in some circumstances it is acceptable to weld adjacent process chambers 10 d and 10 e together in order to effectively seal chambers together to achieve sealing. Welding chambers together can be very costly to the overall disk processing line because it inhibits later chamber exchange and repair.
[0012] One disadvantage to axially aligned and interconnected rectangular process chambers is that removal of one chamber 10 from the row of chambers 10 is difficult and time consuming. A chamber 10 may need to be removed from the process line for numerous reasons including maintenance, repair, cleaning, upgrade, and exchange. Routine maintenance and/or repair is not always possible unless the chamber 10 is removed from the row of chambers. In addition, the individual layer deposition processes used in manufacturing disks have evolved over time and continue to change. Thus, many process chambers also become replaced and/or retrofitted as newer technology emerges. However, in each of these instances manufacturers are forced to sacrifice disk throughput while the process line is stopped so that the chambers may be serviced, upgraded or exchanged. If a chamber 10 is to be removed from a row of chambers, a significant number of electrical lines and plumbing lines initially must be disconnected. Next, the mechanical interconnections must be disconnected, followed by removal of the desired chamber. However, when the target chamber 10 d is moved, a resulting shearing force is exerted on the o-ring 20 . FIG. 5 shows a cross-sectional view of the shearing forces exerted on the o-ring 20 as a result of moving one chamber 10 d relative to an adjacent chamber 10 e. This relative motion between the chambers 10 d and 10 e will twist and perhaps tear the o-ring 20 . Similarly, upon replacement of the repaired or new chamber, the shear force applied by reinserting the target chamber 10 d into the row of chambers may dislodge the o-ring 20 from the groove 22 and/or damage the o-ring 20 , preventing a seal from being achieved. However, it may not be evident that no seal has been achieved until after the processing line is completely reconnected and processing is resumed. If a seal has not been achieved between one or more chambers, the process must again be shut down and the chambers disconnected and separated to correct the problem. Further downtime results in further loss of production time and revenues.
[0013] FIGS. 6A-6C illustrate the conventional chamber exchange/removal process. FIG. 6A illustrates an in-line row of interconnected chambers 10 a - 10 e. First, the electric, plumbing and other connecting lines of the chambers 10 a - 10 e must be disconnected and moved as appropriate. Second, the alignment pins, bolts, and/or other securing means must be removed in order to decouple the target chamber 10 d from its adjacent chambers 10 c and 10 e. Then, as shown in FIG. 6B , the target chamber 10 d itself must be laterally separated on both sides from its adjacent chambers 10 c and 10 e which entails moving all of the chambers comprising the in-line row of chambers 10 a - 10 e. To ensure the sealing elements are not compromised a physical gap 32 must be present on both sides of the target chamber 10 d before the target chamber 10 d can be removed from the process line. Once the adjacent chambers 10 c and 10 e have been literally separated from the target chamber 10 d, it can be removed orthogonally from the process line as shown in FIG. 6C . Once the necessary chamber modification or exchange is made the target chamber 10 d or its replacement the target chamber 10 d must be reinstalled and reconnected to the process line. Again, reconnection is a time consuming and costly process. For example, the target chamber 10 d must be re-aligned with its adjacent chambers 10 c and 10 e with all of the adjacent chambers laterally moved inwardly, the alignment pins 26 must be inserted into the complementary mating apertures in adjacent chambers, the target chamber 10 d must be mechanically recoupled with the adjacent chambers 10 c and 10 e and last, all the necessary electrical, plumbing and other connecting lines must be reconnected. All this time, the process line is not making disks. Thus, substantial savings could be achieved by exchanging chambers in a more time and cost efficient manner.
[0014] Accordingly, there is a need within the disk processing and manufacturing industry for a system that facilitates exchange of the modular process chambers without requiring substantial labor or effort, or that at least minimize the amount of labor needed. In addition, there is a need within the art of disk processing to facilitate the movement, exchange, and maintenance of process chambers without undue process line interruption in order to minimize disruption to disk throughput. Still further there is a need to prolong the useable lifetime of a chamber's sealing means by designing chambers to reduce the shearing forces exerted on the sealing means when the chambers are exchanged. Furthermore, there is a need within the art to have a design that facilitates exchange of modular chambers in order to implement newer and more advanced technology into the process chambers.
SUMMARY OF THE INVENTION
[0015] The design to facilitate exchange of modular chambers generally comprises a plurality of trapezoidal shaped chambers. In one embodiment, the chambers have an isosceles trapezoidal shape, although other trapezoidal shapes will work too. This trapezoidal chamber design has many advantages, including decreasing the amount of time and labor required to exchange or replace chambers in a contiguous line of chamber.
[0016] The present invention provides advantages over the prior art in that trapezoidal chambers facilitate faster and more efficient chamber removal and/or exchange. Decreasing the amount of process line interruption increases disk throughput by increasing the speed with which the chambers can be replaced and/or exchanged. More specifically, when removing a chamber from a line of interconnected chambers, none of the other chambers need to be moved to create lateral space on each side of the chamber being moved. Any chamber may be orthogonally removed or inserted into a line of chambers without damage to the o-ring. Moreover, because the line of chambers do not need to move laterally to create space for removing and/or inserting a single chamber into a preexisting line of chambers, much less disconnection and movement of electrical and plumbing lines needs to occur. This results in a more efficient repair and replacement process and a more productive manufacturing line, which increases productivity and profits.
[0017] The above-described embodiments and configurations are not intended to be complete nor exhaustive. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more features set forth above or described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Several drawings have been developed to assist with understanding the invention. Following is a brief description of the drawings that illustrate the invention and its various embodiments.
[0019] FIG. 1 is a perspective view of a row of linearly aligned and interconnected chambers.
[0020] FIG. 2 is an exploded perspective view of the sealing interface between adjacent chamber sidewalls,
[0021] FIG. 3 is a cross-sectional view of an o-ring positioned within the groove of a chamber sidewall.
[0022] FIG. 4 is a cross-sectional view of an o-ring compressed between adjacent chamber sidewalls and forming a seal between the adjacent sidewalls.
[0023] FIG. 5 illustrates the resulting shear force on an o-ring of the kind shown in FIG. 4 due to relative motion between chambers.
[0024] FIGS. 6A- 6C illustrate a conventional method for chamber removal.
[0025] FIG. 7 is a perspective view of a row of linearly aligned chambers of one embodiment of the present invention.
[0026] FIG. 8 is an exploded perspective view of the sealing interface between adjacent chamber sidewalls of one embodiment of the present invention.
[0027] FIGS. 9A and 9B illustrate a method for chamber removal of one embodiment of the present invention.
[0028] It should be understood that the drawings are not necessarily to scale, and that in certain instances, the disclosure may not include details which are not necessary for an understanding of the present invention, such as conventional details of fabrication and assembly, by those of skill in the art. Also, while the present disclosure describes the invention in connection with those embodiments presented, it should be understood that the invention is not strictly limited to these embodiments.
DETAILED DESCRIPTION
[0029] Turning to FIG. 7 , one embodiment of the in-line system of linearly aligned trapezoidal chambers 50 of the present invention is illustrated. The disks 52 may travel through the series of chambers 50 a - 50 g using automated means known to those of skill in the art. The disks 52 move along a track running between the trapezoidal chambers 50 a - 50 g. The disks 52 may be processed one at a time or in groups. In the preferred embodiment, the trapezoidal chambers 50 a - 50 g are inversely orientated so that the longer end wall 54 of chambers, for example 54 a and 54 b, are on opposite sides of the row. The trapezoidal chambers 50 are connected to one another via their sidewalls. Preferably, the chambers 50 are formed in the shape of an isosceles trapezoid. If there are an odd number of chambers, the row of linearly aligned and interconnected chambers will form the shape of a trapezoid. If there are an even number of chambers, the row of linearly aligned and interconnected chambers will form the shape of a parallelogram.
[0030] Referring to FIG. 8 , the sealing means of one embodiment of the present invention are shown. An o-ring 56 forms a seal between the adjacent trapezoidal chamber sidewalls 58 e and 58 f of two adjacent chambers 50 e and 50 f. In one embodiment, the sidewall 58 e of chamber 50 e includes a groove 60 to receive the o-ring 56 . The adjacent sidewall 58 f of chamber 50 f includes a smooth surface to abut the o-ring 56 . The openings 62 e and 62 f of the adjacent chambers 50 e and 50 f may then be sealed by compressing the o-ring 56 between the adjacent two sidewalls 58 e and 58 f.
[0031] In one embodiment of the present invention, the sidewall 58 e further includes alignment pins 64 . The purpose of the alignment pins 64 is to align the adjacent trapezoidal chambers 50 e and 50 f before the chambers are fastened or secured into place. In one embodiment, cutouts or recesses 66 may be included to provide access to openings 68 designed to receive bolts 70 and nuts 72 to secure adjacent chambers 50 e and 50 f together. The purpose of the bolts 70 and nuts 72 is to ensure compression of the o-ring 56 between the adjacent chamber sidewalls 58 e and 58 f sufficient to form a seal. In another embodiment, the adjacent trapezoidal chambers 50 e and 50 f may be physically interconnected by means of C-clamps spanning the cutouts or recesses 66 . In yet another embodiment, the adjacent trapezoidal chambers 50 e and 50 f may be physically interconnected by means of a threaded bolt and threaded bore. In a further embodiment, adjacent chambers 50 e and 50 f may be welded together. Different fastening means will be known and appreciated by those skilled in the art to physically interconnect the two adjacent trapezoidal chambers.
[0032] A benefit of the trapezoidal shaped chambers 50 a - 50 g of the present invention is a substantial reduction in chamber exchange time. Unlike the conventional design for chamber removal, which is labor intensive and time consuming, the trapezoidal chamber design streamlines the removal and/or exchange process by eliminating certain steps. Importantly, because the chambers are generally trapezoidal in shape, the operator may easily remove and/or exchange chambers from the in-line row of chambers 50 without moving any other chamber. FIGS. 9A and 9B illustrate one embodiment of the trapezoidal chamber exchange and/or removal process. In one embodiment, when a trapezoidal chamber 50 f needs to be serviced, replaced, or otherwise exchanged, the electrical and plumbing lines an disconnected. Then, any mechanical interconnections, such as alignment pins 64 , bolts 70 , C-clamps, or other fastening means, are uncoupled. Because of the angled sidewalls 58 e and 58 f and 58 f and 58 g, the trapezoidal target chamber 50 f can then slide out orthogonally relative to its adjacent trapezoidal chambers 50 e and 50 g (see FIG. 9 b ). This is an improvement over the conventional removal process because lateral space does not need to be created between the chamber 50 f to be removed and the adjacent chambers 50 a - 50 e and 50 g before being removed. The geometry of the trapezoidal chambers 50 eliminates the necessity of creating a physical gap 32 between the chambers before removal as illustrated in FIG. 6B . By not having to move all of the chambers in the in-line row 50 to create a gap 32 , substantial time is saved in the chamber exchange and/or removal process. Moreover, additional time is saved once the trapezoidal target chamber 50 f is ready to be reinserted into the in-line row of trapezoidal chambers 50 because the trapezoidal target chamber 50 f can be positioned into the row of chambers 50 without having to remove a previously created physical gap 32 . Similarly, the electrical and plumbing lines associated with those chambers may remain in place and do not need to be moved either. Once the inserted trapezoidal target chamber 50 f is aligned, the trapezoidal target chamber 50 f may be recoupled to the adjacent trapezoidal chambers 50 e and 50 g and then the electrical and plumbing lines may be reconnected. Overall, the modular trapezoidal chamber 50 design substantially reduces the chamber exchange time. Because the trapezoidal chamber exchange/removal process takes less time the disk processing line may be stopped for less time. Thus, by minimizing the time the disk processing line is nonoperational the amount of disk throughput is increased.
[0033] A further benefit of present invention is that the trapezoidal chamber design decreases the amount of labor required to remove and/or exchange a chamber. The aforementioned savings in time correlate to a similar savings in labor. Less labor is required to remove and/or exchange a chamber because the trapezoidal chambers 50 do not require a gap 32 be present between adjacent chambers 50 e and 50 g before the target chamber 50 f is exchanged. Similarly, less labor is required when a trapezoidal chamber 50 is reinserted because it can positioned in-line more easily without the need to remove a gap 32 . The trapezoidal chamber design requires fewer steps; thus, less labor is required to exchange trapezoidal chambers 50 .
[0034] A still further benefit of the trapezoidal chambers 50 of the present invention is that the shearing forces are reduced during chamber removal and/or exchange. Because the trapezoidal chamber 50 f is more easily able to slide out from the in-line row of chambers 50 , less shear force is exerted on the o-ring 56 . Moreover, because the trapezoidal chamber 50 f may be more easily reinserted back into the in-line row of chambers 50 , less shear force is exerted on the o-ring during reinsertion. Thus, the o-ring 56 is unlikely to become dislodged or damaged and a seal is more likely to be achieved between adjacent trapezoidal chambers 50 e and 50 f. Additionally, less shear stress on the o-ring 56 will extend the life of the o-ring 56 .
[0035] Although this invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in other embodiments that will be apparent to persons skilled in the art. For example, the trapezoid shape of the chambers may vary from chamber to chamber as long as adjacent side walls of a bolting chamber are parallel. Thus, the chambers do not need to be shaped in the form of an isosceles trapezoid. This invention is, therefore, to be construed only as indicated by the scope of the claims and not limited to the embodiments described herein.
[0036] The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing description for example, various features of the invention have been identified. It should be appreciated that these features may be combined together into a single embodiment or in various other combinations as appropriate for the intended end use of the band. The dimensions of the component pieces may also vary, yet still be within the scope of the invention. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g. as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
[0037] The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation. Rather, as the following claims reflect, inventive aspects lie in less than all features of any single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
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A modular chamber design for manufacturing magnetic disks is provided. The modular chambers are linearly aligned, have a trapezoidal shape, and are inversely oriented. In this inverse orientation, a chamber can be exchanged and/or removed without first having to laterally move the other chambers to create space on each side of the chamber being moved. Because the modular chamber design decreases the amount of time and labor required to exchange or replace chambers in a disk processing line, disk throughput is increased. Thus, the modular chamber design facilitates faster and more efficient chamber exchange/removal.
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This is a continuation, of application Ser. No. 07/177,479, filed on Apr. 1, 1988, now U.S. Pat. No. 486 0057, issued 8/22/89.
BACKGROUND OF THE INVENTION
This invention relates to an automatic original circulating and feeding apparatus in a copying machine.
Some of the conventional copying machines is provided with an automatic original circulating and feeding apparatus, i.e. what is called RADF, which, for the purpose of improving the original processing capacity of a copying machine, permits a plurality of originals to be copied in a plurality of cycles by causing the originals to be automatically fed and recovered cyclically.
The RADF of this operating principle is generally provided with a frictional type paper separating mechanism for successively separating one by one originals piled up on an original feeding base from the lowermost original and forwarding them one by one to the copying machine.
Now, the conventional RADF is considered here as applied to the copying of double-faced originals. These double-faced originals piled up in the consecutive order of page numbers are set on the original feeding base in such a manner that the first page will form the uppermost original turned upwardly and the originals will be forwarded to the copying machine in the reverse order of page numbers. In this case, since the last page which is copied first is turned downwardly on the original feeding base, it must be turned upside down before it is forwarded onto a contact glass and set in the copying position. This is because the penultimate page constitutes itself a downwardly turned copy surface on the contact glass when this conveyance of the page is made on a turn feed route. The original in this state, therefore, is turned upside down on a switchback type route so that it will be placed on the contact glass with the last page turned downwardly. This operation inevitably requires each original to be conveyed and set through an idle step which has no part at all in the actual copying machine, entailing waste of time and impairing efficiency of the copying operation. Again when the penultimate page is to be copied, the same original must be sent through the same route before it is set on the contact glass. While one original is being copied, none of the feed routes is allowed to admit the next original. Thus, the conventional RADF necessitates a waiting time and, in this respect, operates with a slow processing rate. Particularly when the copying machine proper is capable of a high-speed processing, it is compelled to be operated at a lowered speed because the RADF of such a slow processing rate cannot keep pace with the high-speed operation of the copying machine. As the result, the use of the RADF prevents any effort to improve the CPM (copies per minute; efficiency of copying work).
When the double-faced originals are piled up consecutively in the order of page numbers with each of the originals turned upside down, the originals can be forwarded solely through a feed route to the copying machine. This setup, however, entails a troublesome work of causing all the originals to set severally upside down.
Even in the case of single-faced originals, they are fed out and recovered consecutively in the order of page numbers with the original-bearing face of each original turned upwardly. Since the time to start feeding the next original is restricted for the purpose of preventing two originals from passing each other on the contact glass, this arrangement also impedes the improvement of CPM.
SUMMARY OF THE INVENTION
In the light of the true state of affairs of the prior art described above, this invention aims to provide an automatic original circulating and feeding apparatus which the originals are set as turned downwardly and fed out consecutively in the order of page numbers, enables the original feeding work to be carried out at a speed matched to the speed of the continuous operation of the copying machine proper, thereby permitting the improvement of the CPM and, at the same time, enabling the feeding work to be optimized to suit either single-faced originals or double-faced originals.
The present invention provides an automatic original circulating and feeding apparatus comprising an original feeding base for receiving a plurality of originals thereon, which are piled up with image faces thereof turned downwardly, an original separating and feeding mechanism for successively separating the piled up originals on the original feeding base one by one from a lowermost original and feeding them one by one in a order separated, a reversible and speed-changeable belt conveyor mechanism disposed in an exposure part for exposing each of said originals fed, and a sensor disposed at a position separated by at least the largest original length from the original separating and feeding mechanism for selectively setting a scanning copy mode for forwarding a given original to a predetermined position above the exposure part, stopping the original at the predetermined position and setting an optical exposure system into a scanning motion for exposure or a sheet through copy mode for stopping the optical exposure system relative to the exposure part and forwarding the original by the belt conveyor mechanism for exposure and for controlling a position of the original for a copy mode selected.
Since the automatic original circulating and feeding apparatus according to this invention is constructed as described above, piled up originals arranged consecutively in the order of page numbers and set on the original feeding base with the image faces turned downwardly can be forwarded continuously in the order of page numbers and copied at a speed matched to the speed of the continuous copying speed of the copying machine proper without being affected by the resistance exerted in the original separating and feeding mechanism. In the copying of single-faced originals, for example, the selection between the scanning copy mode keeping the original stopped and the optical exposure system in operation and the sheet through copy mode keeping the optical exposure system stopped and the original conveying system in operation and the selection between the RADF mode and the ADF mode both can be made freely and the copying machine as a whole is enabled to enjoy an improved CPM.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view illustrating one embodiment of this invention.
FIG. 2 is a schematic view illustrating a drive transmission system in the embodiment.
FIG. 3 is an explanatory diagram illustrating a route for passage of single-faced originals in the embodiment during the course of copying.
FIG. 4 is an explanatory diagram illustrating a route for passage of double-faced originals of the embodiment during the course of copying.
FIG. 5 is a side view illustrating another embodiment of this invention.
FIG. 6 is an explanatory diagram illustrating a route for passage of single-faced originals in the aforementioned another embodiment during the course of copying.
FIG. 7 is an explanatory diagram illustrating a route for passage of double-faced originals in the aforementioned another embodiment during the course of copying.
FIG. 8 is a side view illustrating a modification of the aforementioned another embodiment.
FIG. 9 is an explanatory diagram illustrating a route for passage of double-faced originals in the conventional copying machine during the course of copying.
FIG. 10 is an explanatory diagram illustrating a route for passage of single-faced originals in the conventional copying machine during the course of copying.
FIG. 11 is an explanatory diagram illustrating a looped route for passage of originals in the conventional copying machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention is not limited to the embodiments to be specifically cited herein. It may be practised as modified or altered or altered in numerous ways without departing from the spirit of the invention.
First, the conventional countertype will be described in detail below for clarifying the distinction of the present invention.
When double-faced originals 1 are to be copied as illustrated in FIG. 9, these double-faced originals 1 are consecutively set in the order of page numbers as indicated by P1˜P6 with the first page P1 lying in the uppermost position as turned upwardly and they are fed out in the reverse order of page numbers, with the sixth page P6 to be copied first. Here, the sixth page P6 to be copied first is turned downwardly on the original feeding base, it must be turned upside down so as to be forwarded to and readied for copying on a contact glass 3 which is provided with a conveyor belt 2. Otherwise, the fifth page P5 constitutes itself a downwardly turned copy face on the contact glass 3 when the sheet bearing the sixth page P6 is conveyed along a turn feed route as indicated by ○1 . Thus, the original 1 as held in the state mentioned above is turned upside down by means of a switch-back type feed route as indicated by ○2 , ○3 , and ○4 so that the sixth page P6 will be forwarded to and set on the contact glass 3 as turned downwardly. This means that the original is forwarded and set by being passed through an idle step which has no part at all in the actual copying work, entailing waste of time and impairing the efficiency of copying work. When the fifth page P5 is to be subsequently copied, the same original bearing the fifth original must be similarly passed through the feed route as indicated by ○2 , ○3 , and ○4 before it is set on the contact glass 3. Further, the feed route as indicated by ○1 , ○2 , ○3 , and ○4 , while one original 1 is being copied, is not allowed to admit the next original. Thus, this setup necessitates a waiting time and, in this respect, operates at a low processing rate. Particularly when the copying machine proper is capable of a high-speed processing, it is compelled to be operated at a lowered speed because the RADF of such a slow processing rate cannot keep pace with the high-speed operation of the copying machine. As the result, the use of the RADF prevents any effort to improve the CPM (copies per minute; efficiency of copying work).
When the double-faced originals 1 are piled up in the descending order of P2, P1, P4, P3, P6, and P5 with respect to the diagram of FIG. 9, the originals may be processed only through the feed route of ○1 . This setup, however, entails a disadvantage that all the originals 1 must be set up as arranged in the aforementioned order.
Even in the case of single-faced originals 4, they are set consecutively in the order of page numbers with the image faces thereof turned upwardly as illustrated in FIG. 10, then forwarded through the feed route of ○1 in the reverse order of page numbers, and discharged and recovered through the feed route of ○4 via a discharge roller 5. The time to start feeding the next original is restricted for the purpose of preventing two originals from passing each other on the contact glass 3. Thus, this setup enjoys no improvement of CPM.
Now, the present invention will be described more specifically below with reference to preferred embodiments illustrated in the accompanying drawings. First, as illustrated in FIG. 1 through FIG. 4, an RADF 12 is disposed in such a manner as to cover a contact glass 11 which is disposed on the upper side of a copying machine proper 10. The RADF 12 is provided with a belt conveyor mechanism 17 comprising a conveyor belt 16 supported between a driving roller 13 and a driven roller 14 and furnished with a plurality of pressure rollers 15. At the upstream position to the right of this belt conveyor mechanism 17, an original feeding base 18 and an original separating and feeding mechanism 19 are disposed in the direction of the aforementioned contact glass 11 side. The original feeding base 18 is disposed as inclined toward the contact glass 11 side and adapted to permit a plurality of originals 20 piled up consecutively in the order of page numbers, with the image faces thereof turned downwardly. This original feeding base 18 is provided with a movable side fence 21 adapted to permit positioning of the originals in the direction of width. The original separating and feeding mechanism 19 is interposed between the original feeding base 18 and the contact glass 11 and is provided with a feed route 22 which continues to the loading surface of the original feeding base 18 and communicates with the contact glass 11. Below the original feeding base 18, a semicircular pinching roll 23 made of sponge of coefficient of frictional μ=1.0, and a Milar film 24 adapted to press an original 20 against the pinching roll 23 are disposed. There are further disposed a separating roller 25 made of murubber, for example, and a separating blade 26 held in pressed contact with the separating roller 25 and made of urethane having coefficient of friction μ, of not less than 1.2. Here, an electromagnetic clutch (not shown) is connected to the pinching roll 23 and the separating roller 25. While the feeding of originals is started, it is driven at a rate of one rotation per original. Then it is driven by the motion of the original 20. On the contact glass 11 side, a pair of pullout rollers 27, 28 are disposed.
An original sensor 29 is interposed between the pinching roll 23 and the separating roller 25. Another original sensor 30 is located immediately before the contact glass 11.
A reverse feeding mechanism 31 is disposed on the downstream side to the left of the belt conveyor mechanism 17. This reverse feeding mechanism 31 is formed mainly of a turn roller 32 of a large diameter. A roller 33 and a turn guide 34 disposed contiguously with the turn roller 32 jointly form a reverse route 35 around the periphery of the turn roller 32. The reverse route 35 is provided at the outlet thereof with a switch gate 36 serving to switch a conveyor route as a first switch plate gate device is rotatably disposed. Further, the turn roller 32 is provided on the following roller 14 side thereof with a guide claw 37. Around the inner side (conveyor belt 16 side) of the turn roller 32, a reverse feeding route 38 is formed as directed toward the aforementioned contact glass 11 side. An original sensor 39 is located immediately before the feed roller 33.
A discharging device 41 is also located which is provided with a discharge route 40 substantially horizontally interconnecting the outlet of the reverse feeding mechanism 31 provided with the switch gate 36 and the upper part of the original feeding base 18. The discharge route 40 is formed of a guide part 43 made of a RADF cover 43 as a device cover and a guide member 44. A plurality of paired conveyor rollers 45, 46, and 47 are disposed as opposed to the discharge route 40. A discharge roller 48 is disposed near the original feeding base 18.
A switchback reverse conveyor mechanism 49 as a discharge feeding mechanism adapted to effect selective passage of a document is disposed halfway along the length of the discharge route 40 in the discharging device 41. This switchback reverse conveyor mechanism 49 comprises a turn roller 50 having a diameter equal to the diameter of the aforementioned turn roller 32, a triangular guide member 53 disposed on the paper discharge side from the turn roller 50 and adapted to form a turn route 51 and a straight discharge route 52, a switch claw 54 as second switch gate serving to switch between the turn route 51 and the straight discharge route 52, feed rollers 55, 56 held in contact with the turn roller 50 with the turn route 51, and a switchback route 57 utilizing the upper side of the RADF cover 42.
At a prescribed position of the discharge route 40, at the inlet to the turn roller 50, and on the turn roller 50, original sensors 58, 59, and 60 are respectively disposed. Further, the guide member 53 is provided at the leading end side thereof with a paired conveyor rollers 61. A discharge sensor 62 is disposed on the nearer side of the discharge roller 48.
The present embodiment is allowed to select either the scanning copy mode for keeping the original 20 at the prescribed position P 2 on the contact glass 11 and setting an optical exposure system 64 such as of a lamp 63 into a copying motion from the home position HP or the sheet through copy mode for keeping the optical exposure system 64 such as the lamp 63 directly below the pressure roller 15 on the driven roller 14 side and forwarding the original 20 at a prescribed speed by the conveyor belt 16 to effect desired copying. On part of the optical exposure system 64, a resist sensor 65 is mounted as opposed to the contact glass 11. It is employed for the control of the position for stopping the original during the scanning copy mode or for aligning the leading end of the original 20 in motion with the leading end of the transfer paper on the copying machine proper 10 side during the sheet through copy mode.
Then, the construction of the drive transmission system in the RADF 12 of the present embodiment will be described below with reference to FIG. 2. A first motor 70 for actuating the original separating and feeding mechanism 19 is provided. With a motor cogwheel 71 on the axis of the first motor 70, two stepped cogwheels 72, 73 disposed on pullout roller (upper) shaft 28a are meshed through the medium of an intermediate cogwheel 74. A cogwheel 75 on the separating roller shaft 25a is meshed with the motor cogwheel 71 through the medium of the aforementioned intermediate cogwheel 74. A cogwheel 78 on the pinching roll shaft 23a is meshed with the cogwheel 71 through the medium of a cogwheel 76 coaxial with the cogwheel 75 and an intermediate cogwheel 77. The pullout roller 28 is set at a high pressure enough to forward the original 20 in spite of the pressure of separation exerted on the separating part.
There is also provided a second motor 79 serving to actuate the driving roller 13 for the conveyor belt 16. This second motor 79 is of the DC servo type. A motor cogwheel 80 disposed on the axis of the second motor 79 is meshed with a cogwheel 81 on the aforementioned driving roller shaft 13a through the medium of intermediate cogwheels 82, 83 and a cogwheel 84. The driving roller 13 is reversibly driven by the second motor 79 with the speed thereof freely controlled.
There is further provided a third motor 85 for driving part of the reverse feeding mechanism 31 such as turn roller 32 and the discharge device 41. A pulley 88 is fitted on the axis of a cogwheel 87 which is meshed with a motor 86 on the axis of this third motor 85. Between this pulley 88 and a pulley 89 on the turn roller shaft 31a and pulleys 90, 91, and 92 disposed on the conveyor roller (lower) shafts 45a, 46a, and 47a, a timing belt 94 is passed through the medium of a pressure guide roller 93. Again in this case, the speed at which the turn roller 32, etc. are driven is varied by changing the revolution number of the third motor 85.
There is provided a fourth motor 95 which serves for the switchback reverse feeding mechanism 49 and the discharge roller 48. A pulley 98 is fixed on the shaft of a cogwheel 97 which is rotated by a cogwheel 96 on the shaft of the fourth motor 95. A belt 100 is passed between the pulley 98 and a pulley 99 on the turn roller shaft 50a. Between this pulley 98 and pulleys 101, 102 on the roller shaft 61a and the discharge roller shaft 48a, a belt 103 is passed. The turn roller 50 and the discharge roller 48 are allowed to vary their speeds by the change of the revolution number of the fourth motor 95.
The distance between the turn roller 32 of the reverse feeding mechanism 31 and the turn roller 50 of the switchback reverse feeding mechanism 49 is greater than the maximum length of original (the longitudinal size of A3, for example). The distance between the sheet through position P 3 and the pullout rollers 27, 28 is also greater than the maximum length of the original.
Now, the feeding operation performed on the original 20 set on the original feeding base 18 in the construction described above will be explained below. The originals 20 are set as piled up consecutively in the order of page numbers, with the image faces turned downwardly. As the copy button on the copying machine proper 10 side is turned on, a motor 167 serving for a patition plate 166 which partitions a pile of originals 20 is turned on to set the partition plate 66 on the originals 20. Then, the first motor 70 is set operating and the pinching roller 23 and the separating roller 25 are actuated to separate and feed out the lowermost original 20 toward the pullout rollers 27, 28. It is then forwarded on the contact glass 11 by the pullout rollers 27, 28 and the conveyor belt 16. As regards speeds of operation, the speed of the separating roller 25 is fixed at about 500 mm/s and the speeds of the pullout rollers 27, 28 and the conveyor belt 16 are fixed approximately in the range of 750 to 800 mm/s.
These operations of separating and feeding of originals are carried out in common based on varying operation modes. Now, the operations of varying modes will be described. First, the sheet through copy mode (RADF mode) will be explained. This mode is selected where a finisher or a doggy tail is used for after-treatment of a copy paper and the condition in which the relation of the original to the copy is 1:1 is repeated. In this mode, the optical exposure system 64 is kept stopped directly below the pressure roller 15 on the driven roller 14 side. While the apparatus is in this state, since the original 20 is forwarded as pressed down against the surface of the contact glass 11 by the pressure roller 15, it is not suffered to rise from the contact glass and consequently is prevented from producing an uneven image due to jittering, for example. When the resist sensor 65 detects the arrival at a prescribed point of the leading end of the original 20 which has been brought up on the contact glass 11 by the conveyor belt 16, the speed of the travel of the conveyor belt 16 is changed from a high to a low level and, at the same time, the motion of a transfer paper within the copying machine proper 10 is synchronized with the new speed of the conveyor belt, as a step preparatory to sheet through copying. In this case, the trailing end of the original 20 completes departure from the pullout rollers 27, 28 by the time the leading end thereof reaches the position P 3 for sheet through exposure. Since the position P 3 for the sheet through exposure is set on the left end side of the conveyor belt 16, the original being forwarded on the conveyor belt 16 for the sheet through copying can be advanced and exposed to light at a fixed speed in a state perfectly free from the influence of such load as pressure of separation exerted by the separating roller 25 and the pullout rollers 27, 28. Again in this respect, the freedom of copied image from such adverse phenomena as jittering is ensured all the more.
In the meantime, the leading end of the original 20 being advanced on the conveyor belt 16 as simultaneously exposed to light continues its travel toward the reverse route 35 and the discharge route 40 from above the contact glass 11. At this time, the turn roller 32 or the conveyor rollers 45, 46, and 47 are driven at a speed equal to or slightly lower than the speed of the conveyor belt 16. As the result, the original 20 is not drawn by the turn roller 32 or any other roller but is advanced on the contact glass 11 at the fixed speed governed by the conveyor belt 16.
When the advance of the original 20 in the manner described above proceeds and the leading end of the original reaches the neighborhood of the turn roller 50, since the switch claw 54 keeps the turn route 51 side open during the present mode, the original 20 advances around the turn roller 50 and continues its travel toward the switchback discharge route 57 utilizing the upper surface of the RADF cover 42. At this time, the trailing end of the original completes its departure from the exposure position. As the sensor 60 detects the arrival at a prescribed point of the trailing end of the original, the conveyance on the roller 50 is stopped and the turn roller 50 is driven backwardly. As the result, the original 20 whose leading end has been advancing toward the switchback discharge route 57 is now caused to make a switchback change of its direction of travel and consequently forwarded toward the discharge roller 46 side by the turn roller 50 with the tailing end at the lead. Since these rollers 50, 46 are rotating at high speed in this while, the original 20 is released by the discharge roller 48 onto the original feeding table 18.
Now, the feeding of a subsequent original 20 will be considered. When a prescribed time elapses after the complete departure of the trailing end of the preceding original 20 advanced on the conveyor belt 16 for the purpose of the sheet through exposure is detected by the sensor 30, the first motor 70 is set rotating and the pinching roll 23 and the separating roller 25 are caused to start separating and the lowermost one of the piled originals 20. When the sensor 30 detects the arrival of the leading end of the subsequent original 20, the pullout rollers 27, 28 are switched to a state of low-speed driving to advance the subsequent original toward the contact glass 11 as kept at a fixed distance from the trailing end of the preceding original on the contact glass 11.
In the manner described above, the plurality of originals 20 piled up on the original feeding base 18 are consecutively forwarded in the order of their page numbers toward the contact glass 11 from the lowermost sheet upwardly, subjected to the copying by the sheet through exposure, and recovered successively on the original feeding base 18 again in the order of their page numbers. When the last of the piled originals is fed out, this fact is detected by the gravimetric rotary fall of the partition plate 66. When the last original is recovered, it is set by the motor 67 at the top of the pile. Thus, the pile of originals is ready for the next cycle of feeding. The operation described above is repeated until a desired number of copies has been produced.
During the course of the sheet through copy mode, the original 20 is exposed to light as simultaneously advanced at a fixed speed by the conveyor belt 16. In this case, when the condition of the fixed-speed conveyance of the conveyor belt 16 is rendered variable in a plurality of steps, the copying machine is allowed to produce copies of images magnified by varying ratios.
The scanning copy mode (ADF mode) in which the original is fixed in place and the optical exposure system 64 is caused to produce a scanning motion is selected where a sorter is employed for the aftertreatment of a copied paper and the first of the plurality of originals 20 is repeatedly processed for production of a desired number of copies before the second original is subjected to the same processing instead of causing the plurality of originals to be consecutively passed one by one through the copying unit. In this mode, the original 20 separated from the pile is advanced at a high speed on the contact glass 11 by the conveyor belt 16. When the arrival of the leading end of the original is detected by the resist sensor 65, an encoder in the second motor 79 issues a pulse signal to stop the motion of the conveyor belt and the original is stopped at a fixed position. After the original has undergone scanning exposure (of cycles required for production of a desired number of copies) of the optical exposure system 64. Then, the conveyor belt 16 is set again into motion, enabling the original to be passed through the reverse feeding mechanism 31 and advanced at a high speed through the discharge route 40. During the present mode, since the original 20 is no longer required to be recovered for further feeding on the original feeding base 18, it is passed through the turn route 51 around the turn roller 50 and released onto the switchback discharge route 57. Thus, the upper side of the RADF cover 42 is utilized as a tray. In this case, the RADF cover 42 may be provided on the surface thereof with a stack cover 68 made of translucent acryl resin as indicated by an imaginary line in FIG. 1, for example, to provide protection for the originals 20 released onto the switchback release route 57.
The originals 20 are partly of single-faced type and partly of double-faced type. Now, the treatment proper to each of the types will be described below. In the case of a plurality of single-faced originals, they are set on the original feeding base 18 as piled up consecutively in the order of their page numbers, with the first page P1 on the lowermost position and the image faces of the originals invariably turn downwardly as shown in FIG. 3. In this state, the originals 20 are successively fed out one by one toward the contact glass 11 from the lowermost original and subjected to the sheet through copying or the scanning copying. The originals is advanced through the turn roller 32 and the discharge route 40. In the sheet through copy mode, the original is advanced around the turn roller 50, switched back by the switchback discharge route 57, and released by the discharge roller 48 for recovery. In the scanning copy mode, the original is released onto the switchback discharge route 57. In response to the motion of the original 20 described above, the time for starting the feed of a copying paper 111 to a sensitive member 110 is synchronized within the copying machine proper 10 to effect control of paper feeding, for example, with the result that an image on the sensitive member 110 is transferred onto the transfer paper 111. Then, the copy paper 111 which has undergone the transfer of image is passed through a discharge roller 112, forwarded into a reversing part 113, and released as reversed onto a tray (not shown). Consequently, the transfer papers 111 are piled up as arranged consecutively in the order of page numbers with the image faces thereof turned downwardly.
Incidentally, in the case of single-faced originals, the discharge of the originals through the switchback reverse mechanism 49 brings about the following merit. When a plain RADF is considered as shown in FIG. 2, an original feeding base is installed on a conveyor belt 2 and originals 4 are successively forwarded through a looped circular conveyor route 6 and recovered. While the originals 4 are cyclically conveyed in a number of times, they are gradually disposed to be easily curled under the influence of the shape of the circular conveyor route 6 and the pressure of the turn roller 7, for example. As the result, they extrude from the original feeding base and frequently cause such adverse phenomena as jam. In accordance with the present embodiment, as readily noted from the flow of originals 20 shown in FIG. 3, since the originals are discharged after they are turned by the turn roller 50 in the direction opposite the direction in which they have been turned by the turn roller 32, the curl once imparted is corrected. Particularly since these turn rollers 32, 50 are formed in substantially equal diameters, the effect of correction of the curl is conspicuous and the efficiency of recovery of originals in the original feeding base 18 is high and the possibility of inducing the phenomenon of jam is diminished.
Now, the treatment of originals 20 and transfer papers 111 to be involved when a plurality of double-faced originals are given to be copies will be described below with reference to FIG. 4.
Similarly in this case, the originals 20 are set on the original feeding base 18 as piled up consecutively in the order of their page numbers from the lowermost original. The separation and feeding of the individual originals to the contact glass 11 is carried out in entirely the same manner as in the case of single-faced originals. Since the originals are of the double-faced type in this case, the first original placed on the contact glass 11 is subjected to the copying in such a manner that the first page P1 will constitute the lower side and the second page P2 the upper side respectively. After the originals has undergone exposure to light, it is forwarded toward the reverse route 35. In this case, since the second page p2 remains yet to be copied, the switch claw 36 is switched into a state of closing the discharge route 40 side. As the result, the original 20 is forwarded around the turn roller 32 and into the reverse route 38 this time. The conveyor belt 16 is also driven backwardly. As the result, the original 20 is set on the contact glass 11 in the opposite direction. In this state, the second page P2 of the original is turned downwardly and is ready for exposure to light. In response to the conveyance of the original 20 in the manner described above, the transfer sheet 111 has a copy formed on one side thereof by the sensitive member 110, then reversed by the reverse part 114, and released temporarily into an intermediate tray 115. Then, from the intermediate tray 115, the transfer sheet 111 now bearing a copied image on one side thereof is forwarded through a paper feed roll 116 and a resist roller 117 as synchronized with the motion of the original 20 again to the sensitive member 110, to complete a double-faced. After the production of copies on both sides thereof, the transfer paper 111 is forwarded through the discharge roller 112 and released directly into the tray. In the meantime, the original 20 which has had both sides thereof exposed to light is advanced toward the reverse route 35. This time, since the switch claw 36 has been switched to a new route, the original is advanced through the discharge route 40. Then, since the switch claw 54 of the turn roller 50 is now in a state inhibiting the advance of the original toward the switchback discharge route 57, the original 20 is caused to advance straight through the straight route 52 and then released by the discharge roller 48 onto the original feeding base 18. As the result, the double-faced originals are recovered in a set state. When the originals are released onto the switch-back discharge route 57, they are piled up in an incorrect order.
As noted from the comparison of FIG. 3 and FIG. 4, the route for conveyance of the single-faced originals is different from that of the double-faced originals. Since the route proper for either of the types of originals can be selected by means of the switch claws 36, 54, the originals are not required to be passed through any useless route. In the case of the double-faced originals, the sheet through copy mode cannot be selected because the operation includes a step for returning the originals 20 in the opposite direction on the contact glass 11.
In any event, the present embodiment provides a sequential page feeding RADF 12 which is capable of sheet through copying and, therefore, enables the copying intervals to be shortened and the CPM to be improved by continuously feeding the originals 20 for copying. Since the constructions is capable of effecting not merely the sheet through copying but also the scanning copy mode which is common for ADF, it contributes to diversification of the mode of copying. No matter which copy mode may be selected, the originals can be conveyed at a fixed speed on the conveyor belt 16 in a state free from the influences of pressure of separation because the position of the resist sensor 65 for controlling the conveyance of originals 20 is separated from the original separating and feeding part by a distance greater than the maximum original length. During the through copy mode, therefore, the copied images enjoy high quality because of the freedom from the adverse phenomena such as jittering and the accuracy of alignment of the leading end of original is enhanced. During the scanning copy mode, the accuracy of the stop of original on the contact glass 11 can be improved by the same token. Further in the case of double-faced originals, they can be conveyed through the shorted possible route without entailing any idle feeding. Further, the load required for the conveyance through the discharge system can be lessened since the distance between the turn rollers 32, 50 is greater than the maximum original length. Moreover, since the upper side of the RADF cover 42 can be utilized as a switchback discharge route 57 or a discharge tray, an original which is note desired to be passed repeatedly through the conveyor route may be released onto the upper side of the RADF cover and consequently prevented from sustaining unwanted harm.
Then, other embodiments of the present invention will be described below with reference to the diagrams of FIGS. 5 to 7. From the overall point of view, they are similar to the RADF 12 of the preceding embodiment, excepting ideas for compaction are reflected. Like parts are denoted by like reference numerals. In one of such other embodiments, an original discharge tray 121 is disposed to the left of the contact glass 11. A switchback reverse conveyor mechanism 122 which constitutes a reverse and discharge mechanism together with said reverse feeding mechanism and said discharging device is disposed to the left of the upper side of the reverse roller 32, namely in the direction opposite that of the discharge route 40. This switchback reverse conveyor mechanism 122 comprises a switchback route 123 formed by opening the RADF cover 42 in the horizontal direction, a reversing roller 124 disposed at the outlet, and an original sensor 125 positioned directly before the reversing roller 124. There is provided a switch claw 126 serving the purpose of switching the direction of advance of the original 20 having conveyed to the turn route 35 around the aforementioned turn roller 32 between the discharge route 40 side and the aforementioned switchback route 123 side. This switch claw 126 can be utilized also for the purpose of guiding the original 20 when it is desired to be forwarded through the aforementioned switchback route 123 and returned toward the discharge route 40. This switch claw 126 is further provided with a Mylar valve 127 adapted to prevent backflow.
The aforementioned discharge route 40, as compared with the countertype in the preceding embodiment, is formed linearly as far as the discharge roller 48 part and is additionally furnished with paired conveyor rollers 128, 129.
In still another of the embodiments, one motor is adapted to produce both normal and reverse drivings similarly to the turn roller 32 as far as the reversing roller 124 or the paired conveyor rollers 128, 129. The discharge roller 48 is driven independently by one motor. In this arrangement, the speed of the discharge roller can be freely changed for the purpose of improving the efficiency of recovering and stacking originals 20 on the original feeding base 18. This stacking property is further enhanced by impartation of nerve to the originals 20.
In the construction described above, the scanning copy mode in which the optical exposure system 64 is caused to produce a scanning motion for exposure and the sheet through copy mode in which the optical exposure system 64 is kept in a fixed state and the original 20 is exposed to light as simultaneously conveyed can be carried out in entirely the same manner as in the preceding embodiment.
When single-faced originals are given to be copied, the conveyor route for the original shown in FIG. 6 is selected. When the original 20 which has been exposed to light as simultaneously conveyed onto the contact glass 11 enters the turn route 35 on the turn roller 32 side, since the switch claw 126 has been turned to keep the switchback route 123 side open, the original 20 is advanced although this route and then forwarded by the reversing roller 124 toward the exterior of the RADF cover 42. In this case, the original which has emerged from the RADF cover 42 hangs down and is held up by the discharge tray 121 disposed below. When the original sensor 125 detects the arrival of the rear end of the original 20, the reversing roller 124 is temporarily stopped and then driven backwardly. At the same time, the switch claw 126 is turned to open the discharge route 40 side. As the result, the original 20 which has advanced through the switchback route 123 is caused by the reversing roller 124 to change its direction of travel in the pattern of a switchback and then forwarded through the discharge route 40. It is then released by the discharge roller 48 onto the original feeding base 18 by way of recovery. Consequently, the originals 20 are recovered in the same state as originally set.
Where single-faced originals are to be processed in the scanning copy mode, the originals 20 which have undergone exposure to light may be directly released onto the discharge tray 121 by means of the switchback route 123 and the reversing roller 124. This operation permits a reduction in the route for passage of the original and proves to be advantageous for originals 20 of the nature not desired to be exposed to the friction of passage.
Where double-faced originals 20 are given to be copied, they are forwarded through a route as illustrated in FIG. 7. When the front page of the double-faced original 20 is exposed to light on the contact glass 11, the original is advanced toward the turn route 35. In this case, since the switch claw 126 and 36 have been turned to open the reverse route 38 side around the turn roller 32, the original 20 is advanced through this reverse route 38. At this time, the double-faced original 20 is in a state turned upside down. Also, the conveyor belt 16 is set revolving in the opposite direction. As the result, the original 20 is set on the contact glass 11 with the reverse side thereof turned downwardly and in that state exposed to light. After this exposure, the switch claws 126, 36 are turned to open the ordinary discharge route 40 side. Thus, the original is forwarded around the turn roller 32 and through the discharge route 40 and released by the discharge roller 48 onto the original feeding base 18. In this case, too, the originals are recovered in the same state as initially set.
In yet another embodiment, the RADF cover 42 is formed as an integral component. It is optional that it may be split into two parts, i.e. a RADF cover 42a extending from the neighborhood of the turn roller 32 through the neighborhood of the conveyor roller 129 and a RADF cover 42b formed on the original separating and feeding part as illustrated in FIG. 8, with only the RADF cover 42a side adapted to be freely shut and opened.
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An automatic original circulating and feeding apparatus apparatus comprises an original feeding base for receiving a plurality of originals thereon, which are piled up with image faces thereof turned downwardly, an original separating and feeding device for successively separating the piled up originals on the original feeding base one by one from a lowermost original and feeding them one by one in an order separated, a reversible and speed-changeable belt conveyor device disposed in an exposure part for exposing each of the originals fed, and a sensor disposed at a position separated by at least the largest original length from the original separating and feeding mechanism, for selectively setting a scanning copy mode or a sheet through copy mode and for controlling a position of the original for a copy mode selected.
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This is a continuation of application Ser. No. 631,750 filed July 17, 1984, which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
The present invention relates to a path calculating system for following the path of a naval vessel with the help of magnetic means. It is particularly usable for tracking a vessel which is immunized against the risks of magnetic detection, particularly in stations which check the magnetic immunization of the vessel.
In a magnetic immunization checking station, measurements are made on a ship or a submarine moving above an aligned array of sensors for, among other things, adjusting the immunization loop currents. For this, the position of the vessel must be located with respect to the sensors for each measurement so as to be able to compare the results of measurements from several passages of the vessel.
The improvements made to magnetic detection systems have led to designing more reliable immunization systems allowing the vessels to escape from a magnetic detection system. Thus, it is necessary to accurately test the immunization of the vessel with high precision, and to be able to locate the current vessel position very accurately during such tests.
Until recently, and in numerous cases still at the present time, the means for locating the were essentially manual; the visual sighting of posts either by an operator or by a video image link. At the present time, the positioning and path calculating systems are radioelectric or optical; they consist in performing a triangulation from a mobile marker or beacon (on the vessel) and two or three fixed markers or beacons disposed on land.
Such an assembly is very large with respect to the size of the measuring base and the corrections to be performed; in fact, the site (normally a port) requires ranges of the order of 4 to 5 kilometers;
The positioning accuracy actually attained is on the order of 2 m in the best of cases. Such an installation is therefore very large. It requires an expensive infrastructure (construction, supply beacon, maintenance, etc.).
The path of a surface craft or a submarine can be obtained acoustically. At least three acoustic sensors or hydrophones are placed and fixed to the sea bed. The vessel whose path is to be calculated is equipped with an acoustic transmitter. Measurement of the times at which the emitted signal is received at the hydrophones allows the position of the craft to be calculated. This technique gives good measuring accuracy but requires a specific acoustic base (3 hydrophones) to be set up.
The present apparatus invention provides for calculating the path of a vessel which apparatus is sufficiently accurate, easy to implement and inexpensive.
SUMMARY OF THE INVENTION
The invention provides a system for calculating the path of a naval vessel. The apparatus includes at least one magnetic source disposed on the vessel and emitting a magnetic field of known characteristics, and detection means external to the vessel for detecting the emitted magnetic field.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and other features and advantages will be clear from the following description with reference to the accompanying Figures in which:
FIG. 1 shows one example of setting up a path calculating system in accordance with the invention;
FIGS. 2a and 2b illustrate the magnetic field induction vector diagrams of the system of FIG. 1;
FIG. 3 is an example of the processing installation of the system of the invention;
FIG. 4 shows one embodiment of a magnetic source on board a vessel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The path calculating system of FIG. 1 comprises a magnetic radiation emission source 11 fixed to a naval vessel 10, two magnetometers 12 and 13 and a processing installation 14.
The vessel 10 navigates, on the surface, for example, in a given navigation zone contained in a plane xOy.
The magnetometers 12 and 13 may be triaxial directional magnetometers for measuring the magnetic field in three orthogonal directions. Magnetometers 12 and 15 are fixed to the seabed (including riverbeds, oceanbeds or any ground below the water through which the vessel navigates) at points A and C along a straight line D parallel to axis Ox and inside a zone corresponding to the projection, on the bottom of the sea, of the zone of navigation. Magnetometers 12 and 13 are spaced apart by a distance e and are orientated so that their measurement axes are directed parallel to the axes Ox, Oy and Oz. Each magnetometer has then a first measurement axis parallel to Ox, a second measurement axis parallel to Oy and the third measurement axis parallel to Oz, i.e. parallel to the direction of the magnetic field H.
The processing installation 14 may be situated on land. It is connected by data transmission cables to the magnetometers and provides appropriate processing for the data supplied by the magnetometers.
In FIGS. 2a and 2b, illustrating the magnetic induction vector diagrams, we find the magnetic radiation source 11 moving in a direction uv in a plane P, corresponding to the surface of the sea in a case of a surface craft, as well as the trihedron Oxyz.
Points A and C, where the magnetometers are located, are situated on a straight line d parallel to the axis ox.
Source 11 emits a magnetic field H perpendicular to plane P.
The magnetometers 12 and 13 measure, at points A and C respectively, the components of the magnetic field in three directions parallel to the axes Ox, Oy, Oz.
Assuming that the magnetic source 11 emits a dipolar field, the amplitudes of the components of induction B at a point of coordinates X, Y and Z in the trihedron Oxyz are given by: ##EQU1## where μ o =permeability, and
M: magnetic dipolar moment
By applying these relationships to the points A
and C of respective coordinates X A , Y, Z and X C , Y, Z, and considering that X A 31 X C =e, we obtain: ##EQU2##
The value of Z is known from the immersion depth of the magnetometers.
It should be noted that since the straight line D is parallel to axis Ox, the coordinates Y and Z of points A and C are equal and that only the abscissa X A and X C differ.
It is then possible with the system of the invention, by measuring the magnetic fields at two points A and C, to determine the coordinates with respect to a suitably orientated trihedron Oxyz whose apex O is the center of the magnetic radiation emission source 11. Thus, knowing the positions of points A and C it is easy to determine the position of point O, and thus the boat 10.
Moreover, the values of B Z .sbsb.A and of B Z .sbsb.C have not been used which only requires at A and C magnetometers measuring the components of the magnetic fields only along two perpendicular directions Ox and Oy.
Nevertheless, if the magnetometers used also allow the magnetic field components to be measured along the third direction Oz, this facility could be used for carrying out measurements when the vessel passes straight above the straight line D. In that case, coordinate Y becomes very small then O, and components B Y .sbsb.A and B Y .sbsb.C tend towards O. The equation (1) is indeterminate and can no longer calculate X A . Nevertheless, from the preceding relationships, we obtain the following equation for calculating X A , Z being known: ##EQU3##
With this equation moreover, the depth Z at which the magnetometers 12 and 13 are immersed may be calculated. It can then be used when the measures relate to a submerged submarine and in this case Z is the distance which separates the submarine from the seabed on which the magnetometers are located. This technique may also serve for improving the depth measurement as a function of the state of the sea and of the size of the vessel.
The measuring station 14 comprises computing means for obtaining X A , Y and possibly Z. FIG. 3 represents a diagram of the processing of the signals received by two triaxial magnetometers.
A filtering circuit 30 receives the magnetic field components at points A and C in the form of electrical signals. These signals are bandpass filtered about the operating frequency of the emission source 11. The signals corresponding to the components at A and C of the magnetic fields emitted by source 11 are fed to a detection device 31 which converts their analog value into a digital value. A computer 32 receives the signals thus processed. In addition computer 32 receives the distance e separating the two magnetometers. Computer 32 computes therefrom the coordinates X A , Y, Z and displays the position of the vessel on a display device 33. A test circuit 34 also detects the zero value of Y for the computer 32.
In practice, with a magnetic moment of 10 3 . Am 2 at a frequency of 10 HZ, a vessel may be tracked over a sufficient distance for the operational needs (about 100 meters on each side of the line of sensors). Moreover, for measurement accuracy reasons, the vessel should sail along a line which is transverse and if possible orthogonal to line D and at an equal distance from magnetometers 12 and 13.
So as to avoid the errors diue to poor verticality of the magnetic moment, resulting from the rolling-pitching movements of the vessel, the magnetic source will preferably be suspended.
In the example shown in FIG. 4, the magnetic source is a coil 51 fed with current and is enclosed in a case 50 riveted to the deck of the vessel or the submarine. Coil 51, whose diameter is equal to about 1 meter for example, is suspended about an axis 52 at its center by means of radial downward sloping connections 53. The case is filled with an electrically insulating oil so as to damp the oscillations of the coil, and it also contains supply circuits 54.
In another embodiment, an immunization adjustments station is provided wherein the magnetic source used is a horizontal immunization loop 60 with which the vessel is already provided. Such immunization loops are known in the art, as evidenced by U.S. Pat. No. 3,110,282 to Foerster. The AC current generated for such an immunization station by a current source 62 for producing the field is chosen at a frequency such that the field produced does not modify the magnetic signature and so does not interfere with the immunization adjustment.
In this case, the craft is equipped with an inclinometer giving the slope angle of the craft which is fed to the land station by radio. Depending on the value of the angle, computer 32 computes the position of the craft by computing the required change of axes.
Finally, the two mangetometers 12 and 13 may be chosen from the magnetometers used in the magnetic immunization checking station for the magnetic measurements. In combination with the preceding variant, the invention presents the advantage, by using existing equipment, of requiring no additional installation.
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Apparatus for determining the location of a naval vessel includes a magnetic source connected to the vessel for emitting a predetermined magnetic field. Two magnetic detection devices fixed to the seabed detect and measure at least two components of the emitted magnetic field. Location calculation means are coupled to the two magnetic detection devices for calculating the location of the vessel from the components measured by the two magnetic detection devices.
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RELATED APPLICATIONS
This application is a U.S. National Phase of International Application No. PCT/GB2006/001494, filed Apr. 26, 2006, designating the U.S. and published in English on Nov. 2, 2006, as WO 2006/114597, which claims the benefit of British Application No. GB 0508662.4, filed Apr. 28, 2005 and British Application No. GB 0600813.0, filed Jan. 16, 2006.
FIELD OF THE INVENTION
This invention relates to a new material to be used as a pressure mitigant, e.g. as a protective barrier on or in place of windows. In particular, the invention relates to the use of cross-linked water gels to form a material which can mitigate the consequences of an explosion and damage caused by projectiles.
BACKGROUND OF THE INVENTION
Since the mid 1990's there has been an increase in the use of explosives by criminal organisations against civilian and military targets throughout the World. Their use results in death, injury and destruction of property and buildings. Previously, mitigation of explosion relied upon intelligence and police detection to provide warning of impending attack but recent events make it clear that intelligence and police operations alone cannot be relied upon to prevent explosions. Moreover, some explosions are caused simply by accident, e.g. gas or chemical explosions, and it would be useful if the consequences of such accidental explosions could also be minimised.
Conventional construction can give rise to buildings which will withstand many types of impact but it is still difficult to minimise the effects of explosions. Of particular importance and concern are the windows especially in high rise buildings. Windows are a major cause of trauma and injury caused by explosions; the fragmentation of pieces of glass not only causes death but many other permanent injuries such as loss of eyesight, organ trauma etc.
It is well known therefore for buildings and in particular windows to be protected against explosion damage by materials which mitigate their effects.
One option for minimising the problem of glass fragmentation utilises an adhesive film made of a polyester composite material which can be applied to the inside of a window to contain glass fragments. Such films do not however prevent injury caused by fragments of masonry from cladding or from fragments falling from a height.
Certain other elastomeric polymer materials have been suggested for use as building cladding to prevent damage caused by explosions. The elastomer material is a highly ductile polymer that can be sprayed onto building surfaces including windows to prevent injury caused both by flying glass and masonry. The polymer employed is based on a polyurea and may be suitable for use with temporary structures as well as concrete buildings (Polymer materials for structural retrofit, Knox et al, Air Force Research Laboratory). The polymer is not transparent however and its use on windows is not desirable. Moreover, experiments using the polymer have not shown a reduction in pressure effects inside a building.
There are a number of reports of conventional fire fighting foams being employed as pressure mitigants (Journal of Explosives Engineering, Vol 26, No. 3, 1999). Such foams have the additional advantage of preventing fires often associated with explosions. However, the use of these foams requires that the explosive can be surrounded by the foam in a contained environment. Whilst this is possible when the source of an explosion is identified, where an explosion occurs without warning these foams cannot be used. Nor do these foams allow access to an explosive source by persons working to mitigate an accident or defuse a device controlled by criminals.
A somewhat similar system is sold under the trade name Hydrosuppressor. The system involves spraying the explosive or spraying the area in the vicinity of the explosive with water from various angles. Again however, this technique relies on the identification of an existence of a threat of an explosion prior to any explosion taking place.
A more conventional pressure protection system involves coating windows with a woven fabric mesh which acts to catch fragments of glass during any explosion. However, the mesh necessarily obscures the view through the window since it is not transparent. Moreover, the material does not cause any reduction in primary pressure within a building and hence offers no protection against direct pressure effects.
Recently, pressure impulse mitigation has been significantly improved by the use of blast net curtains and by the retrofitting of laminated glass. However, whilst net curtains provide some protection against fragmentation from glass they do not protect building integrity. Also, laminated glass cannot be used higher than about 7 storeys since it falls in total window size, i.e. does not fragment. This is potentially lethal to those in the street below.
There remains a need therefore for novel classes of pressure mitigation materials to be designed, which overcome the limitations of any of the present generation of such materials including but not limited to those described herein, and in particular to provide protection against zero warning explosions. Moreover, with the increase in criminal activity, the use of pressure impulse mitigation materials in construction may become common place and hence there remains a need to devise cheap, non-toxic materials for pressure impulse mitigation.
SUMMARY OF THE INVENTION
The present inventors have surprisingly found that certain cross-linked mixtures of water and gels (from hereon cross-linked water gels) are particularly suitable for use in barriers/shields to prevent damage caused by explosions. The inventor has surprisingly found that water gels can be formed into structures which can withstand significant over-pressures compared with materials currently used in buildings. Without wishing to be limited by theory, it is envisaged that the inherent elasticity of the cross-linked water gel makes it an excellent material for absorbing the shockwave of an explosion whilst retaining its structural integrity. Moreover, the aqueous nature of the water gel ensures that it is also capable of resisting heat and quenching flame, in particular in the immediate aftermath of an explosion.
In addition, it has surprisingly been found that the cross-linked water gels mitigate damage caused by projectiles such as shrapnel or bullets. The water gels are able to absorb and partially redirect the shockwave created by the projectile through their elasticity whilst also acting to slow and potentially stop the projectile via friction effects throughout the gel bulk. The cross-linked water gels therefore also serve to protect against damage from projectiles and are hence of use as bullet proof materials.
Cross-linked water gels are not themselves new. Cross-linked water gels have been used to deliver bio-molecules and pharmaceuticals either in the form of a biologically degradable capsule or in the form of a matrix from which the active molecule is released during proteolysis in vivo. Amongst the most frequently cited cross linking reagents in this regard is glutaraldehyde (pentane-1,5-dial), which has the chemical formula C 5 H 8 O 2 (see Yamamoto et al., (2000) J. Control. Rel. 133-142; Tabata Y., and Yoshito, I., (1989) Pharma Res., Vol 6, 422-427). Iridoids such as genipin have been used to cross link and thereby harden the coating of gelatin based microcapsules (U.S. Pat. No. 5,023,024).
Other naturally occurring water gels have also been reported to have been chemically cross linked. For example, albumin has been reported to have been cross linked with formaldehyde (Akin, H., and Hasirci N., Proc. Am. Chem. Soc. Polym. Div. Polym. Prepr. 36, 384-385 (1995), and Yamada, K., et al, J. Neurosurg. 86, 871, (1997)) and chondroitin sulphate with diaminododecane catalysed by dicyclohexycarbodiimide (Rubinstein, A., Naker, D., and Sintov, A. Pharm. Res. 9, 278-278 (1992)). Alginates have been cross linked with poly(ethylene glycol)-diamines in order to investigate the changes in elastic modulus that occur with increasing cross linking density and the mass of the cross linker (Eiselt, P., et al. (1999) Macromolecules, 32, 5561-5566).
Collagen cross linked with glutaraldehyde has been shown to produce films with increased mechanical strength when mixed with gelatin. The claimed increase in mechanical strength is thought to be due to the reagent's effect on the isoelctric point of the collagen (critically reducing it to below 6.2) as the same effect could be achieved by acetylation of the collagen with acetic anhydride (see GB 2 052 518 A).
Enzymatic cross linking of water gels can also be achieved in certain circumstances. Poly(ethylene glycol) (PEG) functionalised with a glutaminamide and a lysine containing polypeptide will cross link in the presence of transglutaminase (Sperinde, J. J., Griffith, L. G., Macromolecules 30, 5255-5264 (1997).
Synthetic water gels such as PVP can also be cross linked chemically, by irradiation or photoactivation.
Never before however, have these structures been suggested for use in pressure impulse mitigation.
Thus, viewed from one aspect the invention provides the use of a cross-linked water gel in pressure impulse mitigation, e.g. blast mitigation or mitigating the effects of a projectile.
Viewed from another aspect the invention provides a method for protecting an entity, e.g. a structure or organism, from the effects of an explosion or from the effects of contact with a projectile comprising covering at least a part, preferably at least 10% thereof, e.g. all of said entity in a barrier comprising a cross-linked water gel.
By pressure impulse mitigation is meant, inter alia, that at least one of the effects, preferably all of the effects of an explosive blast, e.g. fragmentation or collapse of buildings or glass, translation of objects within the building and primary and secondary effects of fire are reduced.
Pressure impulse mitigation also covers mitigating the effects of contact with a projectile, i.e. mitigating the potential damage caused by a projectile or in the mitigation of projectile induced damage. The projectile may be, for example, a bullet, missile, shrapnel, space debris etc.
By entity is meant anything which should be protected from the impact of an explosion or from damage by a projectile, e.g. structures, organisms and the general physical environment.
An organism is a living plant or animal, e.g. a human. By structure is meant any inanimate object which could be protected from explosive damage such as buildings (temporary or permanent), industrial plant, civil infrastructure, vehicles, military equipment, computers etc.
By cross-linked water gel is meant a cross-linked mixture of water and a gel which forms a solid elastomeric barrier. The gel should preferably be non-toxic and cheap to manufacture or isolate. It should exhibit elastomeric properties, have a high elastomeric modulus and a high ductility.
Suitable gels include gelatin, gellan gum gels, poly(gamma-benzyl-L-glutamate) (PBLG), agar (preferably composed of 70% agarose, a gelsaccharide and 30% agaropectin), collagen, protein gels, polysaccharide gels, keratin gels, hydrogels, ormosils (organically modified silicates often of formula (R′ n Si(OR) 4-n in which R is typically an alkyl group and R′ an organic group), sol-gels, hydrophilic polymer gels, and glycoprotein gels. Other suitable gels include biogels such as carrageenans, pectins, chitosan (e.g. deacylated chitin), alginates (e.g. xanthan alginates casein), seed gums, egg protein g and Gelacrimide gels. Mixtures of gels can be employed.
These gels can be obtained from commercial sources. A preferred gel is gelatin. The gelatin preferably has a molecular weight range of 20,000 to 300,000 D, e.g. 20,000 to 150,000 D and can be made from the hydrolysis of collagen.
Suitable agents to effect the cross-linking of the gels are multifunctional molecules, e.g. bi, tri or tetrafunctional molecules, capable of linking the polymer chains of the gel in question. The reactive functionalities on the cross-linking agent are conveniently the same and these can be separated by spacer groups. Such a spacer group may preferably comprise a chain of 1 to 20 atoms, e.g. an alkylene chain optional interrupted by heteroatoms such as O, N, P or S linking the reactive functional groups. The spacer group chain length actually selected will depend upon the water gel polymer to be cross linked and the mechanical and physical properties required of the cross linked gel. Suitable reactive cross-linking functional groups are well known and include aldehydes, esters (in particular N-hydroxy succinimide esters and imidoesters), amines, thiols, hydroxyls, acid halides, vinyls, epoxides and the like.
Thus, cross-linking agents may be of general formula (I)
X-Sp-X (I)
wherein each X independently represents the residue of an aldehyde (i.e. —COH), the residue of an ester (i.e. —COOR) in particular N-hydroxy succinimide esters and imidoesters (—CNOR), amine, thiol, hydroxyl, acid halide or vinyl and Sp is a spacer group comprising a chain of 1 to 100 atoms in its backbone, preferably 1 to 50, more preferably 1 to 20, e.g. 4 to 12 atoms, especially 5 to 10 atoms. X may also be epoxide. The group R can be any group which allows the formation of an ester which is preferably labile. R may therefore be a C1-20 alkyl, an optionally substituted N-hydroxy succinimide group and so on.
Alternatively, the cross-linking agent may be a multifunctional species of formula (II)
(X-Sp) n Y
wherein X and Sp are as hereinbefore defined, Y is a carbon atom, C—H or a heteroatom such as a nitrogen or phosphorus atom and n is 3 to 5. Obviously, the value of n varies depending on the nature of the Y atom employed as will be readily understood by the person skilled in the art. Thus when Y is C then n is 4. If Y is C—H then n is 3.
Preferred groups X are electrophilic functional groups such as esters, carboxylic acids or aldehydes or nucleophilic groups such as amines and hydroxyls.
Whilst the X groups may be different, especially preferably, all X groups are the same. Especially preferably these are selected from aldehydes and esters, in particular imidoesters or N-hydroxy succinimidyl esters.
The spacer chain is preferably substantially linear and is formed primarily of carbon atoms which can be interrupted by heteroatoms such as oxygen, nitrogen and sulphur. By substantially linear is meant that the spacer arm is free from branched side chains of three atoms or above, i.e. the spacer may carry short chain branches like methyl or ethyl groups.
The spacer chain is preferably linear (i.e. free of branches) and is preferably formed from a carbon atom backbone, e.g. a C 1-40 carbon backbone, preferably C 1-20 alkylene chain (e.g. methylene or a C 7-9 alkylene chain).
The backbone may contain one or more aryl groups such as phenyl or benzyl in its length, (e.g. two aryl groups), preferably linked through the 1 and 4 positions of the ring. As mentioned above, the backbone may be interrupted by heteroatoms, e.g. oxygen or nitrogen, to form for example, an ether spacer group. Up to 10, preferably up to 5, e.g. up to 3, such as 1 heteroatom may be present. The backbone might also contain oxo groups along its length. Again whilst the Sp groups may all be different, it is preferred if these are the same.
When Y is a heteroatom it is obviously one which can have a valency of at least 3, e.g S, N, P.
Preferably, Y is a nitrogen atom or a phosphorous atom. The subscript n is preferably 3 when Y is nitrogen and 3, 4 or 5, especially 4, when Y is phosphorous.
Highly preferred cross-linking agents are biscarboxylic esters.
Specific cross-linking agents of particular utility in the invention include sebacic acid esters (e.g. the N-succinimidyl ester whose structure is depicted below), bis(sulphosuccinimidyl) suberate,), disuccinimidyl suberate, imidoesters such as dimethyl suberimidate, trissuccinimdyl aminotriacetate (TSAT, Pierce Biotechnology Inc.), beta-tris(hydroxylmethylphosphino) propionic acid (THPP, Pierce Biotechnology Inc.), bisphenol A diglycidyl ether, avidin-biotin. The known gelatin cross-linker gluteraldehyde is preferably not employed.
The SANHSE, in common with other bis-succinimidyl derivatives, is easily synthesised by condensing N-Hydroxysuccinimide with a dicarboxylic acid in the presence of dicyclohexylcarboiimide, the carboxylic acid being selected to provide a spacer of desired length. The resulting product contains two amine-reactive N-hydroxysuccinimide esters. This compound exhibits poor water solubility however. Hydrophilicity (and hence solubility) can therefore be increased by the addition of a sulfonate group into the succinimidyl ring. A number of water soluble bis-succinimidyl cross linkers are now commercially available from PIERCE (e.g. Bis(sulfosuccinimidyl) suberate (BS3).
Viewed from another aspect therefore, the invention provides a water gel mixture (preferably a water gelatin mixture) cross-linked by reaction with an imidoester or conventional ester, in particular a bis imidoester or bis ester, e.g. a sebacic acid ester especially a succinimidyl ester.
The water gels of the invention should preferably have a stiffness in the range of 20 to 100 kPa, preferably 30 to 60 kPa.
Another property of the water gel is its stress relaxation, with values in the range 0.05 to 0.3 kPa being preferred. Higher stress relaxation values indicate an increased ability to withstand impulse pressure.
The cross-linked mixture of water and gel can comprise at least 3% by weight of the gel, preferably at least 4% by weight gel, especially at least 5% by weight gel, up to the limit of solubility of the gel in water, e.g. between 10% by weight and 50% by weight of gel, or in the range 15% by weight to 40% by weight gel, e.g. 20 to 35% wt.
Mixing of the water and gel can be achieved by any convenient means, preferably with stirring or sonication to ensure complete mixing. Thus, the hot gel can be mixed with water in a mould and allowed to cool to form the water gel. The water used may be deionised or distilled if desired but this is not essential. Other sources of water such as tap water are also employable. The cross-linking of the water gel can be carried out using any suitable protocol, e.g. direct addition. Thus, the cross-linking agent could simply be added to an appropriate concentration of water gel mixture at a suitable pH to effect cross-linking. For example, cross-linking may be effected by the addition of an aqueous solution of a water soluble imidoester, such as dimethyl suberimidate.2HCl (DMS), to 20-35% w/v gelatin in aqueous solution, in PBS or other suitable buffer. An appropriate pH for the addition would be in the range 7.5 and 9.5 and temperatures of 20 to 40° C., e.g. 30-35° C. or 22-24° C. could be employed.
The concentration of cross-linker employed may be between 0.25 and 25 mM, e.g. 10 to 20 mM giving, in the case of gelatin, a molar ratio of amino groups to reagent of between 1:2 to 1:5.
Viewed from another aspect therefore the invention provides a process for the preparation of a cross-linked water gel comprising contacting a water gel mixture, preferably comprising 20 to 35 wt % gel, with an imidoester, preferably at a pH of 7.5 to 9.5 and at a temperature of 20 to 45° C., e.g. 25 to 40° C.
Of particular utility however, is a process in which either a weak water gel solution or alternatively a soluble elastomeric monomer or mixture thereof e.g. resilin or elastin (or synthetic analogues of such monomers) is preincubated with a cross-linking agent preferably under carefully controlled conditions of pH and temperature. Thereafter, the preincubated material is contacted with a higher concentration water gel mixture to complete the cross-linking process.
Thus, the cross-linking agent, e.g. sebacic acid bis(N-succinimidyl) ester (SANHSE), can be added to a low concentration water gel mixture, e.g. 0.5 to 5 wt % of gel, preferably 1 to 5 wt %, more preferably 1.8 to 2.0 wt % or 2 to 4 wt % or added to a soluble elastomeric monomer or mixture thereof. Such an elastomeric monomer may be present in an aqueous solution which may preferably be of low concentration, e.g. 15 wt % of monomer, i.e. the concentration of monomer is less than the concentration of water gel used in the second stage.
It may be convenient to dissolve the cross-linking agent in an aqueous or organic solvent such as water, methanol, acetone, DMSO or toluene to allow addition. The nature of the solvent employed depends on the polarity of the cross-linking agent as will be readily understood by the skilled chemist. It may also be useful to buffer the water gel mixtures so that pH values can be maintained throughout the cross-linking procedure. PBS buffer is suitable for this.
The temperature and pH of both stages of the cross-linking reaction are preferably controlled to obtain the desired cross-linking characteristics in each stage of the reaction. The temperature during the preincubation stage is preferably less than that of the second stage. Thus, in preincubation, temperatures are preferably kept around ambient, e.g. 15 to 25° C., preferably 20 to 24° C., especially 22 to 24° C. The pH of the preincubation stage can be greater than that of the second stage (e.g. up to 1 or 2 pH points greater) however it should preferably be the same as or less than that of the second stage. Suitable pH's range from 6.5 to 7.5, e.g. 6.8 to 7.4, e.g. approximately 7.
After a preincubation period (e.g. of between 0.25 to 4 hours, especially 20 to 45 minutes), the preincubated material can be added to a water gel mixture of higher concentration, e.g. 20 to 50 wt % gel, preferably 20 to 40 wt % gel, especially to 35% wt. The gel used may be the same as that employed in the first stage. What is important however, is that the gel employed in the second stage possesses a reactive group which is capable of completing the cross-linking reaction.
Thus, for example, where an N-hydroxysuccinimide ester is employed as the cross-linking agent, the second gel may preferably carry a reactive lysine functional group to complete the cross-linking reaction. It is preferred, however, if the gels employed in both stages are the same, e.g. both gelatin.
Preferred temperature ranges for this step are 38 to 48° C. and preferred pH's are 7.0 to 9, e.g. 7.5 to 8.7, preferably 8.0 to 8.5. For a SANHSE concentration of 0.5 mM to 5.0 mM, at pH 6.75-7.25 and at a temperature of 18 to 22° C., preincubation time is preferably 20 to 45 minutes.
The cross-linked water gel that forms can then be allowed to set for a suitable period at lower temperature, e.g. ambient temperature.
This novel process forms a further aspect of the invention. The invention therefore provides a process for the manufacture of a cross-linked water gel comprising:
contacting a lower concentration water gel or a soluble elastomeric monomer with a cross-linking agent at a first pH and a first temperature to form a preincubated sample;
adding said preincubated sample to a higher concentration water gel at a second temperature and a second pH, said second temperature being higher than the first temperature. Preferably said second pH is the same as or higher than said first pH.
The amount of cross-linking agent required can vary over a wide range although the molar ratio of amino groups in the gelatin to reagent should be 1:10 to 10:1 e.g. approximately 1:1. A 5 mM solution of SANHSE in 50 ml gelatin equates to 1:1. Maximum concentration of cross-linking agent may vary depending on its solubility. Highly preferred concentrations of cross-linking agents such as SANHSE are in the range 1.25 mM to 2.5 mM. It has surprisingly been found that increasing concentrations higher than this range does not necessarily impact favourably on final gel strength and may in fact reduce gel strength.
Whilst the preincubation process gives excellent results with reagents that are soluble in aqueous solution, it will be appreciated that many cross linking agents, including for example N-hydroxysuccinimide esters such as SANHSE, have a very low solubility in aqueous solution, a problem that is exacerbated in the presence of high concentrations of a hydrogel in the aqueous phase e.g. 30% w/w gelatin. This presents a very significant hurdle to using such reagents to crosslink the hydrogel due to rapid precipitation of the reagent. This in turn leads to great difficulty in achieving an even distribution of active reagent through the solution.
The use of a preincubation stage that has the effect of binding the crosslinking reagent to the hydrogel itself, e.g. gelatin molecules (preferably at a low initial concentration e.g. 1.8-2.0% w/w) or to a soluble elastomeric monomer allows the previously insoluble reagent to be carried into the second stage in a fully soluble but still active form. The use of the preincubation phase to overcome the inherently low solubility of many crosslinking agents, such as SANHSE, in the aqueous phase represents a still yet further aspect of the invention. Suitable elastomeric monomers include resilin and elastin or synthetic analogues thereof.
Another cross-linking method involves avidin and biotin. Avidin and biotin form the strongest naturally occurring non-covalent bond. It is entirely specific and with a kD of 10-15 (Green, A. J., (1966) Biochem J. 100:774-780). Cross-linking a water gel using these species is therefore attractive. Two forms of pre-reacted gelatin would be required: form (A)—modified with avidin and form (B) modified with biotin. When a reconstituted gel was required the A and B forms of the pre-reacted gelatin would be prepared as usual in aqueous solution. Once the A and B forms have been completely solubilised they are then mixed in equal proportions and the gel allowed to set. The A and B forms of the gelatin will automatically associate with each other through the interaction of the avidin and biotin. This avidin biotin driven aggregation of the gelatin monomers will result in the creation of a strong semi-covalent bonding network through the gelatin as it sets.
Biotinylation of gels is effectively and simply carried out using N-hydroxy succinimide esters of biotin, which is the same functional group as found in SANHSE. The form of NHS ester used could either be Biotin N-Hydroxysuccinimide or Biotinamidohexanoic acid N-Hydroxysuccinimide Ester. The latter having an amino caproate spacer arm which holds the biotin at a greater distance from the protein to which it is bound. It might also be possible to biotinylate the gelatin using a combination of these reagents to maximise the potential semi-covalent network formed within the gel state.
As with SANHSE the Biotin NHS esters readily react with the ε-amino groups of lysine and the N-terminal α-amino group (where this is not blocked) at pH 8.0-9.0.
Avidin is a glycoprotein extracted from eggs that can readily be attached to proteins.
It is envisaged that the mixing of the two gelatin components here could take place in the field allowing easy transport of water gel in powder form. Once the A and B form of the gelatin have been prepared they can be lyophilised and the powder stored prior to re-hydration and use.
The cross-linked water gels of the invention are inherently non-flammable, cheap and non-toxic making them very attractive building materials.
The cross-linked water gel mixture can be formed into sheets to provide barriers which mitigate the effects of explosion or the effects of contact with a projectile. There is a close relationship between the concentration of gel within a barrier, the thickness of the barrier and its performance, e.g. as a pressure impulse mitigant. The skilled person will be able to tailor concentrations and thicknesses to prepare sheets having desired properties.
The thickness of a protective barrier or sheet may vary depending on the nature of the barrier, e.g. whether it is being used to protect windows, personnel, buildings etc. However, suitable thicknesses are in the range 0.1 cm to 1 m, e.g. 1 to 50 cm such as 1 cm to 20 cm, preferably 2 cm to 10 cm.
Suitable thicknesses for barriers to be used in building cladding are in the range of 10 to 100 mm preferably 10 to 20 mm. Where the material is used to cover windows suitable thickness is in the range of 10 to 50 mm. When the material is used in clothing suitable thickness is in the range of 10 to 70 mm.
When used to protect against high velocity bullets, thicknesses may be of the order of 5 to 30 cm.
Viewed from a still further aspect therefore, the invention provides a barrier suitable for pressure impulse mitigation, e.g. a barrier for a window or armour, comprising a cross-linked water gel, the concentration of gel in the water being at least 3% w/w, said barrier having a thickness of at least 5 mm.
In order to protect the barrier material against degradation by, for example, bacteria or light it may be essential to mix the water gels with antibacterials (e.g. sodium azide) or proteinase inhibitors such as EDTA (e.g. at 5 mM concentration), detergents and/or antioxidants as additives in the water gel formulations. Other additives include colouring agents to produce a tinted product, emulsifiers, viscosity modifiers, organic additives (such as xanthum gum, starch), inorganic additives (such as sodium sulphate, calcium salts, magnesium sulphate, ammonium sulphate) can be employed.
Thus, the cross-linked water gel layer in the barrier of the invention should preferably comprise at least 50% by weight of cross-linked water gel component, more preferably at least 80% by weight, especially at least 95% by weight of water gel, e.g. 98% wt. Ideally, the cross-linked water gel layer should consist essentially of cross-linker, water and gel (i.e. incorporates only minor quantities of impurities or standard additives).
In general, the cross-linked water gel barrier of the invention is an insulator although it can comprise conductive materials if required. In the aftermath of an explosion, the fact that the material is an insulator may prevent electrical fires starting and may prevent electrocution of individuals.
The protective barrier of the invention may also comprise multiple layers. Layers of cross-linked water gel can therefore be mixed with other layers of optionally cross-linked water gel with differing concentrations of gel and/or with other pressure mitigating materials to form composites. In one embodiment therefore, the method of the invention may involve a barrier comprising a number of layers of cross-linked water gel. Moreover, in such a design, the outside cross-linked water gel layer may have the highest concentration of gel with decreasing lower concentrations of gel on the inside of the barrier.
In a preferred embodiment, the cross-linked water gel layer or layers are combined with at least one non water gel layer, for example, a polymer layer (e.g. a polyethylene (LDPE, LLDPE, HDPE), polypropylene or polycarbonate layer), a metal layer (aluminium or steel), a fabric layer (cotton), a ceramic layer, a fibreglass layer, a dilatant layer (polyethylene glycol layer or a silicone layer) or mixtures of such layers. A glass layer can also be used.
A dilatant is a material which thickens upon applied shear stress, e.g. may turn solid upon applied shear stress and examples thereof are polyethylene glycols and silicones.
This forms a further aspect of the invention and viewed from a further aspect the invention provides a barrier, e.g. to protect against the effects of an explosion or from the effects of contact with a projectile comprising a cross-linked water gel layer and a polymer layer, a metal layer, a fabric layer, a ceramic layer, a fibreglass layer, a glass layer, a dilatant layer or mixtures of such layers.
The composite structure could of course contain a number of cross-linked water gel layers and/or a number of other layers depending on the properties desired. Where fabric layers are used, it may be necessary to use a number of such layers in view of their narrow thickness. Thus, a multilayer barrier of use in the invention may comprise 2 to 20 layers, e.g. 3 to 10 layers.
Where a multilayer structure is employed it is preferred if the layers are in contact with each other, i.e. there are no gaps between the layers.
The thickness of additional layers can of course vary depending on the nature of the material involved. Suitable thicknesses range from 0.1 to 20 cm.
It has been surprisingly found that the pressure mitigation properties of the water gels of the invention can be especially enhanced by the addition of a layer of polyethylene glycol, e.g. an at least 0.5 wt % solution thereof, preferably at least 1% wt solution thereof. This layer should preferably be positioned outside the cross-linked water gel layer, i.e. will be contacted by the pressure wave/projectile first. The layer may be 0.1 to 1 cm in thickness.
This forms a further aspect of the invention and viewed from a further aspect the invention provides a barrier, e.g. to protect against the effects of an explosion or damage by a projectile, comprising a cross-linked water gel layer and a polyethylene glycol layer.
A further preferred combination is a polyethylene layer and cross-linked water gel layer, in particular where the polyethylene layer is wetted by the cross-linked water gel, i.e. these layers are in physical contact. Suitable polyethylenes are ethylene homopolymers or copolymers with propene.
Layers of fire retardant material, layers of material impervious to chemicals, radioactivity or biological agents could also be added to the barriers of the invention.
All layers of the protective barrier can be encapsulated in a suitable container if required, e.g. a polymer container such as a polypropylene container, for ease of transport and storage, although this is not essential.
In fact a further advantage of the invention is that the material itself can be transported in non-aqueous form, e.g. powder form, and made up to the water gel when required, e.g. using an avidin biotin cross-linker as described above. A potential difficulty with the water gels may be their weight but the fact that the material can be transported as a powder and made into the water gel only when required is a major advantage.
The cross-linked water gels could have important applications in the military and for the general public close to industrial sites such as chemical storage facilities, nuclear reactors or research laboratories or areas where transportation of hazardous materials occurs. Such compositions could be used in clothing to protect against, fire, explosion, projectile damage and the threat of chemical, biological or radiological contamination. The material may also act as a suppressant to chemical contamination by interacting with any aqueous soluble chemical to reduce the toxicity of the chemical.
The material of the invention may also provide therefore a barrier to chemical or biological contamination, e.g. as the result of a criminal attack or chemical leak. The surface of the water gel material is inherently sticky and hence biological and chemical compounds may attach to the surface of the material thereby preventing further contamination taking place. Water soluble agents may dissolve in the water gel barrier. Organic agents are insoluble in the water gel and will therefore be repelled.
Additionally the water gel material acts as a barrier that, unlike most open weave material, prevents biological materials under the size of 5 microns from passing through to the surface of a material below.
The water gels may also have applications in environments where sterility is required, e.g. in hospitals or laboratories. The water gel could aid in preventing infection e.g. when used as a coating agent in a treatment room which can easily be removed and replaced when necessary.
The water gel material may also act as a barrier to alpha and beta particles of radiation that may be present in sources used in industry and in weapons used by the defence forces. Research from Japan has shown that the effects of thermal radiation are reduced by up to 50% by clothing acting as a barrier to radiation. If beta particle emitters come into contact with the skin a beta burn may result and the water gels of the invention may prevent this occurring.
The effects of radiation were observed in Japan and in the Marshall Islanders in 1954 (Source of case studies in Japan and Marshall Islands, Glasstone and Dolan, The effects of nuclear weapons, US Dept. of Defence pubd 1977 ed). Alpha emitters and beta particles can deposit their entire energy within a small sensitive volume of the body tissue causing damage. Particles of greater than 10 micrometers are filtered out by the nose and 95% of 5-10 micron particles are also filtered but the very fine particles under this size reach the lungs causing internal body damage. Alpha particles can be retained in the lungs for a long time and can cause serious injury to lung, liver and bone. In the Marshal islands studies much of the material contaminated food, water, utensils and other objects in the environment.
Because radiological sources are present in hospitals and industrial locations and are also sought for criminal use, widespread contamination of the environment as well as body effects on people and other organisms is possible.
Currently available biological/radiological masks that have been produced for protection against viruses and organisms such as anthrax are constructed to transmit only particles of under 5 microns when the person is breathing. Special filters are also used for heavy contamination situations, e.g. charcoal which absorb or physically hold the hazard so that it does not reach the person's airway. The water gels of the invention may act as a further physical barrier for use in masks.
Moreover, if a water gel layer was combined with, for example, a boron layer a broader range of radiological effects could be preventable. Thus, gamma radiation or neutrons could be absorbed by a water gel barrier comprising a boron layer.
Water gel barriers also provide the added advantage that post contamination clean up is made much simpler. Since the chemical or biological agent may stick to or dissolve within the water gel, clean up can be effected simply by removing the water gel sheet from the structure in question. This forms a further aspect of the invention and hence viewed from a further aspect the invention provides the use of a cross-linked water gel to protect entities, e.g. structures or organisms against chemical, biological or radiological contamination.
The material may also be used to mitigate contamination after an incident by being applied as a decontamination material, e.g. by unrolling sheets of the material down roads or surfaces.
In some applications there may be several layers to provide various protections from heat and blast with an optional top layer being a throw away contaminatable layer.
The water gel can be formed into any suitable shape or form depending on the nature of the protective barrier desired. The water gels of the invention can be formulated into sheets using known techniques such as injection moulding or thermal cooling of the material. The width of the material will depend on the nature of the use. Thus, where the water gel is being used to prevent fragmentation of glass in a window, the water gel can be formed into a sheet for use in covering the window or for placing within double glazing. The water gels of the invention may also be used as protective barriers, e.g. sheets on or within buildings or on equipment. Thus, water gel sheets could be used as building cladding, blast curtains or formed into thin sheets for covering equipment such as computers.
When used as a protective layer over building cladding, it is most important that the lower part of the building is protected from the effects of a blast. Thus, the protective water gel barrier may be adhered only to the lower part of a building, e.g. the bottom three floors since this is the area which suffers from the greatest blast impact from a ground based explosion. The protective water gel barrier may be continued inside the building on partitions or inside walls to strengthen the structural resistance to blast. The material may also be used as a protective surface across the whole façade of a building to protect against explosive pressures from very large explosions or from air-borne contaminants from an explosion.
Water gels may also be formulated as protective blankets, or clothing for personnel. Thus, the barrier could be in a form to protect the eyes, ears or feet, e.g. as shoes. Alternatively, very large sheets of water gel could be produced for covering critical environmental areas, e.g. reservoirs, or iconic targets. Temporary structures, in particular temporary military structures, may be covered with this material to mitigate the impact of explosions on buildings equipment and personnel.
For convenience, the material for permanent or temporary fixing across doors, windows, on horizontal or vertical surfaces etc may be in rolls that can be cut to create barriers. The material may also be extrudable.
The forming of the water gels into desired shapes can be achieved easily using known equipment, e.g. those used in the food industry to make jelly or those used in the pharmaceutical industry to make capsules.
The water gels of the invention can also act to disrupt the flight of projectiles, i.e. can act as armour by protecting against bullets etc.
It is envisaged that the water gels of the invention may mitigate pressure through the shock absorbing characteristics of the gel. Moreover, the gel fibres are envisaged to change the trajectory of a projectile and create drag on the projectile.
The gel may therefore resist the pressure wave of a projectile by absorption thereof. The gel is able to compress expand during shockwave impact and “bounce back” the pressure wave onto the oncoming projectile or shock wave. This action reduces or eliminates the pressure wave created by the projectile and reduces or eliminates the kinetic shock of the projectile.
The gel also reduces the inherent energy of the projectile through slowing the speed of passage of the projectile through the gel and this reduces the projectile pressure wave on the entity being protected by the gel. The gel also focuses the pressure wave of the projectile back along the trajectory of the projectile thereby creating a pressure effect outside the gel layers and shield material.
Projectiles may be in the form of bullets, rockets or missiles or other projectiles travelling at speeds that may be in excess of 3,500 meters/second.
Thus, the gels of the invention have a range of applications from bullet proof vests and helmets to replacement for sandbags to protect army personnel from enemy fire.
The water gels of the invention may also have utility in the protection of ships from blast or projectiles. Both commercial and military ships have been the recent targets of terrorists and military ships in particular face dangers with mines and missiles. The water gels of the invention may be used to coat either the inside and/or outside of the ship's hull to thereby act as a pressure mitigant. Where a ship has a double hull, the water gel may be used to coat both hulls or used in the cavity between hulls.
The water gel layer employed may be as thin as 2.5 cm and may be applied to the hull using a conventional adhesive. Thicker layers can be applied to parts of the ship where extra protection may be required, e.g. to protect parts of the hull where damage could cause the hull to split or to protect parts of the hull housing weaponry etc.
It is also envisaged that ships could be fitted with permanent or preferably temporary skirts to prevent any damage occurring to the hull at all. The skirts would take the form of vertically suspended panels of water gel made as thin as possible to minimise weight. Such skirts may be suspended from the side of the ship, e.g. using wires, and may prevent attacks on a ship's hull from surface to surface missiles, torpedoes, mines, or terrorists in boats. In view of their weight, these skirts could be employed only on areas of the hull where explosive damage could be critical, e.g. at the centre point of the hull where explosive damage may cause the hull to split.
Also, the skirts could be employed temporarily as a ship passes through potentially dangerous waters, the skirts being removed once the ship returns to safer areas. Thus, skirts could be employed when a ship was in port, near the coastline or in a narrow channel etc but removed in open waters. The skirts create a buffer between the hull and the skirt to mitigate any explosive effects on the hull. Moreover, in view of their make up, the skirts are not visible from afar and are difficult to detect by radar.
The gels could also be used to protect other marine installations such as oil rigs, underwater cables, pipelines, underwater monitoring equipment and could even be used to protect submarine hulls.
The material may also have applications deep underground where tunnels could be lined with the water gels to mitigate the effects of explosions underground. Drilling equipment etc could also be protected.
The water gels can also be moulded to form a protective shell on a vehicle. Military vehicles which carry personnel or equipment are conventionally covered with very thick and hence heavy metal plates to stop incoming small arms fire, rocket propelled grenade rounds, damage from mines and shells. When the water gels of the invention are moulded, e.g. with a fibreglass or polyurethane shell it may be possible to manufacture a light, fast vehicle capable of withstanding damage from these threats. 30 cm of water gel material covering a lightweight body could stop incoming attacks.
The vehicle chassis could be shaped to minimise the chance of the vehicle being detected by radar. Thus, the external appearance of the vehicle may be similar to the inverted hull of a boat or akin to the shape of an armadillo. The water gels of the invention are inherently hard to see with radar and the combination of the water gel and the special vehicle shape may make the vehicles very difficult to detect.
The material could also be used as a fuselage or wing liner in aircraft. In particular, the hold of an aircraft could be lined with the material to mitigate the effects of an explosion within the hold. Furthermore, cargo containers themselves could be lined with the material, internally or externally.
A still further potential application of the water gels is in space where they could be used to cover space vehicles to protect them from space debris. If a satellite, rocket, space station etc comes into contact with an article of space debris, considerable damage can be done in view of the incredibly high speed of impact. A recent space shuttle accident was caused by damage caused by small parts detaching from the upper portions of the rocket and contacting the lower portion of the shuttle vehicle. Such damage could be minimised if the water gels of the invention where employed as coatings.
It is also envisaged that the water gels of the invention may protect against heat, flame and fire. By definition, the water gels of the invention comprise an aqueous component. For this reason, they are capable of absorbing heat and dousing flame much more efficiently than other pressure impulse mitigation materials. It is a particular advantage of the invention that the water gel pressure impulse mitigation material simultaneously can act to protect against fire.
When exposed to heat, it is envisaged that the water gel may partially or completely melt thereby releasing water to help quench any fire. Moreover, during an explosion, the water gel may first absorb the effects of the explosive blast and heat associated therewith and subsequently melt to prevent associated fire damage.
The water gel barriers of the invention may also serve to protect organisms against flame burns from secondary contact with hot objects. A skin temperature of 70° C. will produce the same type of burn as exposure to 48° C. for a few minutes. Skin burns under clothing depend on the colour, thickness and nature of the fabric and if the fabric ignites. Research has suggested that burns were more severe where an individual wore dark clothing than white clothing because of the reflection of heat by white and light fabrics. In this embodiment the water gel could be combined with a thermal insulating layer to prevent heat transfer to the skin.
The water gel barriers of the invention may also help in the event of a conventional fire, particularly in a building in which the external structure is predominantly made from glass. During a fire in such a building, the metal frame of the building tends to expand and the windows can therefore fall out of their frames. The presence of a water gel will slow down any expansion of the building frame thereby allowing fire-fighters more time in which to control the fire.
The water gel would also act as a heat reducer in wooden buildings.
The water gels of the invention are more effective at mitigating the effects of fire at lower gel concentrations, i.e. higher water concentrations. However, the water gels are more effective at pressure impulse mitigation at higher gel concentrations. It is therefore within the scope of the invention to provide a multilayer barrier comprising water gel layers having varying gel concentrations to provide barriers tailored to mitigate the effects of both fire and pressure.
It is a particular advantage of the material of the invention that it is transparent and hence does not affect the amount of light entering a building when used as a window protector or affect the external appearance of a building when used as a cladding. Fixing the material to a structure can be achieved using conventional techniques. For example, for window protection, the material may be adhered to the window surface (inside and/or outside) using known adhesives such as ceramic bonds or other bonding materials that adhere to wood, concrete or glass surfaces. These materials are readily available through suppliers to dentists for bonding of ceramic veneers to teeth, and in the construction industry for bonding materials together.
It is particularly advantageous if the bond between the water gel sheets and the window is stronger than the fixing holding the window frame into the wall.
Within clothing or where sheets are being bonded together to create large surface areas for protection the use of these industrial bonding agents may create seams that should be stronger than the water gel material and protect large surface areas from the pressure of being split at the seams.
The material could be placed in wall cavities or roof space or secured to the outside of a building by adhesives or in a frame. The person skilled in the art can devise alternative methods of fixation.
Other forms of encapsulation of layers of the water gel material may involve vacuum sealing and the use of hydrostatic films as is known in the art. The gels may be acidic or basic giving rise to further options for fixation.
Thus, the water gels of the invention can simultaneously act against the possible detrimental effects of explosions, projectiles, fire, chemical, radiological or biological leakage.
The invention will now be further described with reference to the following non-limiting examples and FIGS. 1 and 2 .
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the energy dissipation on 0.22 bullets for certain cross-linked water gels of the invention.
FIG. 2 compares energy loss with stiffness for said cross-linked water gel.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
Preincubation
2% w/v gelatin was prepared in Peptone Buffer Saline (PBS) and allowed to cool slowly to room temperature. The pH of this 2% solution was then adjusted as required to either pH 7.0 or pH 8.0. This 2% solution was maintained at temperatures between 22-24° C.
The 2% solution was then divided into 50 ml aliquots in 75 ml Pyrex vessels.
Sebacic acid bis N-succinimidyl ester (SANHSE) was prepared immediately prior to use. The reactions described were carried out at a reagent concentration of 5 mM. The SANHSE samples were solubilised/emulsified in 1 ml or 5 ml of either 95% methanol or toluene.
The gelatin solution was placed on a magnetic stirrer and spun into a vortex. The reagent was added and the solution allowed to spin for a further 30 seconds to allow complete dispersal. The samples were maintained at 22-24° C. for 4 hours. Every 15-20 minutes the tubes were gently agitated by rotating them 3-4 times to disperse any SANHSE that was not fully solubilised.
Second Stage
At the end of the pre-incubation period the reacted 2% gelatin was mixed with 150 ml aliquots of concentrated gelatin solution (20% w/v) that had been adjusted to pH 8.0 and was maintained at 38-48° C. The mixing was carried out using a domestic electric food mixer for 30 s to ensure complete miscibility of the two gelatin solutions. Immediately after the mixing was complete the mixed sample was placed in standard plastic 280 ml food containers and allowed to set at room temperature (18-20° C.) for 16 hours. A visible sol-gel transition occurred within 30 minutes. Thereafter the cross linked gelatin samples were stored at 4° C.
Table 1 sets out the 2% w/v gelatin samples produced and the solvent used to dissolve or emulsify the SANHSE.
TABLE 1
Gelatin pH
Cross-linking agent/Solvent
pH 8.0
No Reagent
pH 8.0
5 mM SANHSE
200 mg in 1 ml of Methanol
pH 7.0
5 mM SANHSE
200 mg in 1 ml of Methanol
45 ml at
5 mM SANHSE
pH 8.0
200 mg in 5 ml of Methanol (i.e. 10% solvent)
pH 8.0
5 mM SANHSE
200 mg in 1 ml of Toluene (i.e. approximately 2% v/v in
reaction solution)
Example 2
The cross linked gel samples in the 280 ml plastic food containers were tested for their ballistics capacity using a 0.22 rifle. The entry and exit speeds of the bullet were measured by light gates at entry and on exit. As the mass of the bullet is known the energy dissipated per cm of the approximately 15 cm flight path through the gel can be estimated. The results for energy dissipation in Jcm −1 are set out in FIG. 1 and a comparison of % energy loss and stiffness in KPa are set out FIG. 2 .
% Energy Loss Results
The control sample indicates that average energy loss for the non cross-linked gel is around 0.6 J/cm. The average energy losses fell into three distinct categories with the strongest samples being some 4 times stronger than the control:
A) The control at approximately 0.6 J/cm;
B) The pH 8.0 pre-incubation at both 1% and 5% v/v methanol solvent concentrations, both at approximately 1.1 J/cm; and
C) The pH 8.0 pre-incubation at 2% v/v toluene and the pH 7 pre-incubation, both at approximately 2.2-2.4 J/cm.
The lowest average energy lost per cm was unsurprisingly the non-cross linked control sample. A significant rise in stiffness (approximately 33% over the control sample) was observed with the 2% v/v toluene reaction. Of equal significance was the result that the sample pre-incubated at pH 7.0 and then mixed with the 20% gelatin solution at pH 8.0 gave the best energy dissipation per cm. This would seem to accord with the hypothesis that at pH 7.0 individual gelatin monomers have reacted with the SANHSE but some will still have a free and reactive terminal NHS ester, due to the low total protein concentration and the unfavourable pH both in terms of amino group reactivity and any competing hydrolysis. On addition to the 20% gelatin at pH 8.0 the un-reacted terminal NHS ester groups will rapidly react with the abundant de-protonated amino groups that will now be present, thereby creating an extensive covalently bonded network through the gelatin as it sets.
By way of comparison the 2% gelatin solution pre-incubated with SANHSE at pH 8.0 and then mixed with the 20% gelatin at pH 8.0 had energy absorbing capability being approximately 1.2 J/cm, whereas the energy absorbing capacity for the pH 7.0 pre-incubation sample was double this at 2.2 J/cm, which in turn is some four times that of the control gel. This would suggest that a second phase of cross linking has occurred.
Example 3
Preincubation
A 1.85 to 2.0% w/v gelatin solution was prepared directly in Peptone Buffer Saline (PBS) and allowed to cool slowly to room temperature. The pH of this solution was then adjusted as required to pH 6.75-7.25. The solution was maintained at temperatures between 20-25° C.
The solution was then divided into 100 ml aliquots in Pyrex vessels.
Sebacic acid bis N-succinimidyl ester (SANHSE) was prepared immediately prior to use. The reactions described were carried out at a final theoretical reagent concentration of 5 mM, which equates to 200 mg of SANHSE per ml of solvent. The SANHSE samples were solubilised/emulsified in 1 ml of either 95% methanol, 100% methanol or toluene.
The gelatin solution was placed on a magnetic stirrer and spun into a vortex. The reagent was added and the solution allowed to spin for a further 30 seconds to allow complete dispersal. The preincubated samples were maintained at 22-24° C. for up to 4 hours. Every 15-20 minutes the vessels were gently agitated by rotating them 3-4 times to disperse any SANHSE that was not fully solubilised.
Second Stage
At the end of the pre-incubation period the reacted gelatin was mixed with 400 ml aliquots of concentrated gelatin solution (20-35% w/v) that had been adjusted to pH 8.15-8.65 and was maintained at 38-48° C. The mixing was carried out using a domestic electric food mixer for 30 s to ensure complete miscibility of the two gelatin solutions. Immediately after the mixing was complete the mixed sample was placed in various moulds including a plastic 280 ml food container and allowed to set at room temperature (18-20° C.) for 16 hours. A visible sol-gel transition occurred within 30 minutes. Thereafter the cross linked gelatin samples were stored at 4° C.
Example 4
Production of a 28% w/w Cross Linked Water Gel
A solution of 35% w/w of gelatin in aqueous solution is prepared and adjusted to a final pH of 7.1-7.3 by the addition of 10% sodium hydroxide solution. The solution is maintained at a temperature of 40-45° C. If the resulting gel is to be kept for any length of time methyl paraben (0.2%) and propyl paraben (0.15%) should be included in the final mix as anti-microbial agents. This constitutes Solution A.
The pre-polymer solution is prepared by diluting down a volume of Solution A to produce a final concentration of gelatin of 1.8%, the pH is adjusted to 6.7-6.9, and the solution is allowed to cool to 20-25° C. The SANHSE is emulsified in methanol at a concentration equivalent to a 10% solution. The reagent is then added to the 1.8% gelatin solution and stirred continuously but slowly for 30-35 minutes. The temperature is maintained at 20-25° C. throughout. This constitutes Solution B.
Once the preincubation of Solution B has been completed it is added to Solution A at a ratio of 1:4, whilst being vigorously stirred with a spiral mixer. The mixture is then allowed to stand for 30 minutes at a temperature of 40-42° C. in a sealed container (under laboratory conditions the container can be ideally stood in a preset drying oven).
The final cross linked water gel solution is then adjusted to a final pH of 6.0 by the addition of approximately 3 ml of 10M HCl and then poured into the desired mould and allowed to set.
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A method for protecting an entity from the effects of an explosion or from the effects of contact with a projectile by covering at least a part of the entity in a barrier which includes a cross-linked water gel.
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This application is a continuation of copending application Ser. No. 061,247, filed on July 27, 1979.
BACKGROUND OF THE INVENTION
This invention relates to a key input type data-related apparatus conveying audible output messages, for example, a speech-synthesizer calculator.
The purpose of the present invention is to provide an audible output apparatus which is able to distinguish between audible messages at the time of keying input information and at the time of delivering output information reflecting results of operations, for example.
As a rule, in electronic calculators, etc, in which keys are actuated in a desired order and calculations are performed on keyed information in order to yield calculation results, typical examples of the application of a speech synthesizing technique contain generally (1) the delivery of audible messages indicative of keyed information at the time of key actuations and (2) the automatic delivery of audible messages indicative of calculation results immediately upon the completion of calculations.
The audible messages of the calculation results are very convenient for the operators' transcription. In the case where a person operates a calculator and another transcribes the calculation results derived therefrom onto a sheet of paper or a person actuates keys in succession and upon the delivery of calculation results actuates quickly digit keys to commence further calculations, both the keyed information and the processed information (the calculation results) are numerical data, thus presenting difficulties for the operator in knowing when the messages change from the first keyed information to the second calculation results.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an apparatus in which particular linguistic information is inserted in the form of audible sounds just after the delivery of audible messages of operation results and in substantially the same manner as of the audible answer messages.
For example, for calculator use, if the operator introduces a value B and actuates an "=" key in the order of A X B = , then, its answer is calculated forthwith with a vague distinction (for example, no natural pause). In this case, the linguistic information such as "KOTAE" or "KOTAEWA" (in its English version ANSWER) is provided in the form of audible sounds according to the present invention. In this way, the linguistic information "KOTAEWA . . . DESU" (in its English version IS with a difference in its place between Japanese and English) is provided audibly upon actuation of the key "=".
It is another object of the present invention to provide an apparatus which can provide an audible output indicative of a preceeding actuated key upon actuation of a particular key, thus presenting the possibility of confirming what kind of keys were previously actuated.
In one preferred form of the present invention, necessary information is displayed both audibly and visually, enhancing availability for transcription and check in a speech-synthesizer apparatus and particularly in speech-synthesizer calculators. While it is necessary to increase the capacity of a visual display in order to extend visual messages, an audible output device can be implemented with an LSI technology and extensible in length without an increase in circuit construction and cost of the overall apparatus.
The present invention further makes it possible to confirm whether any keys have been previously actuated, without changing a visual display. With such an arrangement, in the case where a calculation of 125×670, for example, is being executed but is interrupted for a certain reason, the possibility of audibly confirming, without any change in a visual display, whether a key X has actually been actuated is very helpful. Failure to realize whether the key X has been keyed may result in an answer being 125670 in response to subsequent actuations of keys "6", "7" and "0". In this manner, another object of the present invention is to enable precise key entry procedures while the previous state is decided audibly prior to key actuations.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of a speech-synthesizer calculator according one preferred embodiment of the present invention;
FIGS. 2A-2D are logic circuit diagram of a microprocessor CPU;
FIG. 3 is a composite representation of the CPU shown in FIGS. 2A through 2D;
FIG. 4 is a block diagram of an audible output control circuit;
FIG. 5 is a format that of data contained in respective regions of a memory VR; and
FIGS. 6 and 7 are flow charts for explaining the operation of the calculator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is illustrated a block diagram of a speech-synthesizer calculator according to one preferred embodiment of the present invention. A detailed disclosure of operation and structure of a microprocessor CPU are shown in FIGS. 2A-2D.
A dynamic mode display DSP has digit selection electrodes connected to terminals "W" of CPU and segment selection electrodes connected to terminals "SD" of CPU for displaying the contents of a memory M 1 (RAM) of CPU. A key input unit KEY is connected to an I terminal and KN 1 , KN 2 , KF 1 and KF 2 terminals of CPU.
A key "V" in the key input device KEY is to enable the contents of a preceding actuated key to be audibly displayed. The contents of the memory M 1 are both audibly and visually displayed, data being derived from stack registers SX and SA for generating audible messages. A voice synthesizer circuit VSC (see FIG. 4) receives words to be voiced from the stack registers SC and SA when an input signal S 0 comes. The input S 0 is connected to a flag flip flop (F/F) F B in CPU.
A confirmation signal S 2 concerning the completion of the delivery of audible messages is developed from VSC. CPU receives an input α. FIG. 3, a composite diagram of FIGS. 2A-2D, shows a logic wiring diagram of a specific example of the CPU scheme.
FIG. 3 shows how to combine FIGS. 2A-2D concerning the CPU. The following will set forth a logic structure of the CPU.
[CPU ARCHITECTURE]
A random access memory RAM is of a 4 bit input and output capacity and accessible to a specific digit position thereof as identified by a digit address and a file address. The RAM includes a digit address counter BL, a digit address decoder DC 1 , a file address counter BM, a file address decoder DC 2 and an adder AD 1 which serves as an adder and a subtractor respectively in the absence and presence of a control instruction 14 . It further includes a second adder AD 2 and a gate G 1 for providing either a digit "1" or an operand I A to an input to the adder/subtractor AD 1 and delivering I or I A when a control instruction 15 or 16 is developed, respectively. An input gate G 2 is provided for the memory digit address counter BL, which enables the output of the adder/subtractor AD 1 , the operand I A and another operand I B to pass therethrough respectively when control instructions 10 , 11 and 12 are developed. A gate G 3 is disposed to provide a digit "1" or the operand I A to an input to the adder/subtractor, the former being provided upon the development of an instruction 5 and the latter upon the development of an instruction 6 . A gate G 4 is an input gate to the memory file address BM which enables the output of the adder AD 2 , the operand I A and the contents of an accumulator ACC to pass upon the development of instructions 7 , 8 and 9 . A file selection gate G 5 is further provided for the memory RAM. A decoder DC 3 translates the operand I A and supplies a gate G 6 with a desired bit specifying signal. The gate G 6 contains a circuit arrangement for introducing a binary code "1" into a specific bit position of the memory identified by the operand decoder DC 3 and a binary code "D" into a specific bit position identified by DC 3 , respectively, when a control instruction 2 or 3 is developed. Upon the development of an instruction 4 the contents of the accumulator ACC are read out.
A read only memory ROM has its associated program counter PL which specifies a desired step in the read only memory ROM. The read only memory ROM further contains a step access decoder DC 4 and an output gate G 7 which shuts off transmission of the output of the ROM to an instruction decoder DC 5 when a judge flip flop F/F J is set. The instruction decoder DC 5 is adapted to decode instruction codes derived from the ROM and divide them into an operation code area I O and operand areas I A and I B , the operation code being decoded into any control instruction 1 - 61 . The decoder DC 5 is further adapted to output the operand I A or I B as it is when sensing an operation code accompanied by an operand. An adder AD 3 increments one the contents of the program counter PL. An input gate G 8 associated with the program counter PL provides the operand I A and transmits the contents of a program stack register SP when the instructions 20 and 61 are developed, respectively. When the instructions 20 , 61 and 60 are being processed, any output of the adder AD 3 is not transmitted. Otherwise the AD 3 output is transmitted to automatically load "1" into the contents of the program counter PL. A flag flip flop FC has an input gate G 9 therefor which introduces binary codes "1" and "0" into the flag flip flop FC when the instructions 17 and 18 are developed, respectively. A key signal generating gate G 10 provides the output of the memory digit address decoder DC 1 without any change when the flag F/F FC is in the reset state (0), and renders all outputs I 1 -I n "1" whatever output DC 1 provides when FC is in the set state (1). The accumulator ACC is 4 bits long and a temporary register X is also 4 bits long. An input gate G 11 for the temporary register X transmits the contents of the accumulator ACC and the stack register SX respectively upon the development of the instructions 29 and 59 . An adder AD 4 executes a binary addition on the contents of the accumulator ACC and other data. The output C 4 of the adder AD 4 assumes "1" when the fourth bit binary addition yields a carry. A carry F/F C has its associated input gate G 12 which sets "1" into the carry F/F C in the presence of "1" of the fourth bit carry C 4 and "0" into the same in the absence of C 4 (0). "1" and "0" are set into C upon the development of 21 and 22 , respectively. A carry (C) input gate G 18 enables the adder AD 4 to perform binary additions with a carry and thus transmits the output of the carry F/F C into the adder AD 4 in response to the instruction 25 . An input gate G 14 is provided for the adder AD 4 and transfers the output of the memory RAM and the operand I A upon the development of 23 and 24 , respectively. An output buffer register F has a 4 bit capacity and an input gate which enables the contents of the accumulator ACC to enter into F upon the development of 31 . An output decoder SD decodes the contents of the output buffer F into display segment signals SS 1 -SS n . An output buffer register W has a shift circuit SHC which shifts the overall bit contents of the output buffer register W one bit to the right at a time in response to 32 or 33 . An input gate G 16 for the output buffer register W enters "1" and "0" into the first bit position of W upon 32 and 33 , respectively. Immediately before "1" or or "0" enters into the first bit position of W the output buffer shift circuit SHC becomes operative.
An output control flag F/F N p has an input gate G 17 for receiving "1" and "0" upon the development of 34 and 35 , respectively.
The buffer register W is provided with an output control gate G 18 for providing the respective bit outputs thereof at one time only when the flag F/F N p is in the set state (1). There are further provided a judge F/F J, inverters IV 1 -IV 4 and an input gate G 19 for the judge F/F J for transferring the state of an input KN 1 into J upon the development of 36 . In the case where KN 1 =0, J=1 because of intervention of the inverter IV 1 . An input gate G 20 for the judge F/F J is adapted to transfer the state of an input KN 2 into J upon 38 . When KF 1 =0, J=1 becuase of intervention of the inverter IV 3 . An input gate G 22 for the judge F/F J is adapted to transfer the state of the input KF 2 into J upon 39 . When KF 2 =0, J=1 because of the intervened inverter IV 4 . An input gate G 23 is provided for the judge flip flop J for transmission of the state of an input AK into J upon the development of 40 . When AK=1, J=1. An input gate G 24 is provided for the judge flip flop J to transmit the state of an input TAB into J pursuant to 41 . When TAB=1, J=1. A gate G 25 is provided for setting the judge F/F J upon the development of 42 . A comparator V 1 compares the contents of the memory digit address counter BL with preselected data and provides an output "1" if there is agreement. The comparator V 1 becomes operative when 43 or 44 is developed. The data to be compared are derived from a gate G 26 which is an input gate to the comparator V 1 . The data n 1 to be compared are a specific higher address value which is often available in controlling the RAM. n 1 and n 2 are provided for comparison purposes upon the development of 43 and 44 , respectively.
An input gate G 27 is provided for the decision F/F J to enter "1" into J when the carry F/F C assumes "1" upon the development of 45 .
A decoder DC 6 decodes the operand I A and helps decisions as to whether or not the contents of a desired bit position of the RAM are "1". A gate G 28 trnasfers the contents of the RAM as specified by the operand decoder DC 6 into the judge F/F when 46 is derived. When the specified bit position of the RAM assumes "1", J=1. A comparator V 2 decides whether or not the contents of the accumulator ACC are equal to the operand I A and provides an output "1" when the affirmative answer is provided. The comparator V 2 becomes operative according to 47 . A comparator V 3 decides under 48 whether the contents of the memory digit address counter BL are equal to the operand I A and provides an output "1" when the affirmative answer is obtained. A comparator V 4 decides whether the contents of the accumulator ACC agree with the contents of the RAM and provides an output "1" in the presence of the agreement. A gate G 29 transfers the fourth bit carry C 4 occurring during additions into the judge F/F J. Upon the development of 50 C 4 is sent to F/F J. J=1 in the presence of C 4 . A flag flip flop FA has an input gate G 31 which provides outputs "1" and "0" upon the development of 52 and 53 , respectively. An input gate G 32 is provided for setting the judge F/F J when the flag flip flop FA assumes "1". A flag flip flop F B also has an input gate G 33 which provides outputs "1" and "0 " upon 55 and 56 , respectively. An input gate G 34 for the judge flip flop J is adapted to transfer the contents of the flag flip flop F B into the F/F J upon the development of 54 . An input gate G 35 associated with the judge F/F J is provided for transmission of the contents of an input B upon 19 . When B=1, J=1. An input gate G 36 associated with the accumulator ACC is provided for transferring the output of the adder AD 4 upon 26 and transferring the contents of the accumulator ACC after inverted via an inverter IV 5 upon 27 . The contents of the memory RAM are transferred upon 28 , the operand I A upon 13 , the 4 bit input contents k 1 -k 4 upon 57 , and the contents of the stack register SA upon 59 . A stack register SA provides the output outside the present system. A stack register SX also provides the output outside the system. An input gate G 37 associated with the stack register SA transfers the accumulator ACC upon 58 . An input gate G 38 associated with the stack register SX transfers the contents of the temporary register X. A program stack register SP has an input gate G 39 for loading the contents of the program counter PL incremented by "1" through the adder into the program stack register.
An illustrative example of the instruction codes contained within the ROM of the CPU structure, the name and function of the instruction codes and the control instructions developed pursuant to the instruction codes will now be tabulated in Table 1 wherein A: the instruction codes, B: the instruction name, C: the instruction description and D: the CPU control instructions.
TABLE 1______________________________________A B D______________________________________1 I.sub.O SKIP ○422 I.sub.O AD ○23 , ○263 I.sub.O ADC ○23 , ○26 , ○25 , ○14 I.sub.O ADCSK ○23 , ○26 , ○25 , ○0 , ○15 I.sub.O I.sub.A ADI ○24 , ○26 , ○506 I.sub.O I.sub.A DC ○24 , ○26 , ○507 I.sub.O SC ○218 I.sub.O RC ○229 I.sub.O I.sub.A SM ○210 I.sub.O I.sub.A RM ○311 I.sub.O COMA ○2712 I.sub.O I.sub.A LDI ○1313 I.sub.O I.sub.A L ○28 , ○814 I.sub.O I.sub.A LI ○28 , ○8 , ○15 , ○10 , ○4315 I.sub.O I.sub.A XD ○28 , ○8 , ○14 , ○15 , ○10 , ○4416 I.sub.O I.sub.A X ○28 , ○4 , ○817 I.sub.O I.sub.A XI ○28 , ○4 , ○8 , ○5 , ○10 , ○4318 I.sub.O I.sub.A XD ○28 , ○4 , ○8 , ○4 , ○16 , ○10 , ○419 I.sub.O I.sub.A LBLI ○1120 I.sub.O I.sub.A I.sub.B LB ○8 , ○1221 I.sub.O I.sub.A ABLI ○16 , ○10 , ○4322 I.sub.O I.sub.A ABMI ○6 , ○723 I.sub.O I.sub.A T ○2024 I.sub.O SKC ○4525 I.sub.O I.sub.A SKM ○4626 I.sub.O I.sub.A SKBI ○4827 I.sub.O I.sub.A SKAI ○4728 I.sub.O SKAM ○4929 I.sub.O SKN.sub.1 ○3630 I.sub.O SKN.sub.2 ○3731 I.sub.O SKF.sub.1 ○3832 I.sub.O SKF.sub.2 ○3933 I.sub.O SKAK ○4034 I.sub.O SKTAB ○4135 I.sub.O SKFA ○5136 I.sub.O SKFB ○5437 I.sub.O WIS ○3238 I.sub.O WIR ○3339 I.sub.O NPS ○3440 I.sub.O NPR ○3541 I.sub.O ATF ○3142 I.sub.O LXA ○2943 I.sub.O XAX ○29 , ○3044 I.sub.O SFA ○5245 I.sub.O RFA ○5346 I.sub.O SFB ○5547 I.sub.O RFB ○5648 I.sub.O SFC 1749 I.sub.O RFC 1850 I.sub.O SKB 1951 I.sub.O KTA 5752 I.sub.O STPO 5853 I.sub.O EXPO 58, 5954 I.sub.O I.sub.A TML 62, 2055 I.sub.O RIT 61______________________________________
INSTRUCTION DESCRIPTION (C)
(1) SKIP
Only the program counter PL is incremented without executing a next program step instruction, thus skipping a program step
(2) AD
A binary addition is effected on the contents of the accumulator ACC and the contents of the RAM, the addition results being loaded back into the accumulator ACC.
(3) ADC
A binary addition is effected on the contents of the accumulator ACC, the memory RAM and the carry F/F C, the results being loaded back to the accumulator ACC.
(4) ADCSK
A binary addition is effected on the contents of the accumulator ACC, the memory RAM and the carry flip flop C, the results being loaded into the accumulator ACC. If the fourth bit carry C 4 occurs in the results, then a next program step is skipped.
(5) ADI
A binary addition is achieved upon the contents of the accumulator ACC and the operand I A and the results are loaded into the accumulator ACC. If the fourth bit carry C 4 is developed in the addition results, then a next program step is skipped.
(6) DC
The operand I A is fixed as "1010" (a decimal number "10") and a binary addition is effected on the contents of the accumulator ACC and the operand I A in the same way as in the ADI instruction. The decimal number 10 is added to the contents of the accumulator ACC, the results of the addition being loaded into ACC.
(7) SC
The carry F/F C is set ("1" enters into C).
(8) RC
The carry F/F C is reset ("0" enters into C).
(9) SM
The contents of the operand I A are decoded to give access to a desired bit position of the memory specified by the operand ("1" enters).
(10) RM
The contents of the operand I A are interpreted to reset a desired bit position of the memory specified by the operand ("0" enters).
(11) COMA
The respective bits of the accumulator ACC are inverted and the resulting complement to "15" is introduced into ACC.
(12) LDI
The operand I A enters into the accumulator ACC.
(13) L
The contents of the memory RAM are sent to the accumulator ACC and the operand I A to the file address counter BM.
(14) LI
The contents of the memory RAM are sent to the accumulator ACC and the operand I A to the memory file address counter BM. At this time the memory digit address counter BL is incremented. If the contents of BL agree with the preselected value n 1 , then a next program step is skipped.
(15) XD
The contents of the memory RAM are exchanged with the contents of ACC and the operand I A is sent to the memory file address counter BM. The memory digit address counter BL is decremented. In the event that the contents of BL agree with the preselected value n 2 , then a next program step is skipped.
(16) X
The contents of the memory RAM are exchanged with the contents of the accumulator ACC and the operand I A is loaded into the memory file address counter BM.
(17) XI
The contents of the memory RAM are exchanged with the contents of the accumulator ACC and the operand I A is sent to the memroy file address counter BM. The memory digit address counter BL is incremented. In the event that BL is equal to the preselected value n 1 , a next program step is skipped.
(18) XD
The contents of the memory RAM replaces the contents of the accumulator ACC, the operand I A being sent to the memory file address counter BM. The memory digit address counter BL at this time is incremented. If the contents of BL are equal to n 2 , then a next program step is skipped.
(19) LBLI
The operand I A is loaded into the memory digit address counter BL.
(20) LB
The operand I A is loaded into the memory file address counter BM and the operand B to the memory digit address counter BL.
(21) ABLI
The operand I A is added to the contents of the memory digit address counter BL in a binary addition fashion, the results being loaded back to BL. If the contents of BL are equal to n 1 , then no next program step is carried out.
(22) ABMI
The operand I A is added to the contents of the memory file address counter BM in a binary fashion, the results being into BM.
(23) T
The operand I A is loaded into the program step counter PL.
(24) SKC
If the carry flip flop C is "1", then no next program step is taken. (25) SKM
The contents of the operand I A are decoded and a next program step is skipped as long as a specific bit position of the memory specified by the operand I A assumes "1".
(26) SKBI
The contents of the memory digit address counter BL are compared with the operand I A and a next succeeding program step is skipped when there is agreement.
(27) SKAI
The contents of the accumulator ACC are compared with the operand I A and if both are equal to each other a next program step is skipped.
(28) SKAM
The contents of the accumulator ACC are compared with the contents of the RAM and if both are equal a next program step is skipped.
(29) SKN 1
When the input KN 1 is "0", a next program step is skipped.
(30) SKN 2
When the input KN 2 is "0", a next program step is skipped.
(31) SKF 1
When the input KF 1 is "0", a next program step is skipped.
(32) SKF 2
When the input KF 2 is "0", a next program step is skipped.
(33) SKAK
When the input AK is "1", a next program step is skipped.
(34) SKTAB
When the input TAB is "1", a next program step is skipped.
(35) SKFA
When the flag flip flop F/A assumes "1" a next program step is skipped.
(36) SKFB
When the flag flip flop F B assumes "1", a next program step is skipped.
(37) WIS
The contents of the output buffer register W are one bit right shifted, the first bit position (the most significant bit position) receiving "1".
(38) WIR
The contents of the output buffer register W are one bit right shifted, the first bit position (the most significant bit position being loaded with "0".
(39) NPS
The output control F/F N P for the buffer register W is set ("1" enters).
(40) NPR
The buffer register output control flip flop N P is reset ("0" enters therein).
(41) ATF
The contents of the accumulator ACC are transferred into the output buffer register F.
(42) LXA
The contents of the accumulator ACC are unloaded into the temporary register X.
(43) XAX
The contents of the accumulator ACC are exchanged with the contents of the temporary register X.
(44) SFA
The flag F/F FA is set (an input of "1").
(45) RFA
The flag F/F FA is reset (an input of "0").
(46) SFB
The flag flip flop F B is set (an input of "1").
(47) RFB
The flag flip flop F B is reset (an input of "0").
(48) SFC
An input testing flag F/F F C is set (an input of "1").
(49) RFC
The input testing flag F/F F C is reset (an input of "0").
(50) SKB
When an input β is "1", a next program step is skipped.
(51) KTA
The inputs k 1 -k 4 are introduced into the accumulator ACC.
(52) STPO
The contents of the accumulator ACC are sent to the stack register SA and the contents of the temporary register X to the stack register SX.
(53) EXPO
The contents of the accumulator ACC are exchanged with the stack register SA and the contents of the temporary register X with the stack register SX.
(54) TML
The contents of the program counter P L incremented by one are transferred into the program stack register SP and the operand I A into the program counter P L .
(55) RIT
The contents of the program stack register SP are transmitted into the program counter P L .
Table 2 sets forth the relationship between the operation codes contained within the ROM of the CPU structure and the operand.
TABLE 2______________________________________ ##STR1## ##STR2## ##STR3## ##STR4## ##STR5##______________________________________
wherein
I O : the operation codes and
I A , I B : the operands
Taking an example wherein the output of the read only memory ROM is 10 bit long, the instructoin decoder DC 5 decides whether the instruction AD or COMA (see Table 1) assumes "0001011000" or "0001011111" and develops the control instructions 23 , 26 , or 27 . SKBI is identified by the fact that the upper six bits assume "000110", the lower 4 bits "0010" being treated as the operand I A and the remaining ninth and tenth bits "11" as the operand I B . The operand forms part of instruction words and specifies data and addresses for next succeeding instructions and can be called an address area of an instruction.
Major processing operaitons (a processing list) of the CPU structure will now be described in sufficient detail.
[PROCESSING LIST]
(I) A same numeral N is loaded into a specific region of the memory RAM (NNN→X)
(II) A predetermined number of different numerals are loaded into a specific region of the memory (N 1 , N 2 , N 3 , . . . →X)
(III) The contents of a specific region of the memory are transferred into a different region of the memory (X→Y)
(IV) The contents of a specific region of the memory are exchanged with that of a different region (X←→Y)
(V) A given numeral N is added or subtracted in a binary fashion from the contents of a specific region of the memory (X±N)
(VI) The contents of a specific region of the memory are added in a decimal fashion to the contents of a different region (X±Y)
(VII) The contents of a specific region of the memory are one digit shifted (X right, X left)
(VIII) A one bit conditional F/F associated with a specific region of the memory is set or reset (F set, F reset)
(IX) The state of the one bit conditional F/F associated with a specific region of the memory is sensed and a next succeeding program address is changed according to the results of the state detection.
(X) It is decided whether the digit contents of a specific region of the memory reach a preselected numeral and a next succeeding program step is altered according to the results of such decision.
(XI) It is decided whether the plural digit contents of a specific region of the memory are equal to a preselected numeral and a program step is altered according to the results of the decision.
(XII) It is decided whether the digit contents of a specific region of the memory are smaller than a given value and a program step to be next executed is changed according to the decision.
(XIII) It is decided whether the contents of a specific region of the memory are greater than a given value and the results of such decision alter a program step to be next executed.
(XIV) The contents of a specific region of the memory are displayed.
(XV) What kind of a key switch is actuated is decided.
The above processing events in (1)-(15) above are executed according to the instruction codes step by step in the following manner.
(I) PROCEDURE OF LOADING A SAME VALUE N INTO A SPECIFIC REGION OF THE MEMORY (NNN→X)
(Type 1)
______________________________________ ##STR6##
______________________________________
P 1 : The first digit position of the memory to be processed is specified by a file address m A and a digit address n E .
P 2 : The value N is loaded into ACC.
P 3 : The value N is loaded into the specified region of the memory by exchange between the memory and ACC. With no change in the file address of the memory, m A is specified and the digit address is decremented to determine a digit to be next introduced. By determining n 2 as the final digit value n A to be introduced, the next step P 4 is skipped to complete the processing of the Type 1 since BL=n 2 under the condition that the value N has been completely loaded into the specific region.
P 4 : LDI and XD are carried out repeatedly from the program address P 2 up to BL=V.
(Type 2)
______________________________________ ##STR7##
______________________________________
P 1 : The digit of the memory to be processed is determined by the file address m B and the digit address n C .
P 2 : The ACC is loaded with the value N.
P 3 : By exchange between the memory and ACC the value N is loaded into the above specified region of the memory. This completes the processing of Type 2. An operand area of X D is necessary to the next succeeding process and not to this step.
(Type 3)
______________________________________ ##STR8##
______________________________________
P 1 : The first digit of the memory to be processed is specified by the file address m C and the digit address n O .
P 2 : The ACC is loaded with the value N.
P 3 : By exchange between the memory and ACC the value N is loaded into that specified region of the memory. With no change in the file address of the memory m C is specified and the digit address is decremented in order to determine the digit to be next loaded therein.
P 4 : It is decided whether the digit processed during the step P 3 is the final digit n B . If it is n B , then the digit address is decremented to n A . An operand area of the SKI instruction is occupied by n A , thus loading the final digit with the value N. In reaching P 4 , conditions are fulfilled and the next step P 5 is skipped, thereby terminating the type 3. If the conditions are not fulfilled, P 5 is then reached.
P 5 : The program address P 2 is specified and P 2 -P 4 are repeated until BL=n A .
(II) PROCEDURE OF LOADING A PREDETERMINED NUMBER OF DIFFERENT VALUES INTO A SPECIFIC REGION OF THE MEMORY (N 1 , N 2 , N 3 , . . . →X)
(Type 1)
For example, four digit values N 4 N 3 N 2 N 1 are loaded an arbitraray digit position in the same manner as above.
______________________________________ ##STR9##
______________________________________
P 1 : The first processed digit position of the memory is specified by the file address m A and the digit address n E .
P 2 : A constant N 1 is loaded into ACC.
P 3 : Through exchange between the memory and the ACC the value N 1 is loaded into the above specified region of the memory. The file address of the memory remains unchanged as m A , whereas the digit address is up for introduction of the next digit.
P 4 : A second constnat N 2 is loaded into ACC.
P 5 : Since the second digit of the memory has been specified during P 3 , the second constant N 2 is loaded into the second digit position of the memory through exchange between the memory and ACC.
P 6 -P 9 : The same as in the above paragraph.
(Type 2)
Any value of 0-15 is loaded into a predetermined register.
(Type 2)
______________________________________ ##STR10##
______________________________________
P 1 : The value N is loaded into ACC.
P 2 : The value N is transmitted from ACC into the register X.
(III) PROCEDURE OF TRANSFERRING THE CONTENTS OF A SPECIFIC REGION OF THE MEMORY TO A DIFFERENT REGION OF THE MEMORY (X→Y)
(Type 1)
______________________________________ ##STR11##
______________________________________
P 1 : The first memory file address is specified as m A and the first digit address as n E .
P 2 : The contents of the first digit position of the memory are loaded into ACC and its designation, the second memory file address is specified as m B prior to the transmission step P 3 .
P 3 : The first digit memory contents loaded into the ACC are replaced by the same second memory digit contents so that the first memory contents are transmitted into the second memory. In order to repeat the above process, the first memory file address m A is again set. The value of the final digit n A to be transmitted is previously selected to be n 1 . Since BL→n 1 after the overall first memory contents have been sent to the second memory, the next step P 4 is skipped to complete the processing of Type 1. The digit address is progressively incremented until BL=V (the final digit). Through the step P 4 the file address is set up at m A to lead back to P 2 , thereby specifying the first memory.
P 4 : The program address is set at the step P 2 and the instructions P 2 and P 3 are repeatedly executed until BL=n 1 . The transmission step is advanced digit by digit.
(Type 2)
______________________________________ ##STR12##
______________________________________
P 1 : The region of the memory to be processed is determined by the file address m A and the digit address n C .
P 2 : The contents of the memory as specified above are unloaded into ACC and the memory file address is set at m C prior to the next transmission step P 4 .
P 3 : The digit address of the memory, the destination for the transmission process, is specified as m C . The destinated region of the memory is specified via the steps P 2 and P 3 .
P 4 : The contents of ACC are exchanged with the contents of the regions of the memory specified bu P 2 and P 3 . The operand of X has no connection with the present process.
(Type 3)
______________________________________ ##STR13##
______________________________________
P 1 : The region of the memory to be processed is identified by the file address m A and the digit address n C .
P 2 : The contents of the memory region specified during P 1 are unloaded into ACC.
P 3 : The contents of the memory transmitted from ACC are sent to the register X, completing the type 3 processing.
(IV) PROCEDURE OF EXCHANGING CONTENTS BETWEEN A SPECIFIC REGION OF THE MEMORY AND A DIFFERENT REGION (X→Y)
(Type 1)
______________________________________ ##STR14##
______________________________________
P 1 : The first memory file address to be processed is specified as m A and the first digit address as n E .
P 2 : The specific digit contents of the first memory are loaded into ACC and the second memory file address is specified as m B for preparation of the next step.
P 3 : The specific digit contents of the first memory contained within ACC are exchanged with the same digit contents of the second memory specified by P 2 . The file address of the first memory is specified as m A in order to load the contents of the memory now in ACC into the first memory.
P 4 : The contents of the second memory now in ACC are exchanged with the contents of the first memory at the corresponding digit positions so that the contents of the second memory are transferred to the first memory. Exchanges are carried out during the steps P 2 -P 4 . The first memory is specified on by the file address m A , while the digit address is incremented to select a next address. Exchange is carried out progressively digit by digit. The final digit value n A is previously set at n 1 such that B L =n 1 after the exchange operation between the first memory and the second has been effected throughout the all digit positions, thus skipping the next step P 5 and completing the processing of Type 1.
P 5 : The program address P 2 is selected and the instructions for P 2 to P 4 are executed repeatedly until B L =n 1 . The exchange operation is advanced digit by digit.
(Type 2)
______________________________________ ##STR15##
______________________________________
P 1 : The file address of the first memory to be processed is specified as m A and the digit address as n C .
P 2 : The contents of the specific digit position of the first memory are unloaded into ACC and the file address of the second memory is specified as m C and ready to exchange.
P 3 : The digit address of the second memory, the destination for the exchange process, is specified as n O to determine the destinated memory address.
P 4 : The contents of the first memory now within ACC are exchanged with that of the second memory. At the same time the file address m B of the first memory is again specified to transfer the contents of the first memory to the first memory.
P 5 : The digit address n C of the first memory is specified to determine the destination address of the first memory.
P 6 : The contents of the second memory now within ACC are exchanged with the contents of the first memory.
(Type 3)
______________________________________ ##STR16##
______________________________________
P 1 : The file address m A of the first memory to be processed is specified and the digit address n C is specified.
P 2 : The contents of the first memory are loaded into ACC and the file address m C of the second memory is selected.
P 3 : The exchange is carried out between the first and second memory so that the contents of the first memory are loaded into the second memory. Prior to the step P 4 the file address m B of the first memory is selected again.
P 4 : The exchange is effected between the contents of the second memory and the first memory.
(Type 4)
______________________________________ ##STR17##
______________________________________
P 1 : The region of the memory to be processed is specified by the file address m A and the digit address n C .
P 2 : The contents of the memory region specified in P 1 above are loaded into ACC. The file address m B is kept being selected prior to the exchange with the contents of the register X.
P 3 : The exchange is effected between ACC and the register X so that the contents of the memory are shifted to the register X.
P 4 : Through the exchange between ACC containing the contents of the register X and the memory, the contents of the register X are substantially transferred into the memory, thus accomplishing the Type 4 processing.
(V) PROCEDURE OF EFFECTING A BINARY ADDITION OR SUBTRACTION OF A GIVEN VALUE N ONTO A SPECIFIC REGION OF THE MEMORY
(Type 1)
M 1 +N→M
______________________________________ ##STR18##
______________________________________
P 1 : The region of the memory to be processed is specified by the file address m B and the digit address n C .
P 2 : The contents of the memory specified by the step P 1 are unloaded into ACC. The memory file address is set again at m B to specify the same memory.
P 3 : The operand specifies the value N to be added and the contents of the memory contained within ACC are added with the value N, the results being loaded back to ACC.
P 4 : The sum contained with ACC is exchanged with the contents of the memory specified by the step P 2 , thus completing the Type 1 processing.
(Type 2)
X+N→X
______________________________________ ##STR19##
______________________________________
P 1 : The exchange is effected between the register X and ACC.
P 2 : The operand specifies the avlue N to be added and an addition is carried out on the contents of the register X now within ACC and the value N, with the results back to ACC.
P 3 : Through the exchange between the resulting sum within ACC and the contents of the register X, the processing of Type 2 (X+N→X) is performed.
(Type 3)
M 1 +N→M 2
______________________________________ ##STR20##
______________________________________
P 1 : The region of the first memory to be processed is decided by the file address m B and the digit address n C .
P 2 : The contents of the memory specified by P 1 are loaded into ACC. The file address m C of the second memory is specified to return addition results to the second memory.
P 3 : The operand specifies the value N to be added and the value N is added to the contents of the memory now within ACC, with the results being loaded into ACC.
P 4 : The resulting sum within ACC is exchanged with the contents of the second memory as specified by P 2 , thus completing the processing of Type 3.
(Type 4)
M 1 -N→M 1
______________________________________ ##STR21##
______________________________________
P 1 : There are specified the file address m B and the digit address n C of the memory to be processed.
P 2 : Subtraction is carried out in such a way that the complement of a subtrahend is added to a minuend and the F/F C remains set because of the absence of a borrow from a lower digit position.
P 3 : ACC is loaded with the subtrahend N.
P 4 : The complement of the subtrahend to "15" is evaluated and loaded into ACC.
P 5 : In the event that any borrow occurs during the subtraction, the complement of the subtrahend to "16" is added to the minuend. If a borrow free state is denoted as C=1, then a straight binary subtraction of ACC+C+M→ACC is effected.
P 6 : The resulting difference during P 5 is returned to the same memory through the exchange between ACC and that memory.
(Type 5)
M 1 -N→M 2
______________________________________ ##STR22##
______________________________________
P 6 : To load the resulting difference during P 5 into the second memory, the file address m C and the digit address n C of the second memory are selected.
P 7 : Through exchange the resulting difference is transferred from ACC into the second memory as specified by the step P 6 .
(Type 6)
______________________________________ ##STR23##
______________________________________
P 1 : The file address m B and the digit address n C of the memory ready for the step P 5 are selected.
P 2 : Subtraction is carried out in the manner of adding the complement of a subtrahend to a minuend and the F/F C remains set because of the absence of a borrow from a lower digit position.
P 3 : ACC is loaded with the subtrahend N.
P 4 : The complement of the subtrahend to "15" is evaluated and loaded into ACC.
P 5 : To accomplish calculations with the contents of the register X, the memory as specified by P 1 is loaded with the contents of ACC.
P 6 : The contents of the register X are transmitted into ACC through the exchange process. After this step the memory contains the complement of the subtrahend to "15" and ACC contains the contents of X.
P 7 : ACC+M+C corresponds to X-N and the results of a binary subtraction are loaded into ACC.
P 8 : The contents of ACC are exchanged with the contents of X and the value of X-N is transmitted into X, thereby completing the processing of Type 6.
(Type 7)
N-M 1 →M 1
______________________________________ ##STR24##
______________________________________
P 1 : The file address m B and the digit address n C of the memory to be processed are selected.
P 2 : One-digit subtraction is effected in the manner of adding the complement of a subtrahend to a minuend, in which case F/F C remains set.
P 3 : ACC is loaded with a minuend.
P 4 : The exchange is effected between the memory (the subtrahend) and ACC and the memory file address remains as m B for preparation of P 7 .
P 5 : The complement of a subtrahend in ACC to "15" is evaluated and loaded into ACC.
P 6 : In the event that there is no borrow from a lower digit position, the complement of a subtrahend to "16" is added to a minuend. If a borrowless state is denoted as C=1, then N-M is substantially executed by ACC+C+M, the resulting difference being loaded into ACC.
P 7 : Since the memory file address remains unchanged during P 4 , the difference is unloaded from ACC back to the memory, thus completing the proceesing of Type 7.
(Type 8)
N-M 1 →M 2
______________________________________ ##STR25##
______________________________________
P 1 : The file address m B and the digit address n C of the memory to be processed are selected.
P 2 : The contents specified by the step P 1 and corresponding to a subtrahend are loaded into ACC. The file address m C of the second memory is specified for preparation of a step P 5 .
P 3 : The complement of the subtrahend to "15" is evaluated and loaded into ACC.
P 4 : The operand is made a minuend plug "1". This subtraction is one digit long and accomplished by adding the complement of the subtrahend to the minuend. A conventional complementary addition is defined as ACC+C+M as in the Type 7 processing in the absence of a borrow as defined by C=1. Since the ADI instruction carries C, ACC+1 is processed in advance. This completes the processing of Type 8 of N-M, the results being stored within ACC.
P 5 : The difference obtained from the step P 4 is transmitted into the second memory specified by P 2 .
(Type 9)
M±1→M
______________________________________ ##STR26##
______________________________________
P 1 : (When M+1) ACC is loaded with a binary number "0001" (=1).
P 1 ': (When M-1) ACC is loaded with a binary number "1111" (=15).
P 2 : The file address m B and the digit address n C of the memory to be processed are selected.
P 3 : The contents of the memory specified by P 2 are added to the contents contained within ACC during P 1 or P 1 ', the sum thereof being loaded into ACC. In the case of P 1 ACC+1 and in the case of P 1 ' ACC-1.
P 4 : The results are unloaded from ACC to the original memory position, thus completing the processing fashion of Type 9.
(VI) PROCEDURE OF EFFECTING A DECIMAL ADDITION OR SUBTRACTION BETWEEN A SPECIFIC REGION OF THE MEMORY AND A DIFFERENT REGION
(Type 1)
X+W→X
______________________________________ ##STR27##
______________________________________
P 1 : The first digit position of the first memory to be processed is identified by the file address m A and the digit address n E .
P 2 : The carry F/F C is reset because of a carry from a lower digit position in effecting a first digit addition.
P 3 : The contents of the specific digit position of the first memory are loaded into ACC and the file address m B of the second memory is selected in advance of additions with the contents of the second memory during P 4 .
P 4 : "6" is added to the contents of the specific digit position of the first memory now loaded into ACC for the next succeeding step P 5 wherein a decimal carry is sensed during addition.
P 5 : ACC already receives the contents of the first memory compensated with "6" and a stright binary addition is effected upon the contents of ACC and the contents of the second memory at the corresponding digit positions, the results being loaded back to ACC. In the event a carry is developed during the binary addition at the fourth bit position, P 7 is reached without passing P 6 . The presence of the carry during the fourth bit addition implies the development of a decimal carry.
P 6 : In the event the decimal carry failed to develop during the addition P 5 , "6" for the process P 4 is overruded. An addition of "10" is same as a subtraction of "6".
P 7 : The one-digit decimal sum is unloaded from ACC into the second memory and the digit address is incremented for a next digit addition and the file address m A of the first memory is selected. The final digit to be added is previously set at n 1 . Since BL=n 1 after the overall digit addition is effected upon the first and second memory, the next succeeding step P 8 is skipped to thereby complete the processing of Type 1.
P 8 : The program address P 3 is selected and the instructions P 3 -P 7 are repeatedly executed until BL=n 1 . A decimal addition is effected digit by digit.
(Type 2)
X-W→X
______________________________________ ##STR28##
______________________________________
P 1 : The first digit position of the first memory to be processed is specified by the file address m A and the digit address n E .
P 2 : Subtraction is performed in the manner of adding the complement of a subtrahend to a minuend and F/F C is set because of the absence of a borrow from a lower digit position during the first digit subtraction.
P 3 : The contents of the specific digits in the first memory, the subtrahend, are loaded into ACC and the file address m B of the second memory is specified in advance of the step P 7 with the second memory.
P 4 : The complement of the subtrahend to "15" is evaluated and loaded into ACC.
P 5 : In the event that there is no borrow from a lower digit place, the complemnt of the subtrahend is added to the minuend to perform a subtraction. On the contrary, in the presence of a borrow, the complement of the subtrahend is added to the minuend. If a borrowless state is denoted as C=1, then a binary addition of ACC+C+M→ACC is effected. The development of a carry, as a consequence of the execution of the ADSCK instruction, implies failure to give rise to a borrow and leads to the step P 7 without the intervention of the step P 6 . Under these circumstances the addition is executed with the second memory, thus executing substantially subtraction between the first and second memories.
P 6 : In the case where no carry is developed during the execution of the ADCSK instruction by the step P 5 , the calculation results are of the sexadecimal notation and thus converted into a decimal code by subtraction of "6" (equal to addition of "10").
P 7 : The resulting difference between the first and second memories is transmitted from ACC into the second memory. The digit address is incremented and the file address m A of the first memory is specified in advance of a next succeeding digit subtraction. The final digit to be subtracted is previously determined as n 1 . Since BL=n 1 after the overalldigit subtraction has been completed, the next step P 8 is skipped to thereby conclude the processing of Type 2.
P 8 : After selection of the program address P 3 the instructions P 3 -P 7 are repeatedly executed until BL=n 1 . The decimal subtraction is advanced digit by digit.
(VII) PROCEDURE OF SHIFTING ONE DIGIT THE CONTENTS OF A SPECIFIC REGION OF THE MEMORY
(Type 1)
Right Shift
______________________________________ ##STR29##
______________________________________
P 1 : The file address m A and the digit address n A of the memory to be processed are determined.
P 2 : ACC is loaded with "0" and ready to introduce "0" into the most significant digit position when the right shift operation is effected.
P 3 : The exchange is carried out between XCC and the memory and the digit address is decremented to specific a one digit lower position. The memory address is still at m A . XD is repeated executed through P 4 and P 3 . By the step ACC⃡M "0" is transmitted from ACC to the most significant digit position of the memory which in turn provides its original contents for ACC. When the digit address is down via B and XD is about to be executed at P 3 via P 4 , the second most significant digit is selected to contain the original content of the most significant digit position which has previously been contained within ACC. At this time ACC is allowed to contain the contents of the second most significant digit position. The least significant digit is previously selected as n 2 . If the transmission step reaches the least significant digit position BL=n 2 is satisfied and P 4 is skipped. In other words, the digit contents are shifted down to thereby conclude the processing of Type 1.
P 4 : XD is repeated at P 3 until BL=V.
(Type 2)
Left Shift
______________________________________ ##STR30##
______________________________________
P 1 : The file address m A and the least significant digit n E of the memory to be processed are determined.
P 2 : ACC is loaded with "0" and ready to introduce "0" into the least significant digit position when the left shift operation is started.
P 3 : The exchange is carried out between ACC and the memory and the digit address is incremented to specify a one digit upper position. The memory address is still at m A . XD is repeated executed through P 4 and P 3 . By the step ACC→M, "0" is transmitted from ACC to the least significant digit position of the memory which in turn provides its original contents for ACC. When the digit address is up via P 3 and XD is about to be executed at P 3 via P 4 , the second least significant digit is selected to contain the original content of the least significant digit position which has previously been contained within ACC. At this time ACC is allowed to contain the contents of the second least significant digit position. The most significant digit is previously selected as n 1 . If the transmission step reaches the most significant digit position, BL=n 1 is satisfied and P 4 is skipped. In other words, the digit contents are shifted up to thereby conclude the processing of Type 2.
P 4 : XI is repeated at P 3 until BL=V.
(VIII) PROCEDURE OF SETTING OR RESETTING A ONE-BIT CONDITION F/F ASSOCIATED WITH A SPECIFIC REGION OF THE MEMORY
(Type 1)
______________________________________ ##STR31##
______________________________________
P 1 : The file address m B and the digit address n C of a region of the memory to be processed are determined.
P 2 : "1" is loaded into a desired bit N within the digit position of the memory specified by P 1 , thus concluding the processing of Type 1.
(Type 2)
______________________________________ ##STR32##
______________________________________
P 1 : The file address m B and the digit address n C of a region of the memory to be processed are determined.
P 2 : "0" is loaded into a desired bit N within the digit position of the memory specified by P 1 , thus concluding the processing of Type 2.
(IX) PROCEDURE OF SENSING THE STATE OF THE ONE-BIT CONDITIONAL F/F ASSOCIATED WITH A SPECIFIC REGION OF THE MEMORY AND CHANGING A NEXT PROGRAM ADDRESS (STEP) AS A RESULT OF THE SENSING OPERATION
______________________________________ ##STR33##
______________________________________
P 1 : There are specified the file address m B and the digit address n C where a desired one-bit conditional F/F is present.
P 2 : In the case where the contents of the bit position (corresponding to the conditional F/F) specified by N within the memory region as selected during P 1 assume "1", the step proceeds to P 4 with skipping P 3 , thus executing the operation OP 1 . In the event that the desired bit position bears "0", the next step P 3 is skipped.
P 3 : When the foregoing P 2 has been concluded as the conditional F/F in the "0" state, the program step P n is selected in order to execute the operation OP 2 .
(X) PROCEDURE OF DECIDING WHETHER THE DIGIT CONTENTS OF A SPECIFIC REGION OF THEMEMORY REACH A PRESELECTED NUMERAL AND ALTERING A NEXT PROGRAM ADDRESS (STEP) ACCORDING TO THE RESULTS OF THE DECISION
______________________________________ ##STR34##
______________________________________
P 1 : The region of the memory which contains contents to be decided is identified by the file address m B and the digit address n C .
P 2 : The contents of the memory as identified during P 1 are unloaded into ACC.
P 3 : The contents of ACC are compared with the preselected value N and if there is agreement the step advances toward P 5 without executing P 4 to perform the operation OP 1 . P 4 is however reached if the contents of ACC are not equal to N.
P 4 : The program address (step) P n is then selected to perform the operation OP 2 .
(XI) PROCEDURE OF DECIDING WHETHER THE PLURAL DIGIT CONTENTS OF A SPECIFIC REGION OF THE MEMORY ARE EQUAL TO A PRESELECTED NUMERAL AND ALTERING A PROGRAM STEP ACCORDING TO THE RESULTS OF THE DECISION
______________________________________ ##STR35##P.sub.1 : The region of the memory to be judged is identified by the file
P 2 : The value N is loaded into ACC for comparison.
P 3 : The value V within ACC is compared with the digit contents of the specific region of the memory and if there is agreement P 5 is reached without passing P 4 to advance the comparison operation toward the next succeeding digit. P 4 is selected in a non-agreement.
P 4 : In the case of a non-agreement during P 3 the program address (step) P n is specified to execute the operation forthwith.
P 5 : The digit address is incremented by adding "1" thereto. This step is aimed at evaluating in sequence a plurality of digits within the memory. The ultimate digit to be evaluated is previously determined as (V). The comparison is repeated throughout the desired digit positions. If a non-agreement state occurs on the way, the operation OP 2 is accomplished through P 4 . In the case where the agreement state goes on till BL=V, there is selected P 7 rather than P 6 to perform the operation OP 1 .
P 6 : When the agreement state goes on during P 5 , P 3 is reverted for evaluation.
(XII) PROCEDURE OF DECIDING WHETHER THE CONTENTS OF A SPECIFIC REGION OF THE MEMORY ARE SMALLER THAN A GIVEN VALUE AND DECIDING WHICH ADDRESS (STEP) IS TO BE EXECUTED
______________________________________ ##STR36##P.sub.1 : The file address m.sub.B and the digit address n.sub.C of the
P 2 : The contents of the memory as specified during P 1 are unloaded into ACC.
P 3 : N is the value to be compared with the contents of the memory and the operand area specifies 16-N which in turn is added to the contents of ACC, the sum thereof being loaded back to ACC. The occurrence of a fourth bit carry during the addition suggests that the result of the binary addition exceeds 16, that is, M+(16-N)≧16 and hence M≧N. The step is progressed toward P 4 .
P 4 : When M≧N is denied, the program step P n is selected to carry out the operation OP 2 .
(XIII) PROCEDURE OF DECIDING WHETHER THE CONTENTS OF A SPECIFIC REGION OF THE MEMORY ARE GREATER THAN A GIVEN VALUE AND DECIDING WHICH ADDRESS (STEP) IS TO BE EXECUTED
______________________________________ ##STR37##P.sub.1 : The file address m.sub.B and the digit address n.sub.C of the
P 2 : The contents of the memory as specified during P 1 are unloaded into ACC.
P 3 : N is the value to be compared with the contents of thememory and the operand area specifies 15-N which in turn is added to the contents of ACC, the sum thereof being loaded back to ACC. The occurrence of a fourth bit carry during the addition suggests that the results of binary addition exceeds 16, that is, M+(15-N)≧16 and hence M≧N+1 and M>N. The step is progressed toward P 5 with skipping P 4 , thus performing the operation OP 1 . In the absence of a carry (namely, M>N) the step P 4 is reached.
P 4 : When M≧N is denied, the program address (Step) P n is selected to carry out the operation OP 2 .
(XIV) PROCEDURE OF DISPLAYING THE CONTENTS OF A SPECIFIC REGION OF THE MEMORY
(Type 1)
______________________________________ ##STR38## ##STR39##______________________________________
P 1 : The bit number n 1 of the buffer register W is loaded into ACC to reset the overall contents of the buffer register W for generating digit selection signals effective to drive a display panel on a time sharing basis.
P 2 : After the overall contents of the register W are one bit shifted to the right, its first bit is loaded with "0". This procedure is repeated via P 4 until C 4 =1 during P 3 , thus resetting the overall contents of W.
P 3 : The operand I A is decided as "1111" and AC+1111 is effected (this substantially corresponds to ACC-1). Since ACC is loaded with n 1 during P 1 , this process is repeated n 1 times. When the addition of "1111" is effected following ACC=0, the fourth bit carry C 4 assumes "0". When this occurs, the step is advanced to P 4 . Otherwise the step is skipped up to P 5 .
P 4 : When the fourth bit carry C 4 =0 during ACC+1111, the overall contents of W are reduced to "0" to thereby complete all the pre-display processes. The first address P 6 is set for the memory display steps.
P 5 : In the event that the fourth bit carry C 4 =1 during ACC+1111, the overall contents of W have not yet reduced to "0". Under these circumstances P 2 is reverted to repeat the introduction of "0" into W.
P 6 : The first digit position of the memory region which contains data to be displayed is identified by the file address m A and the digit address n A .
P 7 : After the contents of the register W for generating the digit selection signals are one bit shifted to the right, its first bit position is loaded with "1" and thus ready to supply the digit selection signal to the first digit position of the display.
P 8 : The contents of the specific region of the memory are unloaded into ACC. The file address of the memory still remains at m A , whereas the digit address is decremented for the next succeeding digit processing.
P 9 : The contents of the memory is shifted from ACC to the buffer register F. The contents of the register F are supplied to the segment decoder SD to generate segment display signals.
P 10 : To lead out the contents of the register W as display signals, the conditional F/F N P is supplied with "1" and placed into the set state. As a result of this, the contents of the memory processed during P 9 are displayed on the first digit position of the display.
P 11 : A count initial value n 2 is loaded into ACC to determine a one digit long display period of time.
P 12 : ACC-1 is carried out like P 3 . When ACC does not assume "0" (when C 4 =1) the step is skipped up to P 14 .
P 13 : A desired period of display is determined by counting the contents of ACC during P 12 . After the completion of the counting P 15 is reached from P 13 . The counting period is equal in length to a one-digit display period of time.
P 14 : Before the passage of the desired period of display the step is progressed from P 12 to P 14 with skipping P 13 and jumped back to P 12 . This procedure is repeated.
P 15 : N P is reset to stop supplying the digit selection signals to the display. Until N P is set again during P 10 , overlapping display problems are avoided by using the adjacent digit signals.
P 16 : The register W is one bit shifted to the right and its first bit position is loaded with "0". "1" introduced during P 7 is one bit shifted down for preparation of the next succeeding digit selection.
P 17 : It is decided whether the ultimate digit of the memory to be displayed has been processed and actually whether the value n E of the last second digit has been reached because the step P 8 of B L -1 is in effect.
P 18 : In the event that ultimate digit has not yet been reached, P 8 is reverted for the next succeeding digit display processing.
P 19 : For example, provided that the completion of the display operation is conditional by the flag F/F FA, FA=1 allows P 20 to be skipped, thereby concluding all the displaying steps.
P 20 : If FA=1 at P 19 , the display steps are reopened from the first display and the step is jumped up to P 6 .
(Type 2)
______________________________________ ##STR40## ##STR41##______________________________________
P 1 : The bit number n 1 of the buffer register W is loaded into ACC to reset the overall contents of the buffer register W for generating digit selection signals effective to drive a display panel on a time sharing basis.
P 2 : After the overall contents of the register W are one bit shifted to the right, its first bit is loaded with "0". This procedure is repeated via P 4 until C 4 =1 during P 3 , thus resetting the overall contents of W.
P 3 : The operand I A is decided as "1111" and AC+1111 is effected (this substantially corresponds to ACC-1). Since ACC is loaded with n 1 during P 1 , this process is repeated n 1 times. When the addition of "1111" is effected following ACC=0, the fourth bit carry C 4 assumes "0". When this occurs, the step is advanced to P 4 . Otherwise the step is skipped up to P 5 .
P 4 : When the fourth bit carry C 4 =0 during ACC+1111, the overall contents of W are reduced to "0" to thereby complete all the pre-display processes. The first address P 6 is set for the memory display steps.
P 5 : In the event that the fourth bit carry C 4 =1 during ACC+1111, the overall contents of W have not yet reduced to "0". Under these circumstances P 2 is reverted to repeat the introduction of "0" into W.
P 6 : The upper four bits of the first digit position of the memory region which contains data to be displayed are identified by the file address m A and the digit address m A .
P 7 : The contents of the specific region of the memory are unloaded into ACC. The file address of the memory still remains at m A , whereas the digit address is decremented to specify the lower four bits.
P 8 : The contents of ACC, the upper four bits, are transmitted into the temporary register X.
P 9 : The contents of the specific region of the memory are unloaded into ACC. The file address of the memory still remains at m A , whereas the digit address is decremented to specify the upper four bits of the next succeeding digit.
P 10 : The contents of ACC are unloaded into the stack register SA and the contents of the temporary register X into the stack register SX.
P 11 : After the contents of the register W for generating the digit selection signals are one bit shifted to the right, its first bit position is loaded with "1" and thus ready to supply the digit selection signal to the first digit position of the display.
P 12 : To lead out the contents of the register W as display signals, the conditional F/F N p is supplied with "1" and placed into the set state. As a result of this, the contents of the memory processed during P 10 are displayed on the first digit position of the display.
P 13 : A count initial value n 2 is loaded into ACC to determine a one digit long display period of time.
P 14 : ACC-1 is carried out like P 3 . When ACC assumes "0" P 15 is reached and when ACC≠0 (when C 4 =1) the step is skipped up to P 16 . This procedure is repeated.
P 15 : A desired period of display is determined by counting the contents of ACC during P 14 . After the completion of the counting P 17 is reached from P 15 . The counting period is equal in length to a one-digit display period of time.
P 16 : Before the passage of the desired period of display the step is progressed from P 14 to P 16 with skipping P 15 and jumped back to P 14 . This procedure is repeated.
P 17 : N P is reset to stop supplying the digit selection signals to the display. Until N P is set again during P 10 , overlapping display problems are avoided by using the adjacent digit signals.
P 18 : The register W is one bit shifted to the right and its first bit position is loaded with "0". "1" introduced during P 7 is one bit shifted down for preparation of the next succeeding digit selection.
P 19 : It is decided whether the ultimate digit of the memory to be displayed has been processed and actually whether the value n E of the last second digit has been reached because the step p 9 of B L -1 is in effect.
P 20 : In the event that ultimate digit has not yet been reached, P 7 is reverted for the next succeeding digit display processing.
(XV) PROCEDURE OF DECIDING WHICH KEY SWITCH IS ACTUATED (SENSING ACTUATION OF ANY KEY DURING DISPLAY)
__________________________________________________________________________ ##STR42## ##STR43## ##STR44## ##STR45## ##STR46##__________________________________________________________________________
P 1 -P 18 : The display processes as discussed in (XIV) above.
P 19 : After the overall digit contents of the register W are displayed, the flag F/F FC is set to hold all the key signals I 1 -I n at a "1" level.
P 20 : The step is jumped to P 30 as long as any one of the keys connected to the key input KN 1 is actuated.
P 22 -P 27 : It is decided whether any one of the keys each connected to the respective key inputs KN 2 -KF 2 and in the absence of any actuation the step is advanced toward the next succeeding step. To the contrary, the presence of the key actuation leads to P 30 .
P 28 : When any key is not actuated, F/F FC is reset to thereby complete the decision as to the key actuations.
P 29 : The step is jumped up to P 6 to reopen the display routine.
P 30 : When any key is actually actuated, the memory digit address is set at n 1 to generate the first key strobe signal I 1 .
P 31 : It is decided if the first key storbe signal I 1 is applied to the key input KN 1 and if not the step is advanced toward P 33 .
P 32 : When the first key strobe signal I 1 is applied to the key input KN 1 , which kind of the keys is actuated is decided. Thereafter, the step is jumped to P A to provide proper controls according to the key decision. After the completion of the key decision the step is returned directly to P 1 to commence the displaying operation again (P z is to jump the step to P 1 )
P 33 -P 38 : It is sequentially decided whether the keys coupled with the first key strobe signal I 1 are actuated. If a specific key is actuated, the step jumps to P B -P D for providing appropriate controls for that keys.
P 39 : This step is executed when no key coupled with the first key strobe signal I 1 . This step is to increment the digit address of the memory for the developments of the key strobe signals.
P 41 and up: The appropriate key strobe signals are developed and KN 1 -KF 2 are sequentially monitored to decide what kind of the keys are actuated. Desired steps are then selected to effects control steps for those actuated keys.
P A and up: Control steps for the first actuated keys.
P X : P 1 is returned to reopen the display operation after the control steps for the first key.
The foregoing is the description of the respective major processing events in the CPU architecture.
One way to provide suitable outputs will now be described in great detail. FIG. 4 shows an example of an audible output control circuit VSC which includes the read only memory (ROM) VR containing sound quantizing data therein, an address counter VAC for the memory VR, an address decoder VAD for the memory VR, an adder FA, a reset circuit CLA for VAC, a digital to analog converter DAC, a low pass filter LPF, a loud speaker SP, a speaker driver DD, an END code detector JE, and a code converter CC. The input signal to CC is labeled S 1 , the output signal from JE is labeled S 2 , the output signal from VCC is labeled VCC, and the output signal from VR is labeled VR 0 . P 1 , P 2 , . . . represent respective regions for synthesized speech words.
When providing no audible outputs, VAC is reset by CLA. With the address counter VAC in the reset state, no address of VR is there specified nor is any audible output released.
If it is desired to provide a specific audible output, then VAC is set at the initial address of its associated word region P. For example, assuming that the associated word is present within the region P 2 , the initial address is placed into VAC for P 2 . Then, the data signal VR 0 indicative of that initial address is derived.
FA is the addition circuit which increments by one the address of VAC and thus performs the operation of VAC+1→VAC. With VAC in the reset state, FA is not operative and the contents of VAC remains unchanged. In other words, VAC is still kept in the reset state.
When the state of ≠"0" is reached upon the arrival at the initial address, the operation VAC+1→VAC is automatically executed at a given sampling frequency. Once the initial address is set at VAC, the subsequent addresses are automatically selected step by step. The sound quantizing data VR 0 are, therefore, derived in sequence from the region P 2 .
The output VR 0 is converted from a digital form to a corresponding analog form via DAC with its low frequency component passing through LPF. It is desirable to filter the analog output through LPF because the presence of a high frequency component of VR 0 may cause the speaker to release noisy or harsh sounds in the event that the quantizing data are converted in a stepwise fashion. The output of LPF enables the loud speaker SP to release agreeable sound outputs via the speaker driver DD in this manner.
The respective data contained within the respective regions of VR, as indicated in FIG. 5, end with an END code placed at the last section thereof. The END code is derived from VR 0 immediately upon the completion of the delivery of all the desired audible sounds and sensed by JE, thus rendering CLA operative to reset VAC. Under these circumstances any address of VR is not specified any longer, stopping the delivery of a series of audible sounds. The situation is held until a new initial address is set at VAC.
A code converter CC is adapted to determine a desired initial address in response to a word region specifying signal S 1 so as to set the initial address of a desired following word region at VAC.
In the case of providing many words in succession, the output S 2 of JE takes the place of the signals S 1 corresponding to the next succeeding words.
While the code converter is adapted to determine the address of VR upon the receipt of the word region specifying signal S 1 , it may have a built-in gate circuit which conveys code converted signals corresponding to the specifying signal S 1 into VAC only when a trigger signal S 0 comes.
The operation of a speech-synthesizer apparatus implementing the present invention will be described by reference to flow charts of FIGS. 6 and 7. FIG. 6 depicts the processing events in providing audible sounds indicative of keyed data.
The steps n 1 , n 2 , . . . n 3 are effected to decide which key is actuated. For example, when a key "0" is depressed, the step is advanced n 1 →n 4 , followed by the conventional key entry procedure for the key "0".
Subsequent to this the delivery of audible sounds is governed in the following manner. During the step n 7 an operand I 3 is loaded into the accumulator ACC, for example, 4 bits "0000" in the case of actuation of the digit key "0". The contents of ACC are unloaded into the temporary register X during the succeeding step n 8 . The instruction LDI is led out during n 9 (cf. No 12 in the Table 1).
In a given example, the operand assumes "0001" to define the digit key "0", which codes are loaded into the accumulator ACC. The apparatus jumps up to the step n 18 in response to the T instruction at n 10 . The STPO instruction at n 18 transfers the contents of the accumulator ACC and the register X into the stack registers SA and SA, respectively. As a result, the contents of the stack registers are as follows:
______________________________________SX SA.THorizBrace. .THorizBrace.0 0 0 0 0 0 0 1 (representing "0")______________________________________
The outputs of SX and SA are supplied to the S 1 input of the speech-synthesizer circuit VSC. The flag F/F F B is set during n 19 . The output of F B is connected to the S 0 input of VSC. When S 0 =1, the codes of SX and SA are sent to the code converter CC of VSC which in turn develops synthesized a word "REI (in Japanese)" or "ZERO (in English)" indicative of the digit "0". F B which has been set during the step n 20 is then reset.
Upon the press of a key "X" the conventional entry procedure associated with the key "X" takes place during n 6 , followed by the step n 15 of loading a first operand I 8 into the accumulator ACC. The first operand I 8 is unloaded from ACC to the temporary register X during n 16 . A second operand I 9 is introduced into ACC during n 17 . Both the operands are transmitted into the stack registers SX and SA at one time during n 18 . The first and second operands are as follows:
______________________________________ SX SA 0 0 0 1 0 1 0 1 .BHorizBrace. .BHorizBrace. the first the second______________________________________
As shown above, assuming that both the operands are "0001" and "0101" respectively, SX and SA in combination contain codes "00010101". These codes can be regarded as codes corresponding to "X". The use of 8 bits avoids the disadvantage that only 16 words are possible in the case of 4 bits.
After these codes are contained within SX and SA during n 18 , the flag flip flop F B is set during n 19 , allowing the code converter CC in VSC to convert these codes. As a result, the initial address of a word "KAKERU (TIME in English)" corresponding to the key "X" is set at the address counter VAC of the memory VR. Thereafter, the audibel word "KAKERU" is provided.
The way of providing audible sounds after the completion of a particular calculation following actuation of an equal key"=" is depicted in a flow chart of FIG. 7.
When the key "=" is not actuated, the apparatus advances to the step n 22 whereby the contents of a memory m 1 are displayed and the key checkup procedure reopens. Upon the actuation of the key "=" the corresponding process is carried out during the step n 23 with its results loaded into the memory M 1 in the conventional way, followed by n 24 .
The steps n 24 -n 31 are to develop a word or linguistic information "KOTAEWA (ANSWER in English)". The LDI instruction at n 24 places the upper 4 bits of 8 bits specifying the initial address of VSC containing the word "KOTAEWA". During n 25 the upper 4 bits are loaded into the temporary register X, whereas the lower 4 bits are loaded into the accumulator ACC during the next step n 26 . The STPO instruction (the instruction No. 52 in Table 1) at n 27 loades the stack registers SX and SA with these 8 bits. With the flip flop F B in the set state during the step n 28 , the initial address is set up for the synthesized word "KOTAEWA", thus starting the delivery of the corresponding audible sounds.
The step n 30 , n 31 are effected to check if the word "KOTAEWA" has been thoroughly announced. Since one input terminal of CPU is coupled with an end signal S 2 from VSC, n 30 →n 31 -n 31 . . . are repeated in the absence of the signal S 2 (the operand area of the T instruction at n 31 determines the address during n 30 ). Upon the occurrence of the signal S 2 the step n 32 is reached without passing n 31 . The steps n 32 -n 50 are processed to provide audible sounds while the data within the memory M 1 are subject to the so-called zero suppression. As long as they are numerical data, their 4 bits always are full of "0000". To this end the process n 32 is to load "0000" into the accumulator ACC and the process n 33 to convey them to the X register.
The LB instruction at n 34 indicates the most significant digit position of the memory M 1 . The contents of the memory M 1 are unloaded into the accumulator ACC during n 35 . When the process reaches the least significant digit position, the condition BL=V contained within the LD instruction is satisfied, followed by n 37 other than n 36 . Otherwise, n 36 comes into effect and n 38 follows. SKFA contains a decision step as to the state of the flag F/F F A and thus as to whether the upper data assume "0". If the negative answer is obtained, then F A is set. Otherwise, F A is still in the reset state. Therefore, if the most significant digit assumes "0", then the step n 39 is linked to the step n 41 . SKAI at n 41 decides whether the contents of the accumulator ACC agree with the operand I which is "0000" in the above example. In other words, it is decided whether the contents of the memory now in ACC are euqal to a decimal number "0". If ACC=0, then the step n 42 ' is effected instead of the step n 42 , followed by n 35 . This procedure is repeated until ACC≠0.
While the LD instruction is being executed during n 35 , the digit address of the memory is progressively incremented. If ACC=0 in this manner, then n 41 →n 42 →n 43 take place. The step n 43 places the flip flop F A into the set state. During the next succeeding step n 44 the STPO instruction allows the instant numerical codes to be shifted so SX and SA at one time. The flip flop F B is set at n 45 , thus initiating the procedure of delivering audible sounds indicative of numerical information. The steps n 47 and n 49 are to check if the delivery of the audible sounds has been completed. This procedure is repeated until all the necessary audible sounds have been released. Upon the completion of the sound release the apparatus reaches the step n 49 without passing n 48 and returns back to n 35 whereby the next succeeding digit data are unloaded from the memory M 1 to the accumulator ACC. While the apparatus goes ahead n 35 →n 36 →n.sub. 38, the flip flop F A has already been set during the previous step n 43 so that the apparatus further reaches n 40 without n 37 and then n 44 for the processing of the next digit numerical codes. This procedure is repeated later.
If the second least significant digit position of the memory M 1 containing the data is denoted as n 2 , then B L =V(v=n 2 ) at n 35 following the completion of the release associated with the most significant digit, followed by n 37 and then n 50 with skipping n 36 . F A is then reduced into the reset state to thereby terminate the delivery of a series of audible outputs.
The steps n 51 -n 56 thereafter become operative to provide audible sounds indicative of "DESU" (corresponds to "IS" in English with a difference in position between the Japanese and English sentences) according to the teaching of the present invention.
The step n 51 is effected to load the upper 4 bits of the codes indicative of the synthesized word "DESU" into the accumulator ACC, the upper 4 bits being then transferred into the X register at n 52 whereas the lower 4 bits are loaded into the accumulator ACC during n 53 . Both these 4 bits are sent to the stack registers SX and SA at one time. The flip flop F B is set at n 55 , allowing the sound output control circuit VSC to provide the sounds "DESU". The steps n 57 and n 58 recover the initial settings after the completion of the sound output "DESU" and thus keeps the word "DESU" from being interrupted on the way. It will be understood that the above described steps n 1 , n 2 . . . n 3 , n 21 and n 22 depend upon the function procedure (XV) of the CPU architecture.
In this manner, linguistic intelligences other than numerical intelligences, such as the above described the word "DESU" are able to be created after the numerical intelligences reflecting the body of calculation results are audibly displayed, thus establishing a distinction between audible sounds at the time of key entry and the audible display of the calculation results. As an alternative, the linguistic intelligences such as the word "KOTAE" can be provided audibly immediately before the calculation results are displayed
Referring to FIG. 6, the steps m 1 -m 3 are additional ones which allow the contents of a preceding key to be displayed in the form of audible sounds upon actuation of a key "V" of FIG. 1. Upon actuation of a key "X" the step is advanced from m 1 →m 2 to set the flag F/F F B . After the actuation of the keys there is a checkup as to the respective keys "0", "1", . . . "X".
The STPO instruction at n 18 loads the keyed codes into the stack registers SX and SA, these keyed codes being held unchanged as long as any different key is not actuated. Therefore, the flip flop F B is set. If the trigger input S 0 of VSC is supplied with the output F B , then those keyed codes contained within the stack registers SX and SA are interpreted through VSC to thereby provides their corresponding audible sounds. The step m 3 is to reset F B and revert the apparatus to its initial state. In this manner the actuation of the key "V" enables a preceding actuated key to be displayed in the form of audible sounds.
Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to those skilled in the art, and it is intended to encompass such changes and modifications as fall within the scope of the appended claims.
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An audible output device disclosed herein for use in electronic calculators or the like is able to distinguish between audible messages at the time of keying input information and at the time delivering output information reflecting results of operations, for example. The audibel output device relies upon a speech-synthesizer technique which can be implemented with a digital LSI device.
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RELATED APPLICATIONS
[0001] This is a continuation of application Ser. No. 10/120,623, filed Apr. 11, 2002, entitled DESULFURIZATION SYSTEM WITH ENHANCED FLUID/SOLIDS CONTACTING, and hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a method and apparatus for removing sulfur from hydrocarbon-containing fluid streams. In another aspect, the invention concerns a system for improving the contacting of a hydrocarbon-containing fluid stream and sulfur-sorbing solid particulates in a fluidized bed reactor.
[0003] Hydrocarbon-containing fluids such as gasoline and diesel fuels typically contain a quantity of sulfur. High levels of sulfurs in such automotive fuels is undesirable because oxides of sulfur present in automotive exhaust may irreversibly poison noble metal catalysts employed in automobile catalytic converters. Emissions from such poisoned catalytic converters may contain high levels of non-combusted hydrocarbons, oxides of nitrogen, and/or carbon monoxide, which, when catalyzed by sunlight, form ground level ozone, more commonly referred to as smog.
[0004] Much of the sulfur present in the final blend of most gasolines originates from a gasoline blending component commonly known as “cracked-gasoline.” Thus, reduction of sulfur levels in cracked-gasoline will inherently serve to reduce sulfur levels in most gasolines, such as, automobile gasolines, racing gasolines, aviation gasolines, boat gasolines, and the like.
[0005] Many conventional processes exist for removing sulfur from cracked-gasoline. However, most conventional sulfur removal processes, such as hydrodesulfurization, tend to saturate olefins and aromatics in the cracked-gasoline and thereby reduce its octane number (both research and motor octane number). Thus, there is a need for a process wherein desulfurization of cracked-gasoline is achieved while the octane number is maintained.
[0006] In addition to the need for removing sulfur from cracked-gasoline, there is also a need to reduce the sulfur content in diesel fuel. In removing sulfur from diesel fuel by hydrodesulfurization, the cetane is improved but there is a large cost in hydrogen consumption. Such hydrogen is consumed by both hydrodesulfurization and aromatic hydrogenation reactions. Thus, there is a need for a process wherein desulfurization of diesel fuel is achieved without significant consumption of hydrogen so as to provide a more economical desulfurization process.
[0007] Traditionally, sorbent compositions used in processes for removing sulfur from hydrocarbon-containing fluids, such as cracked-gasoline and diesel fuel, have been agglomerates utilized in fixed bed applications. Because fluidized bed reactors present a number of advantages over fixed bed reactors, hydrocarbon-containing fluids are sometimes processed in fluidized bed reactors. Relative to fixed bed reactors, fluidized bed reactors have both advantages and disadvantages. Rapid mixing of solids gives nearly isothermal conditions throughout the reactor leading to reliable control of the reactor and, if necessary, easy removal of heat. Also, the flowability of the solid sorbent particulates allows the sorbent particulates to be circulated between two or more units, an ideal condition for reactors where the sorbent needs frequent regeneration. However, the gas flow in fluidized bed reactors is often difficult to describe, with possible large deviations from plug flow leading to gas bypassing, solids backmixing, and inefficient gas/solids contacting. Such undesirable flow characteristics within a fluidized bed reactor ultimately leads to a less efficient desulfurization process.
SUMMARY OF THE INVENTION
[0008] Accordingly, it is an object of the present invention to provide a novel hydrocarbon desulfurization system which employs a fluidized bed reactor having reactor internals which enhance the contacting of the hydrocarbon-containing fluid stream and the regenerable solid sorbent particulates, thereby enhancing desulfurization of the hydrocarbon-containing fluid stream.
[0009] A further object of the present invention is to provide a hydrocarbon desulfurization system which minimizes octane loss and hydrogen consumption while providing enhanced sulfur removal.
[0010] It should be noted that the above-listed objects need not all be accomplished by the invention claimed herein and other objects and advantages of this invention will be apparent from the following description of the preferred embodiments and appended claims.
[0011] Accordingly, in one embodiment of the present invention there is provided a desulfurization unit comprising a fluidized bed reactor, a fluidized bed regenerator, and a fluidized bed reducer. The fluidized bed reactor defines an elongated upright reaction zone within which finely divided solid sorbent particulates are contacted with a hydrocarbon-containing fluid stream to thereby provide a desulfurized hydrocarbon-containing stream and sulfur-loaded sorbent particulates. The fluidized bed reactor includes a series of vertically spaced contact-enhancing members generally horizontally disposed in the reaction zone. Each of the contact-enhancing members includes a plurality of substantially parallelly extending laterally spaced elongated baffles. The baffles of adjacent vertically spaced contact-enhancing members extend transverse to one another at a cross-hatch angle in the range of from about 60 to about 120 degrees. The fluidized bed regenerator is operable to contact at least a portion of the sulfur-loaded sorbent particulates from the reactor with an oxygen-containing regeneration stream to thereby provide regenerated sorbent particulates. The fluidized bed reducer is operable to contact at least a portion of the regenerated sorbent particulates from the regenerator with a hydrogen-containing reducing stream.
[0012] In another embodiment of the present invention, there is provided a fluidized bed reactor system comprising an elongated upright vessel, a gaseous hydrocarbon-containing fluid stream, a fluidized bed of solid particulates, and a series of vertically spaced contact-enhancing members. The vessel defines a reaction zone through which the hydrocarbon-containing fluid stream flows upwardly at a superficial velocity in the range of from about 0.25 to about 5.0 ft/s. The fluidized bed of solid particulates is substantially disposed in the reaction zone and is fluidized by the flow of the gaseous hydrocarbon-containing fluid stream therethrough. Each of the contact-enhancing members is generally horizontally disposed in the reaction zone and includes a plurality of substantially parallelly extending laterally spaced elongated baffles. The baffles of adjacent vertically spaced contact-enhancing members extend transverse to one another at a cross-hatch angle in the range of from about 60 degrees to about 120 degrees.
[0013] In still another embodiment of the present invention, a fluidized bed reactor for contacting an upwardly flowing gaseous hydrocarbon-containing stream with solid particulates is provided. The fluidized bed reactor generally comprises an elongated upright vessel and a series of vertically spaced contact-enhancing members. The vessel defines a lower reaction zone within which the solid particulates are substantially fluidized by the gaseous hydrocarbon-containing stream and an upper disengagement zone within which the solid particulates are substantially disengaged from the gaseous hydrocarbon-containing stream. Each of the contact-enhancing members is generally horizontally disposed in the reaction zone and includes a plurality of substantially parallelly extending laterally spaced elongated baffles. The baffles of adjacent vertically spaced contact-enhancing members extend transverse to one another at a cross-hatch angle in the range of from about 60 degrees to about 120 degrees.
[0014] In a still further embodiment of the present invention, a desulfurization process is provided. The desulfurization process comprise the steps of: (a) contacting a hydrocarbon-containing fluid stream with solid sorbent particulates comprising a reduced-valence promoter metal component and zinc oxide in a fluidized bed reactor vessel under desulfurization conditions sufficient to remove sulfur from the hydrocarbon-containing fluid stream and convert at least a portion of the zinc oxide to zinc sulfide, thereby providing a desulfurized hydrocarbon-containing stream and sulfur-loaded sorbent particulates; (b) simultaneously with step (a), contacting at least a portion of the hydrocarbon-containing fluid stream and the solid particulates with a series of substantially horizontal, vertically spaced, cross-hatched baffle groups, thereby reducing axial dispersion in the fluidized bed reactor and enhancing sulfur removal from the hydrocarbon-containing fluid stream; (c) contacting at least a portion of the sulfur-loaded sorbent particulates with an oxygen-containing regeneration stream in a regenerator vessel under regeneration conditions sufficient to convert at least a portion of the zinc sulfide to zinc oxide, thereby providing regenerated sorbent particulates comprising an unreduced promoter metal component; and (d) contacting at least a portion of the regenerated sorbent particulates with a hydrogen-containing reducing stream in a reducer vessel under reducing conditions sufficient to reduce the unreduced promoter metal component, thereby providing reduced sorbent particulates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a schematic diagram of a desulfurization unit constructed in accordance with the principals of the present invention, particularly illustrating the circulation of regenerable solid sorbent particulates through the reactor, regenerator, and reducer.
[0016] [0016]FIG. 2 is a side view of a fluidized bed reactor constructed in accordance with the principals of the present invention.
[0017] [0017]FIG. 3 is a partial sectional side view of the fluidized bed reactor, particularly illustrating the series of vertically spaced contact-enhancing baffle groups disposed in the reaction zone.
[0018] [0018]FIG. 4 is a partial isometric view of the fluidized bed reactor with certain portions of the reactor vessel being cut away to more clearly illustrate the orientation of the contacting-enhancing baffle groups in the reaction zone.
[0019] [0019]FIG. 5 is a sectional view of the fluidized bed reactor taken along line 5 - 5 in FIG. 3, particularly illustrating the construction of a single baffle group.
[0020] [0020]FIG. 6 is a sectional view of the fluidized bed reactor taken along line 6 - 6 in FIG. 3, particularly illustrating the cross-hatched pattern created by the individual baffle members of adjacent baffle groups.
[0021] [0021]FIG. 7 is a schematic diagram of a full-scale fluidized bed test reactor system employed in tracer experiments for measuring fluidization characteristics in the reactor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring initially to FIG. 1, a desulfurization unit 10 is illustrated as generally comprising a fluidized bed reactor 12 , a fluidized bed regenerator 14 , and a fluidized bed reducer 16 . Solid sorbent particulates are circulated in desulfurization unit 10 to provide for continuous sulfur removal from a sulfur-containing hydrocarbon, such as cracked-gasoline or diesel fuel. The solid sorbent particulates employed in desulfurization unit 10 can be any sufficiently fluidizable, circulatable, and regenerable zinc oxide-based composition having sufficient desulfurization activity and sufficient attrition resistance. A description of such a sorbent composition is provided in U.S. patent application Ser. No. 09/580,611 and U.S. patent application Ser. No. 10/072,209, the entire disclosures of which are incorporated herein by reference.
[0023] In fluidized bed reactor 12 , a hydrocarbon-containing fluid stream is passed upwardly through a bed of reduced solid sorbent particulates. The reduced solid sorbent particulates contacted with the hydrocarbon-containing stream in reactor 12 preferably initially (i.e., immediately prior to contacting with the hydrocarbon-containing fluid stream) comprise zinc oxide and a reduced-valence promoter metal component. Though not wishing to be bound by theory, it is believed that the reduced-valence promoter metal component of the reduced solid sorbent particulates facilitates the removal of sulfur from the hydrocarbon-containing stream, while the zinc oxide operates as a sulfur storage mechanism via its conversion to zinc sulfide.
[0024] The reduced-valence promoter metal component of the reduced solid sorbent particulates preferably comprises a promoter metal selected from a group consisting of nickel, cobalt, iron, manganese, tungsten, silver, gold, copper, platinum, zinc, tin, ruthenium, molybdenum, antimony, vanadium, iridium, chromium, palladium. More preferably, the reduced-valence promoter metal component comprises nickel as the promoter metal. As used herein, the term “reduced-valence” when describing the promoter metal component, shall denote a promoter metal component having a valence which is less than the valence of the promoter metal component in its common oxidized state. More specifically, the reduced solid sorbent particulates employed in reactor 12 should include a promoter metal component having a valence which is less than the valence of the promoter metal component of the regenerated (i.e., oxidized) solid sorbent particulates exiting regenerator 14 . Most preferably, substantially all of the promoter metal component of the reduced solid sorbent particulates has a valence of 0.
[0025] In a preferred embodiment of the present invention the reduced-valence promoter metal component comprises, consists of, or consists essentially of, a substitutional solid metal solution characterized by the formula: M A Zn B , wherein M is the promoter metal and A and B are each numerical values in the range of from 0.01 to 0.99. In the above formula for the substitutional solid metal solution, it is preferred for A to be in the range of from about 0.70 to about 0.97, and most preferably in the range of from about 0.85 to about 0.95. It is further preferred for B to be in the range of from about 0.03 to about 0.30, and most preferably in the range of from about 0.05 to 0.15. Preferably, B is equal to (1−A).
[0026] Substitutional solid solutions have unique physical and chemical properties that are important to the chemistry of the sorbent composition described herein. Substitutional solid solutions are a subset of alloys that are formed by the direct substitution of the solute metal for the solvent metal atoms in the crystal structure. For example, it is believed that the substitutional solid metal solution (M A Zn B ) found in the reduced solid sorbent particulates is formed by the solute zinc metal atoms substituting for the solvent promoter metal atoms. There are three basic criteria that favor the formation of substitutional solid solutions: (1) the atomic radii of the two elements are within 15 percent of each other; (2) the crystal structures of the two pure phases are the same; and (3) the electronegativities of the two components are similar. The promoter metal (as the elemental metal or metal oxide) and zinc oxide employed in the solid sorbent particulates described herein preferably meet at least two of the three criteria set forth above. For example, when the promoter metal is nickel, the first and third criteria, are met, but the second is not. The nickel and zinc metal atomic radii are within 10 percent of each other and the electronegativities are similar. However, nickel oxide (NiO) preferentially forms a cubic crystal structure, while zinc oxide (ZnO) prefers a hexagonal crystal structure. A nickel zinc solid solution retains the cubic structure of the nickel oxide. Forcing the zinc oxide to reside in the cubic structure increases the energy of the phase, which limits the amount of zinc that can be dissolved in the nickel oxide structure. This stoichiometry control manifests itself microscopically in a 92:8 nickel zinc solid solution (Ni 0.92 Zn 0.08 ) that is formed during reduction and microscopically in the repeated regenerability of the solid sorbent particulates.
[0027] In addition to zinc oxide and the reduced-valence promoter metal component, the reduced solid sorbent particulates employed in reactor 12 may further comprise a porosity enhancer and a promoter metal-zinc aluminate substitutional solid solution. The promoter metal-zinc aluminate substitutional solid solution can be characterized by the formula: M Z Zn (1-Z) Al 2 O 4 ), wherein Z is a numerical value in the range of from 0.01 to 0.99. The porosity enhancer, when employed, can be any compound which ultimately increases the macroporosity of the solid sorbent particulates. Preferably, the porosity enhancer is perlite. The term “perlite” as used herein is the petrographic term for a siliceous volcanic rock which naturally occurs in certain regions throughout the world. The distinguishing feature, which sets it apart from other volcanic minerals, is its ability to expand four to twenty times its original volume when heated to certain temperatures. When heated above 1600° F., crushed perlite expands due to the presence of combined water with the crude perlite rock. The combined water vaporizes during the heating process and creates countless tiny bubbles in the heat softened glassy particles. It is these diminutive glass sealed bubbles which account for its light weight. Expanded perlite can be manufactured to weigh as little as 2.5 lbs per cubic foot. Typical chemical analysis properties of expanded perlite are: silicon dioxide 73%, aluminum oxide 17%, potassium oxide 5%, sodium oxide 3%, calcium oxide 1%, plus trace elements. Typical physical properties of expanded perlite are: softening point 1600-2000° F., fusion point 2300° F.-2450° F., pH 6.6-6.8, and specific gravity 2.2-2.4. The term “expanded perlite” as used herein refers to the spherical form of perlite which has been expanded by heating the perlite siliceous volcanic rock to a temperature above 1600° F. The term “particulate expanded perlite” or “milled perlite” as used herein denotes that form of expanded perlite which has been subjected to crushing so as to form a particulate mass wherein the particle size of such mass is comprised of at least 97% of particles having a size of less than 2 microns. The term “milled expanded perlite” is intended to mean the product resulting from subjecting expanded perlite particles to milling or crushing.
[0028] The reduced solid sorbent particulates initially contacted with the hydrocarbon-containing fluid stream in reactor 12 can comprise zinc oxide, the reduced-valence promoter metal component (M A Zn B ), the porosity enhancer (PE), and the promoter metal-zinc aluminate (M Z Zn (1-Z) Al 2 O 4 ) in the ranges provided below in Table 1.
TABLE 1 Components of the Reduced Solid Sorbent Particulates ZnO M A Zn B PE M Z Zn (1-Z) Al 2 O 4 Range (wt %) (wt %) (wt %) (wt %) Preferred 5-80 5-80 2-50 1-50 More Preferred 20-60 20-60 5-30 5-30 Most Preferred 30-50 30-40 10-20 10-
[0029] The physical properties of the solid sorbent particulates which significantly affect the particulates suitability for use in desulfurization unit 10 include, for example, particle shape, particle size, particle density, and resistance to attrition. The solid sorbent particulates employed in desulfurization unit 10 preferably comprise microspherical particles having a mean particle size in the range of from about 20 to about 150 microns, more preferably in the range of from about 50 to about 100 microns, and most preferably in the range of from 60 to 80 microns. The density of the solid sorbent particulates is preferably in the range of from about 0.5 to about 1.5 grams per cubic centimeter (g/cc), more preferably in the range of from about 0.8 to about 0.3 g/cc, and most preferably in the range of from 0.9 to 1.2 g/cc. The particle size and density of the solid sorbent particulates preferably qualify the solid sorbent particulates as a Group A solid under the Geldart group classification system described in Powder Technol., 7, 285-292 (1973). The solid sorbent particulates preferably have high resistance to attrition. As used herein, the term “attrition resistance” denotes a measure of a particle's resistance to size reduction under controlled conditions of turbulent motion. The attrition resistance of a particle can be quantified using the Davidson Index. The Davidson Index represents the weight percent of the over 20 micrometer particle size fraction which is reduced to particle sizes of less than 20 micrometers under test conditions. The Davidson Index is measured using a jet cup attrition determination method. The jet cup attrition determination method involves screening a 5 gram sample of sorbent to remove particles in the 0 to 20 micrometer size range. The particles above 20 micrometers are then subjected to a tangential jet of air at a rate of 21 liters per minute introduced through a 0.0625 inch orifice fixed at the bottom of a specially designed jet cup (1″ I.D.×2″ height) for a period of 1 hour. The Davidson Index (DI) is calculated as follows:
DI = Wt . of 0 - 20 Micrometer Formed During Test Wt . of Original + 20 Micrometer Fraction Being Tested × 100 × Correction Factor
[0030] The solid sorbent particulates employed in the present invention preferably have a Davidson index value of less than about 30, more preferably less than about 20, and most preferably less than 10.
[0031] The hydrocarbon-containing fluid stream contacted with the reduced solid sorbent particulates in reactor 12 preferably comprises a sulfur-containing hydrocarbon and hydrogen. The molar ratio of the hydrogen to the sulfur-containing hydrocarbon charged to reactor 12 is preferably in the range of from about 0.1:1 to about 3:1, more preferably in the range of from about 0.2:1 to about 1:1, and most preferably in the range of from 0.4:1 to 0.8:1. Preferably, the sulfur-containing hydrocarbon is a fluid which is normally in a liquid state at standard temperature and pressure, but which exists in a gaseous state when combined with hydrogen, as described above, and exposed to the desulfurization conditions in reactor 12 . The sulfur-containing hydrocarbon preferably can be used as a fuel or a precursor to fuel. Examples of suitable sulfur-containing hydrocarbons include cracked-gasoline, diesel fuels, jet fuels, straight-run naphtha, straight-run distillates, coker gas oil, coker naphtha, alkylates, and straight-run gas oil. Most preferably, the sulfur-containing hydrocarbon comprises a hydrocarbon fluid selected from the group consisting of gasoline, cracked-gasoline, diesel fuel, and mixtures thereof.
[0032] As used herein, the term “gasoline” denotes a mixture of hydrocarbons boiling in a range of from about 100° F. to about 400° F., or any fraction thereof. Examples of suitable gasolines include, but are not limited to, hydrocarbon streams in refineries such as naphtha, straight-run naphtha, coker naphtha, catalytic gasoline, visbreaker naphtha, alkylates, isomerate, reformate, and the like, and mixtures thereof.
[0033] As used herein, the term “cracked-gasoline” denotes a mixture of hydrocarbons boiling in a range of from about 100° F. to about 400° F., or any fraction thereof, that are products of either thermal or catalytic processes that crack larger hydrocarbon molecules into smaller molecules. Examples of suitable thermal processes include, but are not limited to, coking, thermal cracking, visbreaking, and the like, and combinations thereof. Examples of suitable catalytic cracking processes include, but are not limited to, fluid catalytic cracking, heavy oil cracking, and the like, and combinations thereof. Thus, examples of suitable cracked-gasolines include, but are not limited to, coker gasoline, thermally cracked gasoline, visbreaker gasoline, fluid catalytically cracked gasoline, heavy oil cracked-gasoline and the like, and combinations thereof. In some instances, the cracked-gasoline may be fractionated and/or hydrotreated prior to desulfurization when used as the sulfur-containing fluid in the process in the present invention.
[0034] As used herein, the term “diesel fuel” denotes a mixture of hydrocarbons boiling in a range of from about 300° F. to about 750° F., or any fraction thereof. Examples of suitable diesel fuels include, but are not limited to, light cycle oil, kerosene, jet fuel, straight-run diesel, hydrotreated diesel, and the like, and combinations thereof.
[0035] The sulfur-containing hydrocarbon described herein as suitable feed in the inventive desulfurization process comprises a quantity of olefins, aromatics, and sulfur, as well as paraffins and naphthenes. The amount of olefins in gaseous cracked-gasoline is generally in a range of from about 10 to about 35 weight percent olefins based on the total weight of the gaseous cracked-gasoline. For diesel fuel there is essentially no olefin content. The amount of aromatics in gaseous cracked-gasoline is generally in a range of from about 20 to about 40 weight percent aromatics based on the total weight of the gaseous cracked-gasoline. The amount of aromatics in gaseous diesel fuel is generally in a range of from about 10 to about 90 weight percent aromatics based on the total weight of the gaseous diesel fuel. The amount of atomic sulfur in the sulfur-containing hydrocarbon fluid, preferably cracked-gasoline or diesel fuel, suitable for use in the inventive desulfurization process is generally greater than about 50 parts per million by weight (ppmw) of the sulfur-containing hydrocarbon fluid, more preferably in a range of from about 100 ppmw atomic sulfur to about 10,000 ppmw atomic sulfur, and most preferably from 150 ppmw atomic sulfur to 500 ppmw atomic sulfur. It is preferred for at least about 50 weight percent of the atomic sulfur present in the sulfur-containing hydrocarbon fluid employed in the present invention to be in the form of organosulfur compounds. More preferably, at least about 75 weight percent of the atomic sulfur present in the sulfur-containing hydrocarbon fluid is in the form of organosulfur compounds, and most preferably at least 90 weight percent of the atomic sulfur is in the form of organosulfur compounds. As used herein, “sulfur” used in conjunction with “ppmw sulfur” or the term “atomic sulfur”, denotes the amount of atomic sulfur (about 32 atomic mass units) in the sulfur-containing hydrocarbon, not the atomic mass, or weight, of a sulfur compound, such as an organosulfur compound.
[0036] As used herein, the term “sulfur” denotes sulfur in any form normally present in a sulfur-containing hydrocarbon such as cracked-gasoline or diesel fuel. Examples of such sulfur which can be removed from a sulfur-containing hydrocarbon fluid through the practice of the present invention include, but are not limited to, hydrogen sulfide, carbonal sulfide (COS), carbon disulfide (CS 2 ), mercaptans (RSH), organic sulfides (R—S—R), organic disulfides (R—S—S—R), thiophene, substitute thiophenes, organic trisulfides, organic tetrasulfides, benzothiophene, alkyl thiophenes, alkyl benzothiophenes, alkyl dibenzothiophenes, and the like, and combinations thereof, as well as heavier molecular weights of the same which are normally present in sulfur-containing hydrocarbons of the types contemplated for use in the desulfurization process of the present invention, wherein each R can by an alkyl, cycloalkyl, or aryl group containing 1 to 10 carbon atoms.
[0037] As used herein, the term “fluid” denotes gas, liquid, vapor, and combinations thereof.
[0038] As used herein, the term “gaseous” denotes the state in which the sulfur-containing hydrocarbon fluid, such as cracked-gasoline or diesel fuel, is primarily in a gas or vapor phase.
[0039] As used herein, the term “finely divided” denotes particles having a mean particle size less than 500 microns.
[0040] In fluidized bed reactor 12 the finely divided reduced solid sorbent particulates are contacted with the upwardly flowing gaseous hydrocarbon-containing fluid stream under a set of desulfurization conditions sufficient to produce a desulfurized hydrocarbon and sulfur-loaded solid sorbent particulates. The flow of the hydrocarbon-containing fluid stream is sufficient to fluidize the bed of solid sorbent particulates located in reactor 12 . The desulfurization conditions in reactor 12 include temperature, pressure, weighted hourly space velocity (WHSV), and superficial velocity. The preferred ranges for such desulfurization conditions are provided below in Table 2.
TABLE 2 Desulfurization Conditions Temp Press. WHSV Superficial Vel. Range (° F.) (psig) (hr −1 ) (ft/s) Preferred 250-1200 25-750 1-20 0.25-5 More Preferred 500-1000 100-400 2-12 0.5-2.5 Most Preferred 700-850 150-250 3-8 1.0-1.5
[0041] When the reduced solid sorbent particulates are contacted with the hydrocarbon-containing stream in reactor 12 under desulfurization conditions, sulfur compounds, particularly organosulfur compounds, present in the hydrocarbon-containing fluid stream are removed from such fluid stream. At least a portion of the sulfur removed from the hydrocarbon-containing fluid stream is employed to convert at least a portion of the zinc oxide of the reduced solid sorbent particulates into zinc sulfide.
[0042] In contrast to many conventional sulfur removal processes (e.g., hydrodesulfurization), it is preferred that substantially none of the sulfur in the sulfur-containing hydrocarbon fluid is converted to, and remains as, hydrogen sulfide during desulfurization in reactor 12 . Rather, it is preferred that the fluid effluent from reactor 12 (generally comprising the desulfurized hydrocarbon and hydrogen) comprises less than the amount of hydrogen sulfide, if any, in the fluid feed charged to reactor 12 (generally comprising the sulfur-containing hydrocarbon and hydrogen). The fluid effluent from reactor 12 preferably contains less than about 50 weight percent of the amount of sulfur in the fluid feed charged to reactor 12 , more preferably less than about 20 weight percent of the amount of sulfur in the fluid feed, and most preferably less than 5 weight percent of the amount of sulfur in the fluid feed. It is preferred for the total sulfur content of the fluid effluent from reactor 12 to be less than about 50 parts per million by weight (ppmw) of the total fluid effluent, more preferably less than about 30 ppmw, still more preferably less than about 15 ppmw, and most preferably less than 10 ppmw.
[0043] After desulfurization in reactor 12 , the desulfurized hydrocarbon fluid, preferably desulfurized cracked-gasoline or desulfurized diesel fuel, can thereafter be separated and recovered from the fluid effluent and preferably liquefied. The liquification of such desulfurized hydrocarbon fluid can be accomplished by any method or manner known in the art. The resulting liquefied, desulfurized hydrocarbon preferably comprises less than about 50 weight percent of the amount of sulfur in the sulfur-containing hydrocarbon (e.g., cracked-gasoline or diesel fuel) charged to the reaction zone, more preferably less than about 20 weight percent of the amount of sulfur in the sulfur-containing hydrocarbon, and most preferably less than 5 weight percent of the amount of sulfur in the sulfur-containing hydrocarbon. The desulfurized hydrocarbon preferably comprises less than about 50 ppmw sulfur, more preferably less than about 30 ppmw sulfur, still more preferably less than about 15 ppmw sulfur, and most preferably less than 10 ppmw sulfur.
[0044] After desulfurization in reactor 12 , at least a portion of the sulfur-loaded sorbent particulates are transported to regenerator 14 via a first transport assembly 18 . In regenerator 14 , the sulfur-loaded solid sorbent particulates are contacted with an oxygen-containing regeneration stream. The oxygen-containing regeneration stream preferably comprises at least 1 mole percent oxygen with the remainder being a gaseous diluent. More preferably, the oxygen-containing regeneration stream comprises in the range of from about 1 to about 50 mole percent oxygen and in the range of from about 50 to about 95 mole percent nitrogen, still more preferable in the range of from about 2 to about 20 mole percent oxygen and in the range of from about 70 to about 90 mole percent nitrogen, and most preferably in the range of from 3 to 10 mole percent oxygen and in the range of from 75 to 85 mole percent nitrogen.
[0045] The regeneration conditions in regenerator 14 are sufficient to convert at least a portion of the zinc sulfide of the sulfur-loaded solid sorbent particulates into zinc oxide via contacting with the oxygen-containing regeneration stream. The preferred ranges for such regeneration conditions are provided below in Table 3.
TABLE 3 Regeneration Conditions Temp Press. Superficial Vel. Range (° F.) (psig) (ft/s) Preferred 500-1500 10-250 0.5-10 More Preferred 700-1200 20-150 1.0-5.0 Most Preferred 900-1100 30-75 2.0-2.5
[0046] When the sulfur-loaded solid sorbent particulates are contacted with the oxygen-containing regeneration stream under the regeneration conditions described above, at least a portion of the promoter metal component is oxidized to form an oxidized promoter metal component. Preferably, in regenerator 14 the substitutional solid metal solution (M A Zn B ) and/or sulfided substitutional solid metal solution (M A Zn B S) of the sulfur-loaded sorbent is converted to a substitutional solid metal oxide solution characterized by the formula: M X Zn Y O, wherein M is the promoter metal and X and Y are each numerical values in the range of from 0.01 to about 0.99. In the above formula, it is preferred for X to be in the range of from about 0.5 to about 0.9 and most preferably from 0.6 to 0.8. It is further preferred for Y to be in the range of from about 0.1 to about 0.5, and most preferably from 0.2 to 0.4. Preferably, Y is equal to (1−X).
[0047] The regenerated solid sorbent particulates exiting regenerator 14 can comprise zinc oxide, the oxidized promoter metal component (M X Zn Y O), the porosity enhancer (PE), and the promoter metal-zinc aluminate (M Z Zn (1-Z) Al 2 O 4 ) in the ranges provided below in Table 4.
TABLE 4 Components of the Regenerated Solid Sorbent Particulates ZnO M X Zn Y O PE M Z Zn (1-Z) Al 2 O 4 Range (wt %) (wt %) (wt %) (wt %) Preferred 5-80 5-70 2-50 1-50 More Preferred 20-60 15-60 5-30 5-30 Most Preferred 30-50 20-40 10-20 10-20
[0048] After regeneration in regenerator 14 , the regenerated (i.e., oxidized) solid sorbent particulates are transported to reducer 16 via a second transport assembly 20 . In reducer 16 , the regenerated solid sorbent particulates are contacted with a hydrogen-containing reducing stream. The hydrogen-containing reducing stream preferably comprises at least 50 mole percent hydrogen with the remainder being cracked hydrocarbon products such as, for example, methane, ethane, and propane. More preferably, the hydrogen-containing reducing stream comprises about 70 mole percent hydrogen, and most preferably at least 80 mole percent hydrogen. The reducing conditions in reducer 16 are sufficient to reduce the valence of the oxidized promoter metal component of the regenerated solid sorbent particulates. The preferred ranges for such reducing conditions are provided below in Table 5.
TABLE 5 Reducing Conditions Temp Press. Superficial Vel. Range (° F.) (psig) (ft/s) Preferred 250-1250 25-750 0.1-4.0 More Preferred 600-1000 100-400 0.2-2.0 Most Preferred 750-850 150-250 0.3-1.0
[0049] When the regenerated solid sorbent particulates are contacted with the hydrogen-containing reducing stream in reducer 16 under the reducing conditions described above, at least a portion of the oxidized promoter metal component is reduced to form the reduced-valence promoter metal component. Preferably, at least a substantial portion of the substitutional solid metal oxide solution (M X Zn Y O) is converted to the reduced-valence promoter metal component (M A Zn B ).
[0050] After the solid sorbent particulates have been reduced in reducer 16 , they can be transported back to reactor 12 via a third transport assembly 22 for recontacting with the hydrocarbon-containing fluid stream in reactor 12 .
[0051] Referring again to FIG. 1, first transport assembly 18 generally comprises a reactor pneumatic lift 24 , a reactor receiver 26 , and a reactor lockhopper 28 fluidly disposed between reactor 12 and regenerator 14 . During operation of desulfurization unit 10 the sulfur-loaded sorbent particulates are continuously withdrawn from reactor 12 and lifted by reactor pneumatic lift 24 from reactor 12 to reactor receiver 26 . Reactor receiver 26 is fluidly coupled to reactor 12 via a reactor return line 30 . The lift gas used to transport the sulfur-loaded sorbent particulates from reactor 12 to reactor receiver 26 is separated from the sulfur-loaded sorbent particulates in reactor receiver 26 and returned to reactor 12 via reactor return line 30 . Reactor lockhopper 28 is operable to transition the sulfur-loaded sorbent particulates from the high pressure hydrocarbon environment of reactor 12 and reactor receiver 26 to the low pressure oxygen environment of regenerator 14 . To accomplish this transition, reactor lockhopper 28 periodically receives batches of the sulfur-loaded sorbent particulates from reactor receiver 26 , isolates the sulfur-loaded sorbent particulates from reactor receiver 26 and regenerator 14 , and changes the pressure and composition of the environment surrounding the sulfur-loaded sorbent particulates from a high pressure hydrocarbon environment to a low pressure inert (e.g., nitrogen) environment. After the environment of the sulfur-loaded sorbent particulates has been transitioned, as described above, the sulfur-loaded sorbent particulates are batch-wise transported from reactor lockhopper 28 to regenerator 14 . Because the sulfur-loaded solid particulates are continuously withdrawn from reactor 12 but processed in a batch mode in reactor lockhopper 28 , reactor receiver 26 functions as a surge vessel wherein the sulfur-loaded sorbent particulates continuously withdrawn from reactor 12 can be accumulated between transfers of the sulfur-loaded sorbent particulates from reactor receiver 26 to reactor lockhopper 28 . Thus, reactor receiver 26 and reactor lockhopper 28 cooperate to transition the flow of the sulfur-loaded sorbent particulates between reactor 12 and regenerator 14 from a continuous mode to a batch mode.
[0052] Second transport assembly 20 generally comprises a regenerator pneumatic lift 32 , a regenerator receiver 34 , and a regenerator lockhopper 36 fluidly disposed between regenerator 14 and reducer 16 . During operation of desulfurization unit 10 the regenerated sorbent particulates are continuously withdrawn from regenerator 14 and lifted by regenerator pneumatic lift 32 from regenerator 14 to regenerator receiver 34 . Regenerator receiver 34 is fluidly coupled to regenerator 14 via a regenerator return line 38 . The lift gas used to transport the regenerated sorbent particulates from regenerator 14 to regenerator receiver 34 is separated from the regenerated sorbent particulates in regenerator receiver 34 and returned to regenerator 14 via regenerator return line 38 . Regenerator lockhopper 36 is operable to transition the regenerated sorbent particulates from the low pressure oxygen environment of regenerator 14 and regenerator receiver 34 to the high pressure hydrogen environment of reducer 16 . To accomplish this transition, regenerator lockhopper 36 periodically receives batches of the regenerated sorbent particulates from regenerator receiver 34 , isolates the regenerated sorbent particulates from regenerator receiver 34 and reducer 16 , and changes the pressure and composition of the environment surrounding the regenerated sorbent particulates from a low pressure oxygen environment to a high pressure hydrogen environment. After the environment of the regenerated sorbent particulates has been transitioned, as described above, the regenerated sorbent particulates are batch-wise transported from regenerator lockhopper 36 to reducer 16 . Because the regenerated sorbent particulates are continuously withdrawn from regenerator 14 but processed in a batch mode in regenerator lockhopper 36 , regenerator receiver 34 functions as a surge vessel wherein the sorbent particulates continuously withdrawn from regenerator 14 can be accumulated between transfers of the regenerated sorbent particulates from regenerator receiver 34 to regenerator lockhopper 36 . Thus, regenerator receiver 34 and regenerator lockhopper 36 cooperate to transition the flow of the regenerated sorbent particulates between regenerator 14 and reducer 16 from a continuous mode to a batch mode.
[0053] Referring now to FIG. 2, reactor 12 is illustrated as generally comprising a plenum 40 , a reactor section 42 , a disengagement section 44 , and a solids filter 46 . The reduced solid sorbent particulates are provided to reactor 12 via a solids inlet 48 in reactor section 42 . The sulfur-loaded solid sorbent particulates are withdrawn from reactor 12 via a solids outlet 50 in reactor section 42 . The hydrocarbon-containing fluid stream is charged to reactor 12 via a fluid inlet 52 in plenum 40 . Once in reactor 12 , the hydrocarbon-containing fluid stream flows upwardly through reactor section 42 and disengagement section 44 and exits a fluid outlet 54 in the upper portion of disengagement section 44 . Filter 46 is received in fluid outlet 54 and extends at least partially into the interior of disengagement section 44 . Filter 46 is operable to allow fluids to pass through fluid outlet 54 while substantially blocking the flow of any solid sorbent particulates through fluid outlet 54 . The fluid (typically a desulfurized hydrocarbon and hydrogen) that flows through fluid outlet 54 exits filter 46 via a filter outlet 56 .
[0054] Referring to FIGS. 2 and 3, reactor section 42 includes a substantially cylindrical reactor section wall 58 which defines an elongated, upright, substantially cylindrical reaction zone 60 within reactor section 42 . Reaction zone 60 preferably has a height in the range of from about 10 to about 150 feet, more preferably in the range of from about 25 to about 75 feet, and most preferably in the range of from 35 to 55 feet. Reaction zone 60 preferably has a width (i.e., diameter) in the range of from about 1 to about 10 feet, more preferably in the range of from about 3 to about 8 feet, and most preferably in the range of from 4 to 5 feet. The ratio of the height of reaction zone 60 to the width (i.e., diameter) of reaction zone 60 is preferably in the range of from about 2:1 to about 15:1, more preferably in the range of from about 3:1 to about 10:1, and most preferably in the range of from about 4:1 to about 8:1. In reaction zone 60 , the upwardly flowing fluid is passed through solid particulates to thereby create a fluidized bed of solid particulates. It is preferred for the resulting fluidized bed of solid particulates to be substantially contained within reaction zone 60 . The ratio of the height of the fluidized bed to the width of the fluidized bed is preferably in the range of from about 1:1 to about 10:1, more preferably in the range of from about 2:1 to about 7:1, and most preferably in the range of from 2.5:1 to 5:1. The density of the fluidized bed is preferably in the range of from about 20 to about 60 lb/ft 3 , more preferably in the range of from about 30 to about 50 lb/ft 3 , and most preferably in the range of from about 35 to 45 lb/ft 3 .
[0055] Referring again to FIG. 2, disengagement section 44 generally includes a generally frustoconical lower wall 62 , a generally cylindrical mid-wall 64 , and an upper cap 66 . Disengagement section 44 defines a disengagement zone within reactor 12 . It is preferred for the cross-sectional area of disengagement section 44 to be substantially greater than the cross-sectional area of reactor section 42 so that the velocity of the fluid flowing upwardly through reactor 12 is substantially lower in disengagement section 44 than in reactor section 42 , thereby allowing solid particulates entrained in the upwardly flowing fluid to “fall out” of the fluid in the disengagement zone due to gravitational force. It is preferred for the maximum cross-sectional area of the disengagement zone defined by disengagement section 44 to be in the range of from about two to about ten times greater than the maximum cross-sectional area of reaction zone 60 , more preferably in the range of from about three to about six times greater than the maximum cross-sectional area of reaction zone 60 , and most preferably in the range of from 3.5 to 4.5 times greater than the maximum cross-sectional area in reaction zone 60 .
[0056] Referring to FIGS. 3 and 4, reactor 12 includes a series of generally horizontal, vertically spaced contact-enhancing baffle groups 70 , 72 , 74 , 76 disposed in reaction zone 60 . Baffle groups 70 - 76 are operable to minimize axial dispersion in reaction zone 60 when a fluid is contacted with solid particulates therein. Although FIGS. 3 and 4 show a series of four baffle groups 70 - 76 , the number of baffle groups in reaction zone 60 can vary depending on the height and width of reaction zone 60 . Preferably, two to ten vertically spaced baffle groups are employed in reaction zone 60 , more preferably three to seven baffle groups are employed in reaction zone 60 . The vertical spacing between adjacent baffle groups is preferably in the range of from about 0.02 to about 0.5 times the height of reaction zone 60 , more preferably in the range of from about 0.05 to about 0.2 times the height of reaction zone 60 , and most preferably in the range of from 0.075 to about 0.15 times the height of reaction zone 60 . Preferably, the vertical spacing between adjacent baffle groups is in the range of from about 0.5 to about 6.0 feet, more preferably in the range of from about 1.0 to about 4.0 feet, and most preferably in the range of from 1.5 to 2.5 feet. The relative vertical spacing and horizontal orientation of baffle groups 70 - 76 is maintained by a plurality of vertical support members 78 which rigidly couple baffle groups 70 - 76 to one another.
[0057] Referring now to FIG. 5, each baffle group 70 - 76 generally includes an outer ring 80 and a plurality of substantially parallelly extending, laterally spaced, elongated individual baffle members 82 coupled to and extending chordally within outer ring 80 . Each individual baffle member 82 is preferably an elongated, generally cylindrical bar or tube. The diameter of each individual baffle member 82 is preferably in the range of from about 0.5 to about 5.0 inches, more preferably in the range of from about 1.0 to about 4.0 inches, and most preferably in the range of from 2.0 to 3.0 inches. Individual baffle members 82 are preferably laterally spaced from one another on about two to about ten inch centers, more preferably on about four to about eight inch centers. Each baffle group preferably has an open area between individual baffle members 82 which is about 40 to about 90 percent of the cross-sectional area of reaction zone 60 at the vertical location of that respective baffle group, more preferably the open area of each baffle group is about 55 to about 75 percent of the cross-sectional area of reaction zone 60 at the vertical location of that respective baffle group. Outer ring 80 preferably has an outer diameter which is about 75 to about 95 percent of the inner diameter of reactor section wall 58 . A plurality of attachment members 84 are preferably rigidly coupled to the outer surface of outer ring 80 and are adapted to be coupled to the inner surface of reactor wall section 58 , thereby securing baffle groups 70 - 76 to reactor section wall 58 .
[0058] Referring now to FIGS. 4 and 6, it is preferred for individual baffle members 82 of adjacent ones of baffle groups 70 - 76 to form a “cross-hatched” pattern when viewed from an axial cross section of reactor section 42 (e.g., FIG. 6). Preferably, individual baffle members 82 of adjacent ones of baffle groups 70 - 76 extend transverse to one another at a cross-hatch angle in the range of from about 60 to about 120 degrees, more preferably in the range of from about 80 to about 100 degrees, still more preferably in the range of from about 85 to about 95 degrees, and most preferably substantially 90 degrees (i.e., substantially perpendicular). As used herein, the term “cross-hatch angle” shall denote the angle between the directions of extension of individual baffle members 82 of adjacent vertically spaced baffle groups 70 - 76 , measured perpendicular to the longitudinal axis of the reaction zone 60 .
[0059] Referring now to FIGS. 3 and 4, a distribution grid 86 is rigidly coupled to reactor 12 at the junction of plenum 40 and reactor section 42 . Distribution grid 86 defines the bottom of reaction zone 60 . Distribution grid 86 generally comprises a substantially disc-shaped distribution plate 88 and a plurality of bubble caps 90 . Each bubble cap 90 defines a fluid opening 92 therein, through which the fluid entering plenum 40 through fluid inlet 52 may pass upwardly into reaction zone 60 . Distribution grid 86 preferably includes in the range of from about 15 to about 90 bubble caps 90 , more preferably in the range of from about 30 to about 60 bubble caps 90 . Bubble caps 90 are operable to prevent a substantial amount of solid particulates from passing downwardly through distribution grid 86 when the flow of fluid upwardly through distribution grid 86 is terminated.
EXAMPLE
[0060] In order to test the hydrodynamic performance of the full-scale desulfurization reactor, a full-scale one-half round test reactor 100 , shown in FIG. 7, was constructed. The test reactor 100 was constructed of steel, except for a flat Plexiglass face plate which provided visibility. The test reactor 100 comprised a plenum 102 which was 44 inches in height and expanded from 24 to 54 inches in diameter, a reactor section 104 which was 21 feet in height and 54 inches in diameter, an expanded section 106 which was 8 feet in height and expanded from 54 to 108 inches in diameter, and a dilute phase section 108 which was 4 feet in height and 108 inches in diameter. A distribution grid having 22 holes was positioned in reactor 100 proximate the junction of the plenum 102 and the reactor section 104 . The test reactor 100 also included primary and secondary cyclones 110 , 112 that returned catalyst to approximately one foot above the distribution grid. Fluidizing air was provided to plenum 102 from a compressor 114 via an air supply line 116 . The flow rate of the air charged to reactor 100 , in actual cubic feet per minute, was measured using a Pitot tube. During testing, flow conditions were adjusted to four target gas velocities including 0.75, 1.0, 1.5, and 1.75 ft/s. Catalyst was loaded in the reactor 100 from an external catalyst hopper, which was loaded from catalyst drums. Fluidized bed heights (nominally 4, 7, and 12 feet) were achieved by adding or withdrawing catalyst.
[0061] Tracer tests were conducted in order to compare the degree of axial dispersion in the reactor 100 when sets of horizontal baffle members were employed in the reactor versus no internal baffles. During the tracer tests with horizontal baffles, five vertically spaced horizontal baffle members were positioned in the reactor. Each baffle member (shown in FIG. 5) included a plurality of parallel cylindrical rods. The cylindrical rods had a diameter of 2.375 inches and were spaced from one another on six inch centers. The spacing of the rods gave each baffle member an open area of about 65%. The baffle members were vertically spaced in the reactor 100 two feet from one another and each baffle member was rotated relative to the adjacent baffle member so that the cylindrical rods of adjacent, vertically spaced baffle members extended substantially perpendicular to one another, thereby creating a generally cross-hatched baffle pattern (shown in FIG. 6).
[0062] The tracer tests were conducted by injecting methane (99.99% purity) from a source 115 into the reactor 100 as a non-absorbing tracer. The methane was injected as a 120 cc pulse into a sample loop. The loop was pressurized to about 40 psig. After filling the loop for two minutes, the sample was injected by sweeping the loop with air flowing at about 10 SCF/hr. As shown in FIG. 7, the methane was injected into the air supply line 116 used to bring fluidizing air into the plenum 102 .
[0063] A Foxboro Monitor Model TN-1000 analyzer 118 was used to measure the outlet concentration of methane supply over time to thereby yield the residence time distribution of methane in the reactor 100 . The analyzer 118 had dual detectors, including a flame ionization detector (FID) and a photo-ionization detector (PID), and sampled at a rate of one measurement per second. The FID was used to detect methane. Methane was sampled from the exhaust line 120 , as shown in FIG. 7. Although it was preferred to sample the methane directly above the fluidized bed of catalyst, in such a configuration catalyst fines could not effectively be excluded from the sample line and clogged the filter within the analyzer 118 . Data were collected electronically by the analyzer 118 , and after the experiment was completed, these data were transferred to a personal computer. Sampling lasted between three and four minutes, depending on the gas velocity and the catalyst bed height, until the tracer gas concentration returned to baseline.
[0064] To indicate axial dispersion in reactor 100 the outlet concentration of methane from the reactor 100 was measured as a function of time. In other words, a residence time distribution curve or tracer curve was measured for a pulse of methane. For small deviations from plug flow, where the Peclet number is greater than about 100, the tracer curve is narrow and appears symmetrical and gaussian. For Peclet numbers less than 100, the tracer curve is broad and passes slowly enough that it changes shape and spreads to create a non-symmetrical curve. In all of the methane tracer tests, the residence time distribution curve was spread and non-symmetrical. The spread for variance of these curves were translated into Peclet numbers.
[0065] In order to determine the Peclet number from the measured peak variance and measured mean residence time, a “closed system” model was employed. In such a closed system, it was assumed that the methane gas moved in plug flow before and after the catalyst bed so that gas axial dispersion is due only to the catalyst. For a closed system, the Peclet number is related to variance and mean residence time in the following equation:
σ 2 t _ 2 = 2 ( 1 / Pe ) 2 [ 1 - exp ( - Pe ) ] .
[0066] In this equation, σ 2 is the variance and {overscore (t)} 2 is the square of the mean residence time. Thus, calculation of the Peclet number depends on the calculation of these two parameters. The mean residence time is the center of gravity in time and can be determined from the following equation, where the denominator is the area under the curve:
t _ = ∫ 0 ∞ tC t ∫ 0 ∞ C t .
[0067] The variance tells how spread out in time the curve is, and is determined from the following equation:
σ 2 = ∫ 0 ∞ t 2 C t ∫ 0 ∞ C t - t _ 2 .
[0068] If the data points are numerous and closely spaced, the mean time and variance can be estimated from the following equations:
t _ = ∑ i t i C i Δ t i ∑ i C i Δ t i = ∑ i t i C i ∑ i C i σ 2 = ∑ i t i 2 C i Δ t i ∑ i C i Δ t i - t _ 2 = ∑ i t i 2 C i ∑ i C i - t _ 2 .
[0069] Since the methane is sampled downstream of the fluidized bed, the residence time distribution curve of the methane can include contributions to peak variance and time from volumes which are located downstream of the catalyst bed and upstream of the analyzer 118 . Fortunately, variances and time are additive, as long as the contributions to peak variance and time occurring in one vessel are independent of the other vessels. Thus, the total variance and total mean time is simply the sum of the variances and mean time attributable to the individual volumes and can be expressed as follows:
σ 2 total =σ 2 catalyst +σ 2 expanded section +σ 2 cyclones/tubing +σ 2 sampling
{overscore (t)}
total
={overscore (t)}
catalyst
+{overscore (t)}
expanded section
+{overscore (t)}
cyclones/tubing
+{overscore (t)}
sampling
[0070] Special injection experiments were made to measure the variance and time due to sampling, the expanded section 106 , the volume of the cyclones 110 , 112 , and the volume of the tubing. The results of these experiments could then be subtracted from the total variance and mean time to obtain the values due only to the catalyst.
[0071] Table 6 summarizes the calculated Peclet number results for fluidization tests employing a fine FCC catalyst at different bed heights, with and without perpendicular horizontal baffles (HBs) in the reactor.
TABLE 6 No HBs 5 Perpendicular HBs Bed Ht. Target U o Measured U o Peclet Measured U o Peclet (ft) (ft/s) (ft/s) Number (ft/s) Number 11 0.75 0.86 2.00 0.92 9.50 11 1.00 1.12 2.30 1.16 18.80 11 1.50 1.48 2.30 1.47 11.80 11 1.75 1.74 1.80 1.65 20.70 7 0.75 0.82 11.70 0.90 19.10 7 1.00 1.12 13.90 1.15 22.70 7 1.50 1.47 14.10 1.43 21.10 7 1.75 1.74 12.70 1.71 19.10
[0072] Table 7 summarizes the calculated Peclet number results for fluidization tests employing a coarse FCC catalyst, with and without perpendicular HBs in the reactor.
TABLE 7 No HBs 5 Perpendicular HBs Bed Ht. Target U o Measured U o Peclet Measured U o Peclet (ft) (ft/s) (ft/s) Number (ft/s) Number 11 0.75 0.83 6.9 0.93 8.8 11 1.00 1.18 6.2 1.15 10.0 11 1.50 1.45 6.0 1.49 9.3 11 1.75 1.65 6.0 1.71 10.2
[0073] Table 8 summarizes the properties of the coarse and fine FCC catalysts employed in the tracer tests.
TABLE 8 “Coarse” Property “Fine” Catalyst Catalyst ρ s , g/cm 3 (He displacement) 2.455 2.379 ρ p , g/cm 3 (a) 0.973 1.075 ρ B , g/cm 3 0.805 0.807 Pore Volume, mL/g (Hg 0.62 0.51 intrusion) Al 2 0 3 , wt % (b) 49 49 Moisture (LOI), wt % 31.54 24.09 Davison Index (DI) 7.08 7.74 d sv (c), microns 51 60 0-20 microns, wt % 2.40 0.47 0-40 microns, wt % 26.74 14.44 Particle Size Distribution >212 microns 0 0 212-180 microns 0 0 180-106 microns 4.54 10.04 106-90 microns 5.87 9.52 90-45 microns 53.94 59.48 45-38 microns 12.48 9.14 <38 microns 23.17 11.82 Geldart Classification A A Fluidity Index 5.39 3.88 U mf , cm/s (calculated) 0.08 0.13
[0074] The results provided in Tables 6 and 7 demonstrated that axial dispersion was dramatically reduced (as indicated by the increased Peclet number) when five perpendicular horizontal baffles were added to the reaction section 104 of the fluidized bed reactor 100 .
[0075] Reasonable variations, modifications, and adaptations may be made within the scope of this disclosure and the appended claims without departing from the scope of this invention.
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A method and apparatus for removing sulfur from a hydrocarbon-containing fluid stream wherein desulfurization is enhanced by improving the contacting of the hydrocarbon-containing fluid stream and sulfur-sorbing solid particulates in a fluidized bed reactor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 238,801, filed Feb. 27, 1981, now abandoned which is a continuation-in-part of application Ser. No. 129,489 filed Mar. 10, 1980 and now U.S. Pat. No. 4,279,085 issued July 21, 1981.
BACKGROUND OF THE INVENTION
This invention relates to excavating buckets.
Excavating buckets, such as those used on apparatus commonly known as a backhoe, are usually pivotally attached to a movable dipperstick, with separate actuators arranged to power bucket pivoting and dipperstick movements, respectively. Such buckets often have teeth-like protrusions along a leading edge which loosen and scoop material as the bucket moves through the substrate to be excavated; and may also include a row of ripper teeth attached to the rear of the bucket (i.e., on the side opposite the leading edge) generally parallel to the leading edge and perpendicular to the direction of the motion of the bucket for dislodging and breaking up tightly compacted substrate. Such ripper teeth are usually arranged to operate with the bucket actuator fixed in a fully extended position, and the ripping motion is powered by the dipperstick actuator.
Such ripper teeth have not been entirely satisfactory. They often penetrate too deeply and tend to "stall out" the dipperstick cylinder. Additionally, the material loosened has a tendency to jam the motion of the bucket and cause it to ride over the material and thus reduce ripping penetration; and efficiency of operation is hindered by the need constantly to reposition the bucket to maintain the proper ripper tooth cutting angle.
It is an object of the present invention to maximize ripping effectiveness while at the same time overcoming the above limitations.
SUMMARY OF THE INVENTION
I have discovered that, by providing a plurality of rippers which protrude downwardly from the bottom (either V-shaped or flat) of an excavating bucket and face towards its front edge, the rippers being staggered from the front edge to the back of the bucket at varying distances from the bucket sides, powered movement of the bucket through a substrate will dislodge pieces without generating drag to stall the bucket's movement. The rippers can be permanently fixed to the bucket bottom or can be part of an adapter which itself may be attached to a bucket.
In preferred embodiments the rippers are not aligned with each other either transversely or longitudinally of the bucket, but are spaced front to rear in a V-pattern. The forward edges of the rippers may all lie on a constant radius measured from the axis of pivotal connection of the bucket to the dipperstick (or, as may sometimes be preferred or from a point above or below the axis of pivotal connector), or may lie on an elliptical arc tailing in towards or away from the bucket bottom. The lead ripper may be positioned either on or behind the bucket front edge; the ripper pattern may be such that each ripper fractures material into the grooves cut by the preceding ripper; all rippers are designed to maintain the optimum cutting angle (generally 35°-55° and, preferably, 45°); and for any ripper the clearance between its teeth and the bottom of bucket is greater than in the case of the rippers forward of it.
DESCRIPTION OF THE PREFERRED EMBODIMENT
We turn now to the preferred embodiments of the invention, first briefly describing the drawings.
FIG. 1 is a side elevation of the bucket, partly broken away.
FIG. 2 is a bottom view of the bucket of FIG. 1.
FIG. 3 is a side elevation of a bucket and attachment therefore, showing another embodiment of the invention.
FIGS. 4 and 5 are detailed views of a ripper used in either of the embodiments of FIG. 1 or FIG. 3.
FIG. 6 is a side elevation of the bucket of FIG. 1, showing variations in ripper radius.
FIG. 7 is a side elevation of a V-bottom bucket embodying the invention.
FIGS. 8A and 8B are schematics showing ripper placement.
STRUCTURE
As shown in FIGS. 1 and 2, backhoe bucket 30 is attached to dipperstick 22 with hinge pin 32 and to link member 24 with hinge pin 34. Piston rod 26 connects hydraulic actuator 28 to link member 24, and link 50 connects member 24 and dipperstick 22. Leading or scooping edge 36 of bucket 30 has five forwardly disposed teeth 38, extending from forward-pointing, "V"-shaped cutting plate 40.
Bucket 30 has curved bottom plate 42, connecting two side walls 45 and 49 and forming both the bottom 44 and back 46 of the bucket, and a top plate 48. Seven rippers 52 are attached to bottom plate 42, staggered at regular intervals from bucket scooping edge 36 to the rear of plate 42. The forward six of ripper 52 are arranged in a V-configuration, with the center one of teeth 38 on edge 36 forming the apex of the V, and the rippers 52 at the rear of the V close to the bucket sides. The rear most ripper 52 is not part of the V, but is aligned with center tooth 38. As shown in FIG. 2, no two rippers 52 are aligned with each other, either from side-to-side or from front to back of bucket 30. Also, as shown in FIG. 1, the clearance between each ripper 52 and the bottom 44 of the bucket progressively increases from front to rear of the bucket.
Referring now to FIGS. 4 and 5, each ripper 52 includes a shank 56 fixed to the bucket bottom 44, and a ripper tooth 54 fitted over the end of the shank and held in place by a pin 60.
Each tooth 54 includes relatively inclined upper and lower surfaces, 62, 64 respectively, which set in a point 66 at the front of the tooth. The points 66 of all of rippers 52 are equidistant from the hinge pin 32 about which bucket 30 rotates relative to dipperstick 22, as illustrated by arc A of radius R. As shown, the center one of teeth 38 also lies on arc A. The upper surface 62 of each tooth 54 defines the tooth cutting angle, a, which, for each of rippers 52, is between about 35° and 55° and, preferably, 45°. The lower surface 64 is positioned so that it will not bottom-out in the trench cut by the tooth as the bucket is pivoted about hinge pin 32. The progressively greater clearance (front to rear) between the ripper and bucket bottom 42 is provided by, as shown, a progressive increase in the length of shanks 56.
FIG. 3 shows an alternative embodiment of the invention in which plate 47' is welded or bolted to the bottom digging surface 44' of bucket 30'. Rippers 52' are attached to plate 47' and are identical to the rippers 52 of bucket 30. Depending on the curvature of surface 44' of a particular bucket, the arc corresponding to A may not necessarily have a constant radius; however, the arrangement of progressively longer shanks and staggering of teeth with respect to edge 36 and the bucket sidewalls remains the same.
FIG. 6 illustrates the effect of mounting rippers 52 on a constant radius measured from a point that is above (P 1 ) or below (P 2 ), rather than coincident with, hinge pin 32. As shown, mounting the rippers on a constant radius R 1 , measured from P 1 causes the arc A, on which the teeth 54, lie to tail in towards the bucket bottom 46 so that, as bucket 30 is rolled about hinge pin 32, the rippers pull away from the ground. With rippers so mounted, an operator would drop boom 22 as the bucket is rolled to maintain contact between the rippers and the ground.
Similarly, mounting the rippers on a constant radius R 2 measured from P 2 causes the arc A 2 on which teeth 54 2 lie to tail away from the bucket bottom 44, and the rippers will engage the ground more aggressively as bucket 30 is rolled about hinge pin 32.
FIG. 7 shows a bucket 30" having a V-shaped bottom 44". Rippers 52" are attached to bottom 44" and are identical to the rippers 52 of bucket 30. Viewed from the side, the arc A 3 on which the points 54" of rippers 52" lie elliptical and, like arc A 1 of FIG. 6, tails in towards the bucket bottom. If desired, the rippers may also be positioned so that teeth 54" lie on an elliptical arc A 4 which, like arc A 2 of FIG. 6, tails away from the bucket bottom. Such elliptical arcs may be provided on either V-bottom buckets (as shown) or on flat-bottom buckets such as those shown in FIGS. 1 and 6.
Referring now to FIGS. 2 and 8-B, the center tooth 38 and rippers 52 a -52 f forming the "V" configuration earlier referred to are of such width and are so placed that, as bucket 30 is rolled, successive teeth fracture substrate into the groove cut by preceding teeth and leave a cut having flat continuous bottom.
Teeth such as those provided on the V-bottom bucket of FIG. 7 may similarly be mounted, as shown in FIG. 8-A, so that each trailing tooth fractures substrate into the groove cut by a preceeding tooth and the teeth forming the "V" configuration (as shown the center leading edge tooth 38" and six following rippers 52") makes cuts extending substantially continuously the bucket width.
Operation
Actuator 28 (the bucket cylinder) pivots the bucket about hinge pin 32 (the bucket's axis of attachment to dipperstick 22) causing the bucket to scoop loose substate with the scooping edge and teeth and to rip compact substrate with the rippers 52. It is also possible to rip by moving dipperstick 22, but much greater force is generally available from extending the bucket cylinder.
Because rippers 52 are not transversely aligned, they sequentially engage the substrate, permitting each tooth to provide the maximum digging force. The side-to-side staggering of the rippers prevents rocks, frozen earth, etc. from being trapped between adjacent teeth, and the progressively increasing clearance between the rippers and the bucket bottom provides room for material loosened by forward teeth to pass between more rearward teeth and the bucket bottom without forcing the bucket up off the substrate which would disengage the more rearward teeth. The preferred "V" configuration (front-to-rear) ripper pattern allows a trailing tooth to fracture the substrate into the groove already cut by a preceding tooth. As shown in FIGS. 2, 7 and 8-A and 8-B, the center lead tooth 38, 38" in the "V" makes the initial cut, ripper 52 a , 52" a fractures material from one side into the groove cut by tooth 38, 38", ripper 52 b , 52" b , fractures material from the other side into the groove cut by tooth 38, 38" ripper 52 c , 52" c fractures material from the first side into the groove cut by tooth 52 a , 52" a and so forth. The width and placement of the center tooth 38 and the rippers 52 are such that, as shown in FIGS. 8-A and 8-B, the successive grooves they cut will essentially abut and span the entire bucket width. As the bucket 30 is pivoted about hinge pin 32, each tooth cuts at the optimum cutting angle, without requiring adjustment or change in the position of the dipperstick.
The sequential ripping of teeth 54 is at controlled depths, and since all teeth are on a constant radius from the pivot point, the flat bottom buckets of FIGS. 1, 2 and 6 cut a flat-bottom trench automatically.
Other Embodiments
In other embodiments the rippers can be arranged in staggered patterns, i.e., patterns in which they do not align transversely or longitudinally, other than the front-to-rear "V"; the rippers may be bolted in place; the front edge of the bucket can be straight rather than "V" shaped; the teeth on the front edge can have other configurations such as flat or bifuracted; or, the front edge may be straight cutting edge and the leading ripper may lie behind the front edge and be mounted on the bucket bottom.
In still further embodiments, as noted with respect to FIG. 3, the radius on which the teeth are mounted may increase or decrease from front to rear of the bucket rather than remaining constant.
These and other embodiments will be within the scope of the following claims.
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An excavating device having a plurality of gouging members protruding downwardly from the bottom of an excavating bucket, and extending therefrom in the direction toward the bucket's scooping edge, the members being staggered at varying distances from the edge and bucket sides.
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BACKGROUND OF THE INVENTION
This invention relates to overload relays and overload protective systems and in particular to electronic overload relays and systems. Presently available thermal overload relays utilize special materials in the heater and detector elements, and require individual adjustment during manufacture to calibrate the device. Each of these factors increase the cost of the present thermal overload relay. A need exists for a low cost overload relay, particularly such a relay that may be conventionally wired to an electromagnetic contactor to provide a motor starter. Electronic overload relays and systems are generally less expensive than the thermal counterparts if power for the relay can be either derived from the motor current or separately supplied in an economical manner.
SUMMARY OF THE INVENTION
This invention provides a low cost electronic overload relay having a power supply in series with the normally closed contact of the overload relay. The power supply is an integral element of the electronic overload relay of this invention. The relay is connectable to an electromagnetic contactor in keeping with conventions of thermal overload relays wherein the contactor coil is connected in series with the normally closed contact of the relay, and therefore also in series with the power supply to provide power for the overload relay when power is supplied to the contactor coil. A processor in the electronic overload relay is instructed to assume a sleep (extremely low power consumption) mode during the closing of the contactor. A semiconductor switch in the power supply is operated by the processor in low voltage coil applications to directly connect the coil of the contactor in shunt of the power supply for the relay while the contactor closes. These and other features and advantages of this invention will become more readily apparent in the following description and claims when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole FIGURE of the drawing is a wiring diagram of the control powered overload relay of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing, a motor 2 is connected to a source of electrical power such as three phase AC source 4 through conductors 6, 8 and 10 by a contactor 12 having contacts 12a, 12b and 12c connected in the conductors 6, 8 and 10, respectively, and a coil 12d. An overload relay 14 is associated with contactor 12 to provide a starter control for motor 2.
Overload relay 14 comprises current transformers CT1, CT2, and CT3 respectively associated with the conductors 6, 8 and 10 to monitor current flowing therethrough and to send representative analog signals of the current levels to a processor 16 as digital signals by means of an analog-to-digital (a/d) converter 18. The processor 16 processes the digitized signals from the current transformers to provide overload protection for motor 2 in a manner which is well known in the art. Processor 16 controls a normally closed contact 16a to open that contact in the event predetermined current/time characteristics in the motor circuit are exceeded.
Overload relay 14 is connected in a control circuit for contactor 12 such that the normally closed contact 16a is connected in series with coil 12d. Power for the control circuit may be supplied by a separate electrical power source such as a separate AC supply or, as shown in the drawings, may be a two phase supply taken from three phase supply 4 by connecting conductors 22 and 24 to conductors 6 and 8, respectively. A control module 20 for contactor coil 12d is connected in the control circuit via conductor 22. Overload relay 14 has terminals 26 and 28 which internally connect to opposite sides of normally closed contact 16a for connecting that contact in a control circuit for the coil 12d in the conventional manner that a normally closed contact of a thermal overload relay would be connected. Processor 16 is one of a family of processors available from Motorola Semiconductor Products, Inc., such as Motorola Catalog No. 68HC05P6.
Electronic overload relay processors require low voltage electric power. If a separate source of low voltage electrical power is provided, additional wires are required to bring the power from the source to the overload relay and additional terminals are necessary on the overload relay 14 for connection of such wires. The separate power supply, additional wire, terminals and labor represent additional cost and diversion from conventional wiring methods used to connect thermal overload relays in contactor circuits. If power for the processor is taken from the control circuit for the coil, such power may become diverted from the contactor coil 12d during closure of the contactor, reducing the closing power for the contactor and its sealing capability.
The overload relay of this invention provides its own zener diode shunt power supply in series with the normally closed contact 16a. Wiring terminals 26 and 28 are provided on the relay preferably on the housing (not shown) at opposite sides of the normally closed contact and the zener power supply for purposes of connecting the normally closed contact 16a in the contactor coil control circuit. The power supply comprises a zener diode Z1 in series with the normally closed contact 16a and coil 12d or other suitable load. The anode of a diode D1 is connected to the cathode of zener diode Z1. The cathode of diode D1 is connected to the positive terminal of a capacitor C1. C1 is referenced to the anode of zener diode Z1 and is connected to terminal 28. Opposite sides of capacitor C1 are connected to the processor 16 by conductors 30 and 32. A low voltage sensing integrated circuit 34 such as a Motorola MC34164 is connected to processor 16 in parallel with conductor 30, the output of circuit 34 being connected to a voltage indicator input of the processor. A pull-up resistor R1 is connected between conductor 30 and the conductor connecting circuit 34 to the voltage indicator input of processor 16.
A command from control module 20 for contactor 12 to close energizes coil 12d through normally closed contact 16a and the zener power supply. Zener diode Z1 is a 5.6 volt device which limits the charge on capacitor C1 to approximately 5 volts. When the voltage at capacitor C1 reaches approximately 3 volts, processor 16 turns on. Low voltage sensing circuit 34 is a voltage monitor having a threshold of 4.65 volts. If this threshold is not crossed, then either an extremely low voltage is present, or coil 12d is a high voltage, high impedance coil. Once the processor 16 is powered from the charged capacitor C1, it is programmed to immediately enter into a low power consumption "sleep" mode for several cycles so that the power to contactor coil 12d is not reduced during contactor closing. If no signal is present at the voltage indicator input of processor 16 indicating that the threshold voltage of low voltage sensing circuit 34 has not been crossed, then coil 12d is a high voltage coil and the relatively small amount of power diverted from the coil circuit for running processor 16 in a sleep mode is a negligible percentage of the power to coil 12d. Conversely, if a signal is present at the voltage indicator input of processor 16, then capacitor C1 has charged to a value exceeding 4.65 volts within a given time interval, indicating that coil 12d is a low voltage coil.
It is important that no power be diverted from a low voltage coil during closure of contactor 12. To this end, a semiconductor switch such as N-channel FET Q1 is connected in parallel with zener diode Z1. FET Q1 is turned on by processor 16 at power-up if a signal is present at the voltage indicator input, thereby to shunt zener diode Z1. Conduction of FET Q1 directly connects coil 12d across the control circuit power through normally closed contact 16a. Diode D1 blocks current flow from capacitor C1 through the conducting FET Q1 to prevent discharge of capacitor C1 through FET Q1, thereby maintaining power to processor 16. Once the contactor 12 has operated and the armature thereof is sealed, power can again be taken from the coil circuit to power processor 16 without penalty to the contactor coil. Accordingly, after a prescribed time interval or number of cycles, processor 16 is instructed to exit the "sleep" mode and to resume its normal operating mode whereupon FET Q1 is turned off. If an overload or other disturbance is sensed on the lines 6, 8 and/or 10 by the current transformers CT1, CT2 or CT3, the processor will operate to open normally closed contact 16a in the control circuit to coil 12d, thereby de-energizing the coil 12d and opening the contacts 12a, 12b and 12c of contactor 12 to disconnect motor 2 from electric power supply 4.
Although the foregoing has described particular embodiments of the invention in detail, it is to be understood that the invention is susceptible of various modifications without departing from the scope of the appended claims.
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An electronic overload relay has an intrinsic power supply connected in parallel with the NC contact of the relay between wire attachment terminals. The power supply is a parallel connected zener diode and capacitor, connected to the processor in parallel with a low voltage sensing circuit that detects the charge on the capacitor, whereby the processor operates to turn on a unijunction transistor for low voltage coil applications to shunt the power supply during contactor closing and turn off a predetermined interval later by which time the contactor should have closed.
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FIELD OF APPLICATION OF THE INVENTION
This invention relates to the field of roofing elements such as those used in low swimming pool shelters and in particular to the adaptations making it possible to improve the transparency and reduce the weight thereof.
DESCRIPTION OF THE PRIOR ART
The roofing elements can be those proposed in document FR 2776000, which describes a swimming pool roofing element structure of the type composed of a cover formed by panels made of a translucent material such as double-wall polycarbonate and a rigid, lightweight and resistant reinforcement for supporting the transparent cover, which reinforcement is formed by arcs arranged in transverse planes and spaced apart by cross-members with two outermost lateral cross-members delimiting two edges of the roofing element. These two lateral edges rest on the longitudinal edges of the basin defining a contact surface with said roofing elements.
These roofing elements have the disadvantage of using double-wall alveolar polycarbonate for the translucent panel.
This alveolar polycarbonate is expensive and does not provide the best possible transparency since it is formed by at least two sheets connected to one another by partitions.
Moreover, the thickness of such an alveolar material defines a bulk that must be dealt with when transporting said panels.
The prior art discloses more transparent, non-alveolar materials, but their use presents other problems, for example:
a sheet of solid material of lower thickness is too flexible, a sheet of solid material with the same rigidity as the alveolar material is too heavy.
Another problem encountered in the exterior use of large panels of a solid material sheet involves the variation of the dimensions to which it can be subjected due to the variation in temperatures.
DESCRIPTION OF THE INVENTION
On the basis of the above, the applicant has conducted research to find an alternative to the use of alveolar panels in roofing elements.
This research has resulted in a technical solution making it possible to use panels of more flexible material with a lower thickness, overcoming the disadvantages mentioned above.
According to the main feature of the invention, the roofing element of the type consisting of a panel of material held inside of a frame is remarkable in that it is composed of a panel made of a single-wall solid material and at least one tensioning means linked to the frame tending to separate certain parts constituting the frame so as to apply tension to said panel,
the frame is composed of two transverse profiles attached to two opposite sides of the panel, with the tensioning means tending to separate said profiles,
the edges of the panel subjected to a pulling force and slid into the profiles are equipped with at least one projection facilitating the transmission of this force, with the profile being itself preformed in order to retain this projection in the direction of the pulling force.
This feature is particularly advantageous in that it makes it possible to use a single-wall panel in spite of its lack of rigidity. It is thus possible to use any material capable of being placed in a frame and capable of supporting the pulling force to which it will be subjected. The tensioning of the panel makes it possible to prevent it from collapsing in the event of dilation due to climatic conditions.
This feature therefore ensures a panel that perfectly matches the general shape of the frame in spite of its flexibility.
This feature is possible whether the panel is transparent or not. Indeed, the feature allows the use of perfectly transparent single-wall non-alveolar panels. The transparency of the material used for the panel makes it possible to see through and offers the possibility of seeing inside the basin protected by the roofing, which is particularly secure. This security functionality could not be implemented in the panels of the prior art, which were alveolar and which could not be considered to be translucent.
The use of a single-wall panel reduces the weight of the structure and requires less bulk for storage or transport.
Thus a special feature of the invention is the association, with the frame or with the reinforcement supporting the flexible and transparent panel, tensioning means tending to separate certain parts forming the frame in order to maintain the tension of said panel.
According to another particularly advantageous feature of the invention, this roofing element consists of two transverse profiles attached to two opposite sides of the panel and connected to one another by cross-members of which at least one comprises tensioning means tending to separate said profiles. The tensioning can be performed for each element ensuring the connection between the two profiles, i.e. for each cross-member.
In the case of a low swimming pool shelter, the profiles into which the panels slide are conventionally arched and form arcs of which each end rests on the edge of the basin. In addition, the two outermost lateral cross-members, which delimit two edges of the roofing element and which rest on the longitudinal edges of the basin, define a contact surface with said roofing elements.
To transmit and control the pulling force, the edges of the panel subjected to a pulling force, slid into the profiles, are equipped with at least one projection facilitating the transmission of this force. The profile is itself preformed to retain said projection in the direction of the pulling force.
These tensioning means can be implemented in a plurality of embodiments.
A first embodiment proposes that at least one end of a cross-member slide transversely with respect to the profile and comprise at least one tensioning means composed of a casing housing a spring that comes into contact with said profile, thus tending to separate the cross-member from the profile.
A second embodiment proposes that the cross-member equipped with tensioning means consist of two parts capable of being moved one with respect to the other and connected to one another by a sliding connection controlled by a spring.
According to a preferred technological choice, the material of the single-wall panel is polycarbonate.
The fundamental concepts of the invention having been described above in their most basic form, other details and features will become clearer on reading the following description and in view of the appended drawings, provided for non-limiting purposes, of an embodiment of a roofing element according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic drawing of a perspective view of an embodiment of a low swimming pool shelter composed of roofing elements according to the invention,
FIG. 2 is a diagrammatic drawing of a partial cross-section view of a roofing element using a first embodiment of the tensioning means,
FIG. 2 a is a diagrammatic drawing of a cross-section of a detail of said tensioning means,
FIG. 3 is a diagrammatic drawing of a partial cross-section view of a roofing element using a second embodiment of the tensioning means.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawing of FIG. 1 shows an embodiment of a low swimming pool shelter referenced A in its entirety ensuring the coverage of a basin referenced B. This low shelter includes a plurality of roofing elements E.
Each roofing element E is composed of a panel of material 100 held inside a frame 200 . This frame 200 is composed of two transverse arched profiles 210 and 220 connected to one another by the panel 100 and by cross-members 230 arranged under the panel 100 . Two outermost lateral cross-members 231 and 232 delimit two edges of the roofing element E. These two lateral edges rest on the longitudinal edges of the basin B defining a contact surface with said roofing elements E.
The edges of the panel 100 slide into the arched profiles 210 and 220 of the frame 200 and cause the panel 100 to adopt the curvature of said profiles. The cross-members ensure the spacing of said profiles in order to ensure the rigidity thereof.
According to the invention, the roofing element E includes a panel 100 made of a single-wall solid material and tensioning means connected to the frame tending to apply tension to said panel 100 , which is flexible due to its thickness and size.
According to a preferred embodiment and according to the invention, the material used is transparent. According to a preferred technological choice, this material is transparent polycarbonate. This polycarbonate is associated with an aluminium frame. The polycarbonate is in the form of a sheet with a thickness of between 1.4 and 2 millimetres, which enables the deformation of its edges, and which provides flexibility enabling it to follow the curvature of the transverse arcs, but which causes a longitudinal bending that must be solved by tensioning means.
According to the invention, at least one cross-member 230 comprises tensioning means tending to separate said profiles 210 and 220 , which hold the edges of the panel 100 , and therefore tension said panel 100 .
According to the embodiment shown in the drawings of FIGS. 2 and 3 , the edges of the panel 100 according to the arrows F 1 subjected to a pulling force are equipped with at least one projection facilitating the transmission of this force. More specifically, each panel edge is preformed in order to have a C-shaped edge, which is positioned in the profile 210 and 220 so that its branches come from each side of a lug 211 and 221 provided for this purpose in the profiles 210 and 220 . Thus, once the panel 100 has slid into the profiles, said panel 100 cannot be released from said profiles 210 and 220 in a longitudinal translation movement, i.e. in the direction of the pulling force. The cooperation between this return 110 and the lugs 210 and 220 provided inside the profiles 100 ensures successful transmission of the pulling force exerted by the tensioning means 300 .
According to the embodiment shown in the drawing of FIG. 2 , at least one end of a cross-member 230 slides transversely according to the double arrow F 2 with respect to one of the profiles 210 and comprises at least one tensioning means 300 composed of a casing 310 housing a spring 320 , which comes into contact with said profile 210 , thus tending to separate the cross-member 230 from the profile 210 .
More specifically, and according to the invention, said casing 310 adopts the shape of a cylindrical tube, which is attached to the cross-member 230 and at a first end of which a stop 311 is provided, with which the spring 320 comes into contact, and the other end of which is open to enable the spring 320 to come into contact with said profile. According to a particularly advantageous feature, the position of the stop 311 can be adjusted inside the casing 310 so as to ensure the adjustment of the force exerted by the spring. According to a preferred embodiment, said stop 311 is threaded and is connected in a screw-type manner to the casing 310 so as to move axially inside it. The end of the spring 320 that comes into contact with the profile 210 or 220 is associated with a stop 321 .
According to a preferred embodiment, each cross-member includes means for tensioning the frame. According to a preferred technological choice, the two outermost lateral cross-members 231 and 232 forming edges are equipped with tensioning means 300 and the cross-members 230 between the two outermost cross-members are equipped with two tensioning means 300 .
An embodiment of the attachment of the two tensioning means at the end of a cross-member 230 is shown in the drawing of FIG. 2 a . In this embodiment, two tubular casings 210 a and 310 b are arranged on each side of the cross-member 230 by being associated with a profile 312 internally including the external profile of the cross-member 230 for its positioning and attachment to the latter. According to a preferred embodiment, the cross-members 230 have a rectangular profile and are slidingly connected at a first end and stationarily connected at the other end to the transverse profiles 210 and 220 , by means of T-shaped parts 400 provided for this purpose.
According to another embodiment shown in the drawing of FIG. 3 , the cross-member 230 equipped with tensioning means 300 consists of two parts 231 and 232 capable of moving according to the double arrow F 2 , one with respect to the other, and connected to one another by a sliding connection controlled by a spring forming the tensioning means 300 .
The two ends of the cross-member are then stationarily connected to the transverse profiles 210 and 220 .
More specifically, said tensioning means 300 consist of a female element 330 associated with a first part 232 of a cross-member 230 cooperating with a male element 340 associated with a second part 231 of the cross-member 230 .
It is understood that the roofing element has been described and shown above for the purpose of disclosure rather than as a limitation. Of course, various arrangements, modifications and improvements can be made to the example above without going beyond the scope of the invention.
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The invention concerns a roofing element (E) of the type of the one consisting of a material board ( 100 ) maintained inside a frame ( 200 ), characterized in that it consists of a single-walled solid material board and of at least one tensioning means ( 300 ) linked to the frame ( 200 ) tending to space apart certain parts constituting the frame ( 200 ) so as to stress said board ( 100 ), the frame consisting of two transverse profiled sections ( 210 and 220 ) fixed to two opposite sides of the board ( 100 ), the tensioning means ( 300 ) tending to space apart said profiled sections ( 210 and 220 ), the edges of the board ( 100 ) subjected to a tensile stress and slid into the profiled sections being provided with at least one projection ( 110 ) facilitating the transmission of said stress, the profiled section being itself preformed to retain said projection in the direction of the tensile stress. The invention is applicable to swimming pool low shelter, veranda and the like.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of and claims the benefit of priority under 35 USC 120 from U.S. application Ser. No. 11/854,904, filed Sept. 13, 2007, now U.S. Pat. No. 7,886,320, which is a continuation of 09/645,277, filed Aug 24, 2000, now U.S. Pat. No. 7,308,698, the entire contents of which are incorporated herein by reference. This application also claims the benefit of priority of 35 USC §119 from European patent Application No. 99306779.2, filed Aug. 26, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a television display device and a method of operating a television system, more particularly to a television display device and system using a television display for displaying television services and an input unit for providing at least one command.
2. Description of the Related Art
It is well known to receive television services and display these on a television display. Devices for receiving broadcast information and producing appropriate display information may be provided integrally with a television display or as a separate unit. In this regard, it is known to display digital television services by means of a Set Top Box in conjunction with a television display.
With the increased number of television services available, together with many other functional devices available throughout the home, users are presented with a large number of control functions. There is a problem that, with this large number of control functions, users become confused and cannot take advantage of all of the functions.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide systems whereby enhanced control can be achieved, whilst providing a more straightforward interface with the user.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method of operating a receiver for receiving electronic information, the method including:
storing a plurality of alarms;
selecting an event and associating an alarm with said event;
selecting an action and associating said alarm with said action;
detecting an occurrence of said event;
upon detecting an occurrence of said event, actuating said selected alarm; and
initiating said action conditional on whether or not a control command is received.
According to the present invention, there is also provided a reception device for receiving electronic information, the device including:
a memory for storing a plurality of alarms;
an event selector for selecting an event and associating said event with a selected one of the plurality of alarms;
an action selector for selecting an action and associating said action with the selected alarm;
a detection section for detecting said event and, in response, actuating the selected alarm; and
a command section for initiating said action conditional on whether or not a control command is provided to the device when the alarm is actuated.
The reception device can be any suitable audio/visual device such as a radio, telephone, television, internet receiver, etc and the alarm can take any form such as a sound or an image. Events can include timer events, internal functions or events signified by the received electronic information.
By allowing a user to select an alarm for a particular event, the user can select an alarm which he or she feels is most appropriate. In this way, when the alarm is activated, the event will be immediately recognized.
By associating an action with an alarm, it is not necessary for the user to consider taking all of the necessary steps for that particular action. The action has been pre-associated with the alarm, such that a simple command from the user will cause that preselected action to take place.
According to the present invention, there is provided a method of operating a television system having a television service receiver, a television display for displaying television services and an input unit, the method including storing a plurality of control images;
selecting an event and associating a control image with said event;
selecting an action and associating said control image with said action;
detecting an occurrence of said event;
upon detecting an occurrence of said event, displaying for a predetermined period said control image on a portion of the television display superposed on the television service being viewed; and
initiating said action conditional on whether or not a control command is received by the television system from the user within said predetermined period.
According to the present invention, there is also provided a television display device for use with a television display for displaying television services and an input unit for providing at least one command to the television display device, the television display device including:
a memory for storing a plurality of control images;
an event selector for selecting an event and associating said event with a selected one of the plurality of control images;
an action selector for selecting an action and associating said action with the selected control image;
a display section for detecting said event and, in response, producing display information for displaying for a predetermined period the selected control image on a portion of the television display superposed on the television service being viewed; and
a command section for initiating said action conditional on whether or not a control command is provided by the input unit within said predetermined period.
In this way, a user may be warned of a pre-selected event by the appearance of a control image on the television display during the reproduction of some television service. The user might select the start of a particular television program as the event, such that, whilst watching some other television program, the appearance of the control image will warn the user that the selected television program is about to start.
By means of the invention also, the event and control image may be associated with a particular action. In this way, the user can select actions such as “change channel” or “start video recorder” so that, upon seeing the control image and depressing a single control button, the system will automatically change to the appropriate television channel or automatically start the video recorder.
By means of the present invention, the user is automatically alerted to an event and is provided with a very simple means, e.g. a single button, by which any pre-selected action may be initiated.
Preferably, a plurality of control images may be selected and associated with a plurality of respective events and actions.
In this way, the user may select a variety of different control images signifying various events, such as various television programs for viewing. Each control image and event may also have its own associated action and all actions may be initiated by means of the same single control button.
A control image need not always be associated with an action. In this case, in response to a particular event, the respective control image will merely be displayed for a predetermined period.
Hence, the control image may merely provide a warning to the user, for instance indicating that a telephone call should be made, but not requiring any automatic action within the system.
Events can include one or more of start of a pre-selected television service, start of a pre-selected category of television service, start of a desired portion of a television service, a system failure and a pre-selected time. Similarly, actions can include one or more of changing the television service being displayed, starting a video recorder and powering down the television display.
The selected action can be initiated automatically when no control command is provided within the predetermined period or, alternatively, only when the control command is provided within the predetermined period. Preferably, this is selectable by the user according to the nature of the event and the required action.
Each control image may include position data such that the display section positions the control image on the television display according to that position data. In this way, the control image may be positioned on the television display at a position appropriate for the image. For instance, an image of an aeroplane signifying the start of a travel program might be positioned at the top of the television display, whereas the image of a car, signifying a motoring program, might be positioned at the bottom of the television display.
Control images may be animated. Hence, the display section can sequentially display the individual images making up the animated control image. Furthermore, the position data may move between sequential images, such that the animated image moves across the television display.
The television display device may be for use with a broadcast stream containing a stream of key files including data representing representative key images, the television display device further including:
a memory for maintaining continuously in memory at least one of said key files; wherein
the display section, when displaying the selected control image, simultaneously displays the key image of one of the data files currently stored superposed on the television service being viewed;
the command section executes the content of the key file of the displayed respective key image conditional on a key command being provided by the input unit within said predetermined period.
In this regard, the present application also provides a television display device for use with a television display for displaying television services, an input unit for providing at least one command to the television display device and a broadcast stream containing a stream of key files including data representing respective key images, the television display device including:
a memory for maintaining continuously in memory at least one of the key files;
a display section for displaying, on occurrence of any of a number of preselected events, the key image of one of the key files currently stored superposed on the television service being viewed; and
a command section for executing the content of the key file of the displayed respective key image conditional on a key command being provided by the input unit within a predetermined period.
Similarly the present application provides a method of operating a television system having a television service receiver, a television display for displaying television services and an input control, the television services including a broadcast stream containing a stream of key files including data representing respective key images, the method including:
maintaining continuously in memory at least one of the key files;
displaying, on occurrence of any of a number of preselected events, the key image of one of the key files currently stored superposed on the television service being viewed; and
executing the content of the key file of the displayed respective key image conditional on a key command being provided by the input unit within a predetermined period.
In this way, key images may be provided superposed on the television display indicating access to some further data and that data, whatever it is, may be accessed by the user operating a single command button. The key image may be an advertiser's logo, such that operating the command button will give access to the full television advertisement.
By associating a key image with a control image, an advertisement will be made available on the television display whenever a control image appears on the display to signify a particular event. Where the events are indicated by signals provided by the service provider, funding for providing the signals will be provided by the associated advertising.
Preferably, each control image includes information for determining the position of an associated key image such that the display section positions the key image on the television display according to that information.
In this way, the control and key images are automatically arranged to interact with one another appropriately on the television display. For instance, with a control image as an aeroplane, the key image could be positioned behind the aeroplane so as to appear as a banner being dragged by the aeroplane.
Preferably, the control image specifies a locator position within the key image such that the display section positions the key image by positioning the locator position on the television display according to the information from the control image.
In this way, where a control image is intended to connect with a key image at the top of the key image, then the display section identifies a locator position at the top of the key image and then positions the key image according to this top locator position.
Preferably, the key image is an animated image and the display section reproduces the animated image.
The key image may include animation data relating to its animation and the display section can allow negotiation between a key image and the control image with which it is to be displayed so as to ensure that their animation characteristics conform.
In this way, where the relative animation characteristics, such as frame rate or cycle time, are important to the overall appearance of the key and control images, the key and control images may negotiate variations to their characteristics to ensure that they are in conformity.
Preferably, after a key file from the memory has been executed by the command section, another key file from the broadcast stream is stored. In this way, a different key file will be available next time an event occurs requiring the display of a key image. This is particularly useful where a selection of advertisements are to be displayed.
Preferably, the television display device is DVB-MHP compliant and may be embodied in a television Set Top Box or in an integrated television system including a television display.
Using a DVB-MHP compliant device allows the functions of the television display device to be implemented in Java on an MHP API.
In this way, a system can easily be adapted to operate the present invention, merely by downloading the appropriate functions as Java applications.
According to the present invention, there is also provided a broadcast system including a carousel of key files for use with the display device.
There is also provided code components that, when loaded on a DVB-MHP compliant device and executed will cause that device to operate as described above.
There is also provided code components that define one or more control images as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a system which can embody the present invention;
FIG. 2 illustrates a control image on a display;
FIG. 3 illustrates selection of a program on an EPG;
FIG. 4 illustrates selection of a control image on a display;
FIG. 5 illustrates selection of a control image for a particular time on a display;
FIG. 6 illustrates a key image in conjunction with a control image; and
FIGS. 7 to 13 illustrate UML diagrams of various objects which may embody the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be more clearly understood from the following description, given by way of example only, with reference to the accompanying drawings.
The present invention may be embodied in an integrated television system in which the television display and all of the various functional units are provided in a single housing. It may also be embodied in a system in which functional components are distributed between different units. However, in the embodiment, illustrated in FIG. 1 , the present invention is embodied in a Set Top Box 2 for use with a television display 4 . Control is provided by means of a input unit 6 which is preferably a remote control hand set.
As illustrated, the Set Top Box 2 includes a tuner 8 for receiving an RF signal and converting it to a digital bit stream. The present invention may be used with RF signals received by any means, such as terrestrial, cable and satellite. The nature of the tuner 8 will be dependent on the RF signal that needs to be received and, typically, a different component is required for each transmission technology. The digital information stream coming from the tuner 8 is passed to a demultiplexer 12 which splits the different wanted and unwanted components. The required audio and video components are passed to the AV decoder 14 which takes the relevant MPEG comprised AV bit streams from the demultiplexer 12 and decompresses them to (higher bandwidth) TV signals. Finally, the TV encoder 16 produces a signal appropriate for reception by a traditional interlaced TV or monitor.
A controller or CPU 18 is provided to control the tuner 10 , demultiplexer 12 , A/V MPEG decoder 14 and TV encoder 16 . Furthermore, operating together with the TV encoder 16 at least, it forms a display section and command section allowing signals to be inserted into the TV signals in order that images may be superposed on the received TV images. In particular, the TV encoder 16 may receive the raw decoded video information from the A/V decoder 14 , together with additional audio and video information from the controller 18 and blend the incoming signals together.
The controller 18 is preferably composed of a CPU, RAM and a Java DVB-MIS' VM (DVB Multimedia Home Platform Virtual Machine). The Java DVB-MHP VM represents an abstraction layer to the hardware and allows a program that is created on a Java compliant machine to be executed on Set Top Boxes of different makes.
The illustrated Set Top Box also includes a persistent or back-up memory 20 . In most cases, this will be a flash memory, a kind of semiconductor memory which can be programmed and which will retain its contents even if the Set Top Box is not supplied with any power. Other kinds of persistent memory may be RAM with battery back-up or a hard disk drive. This memory merely provides a back-up of any data entered into the system.
The control 18 is connected to a remote control interface 22 for interfacing with the input unit 6 and for receiving control commands therefrom.
In the illustrated embodiment, an i-Link interface 24 is provided. This is a high speed bus which is sometimes also referred to as IEEE 1394 or FireWire (Apple). It may be used to interconnect peripheral devices, such as other video/audio or computer devices.
A modem 26 may also be provided in order to link the controller 18 to a network, such as the Internet. This allows the Set Top Box 2 to receive information other than in the broadcast stream. Furthermore, it provides the Set Top Box with a return channel allowing, for instance, voting and collaborative game applications.
During normal use of the Set Top Box 2 , a selected television service, such as a particular television program, is displayed on the television display 4 . In order that the user may be alerted to a particular event, it is now proposed that a control image is displayed on the television display superposed on the television service currently being viewed. This is illustrated in FIG. 2 .
To produce the control image, the controller 18 provides the appropriate display information to the TV encoder 16 such that the control image appears on the television display 4 .
The control image only appears for a short predetermined period, for instance of the order of 3 seconds. The control image may be a static image at one position on the television display. However, preferably, the control image is able to move around the area of the display and, preferably, the control image itself may be animated. Furthermore, the control “image” may actually include two or more images at different positions on the display. The control image may also be accompanied by sounds.
By providing a number of control images, a user can select one of the images which, in his or her view, best indicates an associated event. Thus, having selected a particular control image, when that control image appears on the television display 4 , the user is reminded of the event for which he or she selected that control image. All of the various control images may be stored as control images files in the memory 20 .
Control images should be large enough to be recognized immediately, but small enough not to disturb the normal program or television service. They are chosen by the user so as to have some meaning to the user so that, when a particular control image appears on the television display, it has a definite meaning to that user.
Preferably, the selection of control images can be changed. A user may acquire and/or download additional or different control images. Alternatively, the system might allow the user to create new control images. Hence, in this way, users are able to have control images which best indicate to them the associated event.
In order to provide greater interest, the control images may, as mentioned above, be animated and move about the display 4 . For instance, an image of a train may move across the bottom of the display, whereas an image of a ball may bounce across the bottom of the display. Thus, the control image files include position information, which may be related to animation data, which the controller 18 uses to provide appropriate information to the TV encoder 16 so as to show the image moving over the television display 4 appropriately. The control images may also be associated with sounds appropriate for their images, i.e. the sounds of a train or a ball bouncing for the examples given above.
The control images can be associated with any desired event detectable by the controller 18 . Hence, the control unit 18 might detect a preselected event indicated by a signal in the broadcast stream, over the i-Link or from the modem.
Control image may be activated by any event that can be detected by the Set Top Box. Valid events include:
1) button presses on the remote control,
2) service information events, i.e. events that are described in the DVB-SI tables, e.g. the start or ending of a program,
3) stream events as described by DVB, e.g. a change in the score over football game on another channel,
4) time events;
5) system events, e.g. warnings or failure messages like “VCR end of tape” or “i-Link communication problem”.
According to established standards, such as DVB, television broadcast services include data indicating certain information, for instance the start times, of television programs. Furthermore, it is possible to display on the television display 4 an electronic program guide or EPG. This is illustrated in FIG. 3 .
Having selected a particular program, starting at a particular time on a particular day on a particular channel, it is then possible to assign a control image to the event of that program starting. Preferably, having chosen a particular program and as illustrated in FIG. 4 , the user is presented with a window in which he or she can scroll through the various control images stored in the memory 20 . Having assigned a particular control image, at the start of the selected program, the controller 18 will cause that control image to be displayed on the television display 4 . In this way, the user will be reminded of the start of the selected program.
Apart from individually assigning a control image to a particular television program, standards exist whereby programs are categorized, for instance sport, gardening, films. Therefore, a user can assign a control image an action to a particular category of television program. Similarly, it is also possible for the system itself to build up a profile of a viewer's habits, such that it produces a control image based on the type of programs in which the viewer has previously shown interest.
It may be that the user only requires a reminder. In this respect, the event may merely be a time. For example, as illustrated by FIG. 5 , the user may select a particular time at which he or she is expected to make a telephone call. This might be signified by a control image showing a telephone.
According to the present invention, however, the system also allows an action to be initiated.
Having selected a control image for association with a particular event, the system allows the user to select an associated action. In this way, appearance of a control image not only signifies a preselected event, but also signifies an action which the user might wish to initiate upon occurrence of that event. So that the user does not have to carry out the action, a single predetermined control button is provided on the input unit 6 for initiating such actions. Thus, during the predetermined period in which the control image is displayed on the television display 4 so as to signify a particular event, operation of the control button on the input unit 6 will cause the associated action to be initiated. A record of what action is associated with what event is stored by the controller 18 and memory 20 such that the user need only consider using a single control button.
Upon seeing a particular control image, the user will know that the pre-associated action will be initiated automatically upon depressing the control button of the input unit 6 . The associated actions may be anything under the control of the controller 18 . Thus, the control 18 could change the channel being viewed on the television display 4 , could operate a video recorder or such like or could transmit signals via the modem 26 . By way of example, having set an event as the start of a particular television program, the action could be to change channels to the appropriate channel for that program or to start operation of a video recorder to record that program.
It is envisaged that usually the action will not be taken unless the control button of the input unit 6 is depressed during the predetermined period in which the control image is displayed. However, it is also possible to arrange actions such that they will take place automatically unless the control button of the input unit 6 is depressed during the predetermined period in which the control image is displayed.
The control image should appear for long enough to get the attention of the viewer and for the viewer to have an opportunity to operate the control button of the input unit 6 . However, it should not be so long as to disturb the normal viewing. It is possible for the system to allow the viewer to select the period for which control images should be displayed.
Another use of control images is as follows. At the end of a television program, the broadcaster may inform the audience of another program. This might be unrelated or might be the next part of the same series of programs. The broadcaster can broadcast precise information about the particular event, thereby easily allowing the viewer to associate a control image and action with that event.
In addition to displaying control images, the system may also display key images. These will be discussed below.
The broadcast services received by the Set Top Box 2 may include a carousel of key files. These key files should include key images, together with other data for execution. Typically, the other data would relate to audio/video sequences for display on the television display 4 .
During use, the Set Top Box downloads at least one key file from the carousel and, under the control of the controller 18 stores it in a cache memory. In this way, whenever the Set Top Box wishes to access a key file including the key image and associated executable data, it is immediately available from the cache memory and need not be downloaded.
Events can be preselected by the user or by the broadcaster. In response to these events, for instance the start of a particular television program or the start of a replay in a sports program, the control 18 retrieves the key image from memory and passes appropriate display information to the TV encoder 16 such that the key image is displayed on the television display 4 superposed on the television service currently being viewed.
The key image may be a static image or may be animated. It may also move across the television display. It should be large enough to be recognized immediately, but small enough not to disturb the normal program. As with the control images, the key images may have associated sounds.
The key image is displayed for a predetermined period only. However, if the control 18 detects that a key command has been received from the input unit 6 , it causes the key file to be executed. Typically, as mentioned above, the key file includes an audio/video sequence for display on the television display 4 . Therefore, the controller 18 provides the TV encoder 18 with the appropriate information to display the audio/video sequence on the display 4 . In this respect, the audio/video sequence may be encoded and, the controller 18 may also make use of the A/V decoder 14 . The audio/video sequence can be displayed on only a part of the television display 4 , with the current broadcast service being displayed in the remainder of the television display 4 . However, preferably, the audio/video sequence replaces the current broadcast service until the end of the sequence is reached.
After a key image has been displayed, whether or not the associated file is executed, the file is deleted and a new key file downloaded from the broadcast carousel.
In this way, whenever a preselected event occurs, the controller 18 causes a key image to be displayed on the television display, thereby allowing the viewer to access the associated executable file by means of only a single control button on the input unit 6 . The key images and key files are changed for each consecutive event. The selection of key files from the carousel can be random or in sequence. Alternatively, the controller 18 may build up a profile of the taste of the viewer and select key files according to that profile.
The use of key images is particularly advantageous in conjunction with the control images discussed above. In particular, it is proposed that, whenever a control image is displayed on the television display 4 in response to a preselected event, it is displayed together with a key image. This is illustrated in FIG. 6 . The control images and key images are similar in nature, for instance size. Furthermore, as is clear from the above, they may be static, moving and/or animated.
The provision of key images is particularly useful for providing television advertisements. In particular, whenever a preselected event occurs such that a preselected control image appears on the television display 4 , the controller 18 will cause the key image of a key file held in cache memory to be displayed together with the control image. The key image will be some image identifying a particular advertisement or product, for instance an image of a can of a particular drinks manufacturer or the logo of a particular car manufacturer. The viewer then has to consider only two control buttons on the input unit 6 . By pressing one button, the preselected action for the control image will be executed, for instance changing channels. By pressing the other button, the key file will be executed so that, for instance, the full audio/video sequence from an advertiser will be displayed on the television display 4 .
Preferably, the control images and key images are arranged so as to interact in a pleasing manner.
Preferably, at least the position of the key image should be determined by the control image, in particular from positioning data in the control image file. Hence, a control image can cause the key image to be displayed adjacent to it in some way. Also, movement of the images can also be controlled by the control image. For instance, if a viewer selects an image of a canon to remind him or her of a military program, the control image of the canon could control the associated key image to move across the screen as if fired from the cannon.
In order that the relative positions of the control image and key image can be properly controlled, it is proposed that the control image should define a locator position within the key image. The locator position can be anywhere within the key image, though typically, it is most likely to be at its centre, at the centre of one of its sides or at its corners. In this way, the control image can control the position of the key image by defining the position of the locator position on the television display. Thus, for instance, where the control image is a small figure throwing an object, the locator position would be defined at the bottom of the key image so that the figure could throw and catch the key image from its bottom. In this respect, it is also possible for the locator position to be defined dynamically. In other words, the locator position may be changed during the animation in order to enhance the animation.
Where a key image is to be displayed with a control image, it may be necessary to ensure that their characteristics are similar, particularly if any form of interaction is to take place. Hence, preferably, before any display takes place, some negotiation is conducted between the control image and the key image.
Negotiations may include setting the locator position as mentioned above. They may also include comparing the number of frames in the animation cycle, comparing the total duration of the animation cycles, comparing the aspect ratio of the images, determining whether or not the animations are cyclic and comparing the image frame rate (i.e. the time between consecutive frames) for the animated images. It is also possible that the negotiations may consider the orientations of the images.
In general, where a particular aspect of a control image is not important, it may consider changing that characteristic, for instance dropping one of the frames from its total cycle. However, in general, it is considered that the control images control the key images and, therefore, the key images are modified so as to conform to the control images.
The broadcast stream may contain a number of carousels of key files. In particular, each television service or program may have an associated carousel. Thus, if a viewer has selected the start of a program on a particular channel for the event, the controller 18 will download at least one key file for that particular program. In this way, when the control image appears and grabs a key image, the key image will be appropriate to the selected event. When this is used for advertising, it means that the key image can represent an advertisement for the sponsors of the selected program. This might be of particular importance where a sports program provides broadcast data indicating the start of replays so that a viewer may be alerted to any replays whilst watching another channel. In this case, sponsors of the sports program will want their key files and key images to be presented to the viewer whenever a control image indicates that a replay is taking place in the sports program of the other channel.
It is possible for the key file carousel of the broadcast stream also to include control images. These control images could be downloaded by the Set Top Box so as to increase the selection available to the viewer.
It is proposed that the control images and key images should each take up less than approximately 5% of the surface of the television display. In some systems, it could be arranged that the user can choose the size of the control images. However, preferably, the key images should then automatically be adjusted to have a corresponding size.
New key images are broadcast at a frequency that depends on the current programs, the available bandwidth and the time of day. This may vary, for example, between 1 and 20 per minute.
When a control image selects a key image or at least when the control 18 downloads key images, the choice of key images may be based on a combination of a viewer's profile, the current channel and a control images choice.
The viewer's profile may be built up by the controller 18 by monitoring the channels tuned to by the viewer, the key images opened by the viewer and any Java applications launched by the viewer. The controller 18 could also maintain different profiles linked to different viewers, e.g. members of the family. However, in this case, the individual viewer would have to identify himself.
The choice can be made on the basis of the current channel, since some key images may fit better to the current program than others.
It is preferred that any key image will be associated with any control image. However, since some combinations may look better than others, it is possible for the system to allow key images to be chosen partly at the preference of the control image.
The combination of control image and key image appears on the screen for a short time. Control images, together with the key images, disappear after a few seconds (typically between 1 and 5). This duration may be configured by the viewer. During this period, the viewer may interact with it using the input unit or remote control device 6 . As explained above, there are at least two valid interactions, each of them being triggered by a dedicated button on the remote control.
For example, a green button may instruct the control image to execute an associated action. To each event or event type, the viewer may have associated a single action. If so, the remote control's green button will trigger this action. Valid actions might include an instruction to the TV set or Set Top Box for instance to tune to a given service, to a video channel or Java application or to power off or mute the TV set. Other actions might include instructions to any device that is connected over the I-Link, e.g. if the event is the start on another channel of a program the viewer is interested in, the action may be to start recording that program. Other actions might include the registration of a future event to be notified. If, for example, the event that triggered the control action is a message from the broadcaster indicating that the current program stops and will be resumed next week at the same time, the action could be to ask for a control image to notify the viewer when that program resumes. That new control image will have an associated action to tune to the corresponding channel.
The second dedicated button may be a red button for “opening” the key image. When the viewer presses the red button while a control image and key image are on the screen, the associated file may be executed. It may use all of the Set Top Box resources, e.g. to tune to a commercial (short video/audio), start some animation (possibly full screen) or user return channel to notify the advertiser that the viewer is interested in his advertisement.
It is also possible to provide a third button, for instance an “info” button. The info button instructs the control image to display a message on the screen. This message explains the meaning of the control image's appearance. Although this interaction is possible whenever a control image appears on the screen, the viewer would only occasionally use this possibility, because, with most of the control images, he would remember the associated event and would not need any additional information. Preferably, if information is displayed on the screen, the viewer can remove it by pressing the info button a second time.
The system as described above, can be installed permanently into a Set Top Box. However, it is also applicable to any DVB-MHP compliant device. Thus, the necessary system may be downloaded as a series of applications, such as Java applications. Thus, the controller 18 operates as a Java virtual machine. The DVB-MHP (Digital Video Broadcast-Multimedia Home Platform) provides a standard abstraction API for Set Top Boxes.
Both the control images and the key images are then implemented as Java objects. Each of them can then implement an interface that is used to synchronize location, size and speed of animation.
The viewer may associate the control image of his choice to particular events with the help of different Java applications. Although different Java applications may allow the viewer to subscribe to the same events or event types, at least a following range of applications are considered:
1) set up and configuration applications; these applications allow the viewer to configure the TV's resources (tuner, contrast, etc). They also allow him to set up preferences about events and control images; the viewer can enable or disable the notification of some event types (e.g. system events) and associate control images of his or her choice,
2) clock/alarm applications; these applications allow the viewer to set an alarm to single time points (e.g. on the 17 October at 20.00) or recurring time points (e.g. every Friday at 22.25),
3) electronic program guides (E.P.G.),
4) event notifications (control image appearances); the action associated to a control image may be to be a subscription to another event.
At all times the viewer may start a Java application to display all subscriptions, i.e. selected events. With this application, he can delete a subscription or change the associated control image. Both the viewer profiles and the list of subscriptions or selected events may be exported to and edited by another device (e.g. using the I-Link or a memory stick). The objects of the overall system are illustrated in FIG. 7 . The objects for notification, events, aglets, selected events, event watchers and MPEG-2 streams are illustrated respectively in FIGS. 8 to 13 as ULL diagrams.
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A television display system with a television display for displaying television services and internet information, and an input unit for providing a command, the television display system receiving a data stream containing a plurality of key files, each key file including executable data and a respective key image representing said executable data. The television display system includes a memory for continuously maintaining over a period at least one of the key files, a display section displaying upon occurrence of any of a number of preselected events, a key image stored in said memory, superposed on a displayed said television service, said key image upon activation executing said executable data included in the same key file. The system also includes a command section for executing content of the key file of the displayed respective image conditional upon a key command being provided by the input unit.
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BACKGROUND OF THE INVENTION
This invention relates to hand-held tufting machines and more particularly to a hand-held tufting machine using pneumatic power wherein an operator can precisely control the operation of the stitch forming instrumentalities.
Hand-held tufting machines, also known as mending guns, are universally used for correcting faults in tufted fabric such as carpeting. For example, if for some reason, such as a broken yarn, one or a few needles of a tufting machine in the manufacture of carpeting do not form stitching in the backing material, the missing stitches are inserted by the use of such mending guns. Known prior art mending guns are illustrated in U.S. Pat. Nos. 2,753,820; 2,837,045; 2,862,466; 2,879,731; 2,887,076; 3,142,276; 3,144,844; 3,225,723; 3,229,653; 3,389,667; 3,645,219; 4,006,694; 4,007,698; 4,132,182; and 4,388,881. Other uses of such guns may be found in the manufacture of customized rugs.
Because of the ready availability of the supply of compressed air in carpet mills most of the current mending guns are pneumatically driven, the gun having a small pneumatic rotary turbine motor within the handle for reciprocably driving the needle. Other such guns which use an electric motor for driving the needle are generally used for manufacturing customized rugs or for craft purposes where a supply of pressurized air is not readily available. The only known proposal for a pneumaticaly driven mending gun not having a rotary motor is that illustrated in the aforesaid U.S. Pat. No. 4,388,881 assigned to the common assignee of the present invention. There a piston/cylinder assembly was proposed with the piston reciprocating within a pivotably mounted housing that cyclically pivoted in alternate directions with each stroke of the piston to open and close ports in the piston housing for ingress and egress of air. The piston was double acting and as it reached the end of its stroke at each end of the piston housing, the housing pivoted to receive high pressure air at the end reached by the piston so as to drive the piston in the reverse direction. The piston was eccentrically mounted to a crank for driving the needle. Because of the complexities of the pivotable housing arrangement, that proposal was never adopted for manufacture. It may be pointed out that in all of the aforesaid patents the mending guns or hand-held tufters utilized some form of crank driven stitch forming instrumentalities.
The mending guns currently utilized in carpet mills are of the type illustrated in the aforesaid U.S. Pat. Nos. 3,225,723 and 3,645,219. These mending guns since they are driven by pneumatic motors drive the needle and other stitch forming instrumentalities in a very rapid manner. Although this is desirable for unpatterned carpet fabric since all the operator has to do is hold the presser foot of the gun against the backing material along the row in which the tufting machine did not form stitching and feed the gun to fill in the missing stitches. The rapid action of the stitch forming instrumentalities is therefore useful in such instances. However, a substantial amount of patterned carpet fabric is currently being manufactured, such patterning being performed by sliding one or more needle bars of the tufting machine laterally so that an array of various zig-zag stitches are formed on the backing material surface remote from the pile surface. Some of the patterns are such that some zig-zag stitches overlay other zig-zag stitches. Because of the rapid action of the known mending guns, the operator has no control as to the placement of the stitches applied by the mending gun. Once the trigger of the gun is squeezed, a substantial number of stitches are formed, and it becomes difficult, if not virtually impossible, for an operator to place an array of zig-zag stitching into the backing material where a tufting machine needle has omitted the zig-zag stitch. When this occurs, defective fabric is produced thereby increasing the manufacturing costs.
SUMMARY OF THE INVENTION
Consequently, it is a primary object of the present invention to provide a simple inexpensive pneumatic hand-held tufting machine or mending gun which provides the operator with substantial control so as to place stitches at selected locations.
It is another object of the present invention to provide a hand-held tufting machine or mending gun having a pneumatically driven piston/cylinder assembly wherein one or a selected few stitches may be formed in a backing material.
It is a further object of the present invention to provide a drive assembly for a hand-held tufting machine or mending gun having stitch forming instrumentalities driven in a linear path by means of a pneumatic piston/cylinder assembly fixedly attached to the mending gun.
Accordingly, the present invention provides a pneumatically actuated hand-held tufting machine or mending gun wherein the operator is provided with precise control over the reciprocation of the stitch forming instrumentalities so that stitches may be inserted at precise locations in the backing material for correcting faults in carpet being produced. To this end the present invention provides a pneumatically powered mending gun having a housing to which the casing or housing of a pneumatic piston/cylinder is fixedly mounted, the piston rod of the pneumatic cylinder being connected to a needle drive member. The needle drive member is mechanically coupled to a yarn manipulating needle plunger drive member such that when the needle moves forwardly the plunger moves rearwardly and vice versa. The piston/cylinder is double acting and pushes the needle drive member to drive it forwardly and pulls it back to drive it rearwardly, the action being controlled by operator influenced valving. When the needle is driven forwardly it punches a hole in the carpet backing and when the needle plunger is driven forwardly it grasps yarn carried by the now rearwardly moving needle and pulls a loop of yarn to the desired pile height relative to the backing. The valving may be such that the operator controls each forward and rearward movement of the needle and needle plunger by depressing and releasing a valve influenced trigger to form one stitch each time the trigger is depressed and released, or may be such that depression of the trigger results in the needle slowly moving forwardly and rearwardly to form a series of stitches, the slow action allowing each stitch to be selectively placed at a desired location in the backing.
In the preferred form of the invention the needle drive member and the plunger drive member are each constrained for slidable reciprocation in slideways formed in the housing. The preferred form of the drive members are gear racks having teeth operatively connected to a pinion gear which is rotatably driven in a first direction as the needle rack is driven forwardly by the piston rod and in the opposite direction as the needle rack is driven rearwardly by the piston rod. As the pinion rotates in the first direction, the needle plunger rack is driven rearwardly and when it rotates in the opposite direction the plunger rack is driven forwardly.
The operator influenced valving may include valve means within the housing operable upon depression of the trigger to open an air passage for receiving pressurized air from a main air channel within the housing and when the trigger is released closes the passage. When the passage is closed the needle is in the forward position, and when the passage is open the needle is driven rearwardly and the plunger driven forwardly once, and upon release of the trigger the needle is again driven forwardly. Alternatively, the valving may act to move the plunger and the needle in step-wise fashion slowly through a number of cycles until the trigger is released.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of a hand-held tufting mending gun constructed in accordance with the principles of the present invention;
FIG. 2 is a fragmentary side elevational view of the gun illustrated in FIG. 1 with the housing cover plate and the valving removed depicting the needle just prior to reaching the forward position;
FIG. 3 is a view similar to FIG. 2 depicting the needle plunger just prior to reaching the forward position;
FIG. 4 is a fragmentary top plan view of the working or forward end of the plunger;
FIG. 5 is a fragmentary cross sectional view taken substantially along the line 5--5 of FIG. 2;
FIG. 6 is a fragmentary top plan view of a portion of the mending gun taken substantially along the line 6--6 of FIG. 2 with the needle in the forwardmost position and illustrating the return stroke adjusting means;
FIG. 7 is a fragmentary bottom plan view of the forward end of the gun taken substantially along the line 7--7 of FIG. 2 illustrating the presser foot adjusting means;
FIG. 8 is a fragmentary cross sectional view taken through the handle of the gun substantially along line 8--8 illustrating the trigger actuated air passage control means, and;
FIG. 9 is a schematic view of the valving for selecting either a single stitch or a multiple stitch mode.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIGS. 1 and 2, a hand-held tufting mending gun generally indicated at 10 is illustrated with the needle 12 in the forward position. The gun includes a housing 14 comprising a mounting plate 16 having a pair of spaced apart rails 18, 20, the rail 18 being at the top of the plate and the rail 20 being at the bottom. Secured to the bottom rail 20 by means of screws or the like (not illustrated) is a handle 22 adapted to be grasped by an operator. Formed in the central portion of the mounting plate 16 extending from the rear end of the gun remote from the needle end is a central rail 24 having an arcuate surface 26 at the forward end thereof. Another rail 28, substantially narrower than the rail 24, having an upper surface lying in the same plane as the upper surface of the rail 24 is formed on the mounting plate 16 at the forward end and has an arcuate surface 30 at the rear thereof, the arcuate rear end surface 30 of the rail 28 being spaced longitudinally from the arcuate surface 26 of the rail 24. The space between the lower surface of the upper rail 18 and the upper surface of the rail 24 form a first slideway for receiving a gear rack 32, while the space between the lower surface of the rail 24 and the upper surface of the lower rail 20 form a second slideway for receiving another gear rack 34. The forward end of the gear rack 34 has an upstanding plunger mounting block 36 secured thereto, the upper surface of the plunger mounting block being adapted for sliding against the lower surface of the forward rail 28.
Secured to the mounting plate 16 intermediate the respective arcuate surfaces 26 and 30 of the rails 24 and 28, and intermediate the gear racks 32 and 34 is an annular axle 38. A pinion gear 40 is rotatably disposed about the axle 38 with the teeth thereof meshing with the teeth of the gear racks 32 and 34. A cover plate 42 is secured to the rails 18 and 20 by means of screws 44 or the like, the upper screw at the rear end also may aid in securing the housing of a valve 46 to the cover plate. An additional screw 48 is received within the central portion of the cover plate and is threadedly received within a threaded bore 50 in the axle 38.
Secured at the rear of the gun to the end of the rails 18, 20 and 24 is a cylinder mounting block 52 which also abuts the rear end of the cover plate 42. Fastened to the block 52 is the housing 54 of a pneumatic cylinder having a piston (not illustrated) mounted internally thereof, the piston rod 56 extending through a bore in the mounting block 52 and being threadedly attached to the rear end of the upper gear rack 32 Thus, extension of the piston rod slidably drives the gear rack 32 to the left as illustrated in FIG. 2 and retraction thereof slidably pulls the gear rack 32 to the right as illustrated in FIG. 3. As the gear rack 32 moves to the left it drives the pinion gear 40 causing it to rotate counterclockwise thereby driving the lower gear rack 34 rearwardly to the right as illustrated in FIG. 2, and alternately when the piston rod is retracted the gear rack 32 drives the pinion gear 40 clockwise and the lower rack 34 forwardly to the left as illustrated in FIG. 3.
Secured at the front end of the upper gear rack 32 is the mounting portion 58 of the needle 12, the mounting portion having an offset at its rear end to which the forward end of the rack 32 is secured by screws 60 or the like. The needle 12 has an arcuate cross sectional configuration with a point 62 at the leading edge, and has a narrow plate 64, as illustrated in FIG. 5, extending transversely at its sides spaced slightly from the lower edges of the arcuate form, the leading edge of the plate 64 being disposed rearwardly of the point 62 and extending rearwardly to form a lower surface of the mounting portion 58, the mounting portion having side walls extending downwardly beyond the plate 64. A hollow 66 is thus formed in the needle above the plate 64 and communicates with an aperture 68 in the upper portion of the needle, just forward of the mounting portion, so that yarn Y can be threaded through the hollow and out the pointed end. The channel formed by the plate 64 with the lower portion of the side edges of the needle 12 and the mounting portion 58 receives a longitudinally needle plunger 70, the front portion of the needle plunger having a rectangular configuration with a U-shaped slot at the leading edge. The rear of the plunger is formed with a cylindrical shank 74 which is received within a bore in the plunger mounting block 36 and secured thereto by a set screw or the like (not illustrated).
After the needle has penetrated the backing material of the carpet being repaired, and before the needle is retracted from the backing, the plunger as it moves forward grasps the yarn loop formed between the strand Y extending through the needle and the leg of the yarn from the loose leading end of the yarn or the leg extending from a previous stitch, and pulls the loop forwardly to the end of its travel. As is well known in the art, the two legs of the yarn are then frictionally held in the backing as the plunger begins its return stroke. The yarn is fed through the eyelets of a yarn guide 76 extending through a first eyelet 78 from the supply over the forward face of the yarn guide 76 into a second eyelet 80 and back along the rear face of the yarn guide 76 through the third eyelet 82 prior to entry into the opening 68 in the needle, the three eyelet arrangement being such as to provide tension for preventing the yarn from unthreading from the needle.
Formed in the top of the upper rail 18 extending longitudinally forwardly and rearwardly of the disposition of the pinion gear 40 is a recess 84 for receiving a small block 86 which is secured by shoulder screws 88 to the top of the upper gear rack 32. Preferably, as illustrated in FIG. 6, the front and rear surfaces of the block 86 are arcuate as is the front and rear ends of the recess 84. When the needle reaches the end of its forward stroke the block 86 abuts the leading edge of the recess 84 so that the forward stroke of the needle always terminates at a constant point. In order to control the return stroke of the needle and thus the forward stroke of the plunger 70, and thereby the pile height of the tufted stitch being formed, a pile height adjustment block 90 is adjustably secured to the top of the rail 18. The adjustment block 90 includes a longitudinally extending slot 92 through which the threaded end of a shoulder screw 94 extends and is threaded into the rail 18. The adjustment block 90 can thus be secured in selected positions merely by loosening the screw 94, moving the block to a selected disposition and resecuring the screw 94. In the adjusted position the head of the rear screw 88 of the block 86 abuts the leading edge of the plate 90 to terminate the return stroke of the rack 32, and thus the forward stroke of the plunger 70 so as to adjust the pile height. Clearly to shorten the pile height the adjusting plate 92 is moved forwardly to shorten the overall stroke of the needle and plunger, and moved rearwardly to increase the pile height.
Additionally, a presser foot fence 96 having an upstanding yoke configuration, through which the needle 12 and the plunger may enter on their respective forward strokes and may exit on their respective rear strokes, extends upwardly from a presser foot shank 98 adjustably secured to the bottom rail 20. As illustrated in FIG. 7, the rear of the presser foot shank 98 includes a slot 100 for adjustably receiving the shank of a shoulder screw 102 so that the presser foot fence 96 may be adjustably moved forwardly or rearwardly. When the pile height is to be adjusted by means of the plate 90, the presser foot fence must also be adjusted so that the needle on its return stroke clears the fabric and the rear of the presser foot fence as illustrated in FIG. 3. The presser foot fence 96 is always adjusted in the same direction as the pile height adjusting plate 90, forwardly to shorten the pile height and rearwardly to increase the pile height.
The handle 22 is substantially hollow and includes a fitting 104 at the bottom for connection of the mending gun to a high pressure source of air commonly found in carpet mills. As illustrated in FIG. 8, the interior of the handle includes a conduit 106 connected to the fitting so as to be in flow communication therewith so that when the fitting is connected to an air supply source, air flows through the conduit 106 and out a portal 108 at the outlet end of the conduit 106, the portal communicating with a fitting 110 mounted on the exterior of the handle. Connected to the fitting 110 is one end of a flexible conduit 112, the other end of which is connected by a fitting 114 to the supply port of the valve 46. The valve 46 is a two position balanced spool fourway valve having a supply port, two outlet ports, two exhaust ports and a pilot port, the pilot acting as a control. A valve of this type is manufactured by Clippard Company of Cincinnati, Ohio under the Clippard Eagle E-4 series, and specifically in the preferred embodiment a model E-4-1PS has been utilized successfully. When air is supplied to the supply port through the conduit 106 when the mending gun is connected to an air supply line, a first outlet port of the valve supplies air, and when the pilot port receives air, the second outlet port supplies air, in each case air is exhausted through a separate exhaust port. Accordingly, in order to selectively control the actuation of the pneumatic piston/cylinder 54, and thus the extension of the piston rod 56, a flexible conduit 116 is connected by fittings 118, 120 respectively to the first outlet port of the valve and the head end of the piston/cylinder 54, and a second flexible conduit 122 has its respective ends connected to a fitting 123 at the second outlet port of the valve 46 and a fitting 124 communicating with the piston rod end, or tail end, of the pneumatic piston/cylinder 54. Additionally, a flexible conduit 126 is connected at one end to a fitting 128 at the pilot port of the valve and has its other end connected to a fitting 130 mounted on the handle 22 adjacent to the fitting 110.
The fitting 130 communicates internally into the handle through a port 132 which communicates with a small conduit 134 within the handle 22. Another conduit 136 within the handle selectively communicates the conduit 106 with the conduit 134, a small normally closed, two-way poppet cartridge valve 138, such as Clippard model MAV-2C, extending into the conduit 136 to normally close communication between conduits 136 and 134. The valve 136 has an actuation stem 140 extending outwardly from the handle and to which a trigger button 142 is fastened. Depression of the trigger and thus the stem 140 opens a passageway in the valve 138 to permit air to flow from the conduit 136 into the conduit 134 and thus to the pilot port of the valve 46 which acts to port air to the tail end of the pneumatic piston/cylinder 54. When supply air is attached to the fitting 104 air fed from the port 108 to the supply port of the valve 46 communicates air to the head end of the cylinder to drive the upper rack 32 and the needle 12 forwardly. When the trigger 142 is mashed or squeezed, the valve 138 permits air to flow through the port 132 to the pilot port of the valve 46. This acts to exhaust air from the head end and supplies the air to the tail end to drive the upper rack 32 and the needle 12 rearwardly. Of course, as the needle goes forwardly the yarn grasping plunger 70 moves rearwardly and as the needle moves rearwardly, the yarn grasping plunger 70 moves forwardly to grasp a loop of yarn. When the trigger is released, the valve 138 closes the communication between the conduit 136 and the conduit 134, and the air supplied from the portal 108 to the supply port of the valve 46 again drives the needle 12 forwardly as air is exhausted from the tail end of the cylinder through the second exhaust port.
In operation, an operator prior to mashing the trigger 142 may insert the point of the needle into the backing material of the carpet, thereafter squeeze the trigger 142 to drive the plunger forwardly and the needle rearwardly, so that the slotted portion 72 of the plunger grasps the loop of yarn and holds it, and upon release of the trigger, the plunger moves rearwardly and the needle again moves forwardly. The loop of yarn being held by friction in the backing material remains in the carpet. If a series of stitches is desired to be inserted into the backing material, the operator merely initially inserts the needle, squeezes the button, releases the button and repeats the sequencing for each stitch desired to be inserted into the backing material of the carpet. Since a single stitch is formed each time the trigger is squeezed, the operator can selectively insert a stitch at precise selected positions in the backing so as to form stitches corresponding to the pattern of the carpet produced to substitute stitches for the tufting machine needle or needles that were unthreaded.
The mending gun of the present invention can also be utilized as a slow acting mending gun by valving which permits the piston within the piston/cylinder 54 to move forwardly and rearwardly while the trigger is held squeezed in to form a series of stitches in the backing material, i.e., each time the trigger is held depressed the cylinder will continue to cycle at a very slow rate. In this case the only modification to the gun as heretofore described is the removal of the valve 46 and replacement thereof by other valving, and plugging of the fitting 104. For example, utilization of sequence valving such as a Clippard Model CM-06 sequence subplate for three valves, used in conjunction with two Clippard model R301 three-way valves and one Clippard model R402 four-way valve provides this sequencing. The 3-way valves are single piloted while the 4-way valve is double piloted. The sequence subplate, which has speed selection for the sequencing, mounts the three valves, and has passageways formed therein for directing the air between the valves from the supply, the ports 108 and 138 and the outlets to the cylinder 54. Because the size of such a unit makes the gun heavy, it is not mounted on the mending gun, but mounted above the tufting machine (not illustrated). Air that would be supplied to the fitting 104 is fed to a supply port of the subplate which has two control outlet ports connected in communication with the parts 108, 132 of the mending gun, and two outlet ports for extending and retracting the piston in sequence. All the components are off-the-shelf and utilized in conventional manner. Depression of the trigger 142 begins the cycle and release of the trigger terminates the cycle. Thus the mending gun 10 may be utilized as a very slow acting mending gun to form a series of stitches with the position of the stitches selected readily by the operator.
Moreover, by utilizing a switching arrangement, the valve 46 may be utilized in conjunction with the slow acting sequencing valving to select the mode of operation as either a one-shot firing of the mending gun, or a slow sequence firing of the mending gun upon depression of the trigger 142. For example, as illustrated schematically in FIG. 9, a sequence subplate 144 such as the aforesaid Clippard model CM-06 may be utilized in conjunction with two three-way valves 146, 148 and a four-way valve 150, each valve being of the aforesaid type, the sequencing subplate being supplied with air from a supply conduit 152 which would otherwise be supplied to the plugged fitting 104. The sequence subplate has one outlet 154 connected to the port 108 of the mending gun, and another port 156 connected to a toggle actuated four-way poppet valve 160 having three positions, one of which is vented and the other two of which are jog or manual control. One outlet 162 is connected in communication with the port 132 of the mending gun, while the other outlet is connected to the pilot port fitting 128 of the valve 46. The conduit 122 is connected at one end to the fitting 123 of the valve 46 and at its other end is connected to a first inlet port 164 of a shuttle valve 166, which is a double check valve having two other ports 168, 170 in addition to the port 164, the port 170 being an outlet port connected to the fitting 124 at the tail end of the cylinder 54. Another valve 172 identical to the valve 166 has its outlet port 174 connected to the fitting 120 of the cylinder 54 and has its inlet ports 176, 178 respectively connected to the fitting 118 at the other outlet port of the valve 46, and an outlet port 180 of the sequence subplate 144. The valves 166 and 172 may be Clippard model MSV-1 shuttle valves and the air may be ported from one of the inlets to the outlet, and exhaust through the port where pressure was last applied. When an operator throws the toggle 182 of the four-way poppet valve 160 in one direction and depresses the trigger 142 the valving will actuate the cylinder for one cycle as described above, or if the toggle is thrown in the other direction the valving will be actuated to bypass the valve 46 and activate the sequencing of the valves 146, 148, 150 to cycle the cylinder 54 in a slow cycling mode. The capabilities of a mending gun operating either on a one-shot basis and/or on a slow acting continuous basis has not previously been available in the carpet industry.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A hand-held tufting mending gun has a housing to which a pneumatic cylinder is fixedly mounted, the piston rod of the cylinder being connected to a needle drive member. The needle drive member is a gear rack and has its teeth in mesh with a pinion gear, the pinion gear in turn meshes with another gear rack formining the drive member of a yarn manipulating plunger. A hollow needle is attached to the forward end of the needle drive member and a yarn manipulating member is attached to the front of the plunger drive member. The piston of the pneumatic cylinder is double acting and pushes the needle drive member to drive it forwardly and pulls it back to drive it rearwardly, the action being controlled by operator influenced valving. As the needle moves forwardly, the plunger moves rearwardly and vice versa. An operator influenced trigger may control valving such that each depression and release of the trigger cycles the piston once to form one stitch, or may control valving which results in a series of stitches slowly being formed while the trigger is depressed. The single stitch or the slowly formed stitches provide an operator with control so that stitches may be inserted at precise locations to correct faults in a carpet being produced.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/172,113, filed on Jun. 14, 2002, which is a continuation-in-part of patent application Ser. No. 10/083,189, filed on Feb. 26, 2002, which claims priority from U.S. Provisional Patent Application No. 60/332,950, filed on Nov. 14, 2001.
BACKGROUND
This invention generally relates to solving linear systems. In particular, the invention relates to using array processing to solve linear systems.
Linear system solutions are used to solve many engineering issues. One such issue is joint user detection of multiple user signals in a time division duplex (TDD) communication system using code division multiple access (CDMA). In such a system, multiple users send multiple communication bursts simultaneously in a same fixed duration time interval (timeslot). The multiple bursts are transmitted using different spreading codes. During transmission, each burst experiences a channel response. One approach to recover data from the transmitted bursts is joint detection, where all users data is received simultaneously. Such a system is shown in FIG. 1 . The joint detection receiver may be used in a user equipment or base station.
The multiple bursts 90 , after experiencing their channel response, are received as a combined received signal at an antenna 92 or antenna array. The received signal is reduced to baseband, such as by a demodulator 94 , and sampled at a chip rate of the codes or a multiple of a chip rate of the codes, such as by an analog to digital converter (ADC) 96 or multiple ADCs, to produce a received vector, r . A channel estimation device 98 uses a training sequence portion of the communication bursts to estimate the channel response of the bursts 90 . A joint detection device 100 uses the estimated or known spreading codes of the users' bursts and the estimated or known channel responses to estimate the originally transmitted data for all the users as a data vector, d .
The joint detection problem is typically modeled by Equation 1.
A d +n= r Equation 1
d is the transmitted data vector; r is the received vector; n is the additive white gaussian noise (AWGN); and A is an M×N matrix constructed by convolving the channel responses with the known spreading codes.
Two approaches to solve Equation 1 is a zero forcing (ZF) and a minimum mean square error (MMSE) approach. A ZF solution, where n is approximated to zero, is per Equation 2.
d =( A H A ) −1 A H r Equation 2
A MMSE approach is per Equations 3 and 4.
d =R −1 A H r Equation 3
R=A H A+σ 2 I Equation 4
σ 2 is the variance of the noise, n, and I is the identity matrix.
Since the spreading codes, channel responses and average of the noise variance are estimated or known and the received vector is known, the only unknown variable is the data vector, d . A brute force type solution, such as a direct matrix inversion, to either approach is extremely complex. One technique to reduce the complexity is Cholesky decomposition. The Cholesky algorithm factors a symmetric positive definite matrix, such as à or R, into a lower triangular matrix G and an upper triangular matrix G H by Equation 5.
{tilde over ( A )} or R=GG H Equation 5
A symmetric positive definite matrix, Ã, can be created from A by multiplying A by its conjugate transpose (hermetian), A H , per Equation 6.
Ã=A H A Equation 6
For shorthand, {tilde over (r)} is defined per Equation 7.
{tilde over (r)}=A H r Equation 7
As a result, Equation 1 is rewritten as Equations 8 for ZF or 9 for MMSE.
à d ={tilde over (r)} Equation 8
R d ={tilde over (r)} Equation 9
To solve either Equation 8 or 9, the Cholesky factor is used per Equation 10.
GG H d ={tilde over (r)} Equation 10
A variable y is defined as per Equation 11.
G H d=y Equation 11
Using variable y, Equation 10 is rewritten as Equation 12.
Gy={tilde over (r)} Equation 12
The bulk of complexity for obtaining the data vector is performed in three steps. In the first step, G is created from the derived symmetric positive definite matrix, such as à or R, as illustrated by Equation 13.
G =CHOLESKY ( Ã or R ) Equation 13
Using G, y is solved using forward substitution of G in Equation 8, as illustrated by Equation 14.
y =FORWARD SUB( G,{tilde over (r)} ) Equation 14
Using the conjugate transpose of G, G H , d is solved using backward substitution in Equation 11, as illustrated by Equation 15.
d =BACKWARD SUB( G H ,y ) Equation 15
An approach to determine the Cholesky factor, G, per Equation 13 is the following algorithm, as shown for à or R, although an analogous approach is used for R.
for i = 1 : N for j = max(1, i − P) : i − 1 λ = min(j + P, N) a i : λ, i = a i : λ, i − a i, j * · a i:λ,j ; end for; λ = min(i + P, N) a i : λ, i = a i : λ, i /a ii ; end for; G = Ã or R;
a d,e denotes the element in matrix à or R at row d, column e. “:” indicates a “to” operator, such as “from j to N,” and (·) H indicates a conjugate transpose (hermetian) operator.
Another approach to solve for the Cholesky factor uses N parallel vector-based processors. Each processor is mapped to a column of the à or R matrix. Each processor's column is defined by a variable μ, where μ=1:N. The parallel processor based subroutine can be viewed as the following subroutine for μ=1:N.
j = 1 while j < μ recv(g j:N ,left) if μ < N send(g j:N ,right) end a μ:N,μ = a μ:N,μ − g μ *g μ:N j = j + 1 end a μ:N,μ = a μ:N,μ /{square root over (a μμ )} if μ < N send(a μ:N,μ ,right) end
recv(·,left) is a receive from the left processor operator; send(·,right) is a send to the right processor operator; and g K,L is a value from a neighboring processor.
This subroutine is illustrated using FIGS. 2 a - 2 h . FIG. 2 a is a block diagram of the vector processors and associated memory cells of the joint detection device. Each processor 50 1 to 50 N ( 50 ) operates on a column of the matrix. Since the G matrix is lower triangular and à or R is completely defined by is lower triangular portion, only the lower triangular elements, a k,1 are used.
FIGS. 2 b and 2 c show two possible functions performed by the processors on the cells below them. In FIG. 2 b , the pointed down triangle function 52 performs Equations 16 and 17 on the cells (a □□ to a N□ ) below that μ processor 50 .
v←a μ:N,μ /√{square root over (a μμ )} Equation 16 a μ:N,μ :=v Equation 17
“←” indicates a concurrent assignment; “:=” indicates a sequential assignment; and v is a value sent to the right processor.
In FIG. 2 c , the pointed right triangle function 52 performs Equations 18 and 19 on the cells below that μ processor 50 .
v←μ Equation 18
a μ:N,μ :=a μ:N,μ −v μ v μ:N Equation 19
v k indicates a value associated with a right value of the k th processor 50 .
FIGS. 2 d - 2 g illustrate the data flow and functions performed for a 4×4 G matrix. As shown in the FIGS. 2 d - 2 g for each stage 1 through 4 of processing, the left most processor 50 drops out and the pointed down triangular function 52 moves left to right. To implement FIGS. 2 d - 2 g , the pointed down triangle can physically replace the processor to the right or virtually replace the processor to the right by taking on the function of the pointed down triangle.
These elements are extendable to an N×N matrix and N processors 50 by adding processors 50 (N−4 in number) to the right of the fourth processor 50 4 and by adding cells of the bottom matrix diagonal (N−4 in number) to each of the processors 50 as shown in FIG. 2 h for stage 1 . The processing in such an arrangement occurs over N stages.
The implementation of such a Cholesky decomposition using either vector processors or a direct decomposition into scalar processors is inefficient, because large amounts of processing resources go idle after each stage of processing.
Accordingly, it is desirable to have alternate approaches to solve linear systems.
SUMMARY
A user equipment or base station, generically referred to as a wireless transmit receive unit (WTRU), recovers data from a plurality of data signals received as a received vector. The user equipment determines data of the received vector by determining a Cholesky factor of an N by N matrix and using the determined Cholesky factor in forward and backward substitution to determine data of the received data signals. The WTRU comprises an array of at most N scalar processing elements. The array has input for receiving elements from the N by N matrix and the received vector. Each scalar processing element is used in determining the Cholesky factor and performs forward and backward substitution. The array outputs data of the received vector.
BRIEF DESCRIPTION OF THE DRAWING(S)
FIG. 1 is a simplified diagram of a joint detection receiver.
FIGS. 2 a - 2 h are diagrams illustrating determining a Cholesky factor using vector processors.
FIGS. 3 a and 3 b are preferred embodiments of N scalar processors performing Cholesky decomposition.
FIGS. 4 a - 4 e are diagrams illustrating an example of using a three dimensional graph for Cholesky decomposition.
FIGS. 5 a - 5 e are diagrams illustrating an example of mapping vector processors performing Cholesky decomposition onto scalar processors.
FIGS. 6 a - 6 j for a non-banded and FIGS. 6 e - 6 j for a banded matrix are diagrams illustrating the processing flow of the scalar array.
FIG. 7 is a diagram extending a projection of FIG. 4 a along the k axis to an N×N matrix.
FIGS. 8 a - 8 d are diagrams illustrating the processing flow using delays between the scalar processors in the 2D scalar array.
FIG. 8 e is a diagram of a delay element and its associated equation.
FIG. 9 a illustrates projecting the scalar processor array of FIGS. 8 a - 8 d onto a 1D array of four scalar processors.
FIG. 9 b illustrates projecting a scalar processing array having delays between every other processor onto a 1D array of four scalar processors.
FIGS. 9 c - 9 n are diagrams illustrating the processing flow for Cholesky decomposition of a banded matrix having delays between every other processor.
FIGS. 9 o - 9 z illustrate the memory access for a linear array processing a banded matrix.
FIGS. 10 a and 10 b are the projected arrays of FIGS. 9 a and 9 b extended to N scalar processors.
FIGS. 11 a and 11 b illustrate separating a divide/square root function from the arrays of FIGS. 10 a and 10 b.
FIG. 12 a is an illustration of projecting a forward substitution array having delays between each processor onto four scalar processors.
FIG. 12 b is an illustration of projecting a forward substitution array having delays between every other processor onto four scalar processors.
FIGS. 12 c and 12 d are diagrams showing the equations performed by a star and diamond function for forward substitution.
FIG. 12 e is a diagram illustrating the processing flow for a forward substitution of a banded matrix having concurrent assignments between every other processor.
FIGS. 12 f - 12 j are diagrams illustrating the processing flow for forward substitution of a banded matrix having delays between every other processor.
FIGS. 12 k - 12 p are diagrams illustrating the memory access for a forward substitution linear array processing a banded matrix.
FIGS. 13 a and 13 b are the projected arrays of FIGS. 12 a and 12 b extended to N scalar processors.
FIGS. 14 a - 14 d are diagrams illustrating the processing flow of the projected array of FIG. 12 b.
FIG. 15 a is an illustration of projecting a backward substitution array having delays between each processor onto four scalar processors.
FIG. 15 b is an illustration of projecting a backward substitution array having delays between every other processor onto four scalar processors.
FIGS. 15 c and 15 d are diagrams showing the equations performed by a star and diamond function for backward substitution.
FIG. 15 e is a diagram illustrating the processing flow for backward substitution of a banded matrix having concurrent assignments between every other processor.
FIGS. 15 f - 15 j are diagrams illustrating the processing flow for backward substitution of a banded matrix having delays between every other processor.
FIGS. 15 k - 15 p are diagrams illustrating the memory access for a backward substitution linear array processing a banded matrix.
FIGS. 16 a and 16 b are the projected arrays of FIGS. 15 a and 15 b extended to N scalar processors.
FIGS. 17 a - 17 d are diagrams illustrating the processing flow of the projected array of FIG. 15 b.
FIGS. 18 a and 18 b are the arrays of FIGS. 13 a , 13 b , 16 a and 16 b with the division function separated.
FIGS. 19 a and 19 b are diagrams of a reconfigurable array for determining G, forward and backward substitution.
FIGS. 20 a and 20 b are illustrations of breaking out the divide and square root function from the reconfigurable array.
FIG. 21 a illustrates bi-directional folding.
FIG. 21 b illustrates one directional folding.
FIG. 22 a is an implementation of bi-directional folding using N processors.
FIG. 22 b is an implementation of one direction folding using N processors.
FIG. 23 is a preferred slice of a simple reconfigurable processing element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 3 a and 3 b are preferred embodiments of N scalar processors 54 1 to 54 N ( 54 ) performing Cholesky decomposition to obtain G. For simplicity, the explanation and description is explained for a 4×4 G matrix, although this approach is extendable to any N×N G matrix as shown in FIGS. 3 a and 3 b.
FIG. 4 a illustrates a three-dimensional computational dependency graph for performing the previous algorithms. For simplicity, FIG. 4 a illustrates processing a 5 by 5 matrix with a bandwidth of 3. The functions performed by each node are shown in FIGS. 4 b - 4 e . The pentagon function of FIG. 4 b performs Equations 20 and 21.
y←√{square root over (a in )} Equation 20 a out ←y Equation 21
← indicate a concurrent assignment. a in is input to the node from a lower level and a out is output to a higher level. FIG. 4 c is a square function performing Equations 22 and 23.
y←z* Equation 22 a out ←a in −|z| 2 Equation 23 FIG. 4 d is an octagon function performing Equations 24, 25 and 26.
y←w Equation 24 x←a in /w Equation 25 a out ←x Equation 26 FIG. 4 e is a circle function performing Equations 27, 28 and 29.
y←w Equation 27 x←z Equation 28 a out ←a in −w*z Equation 29
FIG. 5 a is a diagram showing the mapping of the first stage of a vector based Cholesky decomposition for a 4×4 G matrix to the first stage of a two dimensional scalar based approach. Each vector processor 52 , 54 is mapped onto at least one scalar processor 56 , 58 , 60 , 62 as shown in FIG. 5 a . Each scalar processor 56 , 58 , 60 , 62 is associated with a memory cell, a ij . The function to be performed by each processor 56 , 58 , 60 , 62 is shown in FIGS. 5 b - 5 e . FIG. 5 b illustrates a pentagon function 56 , which performs Equations 30 and 31.
y←√{square root over (a ij )} Equation 30 a ij :=y Equation 31
:=indicates a sequential assignment. y indicates a value sent to a lower processor. FIG. 5 c illustrates an octagonal function 58 , which performs Equations 32, 33 and 34.
y←w Equation 32 x←a ij /w Equation 33 a ij :=x Equation 34
w indicates a value sent from an upper processor. FIG. 5 d illustrates a square function 60 , which performs Equations 35 and 36.
y←z* Equation 35 a ij :=a ij −|z| 2 Equation 36
x indicates a value sent to a right processor. FIG. 5 e illustrates a circular function 62 , which performs Equations 37, 38 and 39.
y←w Equation 37 x←z Equation 38 a ij :=a ij −w*z Equation 39 FIGS. 6 a - 6 d illustrate the data flow through the scalar processors 56 , 58 , 60 , 62 in four sequential stages (stages 1 to 4 ). As shown in FIGS. 6 a - 6 d , a column of processors 56 , 58 drops off after each stage. The process requires four processing cycles or N in general. One processing cycle for each stage. As shown in FIG. 5 a , ten (10) scalar processors are required to determine a 4×4 G matrix. For an N×N matrix, the number of processors required is per Equation 40.
No
.
Require
Scalar
Processors
=
∑
i
=
1
N
i
=
N
(
N
+
1
)
2
=
N
2
+
N
2
Equation
40
FIGS. 6 e - 6 j illustrate the processing flow for a banded 5 by 5 matrix. Active processors are unhatched. The banded matrix has the lower left three entries (a 41 , a 51 , a 52 , not shown in FIGS. 6 e - 6 j ) as zeros. As shown in FIG. 6 e , in a first stage, the upper six processors are operating. As shown in FIG. 6 f , the six active processors of stage 1 have determined g 11 , g 21 and g 31 and three intermediate results, α 22 , α 32 and α 33 for use in stage 2 .
In stage 2 , six processors (α 22 , α 32 , α 33 , ã 42 , ã 43 , ã 44 ) are operating. As shown in FIG. 6 g (stage 3 ), values for g 22 , g 32 and g 42 and intermediate values for β 33 , β 43 , β 44 have been determined in stage 2 . In FIG. 6 h (stage 4 ), values for g 33 , g 43 and g 53 and intermediate values for γ 44 , γ 54 and γ 55 have been determined. In FIG. 6 (stage 5 ), g 44 and g 54 and intermediate value δ 55 have been determined. In FIG. 6 j (final stage), the remaining value g 55 is available. As shown in the figures, due to the banded nature of the matrix, the lower left processors of an unloaded matrix are unnecessary and not shown.
The simplified illustrations of FIGS. 6 a - 6 d are expandable to an N×N matrix as shown in FIG. 7 . As shown in that figure, the top most processor 56 performs a pentagon function. Octagon function processors 58 extend down the first column and dual purpose square/pentagon processors 64 along the main diagonal, as shown by the two combined shapes. The rest of the processors 66 are dual purpose octagonal/circle processors 66 , as shown by the two combined shapes. This configuration determines an N×N G matrix in N processing cycles using only scalar processors.
If the bandwidth of the matrix has a limited width, such as P, the number of processing elements can be reduced. To illustrate, if P equals N−1, the lower left processor for a N1 drops off. If P equals N-2, two more processors (a N-11 and a N2 ) drop off.
Reducing the number of scalar processing elements further is explained in conjunction with FIGS. 8 a - 8 e and 9 a and 9 b . FIGS. 8 a - 8 e describe one dimensional execution planes of a four (4) scalar processor implementation of FIGS. 6 a - 6 d . A delay element 68 of FIG. 8 e is inserted between each concurrent connection as shown in FIG. 8 a . The delay element 68 of FIG. 8 e delays the input y to be a sequential output x, per Equation 41.
y:=x Equation 41
For each processing cycle starting at t 1 , the processors sequentially process as shown by the diagonal lines showing the planes of execution. To illustrate, at time t 1 , only processor 56 of a 11 operates. At t 2 , only processor 58 of a 21 operates and at t 3 , processors 58 , 60 of a 31 and a 22 operate and so on until stage 4 , t 16 , where only processor 56 of a 44 operates. As a result, the overall processing requires N 2 clock cycles across N stages.
Multiple matrices can be pipelined through the two dimensional scalar processing array. As shown in FIGS. 8 a - 8 d , at a particular plane of execution, t 1 to t 16 , are active. For a given stage, up to a number of matrices equal to the number of planes of execution can be processed at the same time. To illustrate for stage 1 , a first matrix is processed along diagonal t 1 . For a next clock cycle, the first matrix passes to plane t 2 and plane t 1 is used for a second matrix. The pipelining can continue for any number of matrices. One drawback to pipelining is pipelining requires that the data for all the matrices be stored, unless the schedule of the availability of the matrix data is such that it does not stall.
After a group of matrices have been pipelined through stage 1 , the group is pipelined through stage 2 and so forth until stage N. Using pipelining, the throughput of the array can be dramatically increased as well as processor utilization.
Since all the processors 56 , 58 , 60 , 62 are not used during each clock cycle, when processing only 1 matrix, the number of processing elements 56 , 58 , 60 , 62 can be reduced by sharing them across the planes of execution. FIGS. 9 a and 9 b illustrate two preferred implementations to reduce processing elements. As shown in FIG. 9 a , a line perpendicular to the planes of execution (along the matrix diagonals) is shown for each processing element 56 , 58 of the first column. Since all of the processors 56 , 58 , 60 , 62 along each perpendicular operate in different processing cycles, their functions 56 , 58 , 60 , 62 can be performed by a single processor 66 , 64 as projected below. Processing functions 56 and 60 are performed by a new combined function 64 . Processing functions 58 and 62 are performed by a new combined function 66 . The delay elements 68 and connections between the processors are also projected. Although the left most processing element is shown as using a dual function element 66 , that element can be simplified to only perform the octagonal function 58 , if convenient for a non-banded matrix.
FIG. 10 a is an expansion of FIG. 9 a to accommodate an N×N G matrix. As shown in FIG. 10 a , N processors 66 , 64 are used to process the N×N G matrix. As shown in FIG. 3 a , the processing functions of FIG. 10 a can be performed by N scalar processors 54 . The same number of scalar processors as the bandwidth, P, can be used to process the G matrix in the banded case.
In the implementation of FIG. 3 a , each processor is used in every other clock cycle. The even processors operate in one cycle and the odd in the next. To illustrate, processor 2 (second from the right) of FIG. 9 a processes at times t 2 , t 4 and t 6 and processor 3 at t 3 and t 5 . As a result, two G matrices can be determined by the processing array at the same time by interlacing them as inputs to the array. This approach greatly increases the processor utilization over the implementation of FIG. 7 .
To reduce the processing time of a single array, the implementation of FIG. 9 b is used. The delay elements between every other processor connection is removed, as shown in FIG. 9 b . At time t 1 , only processor 56 of a 11 operates. However, at t 2 , processors 58 , 60 at a 21 , a 22 and a 31 are all operating. Projecting this array along the perpendicular (along the diagonals of the original matrix) is also shown in FIG. 9 b . As shown, the number of delay elements 68 is cut in half. Using this array, the processing time for an N×N G matrix is cell (NP−(P 2 −P)/2). Accordingly, the processing time for a single G matrix is greatly reduced.
Another advantage to the implementations of FIGS. 7 , 3 a and 3 b is that each processing array is scalable to the matrix bandwidth. For matrices having lower bandwidths (lower diagonal elements being zero), those elements' processors 58 , 66 in FIG. 7 drop out. With respect to FIGS. 3 a and 3 b , since the lower diagonal elements correspond to the left most perpendicular lines of FIGS. 9 a and 9 b , the processors projected by those perpendicular lines drop out. To illustrate using FIG. 9 a , the bandwidth of the matrix has the processing elements 58 , 62 of a 41 , a 31 and a 42 as zeros. As a result, the projection to processors 66 (left most two) are unnecessary for the processing. As a result, these implementations are scalable to the matrix bandwidth.
FIGS. 9 c - 9 n illustrate the timing diagrams for each processing cycle of a banded 5 by 5 matrix having a bandwidth of 3 with delays between every other connection. At each time period, the value associated with each processor is shown. Active processors are unhatched. As shown in the figures, the processing propagates through the array from the upper left processor in FIG. 9 c , stage 1 , time 0 (ã 11 ) to the lower right processor in FIG. 9 n , stage 5 (δ 55 ). As shown in the figures, due to the banded nature of the matrix, the lower left processors of an unbanded matrix processing are unnecessary and not shown.
FIGS. 9 o - 9 z illustrate the timing diagrams and memory access for each processing cycle of a linear array, such as per FIG. 9 b , processing a banded 5 by 5 matrix. As shown, due to the 5 by 5 matrix having a bandwidth of 3, only three processors are needed. The figures illustrate that only three processors are required to process the banded matrix. As also shown, each stage has a relatively high processor utilization efficiency, which increases as N/p increases.
To reduce the complexity of the processing elements, the divide and square root function are not performed by those elements (pulled out). Divides and square roots are more complex to implement on an ASIC than adders, subtractors and multipliers.
The only two functions which perform a divide or a square root is the pentagon and octagon functions 56 , 58 . For a given stage, as shown in FIGS. 6 a - 6 d , the pentagon and octagon functions 56 , 58 are all performed on a single column during a stage. In particular, each of these columns has a pentagon 58 on top and octagons 58 underneath. Since each octagon 58 concurrently assigns its w input to its y output, the output of the pentagon 56 flows down the entire column, without the value for w being directly stored for any a ij . The octagon 58 also uses the w input to produce the x output, which is also fed back to a ij . The x output is used by the square and circle functions 60 , 62 in their a ij calculations. As a result, only the value for each octagon's x output needs to be determined. The x output of the octagon is the a ij for that octagon 58 divided by the value of the w input, which is the same for each octagon 58 and is the y output of the pentagon 56 . Accordingly, the only division/square root function that is required to be performed is calculating x for the octagon 58 .
Using Equations 34 and 30, each octagon's x output is that octagon's a ij divided by the square root of the pentagon's a ij . Using a multiplier instead of a divider within each octagon processor, for a given stage, only the reciprocal of the square root of the pentagon's a ij needs to be determined instead of the square root, isolating the divide function to just the pentagon processor and simplifying the overall complexity of the array. The reciprocal of the square root would then be stored as the a ij of the matrix element associated with the pentagon instead of the reciprocal. This will also be convenient later during forward and backward substitution because the divide functions in those algorithms become multiples by this reciprocal value, further eliminating the need for dividers in other processing elements, i.e. the x outputs of FIGS. 12 d and 15 d . Since the pentagon function 56 as shown in FIGS. 9 a and 9 b is performed by the same processor 64 , the processors 66 , 64 can be implemented using a single reciprocal/square root circuit 70 having an input from the pentagon/square processor 64 and an output to that processors 64 , as shown in FIGS. 10 a and 10 b . The result of the reciprocal of the square root is passed through the processors 66 . FIGS. 11 a and 11 b correspond to FIGS. 10 a and 11 b . Separating the reciprocal/square root function 70 simplifies the complexity of the other processor 66 , 64 . Although the divide/square root circuit 70 can be implemented by using a reciprocal and a square root circuit, it is preferably implemented using a look up table, especially for a field programmable gate array (FPGA) implementation, where memory is cost efficient.
After the Cholesky factor, G, is determined, y is determined using forward substitution as shown in FIGS. 12 a and 12 b . The algorithm for forward substitution is as follows.
for j = 1 : N y j = 1 g jj ( r j - ∑ i = 1 j - 1 g ji y i ) end
For a banded matrix, the algorithm is as follows.
for j = 1:N for i = j + 1:min(j + p,N) r i = r i − G ij r j ; end for; end for; y = r j ;
g LK is the corresponding element at row L, column K from the Cholesky matrix, G.
FIGS. 12 a and 12 b are two implementations of forward substitution for a 4×4 G matrix using scalar processors. Two functions are performed by the processors 72 , 74 , the star function 72 of FIG. 12 c and the diamond function 74 of FIG. 12 d . The star 72 performs Equations 42 and 43.
y←w Equation 42 x←z−w*g ij Equation 43
The diamond function 74 performs Equations 44 and 45.
x←z/g ij Equation 44 y←x Equation 45
Inserting delay elements between the concurrent connections of the processing elements as in FIG. 12 a and projecting the array perpendicular to its planes of execution (t 1 to t 7 ) allows the array to be projected onto a linear array. The received vector values from {tilde over (r)}, r 1 -r 4 , are loaded into the array and y 1 -y 4 output from the array. Since the diamond function 74 is only along the main diagonal, the four (4) processing element array can be expanded to process an N×N matrix using the N processing elements per FIG. 13 a . The processing time for this array is 2 N cycles.
Since each processing element is used in only every other processing cycle, half of the delay elements can be removed as shown in FIG. 12 b . This projected linear array can be expanded to any N×N matrix as shown in FIG. 13 b . The processing time for this array is N cycles.
The operation per cycle of the processing elements of the projected array of FIG. 13 b is illustrated in FIGS. 14 a - 14 d . In the first cycle, t 1 , of FIG. 13 a , r 1 is loaded into the left processor 1 ( 74 ) and y 1 is determined using r 1 and g 11 . In the second cycle, t 2 , of FIG. 14 b , r 2 and r 3 are loaded, g 31 , g 21 and g 22 are processed and y 2 is determined. In the third cycle, t 3 , of FIG. 14 c , r 4 is loaded, g 41 , g 42 , g 32 , g 33 are loaded, and y 3 is determined. In the fourth cycle, t 4 , of FIG. 14 d , g 43 and g 44 are processed and y 4 is determined.
FIGS. 12 e - 12 j illustrate the timing diagrams for each processing cycle of a banded 5 by 5 matrix. FIG. 12 e shows the banded nature of the matrix having three zero entries in the lower left corner (a bandwidth of 3).
To show that the same processing elements can be utilized for forward as well as Cholesky decomposition, FIG. 12 f begins in stage 6 . Stage 6 is the stage after the last stage of FIGS. 9 c - 9 n.
Similarly, FIGS. 12 k - 12 p illustrate the extension of the processors of FIGS. 9 o - 9 z to also performing forward substitution. These figures begin in stage 6 , after the 5 stages of Cholesky decomposition. The processing is performed for each processing cycle from stage 6 , time 0 ( FIG. 12 k ) to the final results ( FIG. 12 p ), after stage 6 , time 4 ( FIG. 12 o ).
After the y variable is determined by forward substitution, the data vector can be determined by backward substitution. Backward substitution is performed by the following subroutine.
for j = N : 1 d j = 1 g jj ( y j - ∑ i = j + 1 N g ji * d i ) end
For a banded matrix, the following subroutine is used.
for j = N :1 y j = y j /G JJ H j; for i = min(1, j − P): j − 1 y i = y i − G ij H y j end for; end for; d = y;
(·)* indicates a complex conjugate function. g* LK is the complex conjugate of the corresponding element determined for the Cholesky factor G. Y L is the corresponding element of y .
Backward substitution is also implemented using scalar processors using the star and diamond functions 76 , 78 as shown in FIGS. 15 a and 15 b for a 4×4 processing array. However, these functions, as shown in FIGS. 15 c and 15 d , are performed using the complex conjugate of the G matrix values. Accordingly, Equations 42-45 become 46-49, respectively.
y←w Equation 46
x←z−w*g ij * Equation 47
x←z/g* jj * Equation 48
y←x Equation 49
The delays 68 at the concurrent assignments between processors 76 , 78 , the array of FIG. 15 a is projected across the planes of execution to a linear array. This array is expandable to process an N×N matrix, as shown in FIG. 16 a . The y vector values are loaded into the array of FIG. 16 a and the data vector, d , is output. This array takes 2N clock cycles to determine d . Since every other processor operates in every other clock cycle, two d s can be determined at the same time.
Since each processor 76 , 78 in 16 a operates in every other clock cycle, every other delay can be removed as shown in FIG. 15 b . The projected array of FIG. 15 b is expandable to process an N×N matrix as shown in FIG. 16 b . This array takes N clock cycles to determine d .
The operations per cycle of the processing elements 76 , 78 of the projected array of FIG. 16 b is illustrated in FIGS. 17 a - 17 d . In the first cycle, t 1 , of FIG. 17 a , y 4 is loaded, g* 44 is processed and d 4 is determined. In the second cycle, t 2 , of FIG. 17 b , y 2 and y 3 are loaded, g* 43 and g* 33 are processed and d 3 is determined. In the third cycle, t 3 , of FIG. 17 c , y 1 is loaded, g* 41 , g* 42 , g* 32 and g* 22 are processed and d 2 is determined. In the fourth cycle, t 4 , of FIG. 17 d , g* 43 and g* 44 are processed and d 4 is determined.
FIGS. 15 e - 15 j illustrates the extension of the processors of FIGS. 12 e - 12 j to performing backward substitution on a banded matrix. FIG. 15 e shows the banded nature of the matrix having three zero entries in the lower left corner.
The timing diagrams begin in stage 7 , which is after stage 6 of forward substitution. The processing begins in stage 7 , time 0 ( FIG. 15 f ) and is completed at stage 7 , time 4 ( FIG. 15 j ). After stage 7 , time 4 ( FIG. 15 j ), all of the data, d 1 to d 5 , is determined.
Similarly, FIGS. 15 k - 15 p illustrate the extension of the processors of FIGS. 12 k - 12 p to also performing backward substitution. These figures begin in stage 7 , after stage 6 of forward substitution. The processing is performed for each processing cycle from stage 7 , time 0 ( FIG. 15 k ) to the final results ( FIG. 15 p ). As shown in FIGS. 9 c - 9 n , 12 e - 12 j and 15 e - 15 j , the number of processors in a two dimensional array can be reduced for performing Cholesky decomposition, forward and backward substitution for banded matrices. As shown by FIGS. 9 o - 9 z , 12 k - 12 p , the number of processors in a linear array is reduced from the dimension of matrix to the bandwidth of banded matrices.
To simplify the complexity of the individual processing elements 72 , 74 , 76 , 78 for both forward and backward substitution, the divide function 80 can be separated from the elements 72 , 74 , 76 , 78 , as shown in FIGS. 18 a and 18 b . FIGS. 18 a and 18 b correspond to FIGS. 16 a and 16 b , respectively. Although the data associated with the processing elements 72 , 74 , 76 , 78 for forward and backward substitution differ, the function performed by the elements 72 , 74 , 76 , 78 is the same. The divider 80 is used by the right most processor 74 , 78 to perform the division function. The divider 80 can be implemented as a look up table to determine a reciprocal value, which is used by the right most processor 74 , 78 in a multiplication. Since during forward and backward substitution the reciprocal from Cholesky execution already exists in memory, the multiplication of the reciprocal for forward and backward substitution can utilize the reciprocal already stored in memory.
Since the computational data flow for all three processes (determining G, forward and backward substitution) is the same, N or the bandwidth P, all three functions can be performed on the same reconfigurable array. Each processing element 84 , 82 of the reconfigurable array is capable of operating the functions to determine G and perform forward and backward substitution, as shown in FIGS. 19 a and 19 b . The right most processor 82 is capable of performing a pentagon/square and diamond function, 64 , 74 , 78 . The other processors 84 are capable of performing a circle/octagon and star function 66 , 72 , 76 . When performing Cholesky decomposition, the right most processor 82 operates using the pentagon/square function 64 and the other processors 84 operate using the circle/octagon function 66 . When performing forward and backward substitution, the right most processor 82 operates using the diamond function 74 , 78 and the other processors 84 operate using the star function 72 , 76 . The processors 82 , 84 are, preferably, configurable to perform the requisite functions. Using the reconfigurable array, each processing element 82 , 84 performs the two arithmetic functions of forward and backward substitution and the four functions for Cholesky decomposition, totaling six arithmetic functions per processing element 82 , 84 . These functions may be performed by an arithmetic logic unit (ALU) and proper control logic or other means.
To simplify the complexity of the individual processing elements 82 , 84 in the reconfigurable array, the divide and square root functionality 86 are preferably broken out from the array by a reciprocal and square root device 86 . The reciprocal and square root device 86 , preferably, determines the reciprocal to be in a multiplication, as shown in FIGS. 20 a and 20 b by the right most processor 82 in forward and backward substitution and the reciprocal of the square root to be used in a multiplication using the right most processor data and passed through the processors 84 . The determination of the reciprocal and reciprocal/square root is, preferably, performed using a look up table. Alternately, the divide and square root function block 86 may be a division circuit and a square root circuit.
To reduce the number of processors 82 , 84 further, folding is used. FIGS. 21 a and 21 b illustrate folding. In folding, instead of using P processing elements 82 , 84 for a linear system solution, a smaller number of processing elements, F, are used for Q folds. To illustrate, if P is nine (9) processors 82 , 84 , three (3) processors 82 , 84 perform the function of the nine (9) processors over three (3) folds. One drawback with folding is that the processing time of the reduced array is increased by a multiple Q. One advantage is that the efficiency of the processor utilization is typically increased. For three folds, the processing time is tripled. Accordingly, the selection of the number of folds is based on a trade off between minimizing the number of processors and the maximum processing time permitted to process the data.
FIG. 21 a illustrates bi-directional folding for four processing elements 76 1 , 76 2 , 76 3 , 76 4 / 78 performing the function of twelve elements over three folds of the array of 11 b . Instead of delay elements being between the processing elements 76 1 , 76 2 , 76 3 , 76 4 / 78 , dual port memories 86 1 , 86 2 , 86 3 , 86 4 ( 86 ) are used to store the data of each fold. Although delay elements (dual port memories 86 ) may be present for each processing element connection, such as for the implementation of FIG. 12 a , it is illustrated for every other connection, such as for the implementation of FIG. 12 b . Instead of dual port memories, two sets of single port memories may be used.
During the first fold, each processors' data is stored in its associated dual port memory 86 in an address for fold 1 . Data from the matrix is also input to the processors 76 1 - 76 3 , 76 4 / 78 from memory cells 88 1 - 88 4 ( 88 ). Since there is no wrap-around of data between fold 1 processor 76 4 / 78 and fold 3 processor 76 1 , a dual port memory 86 is not used between these processors. However, since a single address is required between the fold 1 and fold 2 processor 76 1 and between fold 2 and fold 3 processor 76 4 / 78 , a dual port memory 86 is shown as a dashed line. During the second fold, each processor's data is stored in a memory address for fold 2 . Data from the matrix is also input to the processors 76 1 - 76 3 , 76 4 / 78 for fold 2 . Data for fold 2 processor 76 1 comes from fold 1 processor 76 1 , which is the same physical processor 76 1 so (although shown) this connection is not necessary. During the third fold, each processor's data is stored in its fold 3 memory address. Data from the matrix is also input to the processors 76 1 - 76 3 , 76 4 / 78 for fold 3 . Data for fold 3 processor 76 4 / 78 comes from fold 2 processor 76 4 / 78 so this connection is not necessary. For the next processing stage, the procedure is repeated for fold 1 .
FIG. 22 a is an implementation of bi-directional folding of FIG. 21 a extended to N processors 76 1 - 76 N-1 , 76 N / 78 . The processors 76 1 - 76 N-1 , 76 N / 78 are functionally arranged in a linear array, accessing the dual port memory 86 or two sets of single port memories.
FIG. 21 b illustrates a one directional folding version of the array of 11 b . During the first fold, each processor's data is stored in its associated dual port memory address for fold 1 . Although fold 1 processor 76 4 / 78 and fold 3 processor 76 1 are physically connected, in operation no data is transferred directly between these processors. Accordingly, the memory port 86 4 between them has storage for one less address. Fold 2 processor 76 4 / 78 is effectively coupled to fold 1 processor 76 1 by the ring-like connection between the processors. Similarly, fold 3 processor 76 4 / 78 is effectively coupled to fold 2 processor 76 1 .
FIG. 22 b is an implementation of one directional folding of FIG. 20 b extended to N processors. The processors 76 1 - 76 N-1 , 76 N / 78 are functionally arranged in a ring around the dual memory.
To implement Cholesky decomposition, forward and backward substitution onto folded processors, the processor, such as the 76 4 / 78 processor, in the array must be capable of performing the functions for the processors for Cholesky decomposition, forward and backward substitution, but also for each fold. As shown in FIGS. 20 a and 20 b for processor 76 4 / 78 . Depending on the implementation, the added processor's required capabilities may increase the complexity of that implementation. To implement folding using ALUs, one processor (such as 76 4 / 78 processor) performs twelve arithmetic functions (four for forward and backward substitution and eight for Cholesky) and the other processors only perform six functions.
FIG. 23 illustrates a slice of a preferred simple reconfigurable PE that can be used to perform all six of the functions defined in Cholesky decomposition, forward substitution, and backward substitution. This PE is for use after the divides are isolated to one of the PEs (referred to as follows as PE 1 ). Two slices are preferably used, one to generate the real x and y components, the other to generated their imaginary components. The subscripts i and r are used to indicate real and imaginary components, respectively.
The signals w, x, y, and z are the same as those previously defined in the PE function definitions. The signals a q and a d represent the current state and next state, respectively, of a PE's memory location being read and/or written in a particular cycle of the processing. The names in parentheses indicate the signals to be used for the second slice.
This preferred processing element can be used for any of the PEs, though it is desirable to optimize PE 1 , which performs the divide function, independently from the other PEs. Each input to the multiplexers 94 1 to 94 8 is labeled with a ‘0’ to indicate that it is used for PE 1 only, a ‘−’ to indicate that it is used for every PE except PE 1 , or a ‘+’ to indicate that it is used for all of the PEs. The isqr input is connected to zero except for the real slice of PE 1 , where it is connected to the output of a function that generates the reciprocal of the square root of the a q r input. Such a function could be implemented as a LUT with a ROM for a reasonable fixed-point word size.
As shown in FIG. 23 , the output of multiplexers 94 1 and 94 2 are multiplied by multiplier 96 1 . The output of multiplexers 94 3 and 94 4 are multiplied by a multiplier 96 2 . The outputs of multipliers 96 1 and 96 2 is combined by an add/subtract circuit 98 . The output of the add/subtract circuit 98 is combined with the output of multiplexer 94 5 by a subtractor 99 . The output of subtractor 99 is an input to multiplexer 94 8 .
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A wireless transmit receive unit (WTRU) recovers data from a plurality of data signals received as a received vector. The WTRU determines data of the received vector by determining a Cholesky factor of an N by N matrix and using the determined Cholesky factor in forward and backward substitution to determine data of the received data signals. The WTRU comprises an array of at most N scalar processing elements. The array has input for receiving elements from the N by N matrix and the received vector. Each scalar processing element is used in determining the Cholesky factor and performs forward and backward substitution. The array outputs data of the received vector.
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FIELD OF THE INVENTION
[0001] The present invention relates to construction. More particularly, the present invention relates to systems for construction which allow easy assembly and disassembly with minimal reliance on tools or fasteners. Even more particularly, the present invention relates to a modular construction system whereby the universal spacing of slots within structural members affords virtually unlimited options for constructing easily scalable and widely adaptable items having high structural integrity.
BACKGROUND
[0002] As the economy booms, construction and consumption of durable goods is approaching record levels. Many so-called “durable” consumer goods require substantial time and effort in assembly, only to be later deemed obsolete because of expiration of the original intended purpose for the goods. In many different industries, interest is increasing toward construction systems featuring improved versatility, adaptability and reusability. The furniture industry is a notable example.
[0003] Bulky, factory-assembled furniture often fails to meet the needs of today's fast paced and mobile culture. Accordingly, efforts have persisted to develop articles of furniture which can be easily transported, then assembled by an individual with no mechanical aptitude whatsoever. Ideally, assembly could be accomplished in a minimum amount of time with a minimum number of tools. As the need for the assembled item in a particular location ends, the furniture could then easily be disassembled, transported and reconstructed at a different location as the same or different item.
[0004] Efforts in this regard pre-date the Roosevelt administration. Through the years, a central theme has been the utilization of slotted structural members interconnecting with other slotted structural members to provide a stable article of furniture without a need for fasteners, tools and the like. A historical example of this theme is found in U.S. Pat. No. 1,903,631 to Morrison, entitled “Collapsible Table.” Later examples are found in U.S. Pat. No. 2,481,671 to John et al. (Children's table) and U.S. Pat. No. 3,300,245 to Rumble, entitled “Picnic Table.” Though each of these articles represent advances over conventional furniture construction, the finished articles are useful only for a narrowly defined purpose and the individual structural components are useless outside the intended application. Specifically, Morrison's Collapsible Table would make a lousy bookshelf and Rumble's Picnic Table could only be converted to a wine rack after the extensive work of a carpenter and her saw.
[0005] More versatile designs pre-date the Carter administration. Notably, systems of standardized structural elements have been designed to fit together in any one of several predetermined arrangements to provide a range of furniture construction options. A historical example of this is found in U.S. Pat. No. 3,812,977 to Glassman, entitled “Storage Assembly.” Glassman's assembly utilizes rectangular, hinged members having interrelated dimensions to create “an indefinite number of possible geometric configurations.” Although the number of possible geometric configurations taught by Glassman may truly be indefinite, the number of useful geometric configurations is limited to less than a dozen varieties of storage cubicles. Glassman's structure could not be configured to make a functional drafting table or water cooler stand, nor could Glassman's basic structure be “scaled” using standard sized structural members to create larger structures.
[0006] Accordingly, the need remains for a construction system incorporating key aspects of compactness and ease of assembly demonstrated by the above-referenced systems, while providing configuration options far exceeding a single configuration or even a group of related configurations.
[0007] An additional need exists for a construction system which satisfies the previously stated need with relatively few different components.
[0008] Yet another need exists for a system satisfying previously stated needs, which can be readily changed from a configuration for use in one application to a second configuration for use in a totally different application using the same components.
[0009] A further need exists for a system having a predefined scalability such that structural components of one dimension can be seamlessly replaced by or interconnected with structural components of other dimensions.
SUMMARY OF THE INVENTION
[0010] The present invention provides a system for construction whereby a virtually unlimited number of configurations relating to vastly different applications can be assembled using a relatively few different structural members. Succinctly stated, structural members are sized and slotted according to a standardized system. Because all structural members are sized and slotted according to the same standardized system, each structural member is interchangeable with every other structural member. This unlimited interchangeability overcomes conventional restraints which have, historically, limited the flexibility of construction systems.
[0011] In a preferred embodiment of the present invention, using construction of furniture items as an example, the system for construction comprises a plurality of structural members. Most often, these member may be substantially square or substantially rectangular, although they may also embody other shapes. Referring to the most common square and rectangular shapes for illustrative purposes, each structural member has a lengthwise (long) side and a widthwise (short) side. Structural members may have slots on a lengthwise side, a widthwise side, or both.
[0012] Importantly, if a structural member has a first slot, the center line of the first slot is located a predetermined distance X from an adjacent lengthwise or widthwise side (if the slot is on a lengthwise side, the predetermined distance X is measured from the adjacent widthwise side, and vice versa). If the structural member has additional slots, the center line of each additional slot is located at any whole-number multiple of the predetermined distance X from the center line of the first slot. For each embodiment, the last slot on a particular side is also centered a predetermined distance X from the other adjacent lengthwise or widthwise side.
[0013] Optionally, slotted or unslotted structural members may accommodate dowel sections on either or both sides, spaced consistent with the system defined herein, which, when interconnecting structural members, provide a flush, virtually non-visible and potentially multi-directional interconnection.
[0014] Accordingly, it is an object of the present invention to provide a modular furniture system incorporating qualities of compactness and ease of assembly while providing configuration options far exceeding a single configuration or even a group of related configurations.
[0015] It another object of the present invention to provide a furniture system which satisfies the foregoing object with relatively few different components.
[0016] Yet another object of the present invention is to provide a system satisfying previously stated objects which can be readily changed from a configuration for use in one application to a second configuration for use in a totally different application using the same components.
[0017] A further object of the present invention is to provide a system having a predefined scalability such that structural components of one dimension can be seamlessly replaced by or interconnected with structural components of other dimensions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 a depicts a representative lengthwise slotted structural member in accordance with the present invention.
[0019] [0019]FIG. 1 b depicts a perspective view of a representative lengthwise slotted structural member in accordance with the present invention.
[0020] [0020]FIG. 2 depicts a representative widthwise slotted structural member in accordance with the present invention.
[0021] [0021]FIG. 3 depicts a second representative widthwise slotted structural member in accordance with the present invention.
[0022] [0022]FIG. 4 depicts a selection of representative lengthwise slotted structural members in accordance with the present invention.
[0023] [0023]FIG. 5 depicts a selection of representative lengthwise slotted structural members being adapted for dowel implementation in accordance with the present invention.
[0024] [0024]FIG. 6 depicts an exemplary assembly of two lengthwise slotted structural members in accordance with an embodiment of the present invention.
[0025] [0025]FIG. 7 depicts an exemplary assembly of one lengthwise slotted structural member and one widthwise slotted structural member in accordance with an embodiment of the present invention.
[0026] [0026]FIG. 8 depicts an exemplary assembly of structural members in accordance with the present invention.
[0027] [0027]FIG. 9 depicts an exemplary structural assembly derived from two subassemblies.
[0028] [0028]FIG. 10 depicts an exemplary assembly of structural members in accordance with the present invention.
DETAILED DESCRIPTION
[0029] The invention is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.
[0030] Referring now to FIG. 1A, a structural element 10 is shown. Structural element 10 comprises two equal length lengthwise sides 12 , 14 and two equal length widthwise sides 16 , 18 . The respective lengthwise sides 12 , 14 and widthwise sides 16 , 18 define a first planar side 19 and a second planar side 20 (not shown), the planar sides being in parallel planar disposition with respect to each other. Additionally, structural member 10 defines a first slot 21 and a second slot 23 along its lengthwise side 12 . More particularly, the respective first and second slots 21 , 23 are defined by a first slot edge 22 , a second slot edge 24 , and a slot end 26 . Because each of the slots defined by structural member 10 are defined along a lengthwise side 12 , a center line of each slot is generally parallel to the widthwise sides (edges) 16 , 18 of structural member 10 .
[0031] Importantly, first slot 21 is centered a predetermined distance X 28 from adjacent widthwise side 18 . The relationship of other slots, including second slot 23 , to the first slot 21 on structural member 10 is critical and will be later explained in detail with reference to a later figure. Additionally, it is critical to here note that the overall lengths of slotted sides of all members is, similarly, a whole-number multiple of the predetermined distance X, as well. For example, the overall length of the lengthwise (slotted) side 12 is 4 X.
[0032] [0032]FIG. 1B is a tilted perspective view of structural member 10 , illustrating thickness 30 between first planar side 19 and second planar side 20 .
[0033] Referring now to FIG. 2, structural member 100 depicts a configuration in which slots are positioned on at least one widthwise side. More specifically, structural member 100 comprises two equal length parallel lengthwise sides 112 , 114 and two equal length parallel widthwise sides 116 , 118 . The respective lengthwise sides 112 , 114 and widthwise sides 116 , 118 have a thickness and define a first planar side 119 and a second planar side 120 , the respective planar sides being in parallel planar disposition with respect to each other.
[0034] As depicted in representative structural member 100 , a first slot 121 is defined within widthwise side 118 by a first slot edge 122 , a second slot edge 124 and a slot end 126 . Similarly a second slot 123 is defined along widthwise side 116 of structural member 100 by a first slot edge 122 , a second slot edge 124 and a slot end 126 .
[0035] Referring to first slot 121 , it is important to note that first slot 121 is centered a predetermined distance X 128 from the lengthwise side 114 along widthwise side 118 .
[0036] It is here noted that structural member 10 , depicted in FIGS. 1A and 1B, and structural member 100 , depicted in FIG. 2, are merely representative of the possible configuration of various structural members. In other words, structural member 10 could be extended along lengthwise sides 12 , 14 or widthwise sides 16 , 18 for an indefinite distance, limited only by practicality. In such configurations, it is understood that structural members may define additional slots. Similarly, structural member 110 may be extended along either lengthwise sides 112 , 114 or widthwise sides 116 , 118 . However, as later described, the system specifically provides for interconnection between structural members as an alternative to lengthwise or widthwise extensions.
[0037] [0037]FIG. 3 illustrates an embodiment in which the widthwise slotted sides and lengthwise sides of a structural member are elongated. Structural member 200 comprises two equal length parallel lengthwise sides 210 , 220 , and two equal length parallel widthwise sides 230 , 240 . As can be seen, structural member 200 includes first slot 232 , second slot 234 , third slot 242 , and fourth slot 244 . Importantly, first slot 232 is centered a predetermined distance X 250 from first lengthwise side 210 . Second slot 234 is positioned a predetermined distance 3 X 260 from the same first lengthwise side 210 . Importantly, the relationship of the first slot and second slot to the second lengthwise side 220 is noted. Specifically, first slot 232 is centered a predetermined distance 3 X from second lengthwise side 220 and second slot 234 is positioned a predetermined distance X from the same second lengthwise side 220 . Again, as with previously referenced structural members 10 and 100 , structural member 200 is merely an example of a configuration of the present invention intended the show the spacing relationship of slots within various structural members. As with all structural members utilized in the present invention, the lengthwise sides and widthwise sides may vary without restriction, so long as the spacing relationship between slots and their respective first and last lengthwise or widthwise sides, as defined herein, remains as described in reference to FIG. 4, below.
[0038] Turning now to FIG. 4, representative lengthwise slotted structural members embodying the fundamental principle of the present invention are depicted. More particularly, structural members 410 , 420 , 430 , 440 , 450 and 460 each have slots located at positions which are whole-number multiples of a predetermined distance X from a widthwise side 400 (and, as previously described, another whole number multiple X from the opposite widthwise side). As previously described with reference to other figures, predetermined distance X is a distance between a first widthwise side 400 and the center of a first slot. Again, as previously discussed, distances between slots are measured between center lines of the respective slots.
[0039] In the representative examples depicted in FIG. 4, for instance, structural member 410 defines one slot at a predetermined distance X (“1X”) from a first widthwise side 400 . Structural member 420 defines slots at positions 1X and 3X. Structural member 430 defines slots at positions 1X, 2X and 3X, while structural member 440 defines slots at positions 1X, 3X and 5X. Structural member 450 defines slots at positions 1X and 5X, while structural member 460 defines slots at positions 1X, 2X and 5X. As previously described and shown with reference to other figures, the overall length of structural members is also a whole number multiple of the predetermined distance X, and slot centers are all a whole number multiple X from opposing sides. It should be understood that these representative structural members are merely representations of a few of the many slotting combinations possible in keeping with the spirit and scope of the present invention. Similarly, while the structural members depicted in FIG. 4 depict defined slots on a single lengthwise side, it will be understood and appreciated that slots could be defined on both lengthwise sides and/or on one or both widthwise sides, provided the spacing system described herein is applied.
[0040] [0040]FIG. 5 depicts an optional embodiment of the present invention in which dowel sections are used to facilitate vertical, horizontal and diagonal interconnection between certain structural members, preferably on both ends of a particular structural member. More specifically, FIG. 5 depicts structural members 510 , 530 , 540 , 560 and 570 , each defining dowel receiving holes on a second widthwise side, as well as the first widthwise side. Although each of the aforementioned structural members depicts a dowel section already inserted into or otherwise carried by the second widthwise side of the respective structural member, it will be understood and appreciated that, for illustrative purposes, this represents an intermediate step in the modular construction process in which this embodiment is implemented, the intermediate step being the insertion of a dowel section into a respective directly corresponding dowel receiving hole.
[0041] Surface structural members 520 and 550 illustrate required positioning of dowel holes in order to maintain conformity with the critical aspect of the present invention. More specifically, with reference to surface structural member 520 , first dowel holes 525 are centered a predetermined distance X from the first adjacent widthwise side 500 . Similarly, second dowel holes 527 are centered a predetermined distance 3X from the first adjacent widthwise side 500 .
[0042] The same principle holds true in surface structural member 550 , in which first dowel holes 555 are positioned a predetermined distance X from the first widthwise side, while second dowel holes 557 are positioned a predetermined distance 5X from the first adjacent lengthwise side 500 and a predetermined distance X from the opposing lengthwise end. As previously stated, dowel holes may be positioned in any variety of locations and in any number, so long as the positioning conforms to the previously stated principles which embody the inventive aspect of the present invention.
[0043] [0043]FIG. 6 depicts a preferred system of assembly of structural members in a preferred embodiment of the present invention. More specifically, FIG. 6 depicts two lengthwise slotted structural members 10 , 10 ′, interconnected via press-fit of respective first slots 21 , 21 ′ (not shown). Importantly, for structural members such as 10 and 10 to be successfully interconnected in a sufficiently rigidly structure 600 , tolerances for slots such as 21 and 21 ′, as well as thicknesses 30 of other structural members, must be carefully specified and closely monitored during production processes.
[0044] [0044]FIG. 7 depicts a representative structural assembly 700 comprising a lengthwise slotted structural member 10 and a widthwise slotted structural member 100 . The two respective structural members 10 , 100 are interconnected in a well known manner at first slots 21 and 121 (not shown). Again, this is merely a representative example of the interconnection of different structural members to create a larger structural member in accordance with the present invention.
[0045] More elaborate examples of construction options available in accordance with the present invention are depicted in FIGS. 8 and 9. Referring now to FIG. 8, structural assembly 800 is comprised of previously referenced interconnected structural members. More specifically, two lengthwise slotted members 560 , two lengthwise slotted members 530 and two lengthwise slotted members 510 are interconnected to provide a versatile structure with a vast array of possible applications.
[0046] [0046]FIG. 9 depicts an example of the assembly of one large structure from two smaller structures. More particularly, structure 800 is interconnected with an identical structure 900 (illustrated in a rotated orientation) to form superstructure 910 . It is here noted that the scalability of the individual structural members previously described allows interconnection of two different structures without altering the symmetry and proportions of the superstructure 910 . This feature is especially advantageous with assembling large structures from a series of smaller structures in a situation when system stability is desired.
[0047] [0047]FIG. 10 depicts a similarly versatile structure 1000 , comprising six lengthwise slotted structural members 530 and a widthwise slotted structural member 200 .
[0048] Critically, it should be understood and appreciated that because of the standardized slot spacing system of the present invention and the ability to interconnect structural members within the system in such a way as to provide consistent spacing, a virtually unlimited number of structures can be created from relatively few different structural members, limited only by imagination. It is specifically intended that the scope of the present invention not be limited by the preceding discussion of a limited number of embodiments of the present invention, such as in a furniture application, but by the limits set forth in the appended claims.
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A system for construction whereby a virtually unlimited number of structural configurations relating to vastly different applications can be assembled using relatively few different structural members. Structural members are sized and slotted according to a standardized system. Because structural members are sized and slotted according to the standardized system, the vast majority of structural members are interchangeable and inter-connectable with other structural members to allow for scaling and expansion of structural assemblies while maintaining consistent spacing. This wide range of interchangeability and consistently spaced inter-connectibility overcomes conventional restraints which have, historically, limited design flexibility and the resulting utility of conventionally constructed items.
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TECHNICAL FIELD
This invention is in the field of semiconductor chip design. More specifically, this invention relates to the design of logic to achieve timing closure.
BACKGROUND
By dividing a process into steps, and performing the steps simultaneously on different data, the frequency at which the processing system can operate depends on the length of time to complete its slowest step. The same process performed with a shorter “slowest step” can be performed faster. Designing shorter steps in order to achieve higher speed generally requires creating more steps. More steps, given imperfect balancing of the length of steps, require more time to generate the resulting output from any particular input.
Processes are often referred to as pipelines. Storage devices between steps are referred to as pipeline stages. The number of steps in a processing system is referred to as the pipeline depth. Within a system-on-chip (SoC) data moves through a pipeline no faster than one stage per clock cycle. Therefore, the number of stages determines the number of clock cycles for each input datum to be fully processed. Such time is often referred to as latency. Longer latency due to pipeline stages is undesirable, but the faster clock frequency due to pipeline stages is desirable. Designing an optimal number of pipeline stages requires a trade-off between clock frequency and cycles of latency.
Within the design of a data processing chip it is not immediately clear how to optimally apply pipelining. The conventional method of designing a pipeline that works is an iterative process of experimentation. It is time consuming. Furthermore, it rarely results in an optimal design.
The problem is further complicated when the physical layout of the chip is considered. The length of time for data to propagate from a point of production to a point of consumption depends on the distance and the average propagation rate through the wires between those points. Conventionally, the physical layout is considered at a later stage in the chip design process than the decisions about pipelining. To avoid unexpected problems achieving the desired clock frequency during physical design, pipeline stages are placed at smaller increments within the processing logic, thereby leaving extra time for data to propagate between points if they happen to be distant in the physical design. This over-design of pipeline stages costs area, power consumption, and especially latency. Therefore, what is needed is a system and method to automatically determine optional pipeline stages in order to meet clock frequency constraints.
SUMMARY
The disclosed invention is a method and electronic design system to automatically activate optional pipeline stages in order to meet clock frequency constraints. In alternative embodiments of the invention, the location of data processing modules within chips is determined in conjunction with the configuration of pipeline stages.
DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a module, as in SoCs, with pipeline stages.
FIG. 2 illustrates a path between pipeline stages, the path occurring in three modules.
FIG. 3 illustrates a sequence of optional pipeline stages in a path, a subset of which is enabled.
FIG. 4 illustrates signal propagation times through a path.
FIG. 5 illustrates two sequences of optional pipeline stages on correlated paths, a subset of which is enabled.
FIG. 6 illustrates signal propagation times through a correlated path.
FIG. 7 is a process flow diagram according to an embodiment.
DETAILED DESCRIPTION
This invention relies on an ability to determine a number of data path connections within the logic of a system on a chip or system-on-chip (SoC) where a pipeline stage can be inserted. A pipeline stage is an array of flip-flops (flops) that stores at least a word of data. It generally has the benefit of dividing the signal propagation delay through the path into two shorter paths such that a shorter clock period (a higher clock frequency) can be used to synchronize the SoC. Such data path connections are known as optional pipeline stages. The chip can function correctly with or without each pipeline stage. When present, the optional pipeline stage is said to be activated. A set of activated optional pipeline stages is known as a configuration.
FIG. 1 illustrates module 100 , comprising a first pipeline stage 102 and second pipeline stage 104 . Pipeline stages, each comprising parallel flip-flops, are depicted with the conventional symbol of a flip-flop. Lines represent paths through logic elements, the logic elements are not shown. Path 120 connects input 106 to pipeline stage 102 . Path 130 connects pipeline stage 102 to pipeline stage 104 . Path 140 connects pipeline stage 104 to output 108 . Path 150 connects input 110 to output 112 . Path 160 connects input 110 to pipeline stage 104 through logic shared with path 130 and 150 . Path 170 connects pipeline stage 102 to output 112 through logic shared with path 130 and 150 .
This illustrates the four types of path segments on which signals, the time of which can be calculated, can propagate within a module:
input to pipeline stage (paths 120 and 160 );
pipeline stage to pipeline stage (path 130 );
pipeline stage to output (paths 140 and 170 );
input to output (path 150 );
FIG. 2 illustrates a full path between a first pipeline stage 200 and a second pipeline stage 202 . The path occurs in three interconnected modules 210 , 220 , and 230 . The full path comprises a pipeline stage to output path segment from pipeline stage 200 to connection 240 , an input to output path segment from connection 240 to connection 250 , and an input to pipeline stage path segment from connection 250 to pipeline stage 202 .
Every flop, and therefore every pipe stage, has a unit cost in terms of silicon area. It also has a cost in terms of power consumption as a result of the power used to drive flops switching current and power used to toggle the clock tree. The cost is approximately proportional to the number of flops, which is generally approximately proportional to the width of the data in the data path.
In practice, chips are designed with the underlying constraints of target clock frequencies in different parts of the chip and a target cell library for a particular CMOS process node.
Most SoCs are designed as an interconnection of modules. Each module has a number of optional pipeline stages, a number of inputs, a number of outputs, and a number of required registers. Timing within the module from flop to flop, input to flop, flop to output, and input to output can be determined for the module alone. The flop to output and input to flop delay can be added together where there is connectivity between modules in the SoC. Registers comprise flops as do optional pipeline stages when activated.
Some SoC designs contain non-sythesizable logic blocks, such as memory arrays or register files. With regard to delay analysis, those blocks may be described with the same formalism as synthesized gates. Their interface ports are usually comparable to register ports.
FIG. 3 illustrates a sequence of pipeline stages. Pipeline stages are depicted as triangles for simplicity. Each optional pipeline stage is shown in white and can be activated or not. Fixed pipeline stages are shown in grey. The full path occurs in modules 320 , 340 , and 360 . The path begins at pipeline stage 302 , traverses optional pipeline stages 304 , 306 , and 308 , and ends at pipeline stage 310 . Path segment X is from pipeline stage 302 to pipeline stage 304 . Path segment Y is from pipeline stage 304 to pipeline stage 306 . Path segment Z is from pipeline stage 306 to pipeline stage 308 . Path segment Q is from pipeline stage 308 to pipeline stage 310 .
Timelines of signal propagation delays are shown in FIG. 4 . Clock cycle 400 has duration T CLK . FIG. 3 path segments X, Y, Z, and Q take FIG. 4 time T X , T Y , T Z , and T Q time, respectively. Signal propagation time from FIG. 3 register 302 to optional pipeline stage 308 , consisting of path segments X, Y, and Z, takes T X plus T Y plus T Z propagation time, which is shown in FIG. 4 . The cumulative time exceeds the duration of T CLK . Activating optional pipeline stage 304 would break the long timing path. The timing path from pipeline stage 304 through T Y , T Z , and T Q also violates the T CLK timing constraint. Activating pipeline stage 308 would resolve that violation. However, activating pipeline stage 306 would resolve both timing violations with less cost.
The best configuration of pipeline stages is less clear when multiple paths pass through optional pipeline stages. In accordance with various aspects of the present invention, FIG. 5 illustrates the sequence of FIG. 3 with an additional sequence of optional pipeline stages that share a path. The second path begins at register 514 , traverses optional pipeline stages 516 , 304 , 306 , and 308 , and ends at register 310 . Path segment A is from pipeline stage 514 to pipeline stage 516 . Path segment B is from pipeline stage 516 to pipeline stage 304 .
Timelines of signal propagation delays are shown in FIG. 6 , in accordance with the various aspects of the present invention. As in FIG. 4 , clock cycle 400 has duration T CLK . FIG. 5 path segment A signal propagation takes FIG. 6 T A time. FIG. 5 path segment B signal propagation takes FIG. 6 T B time. Signal propagation time from FIG. 5 pipeline stage 514 to optional pipeline stage 306 , consisting of path segments A, B, and Y takes FIG. 6 T A , T B , T Y propagation time. The cumulative time of which exceeds the duration of T CLK . The cumulative time of T X and T Y is less than the duration of T CLK . Therefore, activating pipeline stage 304 resolves the timing violation, but activating pipeline stage 306 does not.
The activation or deactivation of each pipeline stage affects all paths through it, and therefore all other pipeline stages traversed by all of those paths and so forth. Typical SoC designs have thousands of paths sharing each of hundreds of optional pipeline stages.
One approach that designers use is an iterative process of experimentation to determine a best configuration of optional pipeline stages. A method is to begin with no pipeline stages then repeatedly synthesize the design, analyze timing, and add a pipeline stage at the point in the logic of the slowest critical path.
An experienced designer considers all factors and creates an initial configuration that is more likely to meet the constraints. This approach will require fewer iterations and thereby tend to add fewer unnecessary pipeline stages. However, if the initial configuration is too pessimistic then this approach will still have unnecessary pipeline stages.
Another method, in accordance with other aspects of the present invention, would iterate automatically, considering where there is extra slack and accordingly moving pipeline stages farther apart in the logic paths. That will cause paths between other pipeline stages to be shortened, which will cause other pipeline stages to be moved. In this case, even small changes potentially cause changes in many other optional pipeline stages of the chip and so a large number of iterations would still be required to approach an optimal configuration.
Logic Synthesizers
System-on-chip designers commonly use logic synthesizers. Those tools take a logic behavior as input, and produce as an output an arrangement of logical gates that realizes the behavior and meets maximum long path requirements, on a given process node and a target clock frequency. Different configurations of a module with regard to pipeline stages have different behaviors; a logic synthesizer is not able to select a configuration: it tries and optimizes the one it has been given as an input.
The implementation of a logic synthesizer consists of two phases. In a first phase, called mapping, the behavior is translated into an arrangement of gates. In a second iterative phase, called timing optimization, parts of the arrangement are modified to shorten the longest path, while keeping the same behavior. Many timing optimization techniques have been described and all imply using more silicon area and more power. The stronger the timing constraints are, the higher the impact on area and power are expected to be, until the logic synthesizers fails to find a solution to the problem. The optimization is always limited by the longest path: one path longer than required is enough to make the logic synthesizer fail.
Finding the optimal configuration would basically require all configurations to be separately synthesized. The present invention determines, for given constraints of target clock frequency and CMOS process node, without iteration, an optional pipeline stage configuration that, when passed the logic synthesizer mapping phase, presents an even timing optimization problem. The timing optimization is then more likely to converge, in a shorter time frame, and with less area and/or power impact.
Linear Equations
In accordance with the various aspects of the present invention, embodiments of the invention use a mixed integer programming linear equation solver to compute an optimized configuration of optional pipeline stages.
Full system timing can be broken down into smaller tasks by analyzing individual module timings. This makes the full system analysis simpler, as only the number of optional pipeline stages within a module need be considered at a time when calculating timing. Determining the optimal configuration of a module depends on calculating timing with every combination of optional pipelines stages activated. This would require 2 N calculations, where N is the number of optional pipeline stages within the module. In practice, timing calculated with each optional pipeline stage activated alone gives a nearly optimal guess of the best configuration. This method requires only N+1 calculations. In accordance with the disclosure of the present invention as related to the various embodiments, this method is used to improve run time.
Timing is calculated within each module by running a synthesis process on a configuration of a model of each instantiated module. The synthesis does not generate a netlist of standard cells, but does generate a delay estimate of timing arcs between flip-flops, inputs and outputs.
In accordance with various aspects of the present invention, the following steps are performed:
1. Perform a synthesizer mapping phase on each module, once with each optional pipeline stage activated alone and once with no pipeline stage, to generate a timing and area estimate for the module. 2. Build timing arrays of the synthesized timing values for each pipeline stage; with an array for each of input to flop, flop to flop, flop to output, and input to output timing. Sort each array of pipe stages in order of timings. 3. Use a linear programming solver such as the open source Ipsolve mixed-integer linear programming solver.
A resulting optimal configuration of optional pipeline stages is represented as a vector of Boolean values that is the lowest cost solution to a system of linear equations. A linear problem is a set of inequalities of a set of variables. Lpsolve is used to find an optimal solution vector that meets all timing constraints, if possible.
The variables include:
1. the arrival time of signals per module port and
2. Boolean state of activation per optional pipeline stage.
Inequalities for the solver include:
1. For each module output port:
arrival time≧clock-to-output delay of the module; and
arrival time≧input port arrival time+input to output delay.
2. For each input port connected to each activated pipeline stage:
input port arrival time+input port to flip-flop delay clock period.
Within modules, input port to output port, input port to pipe stage, and pipe stage to output port connectivity and a timing estimate for each connection is known from the models of the configuration of each module instance. The timing, as well as an area estimation, is derived from a synthesis algorithm on the instances of configured modules. The synthesis algorithm is generic across process technologies.
The cost function to be minimized is the sum of the cost of each activated pipeline stage. The cost of each activated pipeline stage is determined by the area estimation. In another embodiment cost is a function of area estimation and power consumption.
FIG. 7 shows a process flow diagram in accordance with one aspect of the present invention with an embodiment of automatic pipeline stage insertion. The considerations of pipeline stage cost, connectivity, module location, module timing as determined by a synthesis process, and timing constraints are input to the solver. The solver outputs an optimal configuration if one can be found that meets the criteria of all inequalities.
In accordance with another aspect of the present invention, another embodiment considers the data processing latency introduced by pipeline stages. Forward pipeline stages are ones that store datapath signals in flops such that no forward-going combinatorial paths traverse the pipeline stage. That includes the data path as well as sideband signals and forward-going flow control signals. Backward pipeline stages store datapath signals in flops, thereby having a similar cost as forward-going pipeline stage, but have datapath multiplexing and other forward-going combinatorial logic paths. Backward pipeline stages ensure that no combinatorial paths are present on backward-going flow control signals. A key difference is that forward pipeline stages add a cycle of latency to transactions and backward pipeline stages do not. If a combinatorial logic path may be broken on both forward-going and backward-going signals, it is generally preferable to break the path with a backward pipe stage.
Desired maximum data processing latency between any point of data production and point of data consumption is a constraint on the solver. The embodiment includes the additional variable of a target latency per initiator-target connectivity. An additional inequality is, that for each connection between initiator and target, the number of activated optional pipeline stages in path latency constraint.
In accordance with another aspect of the present invention, another embodiment of the invention considers not just synthesized timing within modules, but the time required for the propagation of signals between modules. The locations of modules within the chip floorplan are used, a simple table of their relative distances is used, or both are used with a function between delay and distance. Module locations are represented in a simplified format, with a single x and y coordinate. In accordance with one aspect of the present invention, in one embodiment the function is a simple delay proportional to the Manhattan distance between modules. In accordance with another aspect of the present invention, in another embodiment the delay is a super-linear function of distance in order to account for vias, obstructions, and varying propagation times on different metal layers. Output port to input port connectivity between modules is known from the SoC architecture level netlist. Output port to input port delay is estimated by a signal propagation speed multiplied by the distance.
The application of a linear equation solver to the configuration of optional pipeline stages is extended from that previously described. Additional variables include:
3. x axis location per module;
4. y axis location per module;
5. distance per connected pair of modules;
Additional inequalities include:
3. For each pair of connected module 1 and module 2 :
distance≧x 1 −x 2 +y 1 −y 2 ;
distance≧x 1 −x 2 +y 2 −y 1 ;
distance≧x 2 −x 1 +y 1 −y2; and
distance≧x 2 −x 1 +y 2 −y 1 .
4. For each module input port:
arrival time≧arrival time at a connected output port+distance*signal propagation rate.
A resulting optimal configuration of optional pipeline stages is represented as a vector of Boolean values along with arrays of x and y coordinates for each module.
A network-on-chip is a component within the design of an SoC. A network-on-chip, designed modularly, lends itself to presenting data path connections where a pipeline stage can be simply inserted without changing the correctness of chip functionality. The logic and wires of a network-ok-chip span relatively long distance. As a result, some embodiments of this invention are applied particularly to a network-on-chip.
The various aspects of the present invention may be implemented in software, hardware, application logic, or a combination of software, hardware, and application logic. The software, application logic and/or hardware may reside on a server, an electronic device, or a service. If desired, part of the software, application logic and/or hardware may reside on an electronic device, part of the software, application logic and/or hardware may reside on a server.
While the present invention has been described with reference to the specific applications thereof, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process step or steps, to the objective, spirit and scope of the present invention. All such modifications are intended to be within the scope of the claims appended hereto.
The foregoing disclosures and statements are illustrative only of the present invention, and are not intended to limit or define the scope of the present invention. The above description is intended to be illustrative, and not restrictive. Although the examples given include many specificities, they are intended as illustrative of only certain possible applications of the present invention. The examples given should only be interpreted as illustrations of some of the applications of the present invention, and the full scope of the present invention should be determined by the appended claims and their legal equivalents. Those skilled in the art will appreciate that various adaptations and modifications of the just-described applications can be configured without departing from the scope and spirit of the present invention. Therefore, it is to be understood that the present invention may be practiced other than as specifically described herein. The scope of the present invention as disclosed and claimed should, therefore, be determined with reference to the knowledge of one skilled in the art and in light of the disclosures presented above.
Although various aspects of the present invention are set out in the independent claims, other aspects of the invention comprise any combination of the features from the described embodiments and/or the dependent claims with the features of the independent claims, and not the solely the combination explicitly set out in the claims.
Unless defined otherwise, 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. Any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention.
All publications and patents cited in this specification are herein incorporated by reference as if each individual publication or patent were specifically and individually indicated to be incorporated by reference and are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The citation of any publication is for its disclosure prior to the filing date and should not be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.
It is noted that, as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.
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The optimal configuration of a number of optional pipeline stages within the data paths of systems-on-chip is determined by application of a solver. The solver includes variables such as: the placement of modules physically within the floorplan of the chip; the signal propagation time; the logic gate switching time; the arrival time, after a clock edge, of a signal at each module port; the arrival time at each pipeline stage; and the Boolean value of the state of activation of each optional pipeline stage. The optimal configuration ensures that a timing constraint is met, if possible, with the lowest possible cost of pipeline stages.
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[0001] This invention claims priority, under 35 U.S.C. §120, to the U.S. Provisional Patent Application No. 60/681,223 to Norman L. Clifton filed on May 13, 2005, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to door accessories, specifically to door lock and carry systems and devices.
[0004] 2. Description of the Related Art
[0005] During construction of buildings it is generally accepted that doors are installed in the final stages of construction. Having door frames but not doors provides workers with easier access to all portions of a building and generally speeds up the building process, especially in the final stages. However, there are times when doors are needed and/or wanted. Examples include: in the evening for security, to restrict air flow from one room to another, to reduce noise pollution from one portion of a facility to another, etc. Further, similar considerations are present during remodeling, painting, etc.
[0006] To accommodate such needs it is known to prematurely install one or more doors, to hang a covering such as a plastic sheet over a door frame, and to lean a substantially planar material against a door frame to block the frame. Other examples of attempts to provide temporary portions of doors include the following patents which are hereby incorporated by reference herein:
[0007] U.S. Pat. No. 5,325,685 to Frank discloses a portable auxiliary door lock including a lock cylinder slidable upon a bar having toothed edges to engage the locking means within the cylinder. The device differs from such locks for sliding panels, as it provides for temporary attachment between the edge of an arcuately hinged door and the adjacent door jamb to secure the door when it is closed. One end of the bar is bent at a 90 degree angle to insert into the latch recess of the striker plate. However, rather than using the lock cylinder to abut against the door and thereby at least partially blocking access to the lock cylinder for actuation due to the adjacent door knob assembly, the cylinder faces away from the knob assembly and an additional stop plate is used to retain the door. Other improvements are provided, such as adjustment for the spacing between the door and the jamb and additional security to preclude the forced removal of the lock cylinder from the bar.
[0008] Further, U.S. Pat. No. 4,046,185 to Bruning discloses a temporary door installation for a grain carrying freight car wherein the pry board is upwardly tapered to eliminate the need for special sealing.
[0009] However, these solutions fail to provide a system and/or device facilitating a sturdy temporary door that is easily installed and easily removed.
[0010] What is needed is a door system and/or device that solves one or more of the problems described herein and/or one or more problems that may come to the attention of one skilled in the art upon becoming familiar with this specification.
SUMMARY OF THE INVENTION
[0011] The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been filly solved by currently available door systems and/or devices. Accordingly, the present invention has been developed to provide a lock and carry system or kit for doors.
[0012] In one embodiment of the invention, there is a removable door locking system or lock and carry kit, including one or more of the following: a door blank configured to be disposed in a door frame; a first elongated member configured to pass through the latch hole and extend therefrom; a second elongated member disposable in the lock body hole and configured to extend therefrom; a flange extending radially from a first end of the elongated member and configured to stop passage of the first end through the lock body hole of the door; an aperture through the second elongated member; and/or a detachable lock coupleable to the aperture and configured to stop passage of the second end through the lock body hole when coupled to the aperture.
[0013] In another embodiment the door blank may include a lock body hole through the door blank and configured to receive a lock body and/or a latch hole through the door blank and in communication with the lock body hole.
[0014] In still another embodiment, the elongated member may include a first end shaped to substantially prevent egress of the first elongated member from the latch hole through the lock body hole when the first end is disposed in the lock body hole and/or a second end disposable through the lock body hole.
[0015] In a further embodiment, there may be a flexible member coupled to the second end and configured to facilitate threading the second elongated member through the lock body hole.
[0016] In a still further embodiment, there may be a door fitting slot disposed on an exterior surface of the first end.
[0017] In yet another embodiment, the first elongated member may include a plurality of telescoping members disposable in an extended and a retracted position. The first elongated member may further have a spring disposed within the plurality of telescoping members. The spring may bias the telescoping members in the extended position.
[0018] In a still yet further embodiment, there may be one or more eyelets coupled to the first and/or second elongated members. Such eyelets may provide anchoring for straps, thongs, key-chains, mechanical coupling, clips, hooks, etc.
[0019] Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, us language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language throughout this specification may, but do not necessarily, refer to the same embodiment.
[0020] Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.
[0021] These features and advantages of the present invention will become more filly apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DECEPTION OF THE DRAWINGS
[0022] In order for the advantages of the invention to be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
[0023] FIG. 1 illustrates a side perspective view of a rod-shaped member 100 according to one embodiment of the invention;
[0024] FIG. 2 illustrates a side perspective view of a bolt 200 according to one embodiment of the invention;
[0025] FIG. 3 illustrates an exploded view of a bolt 200 according to one embodiment of the invention;
[0026] FIG. 4 illustrates a perspective view of a lock and carry system being placed in operation according to one embodiment of the invention; and
[0027] FIG. 5 illustrates a perspective view of a lock and carry system for a door according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
[0029] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0030] FIG. 1 shows a side perspective view of a rod-shaped member or second elongated member 100 according to one embodiment of the invention. The illustrated rod-shaped member 100 is generally cylindrical. There is a first end or door fitting portion 120 and a second end or handle 110 . The first end is shaped to substantially prevent egress of a first elongated member 200 (See FIG. 4 ) from a latch hole 460 (See FIG. 4 ) when the first end 120 is disposed in a lock body hole 430 (See FIG. 4 ).
[0031] The illustrated handle portion 1 10 is smaller in radius than the door fitting portion 120 and is shaped and sized to be disposable through an associated lock body hole 430 , such as a standard sized lock body hole for a particular type of door. There is also shown a cavity or aperture 130 through the second elongated member 100 . The illustrated cavity 130 is in a door fitting portion 120 . The cavity 130 may be configured to receive mechanisms, such as but not limited to locks, bolts, and bolt mechanisms.
[0032] There is also shown a cavity bar 135 defining a portion of the cavity 130 . The cavity bar 135 may be configured to provide a feature around which a detachable lock 520 (See FIG. 5 ) may couple. There is also shown a door fitting slot 140 . The door fitting slot 140 may be included in the door fitting portion 120 . The illustrated door fitting slot 140 includes a ridge 142 and may be configured to accommodate mechanisms and/or portions of a door hole that may be non-cylindrical and/or non-circular. The ridge 142 and door fitting slot 140 may enable proper radial alignment and/or proper longitudinal alignment of the rod-shaped member 100 . The door fitting slot 140 may enable proper alignment of a bolt 200 (See FIG. 2 ) and/or may prevent easy removal of a bolt 200 .
[0033] The illustrated rod-shaped member 100 is configured to fit within a hole in a door. Preferably the rod-shaped member 100 is configured to fit within a standard sized hole drilled into doors for the purpose of installing locks. The rod-shaped member 100 may be configured to fit snugly within a standard sized door hole. The rod-shaped member 100 may have a circular, ellipsoid, oval, rectangular, irregular, polygonal, etc. cross section that may correspond to a door hole. The rod-shaped member 100 may be longer than a width of the rod-shaped member 100 or may be equal to or shorter than a width of the rod-shaped member 100 .
[0034] The rod-shaped member 100 may be made of a great variety of materials. In one embodiment, the rod-shaped member 100 is constructed including a durable rigid material. The rod-shaped member 100 may include wood, metal, composite, resin, fiber, polymer, ceramic, and/or any other durable and/or rigid material. The rod shaped member 100 may include more than one material.
[0035] The rod-shaped member 100 may be oblong and/or may be sufficiently long to extend through a hole or lock body hole 430 (See FIG. 4 ) in a door or door blank 450 (See FIG. 4 ) configured to be disposed in a door frame. The rod-shaped member 100 may be sufficiently long to extend through a lock body hole 430 in a door 450 and simultaneously extend outward substantially perpendicular from the door 450 . The rod-shaped member 100 preferably is sufficiently long to extend outward from a door 450 enough to provide a gripping surface large enough to accommodate one or two human hands. This structure may be a handle. There may be a second handle extending out from a second side of the door 450 .
[0036] The rod-shaped member 100 may have an exterior surface configured to enable gripping of the rod-shaped member 100 . In one embodiment, the rod-shaped member 100 may have an outer surface comprising a material including properties that enhance friction between a hand and the rod-shaped member 100 . For example, and not as limitation, the outer surface may include rubber, plastic, and/or any other polymer. The rod-shaped member 100 may have an outer surface shaped to enhance gripping of the rod-shaped member 100 . There may be ripples, hand grips, one or more longitudinal ridges, circumferential ridges, and/or any other structures/shapes known in the art to enhance grippability of an object, particularly a rod-shaped object.
[0037] There may be a multiplicity of ribs 150 defining an outer shape of the rod-shaped member 100 . The ribs 150 may have cavities 160 therebetween. Such ribs and cavities 160 may beneficially enhance gripping and/or reduce a weight of the second elongated member 100 .
[0038] There is shown a sloping section 170 configured to transition the handle portion 10 to the door fitting portion 120 . The sloping section advantageously provides a radial transition between the first and second ends 120 and 110 without having any sharp corners that may damage a door blank and/or a user.
[0039] There is shown an eye or eyelet 180 configured to receive member(s) coupled thereto, such as, but not limited to elongated flexible materials 410 (See FIG. 4 ), such as leather strips or thongs. The eyelet 180 may provide an anchoring portion for attachment and/or storage of one or more accessories.
[0040] There may be a flange 190 at an end of the rod-shaped member 100 . The flange 190 may be with a larger radius than a hole in a door. The flange 190 may be configured with a larger radius than a standard sized hole in a door. The flange 190 may prevent the rod-shaped member 100 from passing through a lock body hole 430 (See FIG. 4 ) in a door 450 (See FIG. 4 ).
[0041] The rod-shaped member 100 may include a door locking mechanism 520 (See FIG. 5 ). The door locking mechanism 520 may be configured to function while the rod-shaped member 100 is within a lock body hole 430 . The locking mechanism 520 may include a bolt 200 that may be configured to extend through a bolt hole or latch hole 460 (See FIG. 4 ) in a door 450 (See FIG. 4 ) and extend into a receiving hole in a door frame as is commonly practiced in the art of doors. The locking mechanism 520 may include an outer face on the rod-shaped member 100 that may be configured to enable locking and unlocking of the door. Locking and unlocking of the door may be by means of a key or by any other means for triggering locking and/or unlocking known in the art.
[0042] The locking mechanism 520 may include an actuating member (not shown), such but not limited to a button, lever, dial, etc., configured to trigger locking and/or unlocking the door and may be integral the rod-shaped member 100 . The actuating member may be positioned on a handle portion 110 of the rod-shaped member 100 . The actuating member may be a lever, a slide, a button, and/or any other mechanism known in the art to trigger or actuate a locking mechanism 520 . Locking may be accomplished by installing the rod-shaped member 100 in a hole in a door 450 thereby forcing a bolt or first elongated member 200 through a bolt hole 460 in the door 450 and into a bolt receiving hole in a door frame.
[0043] In one embodiment, the bolt 200 is separate from the rod-shaped member 100 and only adjacent the rod-shaped member 100 when the rod-shaped member 100 is in the lock body hole 430 in the door 450 . The bolt 200 may be permitted to withdraw from the receiving hole in the frame when the rod-shaped member 100 is removed at car least partially from the door 450 .
[0044] There may be a threading device 410 (See FIG. 4 ) coupled to the rod-shaped member 100 . The threading device 410 may be configured to facilitate installation of the rod-shaped member 100 in a door. The threading device 410 may be coupled to an end of the rod-shaped member 100 . The threading device 410 may be thinner than the rod-shaped member 100 . The threading device 410 may be flexible. The threading device 410 may be a wire, may be a leather strip, may be a plastic strip, may be a doubled strip, and/or may be a loop. The threading device 410 may be any means configured to facilitate inserting the rod-shaped member 100 into a hole in a door.
[0045] There may be a fitting mechanism (not shown). The fitting mechanism may enable a user to adjust a property of an embodiment of the invention to enhance fitting the embodiment in a hole in a door. The fitting mechanism may adjust an effective radius of a rod-shaped member 100 or a portion thereof by actuation or otherwise. The fitting mechanism may include a bladder, a wedge, a screw, a lever, and/or any other structure known in the art to enhance the fit of an object within a hole. Such may be coupled to any surface of a rod-shaped member 100 , thereby enabling alteration of a cross-section of the rod-shaped member 100 .
[0046] In one embodiment of the invention there may be one or more safety features. A safety feature may include a design, a paint color, a flexibility of a portion of an embodiment, a release mechanism, and/or a securing device. There may also be a decorative portion that may include a design, a color, a label, a mark, a translucent member, a transparent member, and/or a decorative feature and/or structure.
[0047] In one embodiment there may be a modular configuration of one or more components, features, options, elements, and/or portions of the embodiment. There may be one or more sizes and/or configurations for one or more of the modular configurations or modular components.
[0048] Looking to FIGS. 4 and 5 , in operation of one embodiment of the invention, there may be a kit provided including one or more of the portions, objects, features, etc. described herein. A user may thread a threading member 410 that is attached to an eye 180 of a rod-shaped member 100 through a hole 430 in a door 450 in a direction from an inside of a room to an outside of a room intended to be locked from the outside, thereby securing valuables, such as construction tools, therein. A bolt 200 , for example an adjustable bolt, may be detached from a keychain and inserted in a bolt hole 460 in a door 450 . The door 450 may then be closed. The rod-shaped member 100 may be pulled into the door hole 430 from the inside of the room by the threading member. The rod-shaped member 100 may be aligned with the bolt 200 . The bolt 200 may be pushed further through the latch hole 460 and into a bolt hole in the frame of the door 450 , thereby securing the door 450 in a shut position. The rod-shaped member 100 may be pulled outwards till a flange 190 of the rod-shaped member 100 abuts the surface of the door, thereby restricting any further outward motion of the rod-shaped member 100 . A padlock 520 or other locking mechanism may be attached by a locking rod 522 about a cavity bar 135 and through a cavity 130 in the rod-shaped member 100 and locked. Thereby a door 450 may be locked. Such may be done as a temporary lock during construction of a facility, such as but not limited to locking an otherwise accessible area for the night to protect tools and/or raw materials.
[0049] In operation of one embodiment, a rod-shaped member 100 may be inserted into a lock body hole 430 of a door 450 . The rod-shaped member 100 may be passed through the door hole till a flange 190 abuts a surface of the door, restricting further motion of the rod-shaped member 100 . A person may grip the rod-shaped member 100 , thereby enhancing grip of the door 450 .
[0050] FIG. 2 shows a side perspective view of a bolt 200 according to one embodiment of the invention. The bolt 200 illustrated may be a telescoping bolt 200 . Thereby the bolt 200 may be adjustable. The bolt 200 may also include an attachment eye 210 for attaching a mechanism to the bolt 200 . For example, without limitation, the attachment eye 210 may attach to a keychain of a user. There may be a lip portion 220 configured to mate with a ridge 142 (See FIG. 1 ) of a slot 140 (See FIG. 1 ), thereby securely coupling the bolt 200 to the rod-shaped member 100 .
[0051] FIG. 3 shows an exploded view of a bolt 200 according to one embodiment of the invention. There is a base portion 300 including an eye 310 configured for attachment, for example to a keychain. The base portion may be detachable from the bolt 200 . There is a cap portion 320 that may include a cap flange 322 . There is a first telescoping member 330 and a second telescoping member 340 . The first telescoping member 330 is configured to fit within the second telescoping member 330 . A spring 350 may be internal the bolt 200 and may provide force to extend the telescoping members 330 and 340 to an adjustable desired length. Thereby a single bolt 200 may be used in a variety of doors and/or frame configurations.
[0052] It is understood that the above-described preferred embodiments are only illustrative of the application of the principles of the present invention. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiment is to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claim 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.
[0053] It is expected that there could be numerous variations of the design of this invention. Finally, it is envisioned that the components of the device may be constructed of a variety of materials. There may be metal, fiber, resin, wood, plastic, polymer, ceramic, composite, and/or mineral.
[0054] Thus, while the present invention has been fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made, without departing from the principles and concepts of the invention as set forth in the claims.
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A lock and key system and device for doors. It is a removable door locking system or lock and carry kit, including: a door blank disposed in a door frame; a first elongated member passing through the latch hole and extend therefrom; a second elongated member disposable in the lock body hole and extending therefrom; a flange extending radially from a first end of the elongated member and stops passage of the first end through the lock body hole of the door; an aperture through the second elongated member; and/or a detachable lock coupleable to the aperture and stops passage of the second end through the lock body hole when coupled to the aperture. The door blank may include a lock body hole through the door blank that receives a lock body and a latch hole through the door blank and in communication with the lock body hole.
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BACKGROUND OF THE INVENTION
The present invention relates to ultrasonotomography based on a Doppler signal from an object to be examined and more particularly to ultrasonotomography suitable for improving the performance of an ultrasonic diagnostic apparatus.
When an ultrasonic beam is applied at an incident angle to a blood flow inside a human body, the frequency of an ultrasonic wave reflected from the blood flow is shifted in accordance with velocity of the blood flow and a Doppler signal can be obtained. Thus, the blood flow velocity can be determined from this Doppler signal. Conventionally, in an ultrasonic diagnostic apparatus in which a Doppler signal is obtained to display a blood flow two-dimensionally, a blood flow in a tomogram plane from which a two-dimensional tomogram is obtained is measured and displayed. More particularly, where the array direction (azimuth direction) of transducers of a probe is y axis and a direction (elevation direction) orthogonal to the azimuth direction is x axis, focusing is effected in general in the elevation direction by means of a fixed lens (acoustic lens of fixed focus) and an ultrasonic beam is scanned in only the azimuth direction, whereby tomogram and Doppler data are obtained through scan in only the azimuth direction. One-dimensional electronic scan or mechanical scan is permitted by in order to effect two-dimensional scan, the operator manually moves a probe by changing the angle relative to x-axis direction to scan an ultrasonic beam broadly. Variable aperture in elevation direction and focus in elevation direction necessary for making a beam small in the x-axis direction have already been discussed in, for example, Ultrasonic B-scanner with multi-line array by D. Hassler, D. Honig and R. Schwarz, Medical division Siemens, Ultrasonic Imaging 4, pp. 32-43, 1982. Further, a method of applying this technique to obtaining Doppler data is described in JP-A-3-158144. Also, beam scan in the x-axis (elevation direction) is disclosed in, for example, JP-B-62-4988.
SUMMARY OF THE INVENTION
In the above prior art, when the diameter of an ultrasonic beam is larger than that of a vessel, resulting in degraded resolution, the S/N ratio of a Doppler signal of a blood flow is degraded. To overcome this problem, the ultrasonic beam is restricted in the azimuth direction by using the variable aperture and variable focusing. In the elevation direction, however, focusing is effected by means of an acoustic lens of fixed focusing point and if the ultrasonic beam in the elevation direction is thick, it is affected by a soft tissue and disadvantageously the S/N ratio of a Doppler signal is degraded. In addition, the prior art fails to take into consideration scanning of a Doppler beam standing for an ultrasonic beam for obtaining a Doppler signal in the x-axis (elevation) direction and a signal data processing method which uses a signal int eh x-axis (elevation) direction to measure a Doppler signal at a high S/N ratio, having difficulties in displaying a thin vessel outside the ultrasonic beam.
The present invention contemplates elimination of the above problems and its object is to provide an ultrasonotomographic method which uses an ultrasonic diagnostic apparatus having a variable aperture in elevation direction and the function of focus in elevation direction to provide a slightly sector scanned ultrasonic beam even in the elevation direction in order that a vessel outside the ultrasonic beam, undetectable with the prior art, can be found out with ease, thereby finding suitability to improving the S/N ratio of measured data.
According to the invention, to accomplish the above object, an ultrasonotomographic method for measuring and displaying a tomogram signal of an object to be examined and a Doppler signal of a blood flow by using an ultrasonic probe having, on a transmission/reception plane of an ultrasonic beam, a plurality of ultrasonic transducers arrayed in a first axis direction (azimuth direction) standing for a scan direction of the ultrasonic beam and a plurality of ultrasonic transducers arrayed in a second axis direction (elevation direction) orthogonal to the first axis direction, comprises the steps of: (a) changing the aperture for transmission and/or reception of the ultrasonic beam in the second axis direction, (b) obtaining a tomogram by effecting transmission/reception of the ultrasonic beam plural times in an angular direction substantially perpendicular to the second axis direction, (c) obtaining a plurality of Doppler signals by effecting transmission/reception of the ultrasonic beam plural times in angular directions making a plurality of different angles to the second axis direction on a plane which the tomogram is obtained, is substantially parallel to the second axis direction and contains the normal direction of the aperture portion on the transmission/reception plane, (d) performing each of the steps (a) and (c) by sequentially scanning the ultrasonic beam in the first axis direction, and (e) displaying the tomogram of the object to be examined and the plurality of Doppler signals in superimposed fashion.
The ultrasonotomography according to the invention also comprises obtaining a plurality of Doppler signals by effecting transmission/reception of the ultrasonic beam plural times in angular directions making a plurality of different angles to the second axis direction on a plane which is substantially perpendicular to a plane on which the tomogram is obtained, is substantially parallel to the second axis direction and contains the normal direction of the aperture portion on the transmission/reception plane, and adding/averaging or adding the plurality of Doppler signals to provide Doppler data.
The ultrasonotomography according to the invention also comprises obtaining a plurality of Doppler signals by effecting transmission/reception of the ultrasonic beam plural times in angular directions making a plurality of different angles to the second axis direction on a plane which is substantially perpendicular to a plane on which the tomogram is obtained, is substantially parallel to the second axis direction and contains the normal direction of the aperture portion on the transmission/reception plane, and displaying the plurality of Doppler corresponding to each direction of transmission/reception of the ultrasonic beam.
More specifically, the ultrasonotomography according to the invention comprises dividing ultrasonic transducers in the scanning direction and in a direction (elevation direction) orthogonal to the scanning direction and obtaining a tomogram and a Doppler signal of a blood flow by changing the aperture desirably in the elevation direction through focus in elevation direction and displaying them two-dimensionally, and obtaining Doppler data by effecting slight angle scan of the ultrasonic beam mechanically or electronically in the elevation direction.
The ultrasonotomography according to the invention also comprises adding/averaging or adding data pieces for the same raster of a plurality of Doppler data pieces obtained through the slight angle scan in the elevation direction to measure a Doppler signal at a high S/N ratio and display the Doppler signal.
In the present invention, by effecting the slight angle scan of the ultrasonic beam in the elevation direction orthogonal to a tomogram plane, a vessel at a position deviant from the tomogram plane can be found. Also, by virtue of the variable aperture in elevation direction and the function of focus in elevation direction, the resolution of tomogram in the orthogonal direction can be improved to promote the intensity of signal and besides by adding/averaging or adding blood flow signals, the S/N ratio can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram for explaining an embodiment of a method for scan in the x axis direction according to the invention;
FIG. 2 is a block diagram showing the construction of an ultrasonic diagnostic apparatus to which ultrasonotomography of the invention is applied;
FIG. 3 is a diagram for explaining an embodiment of basic, data obtaining sequence according to the invention;
FIG. 4 is a diagram for explaining an embodiment of data obtaining sequence through addition/averaging or addition according to the invention;
FIG. 5 is a diagram for explaining an embodiment of data obtaining sequence by means of an MTI filter according to the invention;
FIG. 6 is a diagram for explaining an embodiment of a method for angle setting upon scan in the x axis direction according to the invention;
FIG. 7 is a diagram for explaining an embodiment of variable aperture in elevation direction according to the invention; and
FIG. 8 is a diagram for explaining an embodiment of a method for detection of the blood flow direction according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the invention will no be described with reference to the accompanying drawings.
In FIG. 2, reference numeral 21 designates an amplifier, 22 a mixing circuit, 23 and 24 A/D (analog to digital) converters, 25 and 26 MTI (moving target indication) filters, 27 a velocity calculating unit, 28 a color DSC (digital scan converter) and 29 a display.
With the above construction, a received Doppler signal is amplified and mixed with a 90° dephased signal by means of the amplifier 21 and then converted into a digital signal by the A/D converter 23 or 24. Data received during one round preceeding transmission is subtracted from the digital signal by means of the MTI filter 25 or 26 to remove a signal produced from a still portion (clatter signal), blood flow velocity and the like factors are calculated by the velocity calculating unit 27, and the direction, velocity and dispersion of a blood flow are indicated in color by the color DSC 28 and displayed on the display 29.
An ultrasonic beam is scanned in a manner as shown in FIG. 1 to obtain a Doppler signal. For simplicity of explanation, the scanning method shown is based on a linear array probe. In FIG. 1, reference numeral 11 designates array transducers for generation of an ultrasonic wave, and y-axis direction corresponds to scanning direction (azimuth direction) and x-axis direction corresponds to orthogonal direction (elevation direction) to the scanning direction. The array transducers may be constructed by dividing a piezoelectrical material in y-axis and x-axis directions or by dividing a piezoelectrical material in the y-axis (azimuth) direction and dividing an electrode in the x-axis (elevation) direction. The sequence of scanning of an ultrasonic beam in the y-axis direction is indicated by l to n.
In the present embodiment, slight angle scan in the x-axis direction is effected by scanning a variable aperture in elevation direction and a variable focusing probe in elevation direction mechanically or through electronical scanning under varying conditions for variable focus in elevation direction. FIG. 1 shows the behavior of sector scan based on slight angle scan in three angular directions a, b and c.
The basic sequence of obtaining data in this scan is shown in FIG. 3.
In FIG. 3, D represents obtaining the Doppler data and B represents obtaining the tomogram data. Numerals suffixed to a, b and c indicate the sequence of scanning in the y-axis direction shown in FIG. 1.
In this case, Doppler data D and tomogram data B are obtained in a front angular direction b of a scanning plane which is substantially perpendicular to the x-axis direction of the array transducers 11, Doppler data is obtained in angular directions a and b of scanning planes which are inclined relative to the x-axis direction of the array transducers 11, and the thus obtained Doppler data pieces are simultaneously superimposed on the tomogram data so as to be displayed. Thus, in the basic sequence, data is obtained in the order of Doppler data in al, tomogram data in b1, Doppler data in b1, Doppler data in c1, Doppler data in a2, tomogram data in b2, Doppler data in b2 and Doppler data in c2.
The Doppler data pieces are added/averaged or added to improve quality of image and S/N ratio in a manner to be described below. FIG. 4 is a diagram for explaining an embodiment of the data obtaining sequence based on addition/averaging or addition according to the invention and FIG. 5 is a diagram for explaining an embodiment of the data obtaining sequence based on the MTI filter.
In the present embodiment, data pieces obtained in the angular directions a, b and c shown in FIG. 1 are added/averaged or added in accordance with the sequence shown in FIG. 4. For example, when obtaining data in a1, a plurality of Doppler data pieces, for example, three Doppler data pieces D1, D2 and D3 are obtained in order to improve the S/N (signal to noise) ratio. In a similar way, data in b1 and data in c1 are obtained in this order and the thus obtained data pieces are added/averaged or added by means of the velocity calculating unit 27. In an alternative method, data pieces obtained in each of the angular directions a, b and c are added/averaged or added and superimposed on each other for display. In this case, even when Doppler data is present in any one of the angular directions a, b and c alone, images of high quality can be displayed.
In case where the MTI filter 25 is applied to rasters in the angular directions a, b and c, the sequence shown in FIG. 5 is used. For example, the MTI filter 25 is applied to Doppler data obtained in the order of a1, b1 and c1, tomogram data in b1 is then obtained and subsequently Doppler data and tomogram data in a2, b2 and c2 are obtained in a similar way. When obtaining data in each of the angular positions a1, b1 and c1, a plurality of Doppler data pieces, for example, three Doppler data pieces D1, D2 and D3 are obtained and added/averaged or added in order to improve the S/N (signal to noise) ratio.
Angle setting to be done when the slight angle scan is effected in the x-axis direction will now be described. FIG. 6 is a diagram for explaining an embodiment of a method for angle setting upon the x-axis direction scan according to the invention. In FIG. 6, reference numerals 62 and 63 designate vessels of which the vessel 62 stands for a thin vessel undetectable by scan in the angular direction b alone.
In the present embodiment, by performing scan in the angular directions a and c in addition to the conventional ordinary scan (scan in the angular direction b), data of the vessel 62 can also be obtained which cannot be obtained in the angular direction b. By performing sector scan through the slight angle in this manner, a blood flow can be obtained in the angular direction a and displayed in color. In this case, the angle is determined by vessel diameter r and depth z and may be related to them by "slight angle θ=arctan(r/z)".
The range of scan of an ultrasonic beam can be set automatically by using the intensity (strong or weak) of a blood flow signal or manually by using a fixed value inputted by the operator in advance. Specifically, on the assumption that relative to a vessel displayed through the ordinary scan, a different vessel having the same diameter as that vessel lies in the x-axis direction, the ultrasonic beam is further scanned in the x-axis direction to provide a display or an empirical value of scan range depending on diagnosis and an object to be displayed is inputted by the operator and a new value is inputted each time the examination object changes.
Doppler signals can be produced from the vessel 63 shown in FIG. 6 by using rasters in the angular directions a and b. In this case, by adding/averaging or adding the Doppler signals within a range of pixels represented in terms of the depth direction, the S/N ratio can be improved.
Further, it is assumed that the number of repetitive transmissions for obtaining Dopper data of one raster when the sector scan is not effected in the x-axis (elevation) direction is N. Then, if the sector scan is effected in the x-axis direction under the same condition, the frame rate is reduced to about 1/3 in the present embodiment and therefore, by making the number of repetitive transmissions for obtaining Doppler data of one raster equal to N/3, the frame rate can be kept to be substantially constant.
Variation of aperture in elevation direction in the present embodiment will now be described. FIG. 7 is a diagram for explaining an embodiment of variable aperture in elevation direction according to the invention. In FIG. 7, reference numeral 74 designates a vessel. In the present embodiment, by varying the aperture in the x-axis direction, a sharp beam is formed to draw thinner vessels. For example, when obtaining data at a short distance, the azimuth resolution at the short distance can be improved by making the aperture small in the x-axis direction of the array transducers, so that a vessel 74 at the short distance can be drawn. With the small aperture, however, a vessel 74 at a medium distance is buried in the ultrasonic beam and cannot be drawn. Accordingly, the aperture in the x-direction of the array transducers is enlarged to permit the vessel 74 at the medium distance as shown in FIG. 7 to be drawn. The operation of varying the aperture in the x-axis direction may be effected during only reception or during both transmission and reception. A similar effect can be attained by varying the focal position in the direction of depth of the examination object.
Detection of directivity of a blood flow will now be described. FIG. 8 is a diagram for explaining an embodiment of a method for detection of blood flow direction according to the invention. In FIG. 8, reference numeral 85 designates a vessel and the direction of a blood flow is indicated by arrow. For example, when data on different rasters are superimposed on each other without being subjected to addition/averaging or addition, the direction of a blood flow will be displayed oppositely in some case. In FIG. 8, it is decided by an ultrasonic beam a that the blood flow approaches the ultrasonic beam, and a display is effected in red. However, it is decided by an ultrasonic beam c that the blood flow departs from the ultrasonic beam and a display is effected in blue. In this manner, the direction of even the same blood flow is sometimes decided oppositely. The same result of decision of direction is obtained for the ultrasonic beam c and an ultrasonic beam b. Therefore, by adding/averaging or adding data pieces within the same pixel, the correct direction can be displayed. For example, when the blood flow is parallel to the array transducers 11, data pieces will be collapsed through addition/averaging but they may be confirmed if data on each raster of each of the angular direction a, b and c is displayed on time series basis. Data pieces may be added at the same timing on raster in the x-direction or at a constant distance from the surface.
In order for the user to perform the scan in the x-axis direction, a scanning method can be selected which adopts, for example, a broad scan mode in the x-axis direction wherein an ultrasonic beam is transmitted and received within a wide angular range covering a direction substantially perpendicular to the x-axis direction and a plurality of directions inclined relative to the x-axis direction, and effects the sector scan in the x-axis direction by using the broad scan mode. Alternatively, a scanning method can be employed in which contact of an ultrasonic probe to a human body is detected automatically and during only a predetermined interval of time following the detection, the broad scan mode is carried out automatically. Advantageously, through the above scanning methods, the blood flow can be displayed easily and an approximate position of the blood flow can be detected. For detection and display of the approximate position of the blood flow, a method may also be employed in which Doppler data and tomogram data are both obtained and displayed through sector scan in the x-axis direction in the broad scan mode. If the scanning direction of an ultrasonic beam in the x-axis direction useful for diagnosis exists, this scanning direction in the x-axis direction can be fixed and the ultrasonic beam can be scanned in the y-axis direction to obtain Doppler data and tomogram. In this case, the scanning direction in the x-axis direction may be fixed by the user or it may be set automatically in accordance with the intensity (strong or weak) of the Doppler data (blood flow signal). For example, the intensity of the Doppler data (blood flow signal) may be decided automatically and the direction of transmission/reception of an ultrasonic beam in the x-axis direction may be so fixed as to lie in a direction in which the maximum intensity of the Doppler data is obtained.
While the present embodiment has been described as using the linear array probe, similar effects may be obtained with an electronically scanning convex array probe or a phased array probe.
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In ultrasonotomography, ultrasonic transducers are divided in the scanning direction and in a direction (elevation direction) orthogonal to the scanning direction and by changing the aperture in the elevation direction through focus in elevation direction, a tomogram and a Doppler signal of a blood flow can be obtained and displayed two-dimensionally. Doppler data is obtained by effecting slight angle scan of the ultrasonic beam mechanically or electronically in the elevation direction. Data pieces for the same raster of a plurality of Doppler data pieces obtained through the slight angle scan in the elevation direction are added/averaged or added to improve the S/N ration. By effecting the slight angle scan of the ultrasonic beam in the elevation direction orthogonal to a tomogram plane, a vessel at a position deviant form the tomogram plane can be found. Also, by virtue of the variable aperture in elevation direction and the function of focus in elevation direction, the resolution of tomogram in the orthogonal direction can be improved to promote the intensity of signal. In addition, by adding/averaging or adding blood flow signals, the S/N ratio can be improved.
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[0001] This is a continuation-in-part of application Ser. No. 11/331,024, filed Jan. 13, 2006.
[0002] The present invention generally relates to nozzle assemblies for steam turbines and particularly relates to a welded nozzle assembly and fixtures facilitating alignment and manufacture of the nozzle.
BACKGROUND OF THE INVENTION
[0003] Steam turbines typically comprise static nozzle segments that direct the flow of steam into rotating buckets that are connected to a rotor. In steam turbines, a row of nozzles, each nozzle including an airfoil or blade construction, is typically called a diaphragm stage. Conventional diaphragm stages are constructed principally using one of two methods. A first method uses a band/ring construction wherein the airfoils are first welded between inner and outer bands extending about 180°. Those arcuate bands with welded airfoils are then assembled, i.e., welded between the inner and outer rings of the stator of the turbine. The second method often consists of airfoils welded directly to inner and outer rings using a fillet weld at the ring interfaces. The latter method is typically used for larger airfoils where access for creating the weld is available.
[0004] There are inherent limitations using the first-mentioned band/ring method of assembly. A principle limitation in the band/ring assembly method is the inherent weld distortion of the flowpath, i.e., between adjacent blades and the steam path sidewalls. The weld used for these assemblies is of considerable size and heat input. That is, the weld requires high heat input using a significant quantity of metal filler. Alternatively, the welds are very deep electron beam welds (EBWs) without filler metal. This material or heat input causes the flow path to distort e.g., material shrinkage causes the airfoils to bow out of their designed shaped in the flow path. In many cases, the airfoils require adjustment after welding and stress relief. The result of this steam path distortion is reduced stator efficiency. The surface profiles of the inner and outer bands can also change as a result of welding the nozzles into the stator assembly further causing an irregular flow path. The nozzles and bands thus generally bend and distort. This requires substantial finishing of the nozzle configuration to bring it into design criteria. In many cases, approximately 30% of the costs of the overall construction of the nozzle assembly is in the deformation of the nozzle assembly, after welding and stress relief, back to its design configuration.
[0005] Also, methods of assembly using single nozzle construction welded into rings do not have determined weld depth, lack assembly alignment features on both the inner and outer ring and also lack retainment features in the event of a weld failure. Further, current nozzle assemblies and designs do not have common features between nozzle sizes that enable repeatable fixturing processes. That is, the nozzle assemblies do not have a feature common to all nozzle sizes for reference by machine control tools and without that feature, each nozzle assembly size requires specific setup, preprocessing, and specific tooling with consequent increase costs. Accordingly, there has been demonstrated a need for an improved steam flowpath for a stator nozzle which includes low input heat welds to minimize or eliminate steam path distortion resultant from welding processes as well as to improve production and cycle costs by adding features that assist in assembly procedures, machining fixturing, facilitate alignment of the nozzle assembly in the stator and create a mechanical lock to prevent downstream movement of the nozzle assembly in the event of a weld failure.
BRIEF SUMMARY OF THE INVENTION
[0006] In accordance with one exemplary non-limiting embodiment, the invention relates to a nozzle blade comprising radially inner and outer walls with an airfoil portion extending therebetween; the inner and outer walls formed with alignment features on respective oppositely-facing surfaces aligned with a longitudinal center axis through the nozzle blade.
[0007] In another non-limiting aspect, the invention relates to a nozzle blade in combination with a machining fixture, wherein the nozzle blade comprises radially inner and outer walls with an airfoil portion extending between the inner and outer walls; the inner wall formed with an alignment feature on a surface thereof aligned with a longitudinal center axis through the nozzle blade; and wherein the machining fixture comprises a first rotatable fixture component engaged with the alignment feature.
[0008] In still another non-limiting aspect, the invention relates to a nozzle blade in combination with a machining fixture, wherein the nozzle blade comprises radially inner and outer walls with an airfoil portion extending between the inner and outer walls; and universal alignment features on the nozzle blade and the machining fixture, the alignment feature on the blade located to align the blade with a machine center axis about which the blade is rotated during machining, when the alignment feature on the blade is engaged with the alignment feature on the machining fixture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic line drawing illustrating a cross-section through a diaphragm stage of the steam turbine nozzle according to the prior art;
[0010] FIG. 2 is a line drawing of a steam turbine stage incorporating a nozzle assembly and weld features in accordance with a preferred embodiment of the present invention;
[0011] FIG. 3 is a perspective view of a singlet nozzle assembly;
[0012] FIG. 4 is a schematic illustration of an assembly of the singlet nozzle of FIG. 3 between the inner and outer rings of the stator;
[0013] FIGS. 5 and 6 are enlarged perspective views of singlet nozzles incorporating alignment and reference features;
[0014] FIGS. 7 and 8 show partial perspective views of a nozzle assembly illustrating further embodiments of the alignment and reference features hereof;
[0015] FIG. 9 is a perspective view of a singlet nozzle held in a jig for machining;
[0016] FIG. 10 is a side elevation of the nozzle and jig of FIG. 9 ;
[0017] FIG. 11 is a perspective view of the singlet nozzle shown in FIGS. 9 and 10 ;
[0018] FIG. 12 is an exploded view of the nozzle and jig arrangement shown in FIGS. 9 and 10 ; and
[0019] FIGS. 13 and 14 are perspective views of a singlet nozzles illustrating alignment and reference features in accordance with other exemplary embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIG. 1 , there is illustrated a prior art nozzle assembly generally designated 10 . Assembly 10 includes a plurality of circumferentially spaced airfoils or blades 12 welded at opposite ends between inner and outer bands 14 and 16 , respectively. The inner and outer bands are welded between inner and outer rings 18 and 20 , respectively. Also illustrated is a plurality of buckets 22 mounted on a rotor 24 . It will be appreciated that nozzle assembly 10 in conjunction with the buckets 22 form a stage of a steam turbine.
[0021] Still referring to FIG. 1 , the airfoils 12 are individually welded in generally correspondingly shaped holes, not shown, in the inner and outer bands 14 and 16 respectively. The inner and outer bands 14 and 16 typically extend in two segments each of about 180 degrees. After the airfoils are welded between the inner and outer bands, this subassembly is then welded between the inner and outer rings 18 and 20 using very high heat input and deep welds. For example, the inner band 14 is welded to the inner ring 18 by a weld 26 which uses a significant quantity of metal filler, or which requires a very deep electron beam weld. Additionally, the backside, i.e., downstream side, of the weld between the inner band and inner ring requires a further weld 28 of high heat input. Similarly, high heat input welds 30 , 32 including substantial quantities of metal filler or very deep electron beam welds are required to weld the outer band 16 to the outer ring 20 at opposite axial locations as illustrated. Thus, when the airfoils 12 are initially welded to the inner and outer bands 14 , 16 and subsequently welded to the inner and outer rings 18 and 20 , those large welds cause substantial distortion of the flowpath as a result of the high heat input and shrinking of the metal material and which causes the airfoils to deform from their design configuration. Also, the inner and outer bands 14 , 16 may become irregular in shape from their designed shape, thus, further distorting the flowpath. As a result, the nozzle assemblies, after welding and stress relief, must be reformed back to their design configuration which, as noted previously, can result in 25-30% of the cost of the overall construction of the nozzle assembly. Lastly, if an EBW is used it may be used entirely from one direction going all the way to the opposing side (up to 4 inches thick).
[0022] There are also current singlet type nozzle assemblies which do not have a determinant weld depth and thus employ varying weld depths to weld the singlets into the nozzle assembly between the inner and outer rings. That is, weld depths can vary because the gap between the sidewalls of the nozzle singlet and rings is not consistent. As the gap becomes larger, due to machining tolerances, the weld depths and properties of the weld change. A tight weld gap may produce a shorter than desired weld. A larger weld gap may drive the weld or beam deeper and may cause voids in the weld that are undesirable. Current singlet nozzle designs also use weld prep at the interface and this requires an undesirable higher heat input filler weld technique to be used.
[0023] Referring now to FIG. 2 , there is illustrated a preferred embodiment of a nozzle assembly according to the present invention which utilizes a singlet i.e., a single airfoil with sidewalls welded to inner and outer rings directly with a low heat input weld, which has mechanical features providing improved reliability and risk abatement due to a mechanical lock at the interface between the nozzle assembly and inner and outer rings as well as alignment features. Particularly, the nozzle assembly in a preferred embodiment hereof, includes integrally formed singlet subassemblies generally designated 40 . Each subassembly 40 includes a single airfoil or blade 42 between inner and outer sidewalls 44 and 46 , respectively, the blade and sidewalls being machined from a near net forging or a block of material. As illustrated, the inner sidewall 44 includes a female recess 48 flanked or straddled by radially inwardly projecting male steps or flanges 50 and 52 along leading and trailing edges of the inner sidewall 44 . Alternatively, the inner sidewall 44 may be constructed to provide a central male projection flanked by radially outwardly extending female recesses adjacent the leading and trailing edges of the inner sidewall. Similarly, the outer sidewall 46 , as illustrated, includes a female recess 54 flanked or straddled by a pair of radially outwardly extending male steps or flanges 56 , 58 adjacent the leading and trailing edges of the outer sidewall 46 . Alternatively, the outer sidewall 46 may have a central male projection flanked by radially inwardly extending female recesses along leading and trailing edges of the outer sidewall.
[0024] The nozzle singlets 40 are then assembled between the inner and outer rings 60 and 62 , respectively, using a low heat input type weld. For example, the low heat input type weld uses a butt weld interface and preferably employs a shallow electron beam weld or shallow laser weld or a shallow flux-TIG or A-TIG weld process. By using these weld processes and types of welds, the weld is limited to the area between the sidewalls and rings adjacent the steps of the sidewalls or in the region of the steps of the inner and outer rings if the configuration is reversed at the interface than shown in FIG. 2 . Thus, the welding occurs for only a short axial distance, preferably not exceeding the axial extent of the steps along opposite axial ends of the sidewalls, and without the use of filler weld material. Particularly, less than ½ of the axial distance spanning the inner and outer sidewalls is used to weld the singlet nozzle between the inner and outer rings. For example, by using electron beam welding in an axial direction from both the leading and trailing sides of the interface between the sidewalls and the rings, the axial extent of the welds where the materials of the sidewalls and rings coalesce is less than ½ of the extent of the axial interface. As noted previously, if an EBW weld is used, the weld may extend throughout the full axial extent of the registration of the sidewalls and the rings.
[0025] A method of assembly is best illustrated in FIG. 4 where the assembly process illustrated includes disposing a singlet 40 between the inner and outer rings 60 , 62 when the rings and singlets are in a horizontal orientation. Thus, by rotating this assembly circumferentially relative to a fixed e-beam welder or vice versa, and then inverting the assembly and completing the weld from the opposite axial direction, the nozzle assemblies are welded to the inner and outer rings in a circumferential array thereof without high heat input or the use of filler material.
[0026] As clearly illustrated in FIG. 2 , there is also a mechanical interface between the singlets 40 , 50 , 52 , 56 , 58 and the rings 60 , 62 . This interface includes the steps or flanges which engage in the recesses of the complementary part. This step and recess configuration is used to control the weld depth and render it determinant and consistent between nozzle singlets during production. This interlock is also used to axially align the nozzle singlets between the inner and outer rings. The interlock holds the nozzles in position during the assembly of the nozzle singlets between the inner and outer rings and the welding. That is, the nozzle singlets can be packed tightly adjacent one another and between the inner and outer rings while remaining constrained by the rings. Further, the mechanical interlock retains the singlets in axial position during steam turbine operation in the event of a weld failure, i.e., prevents the singlet from moving downstream into contact with the rotor.
[0027] Referring particularly to FIGS. 5, 6 and 7 there are further illustrated features added to the singlet design that assists with fixturing the nozzle singlet while it undergoes milling machine processes. These features are added to the nozzle singlet design to give a consistent interface to the machining singlet supplier. For example, in FIG. 5 , one of those features includes a rib or a rail 70 on the top or bottom sidewall. Another fixturing feature is illustrated in FIG. 7 including a forwardly extending rib 72 along the outer sidewall 46 . It will be appreciated that the rib 72 can be provided along the inner sidewall 44 and in both cases may be provided adjacent the trailing surfaces of those sidewalls. In FIG. 6 , flats 74 may be provided on the outer surface of the outer sidewalls as well as flats 76 on the outer surface of the inner sidewall. Those flats 74 and 76 serve as machining datum to facilitate fixturing during machining processes. Current designs have a radial surface which is more complex and costly to machine as well as difficult to fixture for component machining.
[0028] In FIG. 8 , a pair of holes may be provided on the forward or aft outer sidewalls or on the forward or aft inner sidewalls. Those holes can be picked up consistently by the machining center between several nozzle designs and sizes to facilitate fixturing for machining purposes. Thus, by adding these features, a consistent interface to the machine supplier is provided which serves to reduce tooling, preprocessing, and machining cycle for the machining of the singlet. These fixturing features meet the need to provide a reference point so that the numerically controlled machining tool can identify the location of a feature common to all nozzles. For example, the two holes 78 illustrated in FIG. 8 , provides two points on a fixture and establishes two planes which controls the entire attitude of the nozzle during machining enabling the machine to form any size of integral nozzle singlet.
[0029] Turning now to FIGS. 9, 10 and 12 , a jig assembly 80 is shown to include a machining fixture 82 mounted on a table (not shown) that is rotatable about a machine center axis A. The fixture 82 is provided with a slot 84 (or alignment feature) that receives another alignment feature in the form of a top rail or ridge 86 (similar to rail 70 in FIG. 5 ) extending across the inner sidewall 88 of the singlet 90 . Note that a wall portion 83 (omitted in FIG. 12 ) of the fixture 82 may be slidably mounted to facilitate clamping of the nozzle rail 86 within the slot 84 . Thus, the lower surface of the slidable wall 83 defines the upper surface of the slot 84 . As best seen in FIG. 11 , a notch 92 is formed in the center of rail 86 . The notch 92 is adapted to engage a tab 94 provided in the slot 84 . The top rail 86 and slot 84 intersect the machine center axis A, and the notch 92 and tab 94 serve to align the center of the airfoil portion of the nozzle with the axis A, and to also prevent lateral movement of the singlet. A support rod 96 , lying on the center axis A, is engaged within a recess 93 formed in the outer sidewall 95 of the singlet nozzle 90 during machining. In this regard, the jig assembly 80 rotates the singlet nozzle 90 about axis A, relative to a tool (not shown) that machines the airfoil to its final specifications.
[0030] Note that using the same width and thickness for rails on various nozzles, and by having the rails pass through or cross the machine center, the respective alignment features permit universal application of the fixture 82 to all nozzle designs provided with an appropriately located top rail and notch as described above.
[0031] It will be appreciated that the fixturing rail 86 on each nozzle singlet can remain on the singlet or be removed from the singlet after machining of the airfoil is completed. If the rail remains, it may be received in an appropriately sized groove in the inner or outer ring.
[0032] FIGS. 13 and 14 illustrate nozzles 96 , 98 , respectively, that are similar to those shown in FIGS. 9-12 , but the respective rails 100 , 102 are reoriented relative to the respective outer sidewalls 104 , 106 and airfoils 108 , 110 due to nozzle design differences. For example, in FIG. 13 , the rail 100 extends perpendicular to the sidewall edge 112 of the outer ring, and notch 114 is centered along the rail 100 . In FIG. 14 , the rail 102 extends parallel to the sidewall edge 116 , and the notch 118 is asymmetrically located along the length of the rail. In all cases, however, the rail passes through the center of the airfoil portion and, with the tab/notch arrangement, may be used with the same fixture 82 to align the singlet with the machine center axis A for machining the airfoil.
[0033] It will be appreciated that the location of the fixturing features as described above in connection with the inner and outer walls may be reversed, and that the tab and notch arrangement may have other suitable shapes that perform the desired alignment function.
[0034] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A nozzle blade comprising radially inner and outer walls with an airfoil portion extending therebetween; the inner and outer walls formed with alignment features on respective oppositely-facing surfaces aligned with a longitudinal center axis through the nozzle blade.
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This is a divisional of U.S. patent application Ser. No. 11/181,056 filed Jul. 14, 2005, now U.S. Pat. No. 7,458,384 which claims the benefit of priority to U.S. Provisional Patent application Ser. No. 60/588,097 filed on Jul. 15, 2004.
FIELD OF THE INVENTION
This invention relates to the control of pressure drop in fluid flow technology and more particularly to a method and composition of matter for reducing friction or pressure drop in oil and gas pipelines and similar processing structures using surfactant incorporated functional nano particles.
BACKGROUND AND PRIOR ART
The chemical industry and the petroleum industry use pipes, commonly called “pipelines” or “oil and gas pipelines” for conveying gas, water, chemical reagents, petroleum effluents, and the like, over long distances. It is well known that friction or “drag” between the fluids and the pipe or vessel wall causes substantial pressure drops as the fluids move along each wall. The drag experienced by flowing fluids in a pipeline has been directly related to the “roughness” of the inner wall of the pipeline and the roughness of interface between the liquid and gas. At the pipe wall, the roughness is caused by microscopic and/or larger pits, scratches, and other imperfections in the pipe wall which result during the manufacture of the pipe or from corrosion, abrasion, and the like during use. At the gas/liquid interface, waves are present which given the appearance of a rough surface. It has been found that the higher the value of the roughness, the more friction or drag flowing fluids will encounter in the pipeline and the greater the pressure drop of the flow. The pressure drop generated as fluid flows through a pipe is an unwelcome culprit that creates bottlenecks, interferes with fluid flow and increases production costs substantially.
To compensate for these pressure losses, pump and/or compressor stations are spaced along the pipeline to boost the pressure of the flowing fluids to a desired flow rate and to insure that the fluids will reach their destination. Due to the high costs associated with installing, maintaining, and operating such booster stations, other techniques have developed to reduce the friction or drag of fluids with pipelines as discussed below.
The current art for reduction of pressure drop in a fluid circulating in a pipe includes use of a porous inner wall within a metal pipe that allows fluid to circulate in the porous inner layer to limit the pressure drop as reported in U.S. Pat. No. 6,732,766 B2 to Charron. The Charron arrangement would substantially increase the cost and manufacture of the pipe used to convey fluids.
Rojey in U.S. Pat. No. 5,896,896 describes a pipeline wherein the pipe has a porous structure or lining into which a fluid is injected. The injected fluid is retained in the pores and is at least partially immiscible with the fluid being conveyed. The fluid retained in the pores serves as a lubricant and reduces pressure drop of fluid flowing through the pipeline. The drawback of this system is that the porous lining and injected lubricant must be adjusted to receive hydrophilic or oleophilic fluids.
U.S. Pat. No. 5,220,938 to Kley uses a friction reducing material, which includes polymeric material, liners and liners with riblets to reduce pressure drops generated by fluid flow; such materials can be an expensive addition to a pipeline.
Lowther in U.S. Pat. No. 4,958,653 describes the use of hydrocarbon drag reducers and the monitoring of pressure drop between a first point and a second point wherein the injection rate of the drag reducer is adjusted to provide the maximum flow rate with a minimum amount of drag reducer.
None of the prior art references use surfactant incorporated nano particles to reduce pressure drop and thereby increase or improve the flow rate of fluids in a pipeline. Thus, the novel product of the present invention meets a commercial need for an efficient, inexpensive product and system to reduce friction, which occurs between a fluid in a state of flow and the wall of a pipe or vessel in which it is being conveyed.
SUMMARY OF THE INVENTION
It is a primary objective of the present invention to provide a method and composition of matter for reducing the pressure drops generated as a fluid flows through a pipe.
A second objective of the present invention is to provide passive control of fluid flow by introducing a surfactant incorporated nano ceria particle into a fluid flowing through a pipe.
A third objective of the present invention is to provide a surfactant incorporated nanostructure for pressure drop reduction in oil and gas pipelines.
A fourth objective of the present invention is to provide a surfactant incorporated nanostructure that can act as a corrosion inhibitor.
A fifth objective of the present invention is to provide a ceria nanoparticle mixture with organic surfactants that reduces wall friction by lowering the absolute roughness of the pipe wall.
A sixth objective of the present invention is to provide a ceria nanoparticle mixture with organic surfactants that reduces interfacial friction at the gas/liquid interface.
Preferred embodiments of the invention include a two-step process consisting of a first step of using a microemulsion technique to prepare a non-agglomerated mixture of surfactant incorporated nano ceria particles suspended in a non-polar hydrocarbon solvent, such as toluene, and a second step of spraying the nano ceria mixture onto single phase or multiphase (gas, liquid, semi-solid) fluid in pipelines to reduce the pressure drop along the pipeline. The toluene-surfactant-nanoceria mixture, hereinafter called, “nanoceria mixture” helps reduce the wall and interfacial friction factors by lowering the absolute roughness at the pipe wall and reducing the interfacial friction at a gas/liquid interface. Since only nanolayers of the mixture are deposited, very little of the nanoceria mixture is needed to treat long length pipelines; thus, providing a great economical benefit.
A preferred method of providing non-agglomerated, nano-sized particles, suspended in a non-polar hydrocarbon solvent, which uniformly incorporates a surfactant and reduces pressure drop of fluid streams in pipelines, includes preparing an aqueous solution of a rare earth metal salt, dissolving a surfactant in a nonpolar hydrocarbon solvent, combining the aqueous solution of the rare earth metal salt with the nonpolar solvent and surfactant into a mixture, stirring the mixture to form micelles, treating the micelles with hydrogen peroxide, allowing nucleation and growth of nano-particles of a rare earth metal oxide, and introducing the rare earth metal oxide nano-particle reaction product into a pipeline.
The preferred rare earth metal salts are cerium salts, ceria doped with lanthanum salts and mixtures thereof. The more preferred rare earth metal salt is cerium nitrate.
The preferred non-polar solvent for suspending the rare earth metal salt and dissolving the surfactant is a hydrocarbon, namely toluene and octane. The preferred surfactant is sodium bis(2-ethylhexyl) sulfosuccinate (AOT). The preferred non-polar solvent is also a carrier liquid for the rare earth metal oxide nano-particles that can be sprayed onto a fluid stream in a pipeline.
A preferred method for decreasing pressure drop generated by fluid flow in a pipeline, includes providing a pipeline having roughness on the inner wall, conveying a fluid stream in the pipeline, providing a gas/liquid interface having an interfacial roughness, spraying a mixture of nano-sized cerium oxide particles onto the fluid stream, and monitoring the flow rate of the fluid. A more preferred method includes using a surfactant in the mixture of nano-sized cerium oxide particles. The preferred nano-sized cerium oxide particles are in a size range from approximately 3 nanometers (nm) to approximately 7 nanometers (nm) in diameter, more preferably, in a size range between approximately 2 nanometers (nm) to approximately 5 nanometers (nm) in diameter. The preferred surfactant is sodium bis(2-ethylhexyl) sulfosuccinate (AOT).
The preferred fluid being conveyed in the pipeline consists of a single phase fluid and a multiphase fluid. The preferred single phase fluid is gas, water, and fluid hydrocarbons. The preferred multiphase fluids are combinations of gas/liquid, gas/solid, liquid/liquid, or gas/liquid/solid phases.
A preferred composition of matter consists of a suspension of cerium oxide nanoparticles in non-polar hydrocarbon solvent that is useful in reducing the pressure drop in oil and gas pipelines. The composition of matter further includes a surfactant, such as, sodium bis(2-ethylhexyl) sulfosuccinate (AOT). The preferred non-polar hydrocarbon solvent is toluene.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments, which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A shows an initial step of adding aqueous cerium nitrate to a non-polar solution with a surfactant to form reverse micelles for the synthesis of ceria nanoparticles.
FIG. 1B shows the formation of nano-sized micelles.
FIG. 1C is an enlarged drawing of one micelle showing an aqueous precursor solution surrounded by coordinated surfactant molecules.
FIG. 2 shows the sequence of particle formation in the synthesis of ceria nanoparticles that are less than 10 nanometer (nm) in diameter; preferably in a range from approximately 4 nm to approximately 7 nm in diameter.
FIG. 3 is high resolution transmission electron microscopy (HRTEM) image of non agglomerated ceria particles having spherical morphology with particle size of approximately 5 nanometers (nm) in diameter for non-agglomerated ceria sol prepared and stabilized using hydrogen peroxide.
FIG. 4 is a flowchart of method steps of providing nano-sized particles in a of toluene for use as a pressure drop reduction pipeline additive.
FIG. 5 is an experimental layout of a fluid flow loop.
FIG. 6 is the layout of a nanoceria mixture storage vessel and the injection port of a pipeline.
FIG. 7 is a graph of pressure drop measurements in a stainless steel pipe and a rusty carbon steel pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown since the invention is capable of further embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
Acronyms used throughout the description of the present invention are defined as follows:
AOT refers to sodium bis(2-ethylhexyl) sulfosuccinate, a surfactant supplied by Aldrich Chemical Company, Inc., Milwaukee, Wis. Ce(NO 3 ) 3 refers to cerium nitrate. H 2 O 2 refers to hydrogen peroxide. HRTEM refers to high resolution transmission electron microscopy, a technique for examining nano-sized ceria particles, in size, shape and structure. RM refers to reverse micelles, a microemulsion technique for synthesizing rare earth metal oxide particles less than 10 nanometers (nm) in diameter.
According to the present invention, the objectives stated above are met by preparing agglomerate-free, nanoceria particles, suspended in a compatible medium, then spraying the nanoceria mixture onto a fluid stream (gas, liquid or semi-solid) to reduce the roughness of the inside surface of pipe being used to transport the fluid. Also, if there is a mixture of fluids, for example both gas and liquid flowing in a pipeline, the interfacial friction between the two fluids is decreased when the nanoceria mixture is injected into the pipeline.
For purposes of illustrating the present invention, but not as a limitation, ultrafine nanoparticles of ceria having a diameter less than 10 nanometers (nm), preferably in a range from 3 nm to approximately 9 nm, are produced using an emulsion technique described below. To avoid agglomeration, sodium bis(2-ethylhexyl)sulfosuccinate (AOT), a surfactant, is added, and the nanoparticles are suspended in toluene for delivery. The surfactant has a dual function; first, to prevent agglomeration of the nano particles and second, to function as the carrier fluid for the ceria nanoparticles. The nanoceria mixture is injected into both dry gas and multiphase pipelines and the pressure gradient is measured and compared to the pressure gradient without the nanoceria mixture. The pressure gradient is decreased by 10-30% depending on the gas velocity, roughness of the pipe, and the relative flowrates of the gas and liquid. Further spraying reduced the pressure gradient even further. Previous technologies could only reduce the pressure gradient by 5-15% as discussed by Chen et al. in Paper 00073 , Corrosion 2000 , NACE International Annual Conference . The significant decrease in pressure gradient means better recovery and yield of the gas or other fluid flowing though the pipeline.
In the present invention, the surfactant incorporated engineered oxide nanoparticles can be generally prepared by mixing, with continuous agitation, an aqueous solution of rare earth metal salt, e.g., a carbonate, nitrate, sulfate, chloride salts and the like, in the surfactant dissolved in a hydrocarbon solution. The hydrocarbon is a non-polar solvent such as toluene, octane and higher-octane compounds and can be any of the broad class of saturated hydrocarbons that form a compatible chemical solution wherein the nanoparticles are suspended and evenly dispersed without agglomeration or settling. After mixing the aqueous solution of rare earth metal salt, surfactant and non-polar solvent, the dropwise addition of hydrogen peroxide causes the formation of the oxide nanoparticles capable of significant pressure drop reductions in pipelines conveying fluids.
FIGS. 1A , 1 B, 1 C and 2 illustrate how the nanoceria particles are engineered. In FIG. 1A , a mixing vessel 10 , contains approximately 0.5 grams (gm) of surfactant (AOT) 12 that is dissolved in 50 milliliters (ml) of toluene 14 and approximately 2.5 ml of approximately 0.1 mole (M) cerium nitrate aqueous solution 16 is added. FIG. 1B shows several micelles of AOT molecules 20 are formed due to the polarity of the aqueous solution. FIG. 1C is an enlarged view of micelle 20 showing an aqueous precursor solution 22 surrounded by surfactant molecules 12 forming a nano particle.
The stepwise sequence of cerium oxide nanoparticle formation by single microemulsion process is shown in FIG. 2 . Starting with a micelle 20 , 7.5 ml of 30% hydrogen peroxide (H 2 O 2 ) 25 is added to begin nucleation 27 and growth 29 in the process to synthesize cerium oxide nanoparticles. The solution obtained by the microemulsion process is used as is; no separation or other processing is involved.
EXAMPLE
Preparation of Nano Ceria Mixture
Cerium oxide nanoparticles of a size approximately 2 nm to approximately 10 nm in diameter, are prepared by a process including the steps of dissolving approximately 0.5 grams to approximately 1.0 grams of Ce(NO 3 ) 3 .6H 2 O in deionized water to make approximately 10 mls of solution to form a first solution, followed by dissolving approximately 3 grams to approximately 4 grams of AOT (surfactant) in approximately 200 ml of solvent to form a second solution, followed by combining the first and the second solutions, followed by stirring the combined solutions for approximately 30 minutes, and drop wise adding approximately 30% hydrogen peroxide (H 2 O 2 ) until the stirred combined solution becomes yellow, and subsequently stirring for approximately 30 minutes to approximately 60 minutes more.
Thus, aqueous reverse micelles (RMs) formed of surfactant aggregates in nonpolar solvents that enclose packets of aqueous solution in their interior. The size of the water droplet can be tuned by varying the ratio of water to surfactant. RMs are used as reaction media in the production of nanoparticles whose size and shape are controlled by water and surfactant ratio.
FIG. 3 is an HRTEM image of ceria nanoparticles, prepared by the microemulsion technique described above. The HRTEM image shows spherical particle 35 morphology with uniform particle size distribution. The ceria nano particles are less than 10 nanometers (nm) in diameter, preferably in a range from approximately 2 nm to approximately 9 nm with a mean size of approximately 5 n.
FIG. 4 is a flowchart of method steps of providing nano-sized particles into a pipeline. The method can include an efficient method of providing nano-sized particles, that are non-agglomerated and suspended in a nonpolar solvent, then injected into a fluid pipeline. The method steps can include the steps of preparing an aqueous solution of a rare earth metal salt 110 and dissolving a surfactant in a nonpolar solvent 120 , and combining the aqueous solution of the rare earth metal salt with the nonpolar solvent and surfactant 130 . Next, the mixture is sired to form micelles 140 , followed by treating the micelles with hydrogen peroxide 150 , and allowing nucleation and growth of nano-particles of a rare earth metal oxide 160 , and injection the rare earth metal oxide nano-particle reaction product (“nanoceria mixture”) into fluid flowing through a pipe 170 .
In a multiphase flow loop shown in FIG. 5 , the fluid 50 can be either single phase, such as, gas, aqueous or hydrocarbon (non-aqueous), or combinations of phases, such as, gas/liquid, gas/solid, liquid/liquid, or gas/liquid/solid. The liquid mixture is either water and/or oil and is placed in storage tank 52 . If solids are required, they are also inserted with the liquid 50 . The flow loop has a pump 54 to circulate fluid in the pipeline, a drain valve 74 and valves 80 , 81 , 82 , 83 , 84 and 85 are at strategic locations for safety and control of fluids from storage vessel to outlet pipe. Fluid 50 is pumped into a 20-meter long Plexiglas pipe 200 .
To mimic the conditions for gas lines, carbon dioxide gas from a second storage tank 56 is added to the pipeline 200 , using gas flow meter 58 . The mixtures flow along the pipeline 200 . The pressure gradient is measured as the fluid passes through the Plexiglas section of pipe, using pressure tappings 60 , 62 on each side of the pipeline 200 . The mixture 50 then flows around a loop and back into the liquid storage tank 52 after traveling along a 24 meter return loop having a pigging port 72 at an end opposite the storage tank 52 , a chemical injection port 76 for the introduction of the surfactant incorporated nanoparticles, and a section of metal pipe 250 for determining pressure drop reduction. The metal pipe section 250 has pressure tappings 64 and 66 on each side of the pipe section 250 .
When liquid flowing through the pipeline 200 and section 250 reaches the liquid storage tank 52 , the liquid is separated and the gas vented to the atmosphere via outlet pipe 70 . All types of liquids and gases can be used in the multiphase flow loop.
FIG. 6 shows an arrangement of the pressurized nanoparticle storage vessel 90 containing a nanoceria mixture 92 , connected by a hose or other conduit 94 to a spray nozzle 96 located at injection port 76 (shown in FIG. 5 ) along pipeline 200 .
FIG. 7 shows changes in pressure drop (Pa) for a smooth, stainless steel pipe, and a rough, rusted carbon steel pipe. The pressure drop is measured across the metal pipe. For the rough pipe, the friction is high due to the high roughness of the pipe and hence the pressure drop is high. When the nanoparticles are injected, immediately the pressure drop decreases by 10 to 25 Pa, which ranges from 6-18% decrease from baseline conditions. The highest performance is at the higher gas velocities. For the smoother stainless steel pipe, the effectiveness of injecting nanoparticles is minimal below 6 meters per second (m/s) flow rate. However, above this gas velocity, the effectiveness again increases to about 15-20% pressure drop decrease from baseline conditions. It is noted that the nanoparticles move in the direction of the pipe wall and help reduce the roughness there by filling in the imperfections in the pipe wall surface.
The following methods and techniques can be used to introduce the nanoceria mixture of the present invention to pipelines carrying compatible fluids. Compatible fluids are defined as those that are not degraded in anyway by the nanoceria mixture. The compatible fluids may be gases, liquids, semi-solids (i.e., solids mixed with liquids) or mixtures thereof. Further, the compatible fluids can flow in single phase or multiphase. A single-phase system is used to transport a single fluid, the fluid in the pipeline is considered to be homogeneous. The multiphase system transports both liquid and gaseous phases of fluid in the same pipe; the two phases tend to undergo separation because of gravity, particularly at low flow rates, with the liquid tending to flow in the lower part of the pipe and the gas in the upper part.
The present invention provides a composition of matter for innovative oil and gas recovery; improves production efficiency in all industries, using pipelines to transport fluids that are not compromised by the addition of a nanolayer of the nanoceria mixture.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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Nano-sized rare earth metal oxide particles are prepared from aqueous reverse micelles. The engineered nanoparticles have large surface area to volume ratios, and uniformly incorporate a surfactant in each particle, so that when applied to the inner surface of a pipeline or sprayed onto a fluid stream in a pipeline, the particles reduce the roughness of the inside surface of pipe being used to transport fluid. The application of a nanolayer of this novel nanoceria mixture causes a significant reduction in pressure drops, friction, and better recovery and yield of fluid flowing through a pipeline.
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ClAIM OF PRIORITY
This application claims priority to, and incorporates by reference herein in its entirety, pending U.S. Provisional Patent Application Ser. No. 60/693,158, filed Jun. 23, 2005, and entitled “Multi-Band Hybrid SOA-Raman Amplifier for CWDM.”
FIELD OF THE INVENTION
The present invention relates generally to transporting multiple wavelength channels on a single optical fiber over moderate distances and, more particularly, to a multiband hybrid amplifier for use in coarse wavelength division multplexing transmission systems.
BACKGROUND OF THE INVENTION
Coarse wavelength division multiplexing (CWDM) has recently emerged as an inexpensive technology for transporting multiple wavelength channels on a single optical fiber over moderate distances. CWDM's low cost relative to dense wavelength division multiplexing (DWDM) is attributed to the fact that the CWDM spectrum is orders of magnitude sparser than a typical DWDM spectrum. The ITU standard for CWDM defines a maximum of 18 wavelength channels with a channel-to-channel wavelength separation of 20 nm. That large channel spacing permits a 13-nm channel bandwidth, which in turn makes possible the use of inexpensive CWDM optics and directly modulated, un-cooled semiconductor laser transmitters. In contrast, DWDM systems, with typical channel spacings of 0.8 or 0.4 mm, require tightly specified and controlled laser transmitters, since the laser wavelength must fall within a small fraction of a nanometer over the entire life of the laser (typically ±0.1 nm for a system with 0.8-nm channel spacing). Their relatively small channel counts make CWDM systems the natural choice for transporting wavelengths at the edge of the network, where traffic is not highly aggregated as it is in the network core.
CWDM is considered an un-amplified technology since the large wavelength spread occupied by all channels in a typical commercial CWDM system (73 nm for a 4-channel system, 153 nm for an 8-channel system) cannot be accommodated by readily available low cost optical amplifiers. For example, inexpensive erbium-doped fiber amplifiers have an optical bandwidth of only about 30 nm. Being an un-amplified technology limits the reach of most commercial CWDM systems to approximately 80 km. That constraint could be overcome with the invention of a low-cost, broadband optical amplifier.
Although, in practice, semiconductor optical amplifiers (SOA) are capable of amplifying as many as 4 CWDM channels per SOA, the trade-off between maintaining sufficient optical signal-to-noise ration (OSNR) and reducing gain saturation induced crosstalk reduces the dynamic range of pure SOA solutions while rendering them inadequate for systems with cascaded amplifiers.
Raman amplifiers have been tried in this application. A Raman amplifier is based on the nonlinear optical interaction between the optical signal and a high power pump laser. The gain medium may be the existing optical fiber or may be a custom highly non-linear fiber. A recently disclosed all-Raman amplifier covering the commercially-standard 8 CWDM channel wavelengths exhibited approximately 10 dB lower gain yet required 7 Raman pumps with widely varying pump powers, a total launched power over 1100 mW, and a custom highly nonlinear fiber (HNLF) gain medium.
Several fiber network providers are currently either evaluating or deploying CWDM systems to reduce costs. All those who deploy CWDM will have situations that require extending reach. With present technology, their only solution will be to install an expensive regenerator to perform the following steps: 1) optically demultiplex the CWDM channels; 2) convert each optical channel to analog electrical signals; 3) amplify the analog electrical signals; 4) recover the system clock; 5) use a decision circuit to regenerate a re-timed digital electrical data stream from the analog data and the recovered system clock; 6) use this electrical data to drive a CWDM laser transmitter for each channel; and 7) multiplex the various CWDM wavelengths onto the common transmission fiber. All of those (steps 1-7) could be replaced by a single low-cost optical amplifier.
There remains a need for a cost-effective amplifier that is useful with commercially-available CWDM systems, while minimizing the above-described disadvantages.
SUMMARY OF THE INVENTION
The present invention addresses the needs described above by providing a method and system for amplifying an optical signal. In one embodiment of the invention, a data transport system is provided. The system includes an optical fiber cable, at least one coarse wavelength division multiplexer (CWDM) for transmitting an optical signal on the fiber within plurality of signal channels in a wavelength range, at least one Raman pump having a pumping wavelength outside any signal channel, coupled to the fiber to amplify the signal, and at least one semiconductor optical amplifier (SOA) having a gain over at least one of the signal channels, connected to the fiber to amplify the signal.
A gain of the at least one Raman pump may increase as a function of wavelength within the wavelength range, and the gain of the at least one SOA may decrease within the wavelength range. The sum of those gains may be more constant over the wavelength range than the individual gains.
The at least one Raman pump may comprise a plurality of Raman pumps, outputs of which are multiplexed by a pump multiplexer. The output of the pump multiplexer may be coupled onto the optical fiber cable via an optical circulator.
Another embodiment of the invention is a hybrid optical amplifier for amplifying an optical signal. The optical signal is transmitted on an optical fiber and has a frequency range. The amplifier includes at least one Raman pump coupled to the fiber, having a gain within the frequency range and creating a Raman amplified signal. The hybrid amplifier further includes a band demultiplexer for splitting the Raman amplified signal propagating in the fiber into a plurality of band signals having band frequency ranges, at least one semiconductor optical amplifier (SOA), each said SOA connected for amplifying a band signal of the plurality of band signals, and having a gain within the band frequency range of the band signal, and a band multiplexer for recombining the band signals after amplification.
In that embodiment of the hybrid amplifier, the at least one Raman pump may comprise three Raman pumps, outputs of which are multiplexed by a pump multiplexer. An output of the pump multiplexer may be coupled onto the optical fiber cable via an optical circulator.
The optical signal may comprise a plurality of wavelength bands, in which case a summed gain of the Raman pumps increases monotonically across each wavelength band.
The optical signal may include at least two frequency channels having a null frequency range between the channels, and at least one of the Raman pumps in that case may include a pump laser having a frequency within the null frequency range.
The Raman pumps may include a first pump laser having emission wavelength 1365 nm and optical power coupled into the Raman gain medium 200 mW, a second pump having emission wavelength 1430 nm and optical power coupled into the Raman gain medium 250 mW, and a third pump having emission wavelength 1500 nm and optical power coupled into the Raman gain medium 150 mW.
The at least one SOA may comprise a plurality of SOAs, one connected for amplifying each band signal. The optical signal may comprise at least two frequency bands, wherein the at least one SOA comprises a single SOA amplifying a first of said frequency bands, and a second of said frequency bands is not amplified by an SOA. The optical signal may comprise an 8-channel spectrum, and wherein the band demultiplexer may split the spectrum into two 4-channel bands.
Yet another embodiment of the invention is a method for amplifying a CWDM optical signal having at least first and second frequency bands. The method includes the steps of amplifying the CWDM optical signal using at least one Raman pump coupled to the optical fiber cable, splitting the amplified CWDM optical signal into the at least two frequency bands, further amplifying at least one of the frequency bands using a semiconductor optical amplifier (SOA), and recombining the at least two frequency bands.
The at least one Raman pump may comprise a plurality of pump lasers, each having a different wavelength. The bands of the CWDM optical signal may comprise channels having null frequency ranges between them, in which case a wavelength of at least one of the plurality of pump lasers may be within the null frequency.
A net gain of the Raman amplifying step and the SOA amplifying step may be flat over the CWDM frequency range to within 5 dB. The CWDM optical signal may comprise an 8-channel spectrum split into two 4-channel bands, and each band may be separately amplified by an SOA. A wavelength spread occupied by the CWDM optical signal may be approximately 153 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a prior art hybrid amplifier.
FIG. 2 is a gain versus wavelength plot representing several components of the amplifier of FIG. 1 .
FIG. 3 is a schematic representation of a hybrid amplifier according to one embodiment of the invention.
FIG. 4 is a gain versus wavelength plot representing several components of the amplifier of FIG. 3 .
FIG. 5 is a schematic representation of a hybrid amplifier according to another embodiment of the invention.
FIG. 6 is a gain versus wavelength plot representing several components of the amplifier of FIG. 5 .
FIG. 7 is a flow chart showing a method according to one embodiment of the invention.
DESCRIPTION OF THE INVENTION
The presently-described invention is a multi-band hybrid SOA-Raman amplifier capable of amplifying all 8 CWDM channels typically used in today's commercial systems. As described herein, the unique design of this amplifier not only facilitates simultaneous amplification of the 8-channel band, but makes possible relatively long distance transmission via a multi-amplifier cascade.
The Hybrid Amplifier
The inventors recently measured gain and transmission system bit-error rate performance for a broadband (4 channels from 1510 nm to 1570 nm) hybrid amplifier based on a single SOA and a single Raman pump laser. That amplifier 100 , which has been previously demonstrated for DWDM systems, is shown schematically in FIG. 1 . A backward propagating semiconductor Raman pump laser 120 is coupled to the transmission fiber 110 with a wavelength division multiplexing (WDM) coupler 130 , followed by a conventional polarization independent SOA 140 and an optical isolator 150 .
The Raman pump wavelength is chosen to compliment the SOA such that the combined gain of the hybrid amplifier is both increased and flattened as compared to the SOA alone. A plot 200 of measured gains of the components of the hybrid amplifier of FIG. 1 is presented in FIG. 2 . Specifically, that figure shows the measured gain spectra 230 of the SOA alone (triangles), Raman amplifier 220 alone (diamonds), and the hybrid amplifier 250 (squares). In this case, the Raman pump laser operated at 1480-nm wavelength with 300-mW coupled into the transmission fiber, and the SOA gain peak was approximately 1510-nm wavelength. The transmission fiber, which is necessary to provide Raman gain, was 60 km of standard reduced water peak fiber (OFS AllWave® fiber). Similar performance is expected for other common transmission fiber types including standard single-mode fiber.
As shown by the curves of FIG. 2 , the SOA gain 230 decreases monotonically from short wavelength to long wavelength within the 4 channel CWDM band 210 . The Raman gain 220 has the opposite trend, increasing with increasing wavelength. Aside from the obvious gain enhancement and gain-tilt compensation, this amplifier arrangement has another more subtle advantage: this design alleviates the power penalty due to cross-gain modulation (saturation) in the SOA. The pre-emphasis of the long-wavelength channels by the Raman gain permits positioning of the 4 channel band 210 to the long-wavelength side of the SOA gain peak, where cross-gain modulation is reduced. Those three attributes make this amplifier far more promising as a candidate for multi-amplifier cascades. The increase in gain and gain flatness helps preserve optical signal-to-noise ratio over a multi-amplifier cascade, and the resistance to cross-gain modulation prevents signal degradation due to crosstalk. Naturally, with the proper choice of Raman pump wavelength and SOA gain peak, that same arrangement could be implemented to cover any contiguous 4 channel band within the 18-channel CWDM spectrum; however, higher pump power would be required at shorter wavelengths due to increased fiber loss.
The Hybrid Multi-Band Amplifier
Although the optical bandwidths of the SOA and Raman gain are naturally well suited to a 4-channel hybrid amplifier design, most commercial CWDM systems employ 8 CWDM channels from 1470 nm to 1610 nm. The inventors have developed novel two-band variations of the hybrid SOA-Raman amplifier capable of amplifying the entire commonly used 8 channel band. FIG. 3 is a schematic representation of a hybrid two-band amplifier 300 . Multiple pumps 320 , 322 , 324 , shown in the drawing as P 1 , P 2 and P 3 , are multiplexed together in a pump multiplexer 326 and coupled onto the transmission fiber 310 via an optical circulator 330 . The Raman amplified 8-channel spectrum is split into two 4-channel bands in the band demultiplexer 340 , and each band is separately amplified by SOAs (B 1 ) 342 and (B 2 ) 344 . The SOAs 342 , 344 are followed by optical isolators 350 , 352 , and the amplified bands are recombined in band multiplexer 355 .
Although the hybrid amplifier 300 of FIG. 3 is shown with three Raman pumps 320 , 322 , 324 , the number of pumps, pump wavelengths and pump powers may vary depending on the desired peak gain and gain shape. One exemplary configuration having three Raman pumps is represented in the plot 400 of FIG. 4 . The curve 420 (diamonds) shows the calculated on-off Raman gain for three pumps 320 , 322 , 324 with wavelengths 1365 nm, 1430 nm, and 1500 nm, and having pump powers of 200 mW, 250 mW, and 150 mW, respectively. The moderate net resulting Raman gain 420 , monotonically increasing across each of the two 4 channel bands, serves the same purpose as the Raman gain in the previously described single-band amplifier: it improves gain, improves optical signal-to-noise ratio (OSNR) and decreases gain tilt across each 4-channel band, while allowing operation in the low-crosstalk region of the SOA spectra. The 1500-nm pump, although falling within the overall 8-channel band, is situated at the null between the 1490-nm and 1510-nm channels and thus should not result in excessive Rayleigh backscattered pump light impinging on the channel receivers.
Typical SOA gains for SOAs (B 1 ) 430 (triangles) and (B 2 ) 432 (circles), respectively, are then added to the Raman gain resulting in the overall calculated net gain 450 of the hybrid two-band amplifier (squares). The net gain is relatively flat over the 8-channel band, with a peak gain of 21.2 dB at 1530 nm and a minimum gain of 17.7 dB at 1610 nm. The fact that Raman gain for a single pump wavelength naturally increases with increasing signal wavelength, results in a simpler and less costly Raman implementation for this 2-band hybrid amplifier as compared to an all-Raman design.
FIG. 5 shows a variation 500 of the two-band hybrid SOA-Raman amplifier which uses only one SOA 542 rather than two. The SOA 542 is followed by an optical isolator 550 and is between demultiplexer 540 and multiplexer 555 , as in the example of FIG. 3 . Signals 544 within one of the bands do not pass through an SOA. That simpler design comes at the expense of increased Raman pump powers. Three backward propagating pump lasers, P 1 ( 520 ) at 1365 nm, P 2 ( 522 ) at 1455 nm and P 3 ( 524 ) at 1500 nm, have output powers of 300 mW, 320 mW, and 220 mW, respectively.
Although only one SOA 542 is used, the proposed amplifier 500 still employs a dmux-mux pair 540 , 555 to split (combine) the 8-channel band before (after) SOA B 1 . That conservative design may not be necessary if SOA B 1 exhibits sufficiently low excess loss and polarization dependant loss (PDL) over the long wavelength half of the spectrum (in which case, the dmux and mux 540 , 555 can be omitted).
The calculated gain for this amplifier configuration is shown in FIG. 6 . Diamonds again represent the calculated Raman gain 620 . In this case, rather than a Raman gain spectrum that increases over each of the two 4-channel sub-bands, the Raman gain increases over the short wavelength 4 channel band (1470 μm, 1490 nm, 1510 nm, and 1530 nm), but remains relatively flat over the long wavelength 4-channel band (1550 nm, 1570 nm, 1590 nm, and 1610 nm). Thus, the Raman process provides all of the amplification for the long-wavelength sub-band, while the net short wavelength gain 650 (squares) is due to both Raman gain and the gain 630 from SOA B 1 (triangles).
For these particular Raman pump powers and SOA gain shape, this design exhibits slightly higher gain variation than the previous two-SOA design. The calculated net gain varies between a minimum of 17.4 dB and a maximum of 21.9 dB.
A Method According to the Invention
The invention described herein further contemplates a method 700 , shown in FIG. 7 , for amplifying a CWDM optical signal having at least first and second frequency bands. The wavelength spread occupied by the CWDM optical signal may be approximately 153 nm, the spread of many commercially-available CWDM systems. The CWDM optical signal may comprise an 8-channel spectrum split into two 4-channel bands.
The CWDM optical signal is amplified (step 710 ) using at least one Raman pump coupled to the optical fiber cable. The at least one Raman pump may be a plurality of pump lasers, each having a different wavelength. The bands of the CWDM optical signal may comprise channels having null frequency ranges between them, in which case a wavelength of at least one of the plurality of pump lasers may be within that null frequency, to prevent excessive Rayleigh backscattered pump light impinging on the channel receivers.
The amplified CWDM optical signal is then split (step 720 ) into frequency bands. At least one of the split frequency bands is further amplified (step 730 ) using a semiconductor optical amplifier (SOA). In a preferred embodiment, the net gain of the Raman amplifying step and the SOA amplifying step is flat over the CWDM frequency range to within 5 dB. Each band of the CWDM signal may be separately amplified by an SOA. The bands are then recombined (step 740 ).
SUMMARY
The inventors have proposed several new multi-band hybrid SOA-Raman amplifier designs for CWDM transmission systems. Both implementations are capable of simultaneously amplifying 8 CWDM channels from 1470-1610 nm. Calculations made by the inventors suggest that those cost effective designs will outperform both all-SOA and all-Raman amplifiers in terms of peak gain, gain shape and crosstalk tolerance, and are therefore well suited to applications that require cascaded amplifiers. Furthermore, the maximum individual pump powers required for each of the two designs (250 mW and 300 mW, respectively) are readily available from commercial semiconductor pump lasers.
The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. For example, while the method of the invention is described herein with respect to optical transmission using CWDM, the method and apparatus of the invention may be used with other optical multiplexing schemes wherein a relatively wide wavelength band width is occupied by the signal. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention.
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A multi-band hybrid amplifier is disclosed for use in optical fiber systems. The amplifier uses Raman laser pumps and semiconductor optical amplifiers in series to produce a relatively level gain across the frequency range of interest. Multiple Raman pumps are multiplexed before coupling into the fiber. The Raman amplified optical signal may be demultiplexed and separately amplified by the SOAs before re-multiplexing. Gain profiles of the Raman pumps and the SOAs are selected to compensate for gain tilt and to alleviate the power penalty due to cross-gain modulation in the SOAs. The disclosed hybrid amplifier is especially useful in coarse wavelength division multiplexing (CWDM) systems.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the insecticide carbofuran and to its use in soils where its insecticidal activity declines upon repeated applications. In particular, this invention relates to means of restoring the insecticidal activity of carbofuran in such soils.
2. Description of the Prior Art
"Carbofuran" is the common name for 2,3-dihydro-2,2-dimethyl-7-benzofuranyl methylcarbamate, which is represented by the following formula ##STR2##
This compound is claimed in U.S. Pat. Nos. 3,474,170 and 3,474,171, both issued on Oct. 21, 1969, to W. G. Scharpf, and both assigned to FMC Corporation. In addition to its common name, the compound is known to the public under the FMC Corporation trademark "Furadan®" and the Bayer AG trademark "Curaterr®". In its technical form, the compound is a colorless crystalline solid. It is normally used, however, as a wettable powder containing 750 g active ingredient per kilogram, a flowable paste containing 480 g active ingredient per liter, or granules containing 20, 30, 50, or 100 g active ingredient per kilogram.
Carbofuran is a systemic insecticide, acaricide, and nematicide. It is applied to plant foliage at 0.25 to 1.0 kilograms active ingredient per hectare (kg/ha) for the control of insects and mites, broadcast at 6 to 10 kg/ha for the control of nematodes, or applied to soil (particularly seed furrows) at 0.5 to 4.0 kg/ha for the control of foliar-feeding and soil insects. The present invention is directed to the soil application.
In certain soils, repeated applications of carbofuran have produced successive decreases in insecticidal activity. With a sufficient number and frequency of applications, the insecticide can become totally ineffective. It is therefore an object of this invention to restore the insecticidal activity of carbofuran in soils where repeated application has either substantially lessened its activity or destroyed its activity altogether.
SUMMARY OF THE INVENTION
It has now been discovered that the insecticidal activity of carbofuran in soil which has been previously treated with carbofuran and to which second or subsequent applications have produced a declining level of insecticidal activity (hereinafter referred to as "problem soil") can be restored at least in part by applying to the soil, together with an insecticidally effective amount of the insecticide, an organophosphorus compound of the formula ##STR3## in which R 1 is C 1 -C 4 alkyl,
R 2 is C 1 -C 4 alkyl,
R 3 is C 1 -C 4 alkylene,
X is oxygen or sulfur, and
n is zero or one,
in an amount sufficient to restore at least a portion of the lost activity. This is particularly surprising in view of the fact that organophosphorus compounds within the above formula have little or no insecticidal activity of their own.
Within the scope of the above formula, certain compounds are preferred, namely those having the formula ##STR4## in which R 1 , R 2 , R 3 , and n are as defined above.
The term "alkyl" is used in its normal sense and is intended to include both straight-chain and branched-chain groups. Examples are methyl, ethyl, propyl, isopropyl, butyl, t-butyl, etc. The term "alkylene" designates multiples of the methylene radical --CH 2 --, optionally substituted with alkyl groups forming side chains. Examples include --CH 2 -- (methylene), --CH 2 CH 2 -- (ethylene), --CH 2 CH 2 CH 2 -- (propylene), --CH 2 CH 2 CH 2 CH 2 -- (butylene), --CH(CH 3 )CH 2 CH 2 -- (1-methylpropylene), --CH(CH 2 CH 3 )CH 2 -- (1-ethylethylene), etc. All carbon atom ranges are intended to be inclusive of their upper and lower limits.
The terms "insecticidally effective amount" and "insecticidal" refer to any amount of the compound or composition described which, when applied to the soil, will kill, interrupt the life cycle of, or delay the maturation of at least a measurable portion of the insect population residing therein.
The present invention resides in an insecticidal composition for use in problem soil comprising an insecticidally effective amount of carbofuran and an amount of an organophosphorus compound within the above description sufficient to restore at least a portion of the carbofuran activity; a method of controlling insects in problem soil comprising applying such a composition to the soil; and a method of restoring the insecticidal activity of carbofuran in problem soil comprising applying an effective amount of the organophosphorus compound to the soil in conjunction with the carbofuran.
DETAILED DESCRIPTION OF THE INVENTION
Carbofuran is a commercially available material. It is manufactured by the simultaneous thermal rearrangement and cyclization of 1-methallyloxy-2-nitrobenzene to form 2,3-dihydro-2,2-dimethyl-7-nitrobenzofuran, which is then reduced to the amine, then diazotized and converted to 2,3-dihydro-2,2-dimethylbenzofuran-7-ol, and then esterified with methyl isocyanate. In an alternative procedure, 2-methallyloxyphenol is thermally rearranged and cyclized to form 2,3-dihydro-2,2-dimethylbenzofuran-7-ol, which is then treated simultaneously with methyl isocyanate and triethylamine. The starting material 2-methallyloxyphenol can be prepared by reacting catechol with potassium carbonate and potassium iodide in dry acetone under a nitrogen atmosphere. Further particulars of each of these procedures will be readily apparent to those skilled in the art.
The organophosphorus compounds described above are prepared by reacting an appropriately substituted O,O-dialkyl phosphorohalothioate (chlorine is the preferred halogen) with either a phenol or a phenyl alkanol, depending on the desired product. The reaction can be conducted in tetrahydrofuran in the presence of sodium hydride or powdered sodium hydroxide. Again, the system parameters for the process will be apparent to those skilled in the art. The starting materials are commercially available or readily prepared by known techniques.
The objects of the present invention are achieved by applying the organophosphorus additive to the soil at an agricultural field site in conjunction with carbofuran. The two compounds can be applied simultaneously in a single pre-mixed formulation, simultaneously in separate formulations, or in succession in either order. In successive application, it is preferable to add the compounds as close in time as possible.
The restorative effect of the organophosphorus additive on the carbofuran activity occurs over a wide range of ratios of the two compounds, with no critical range being apparent. It is most convenient, however, to apply the compounds at a ratio of from about 0.1:1 to about 50:1 (carbofuran:additive), preferably from about 0.5:1 to about 30:1, on a weight basis.
The following examples are offered to illustrate the restorative capabilities of the organophosphorus compounds and the utility of the composition as a whole in controlling the proliferation of insects in soil. These examples are not intended to limit or define the invention in any manner.
EXAMPLE 1
This example demonstrates the declining activity of carbofuran after repeated applications to the same soil batch, and the effectiveness of O,O-diethyl-O-phenyl phosphorothioate in restoring the activity of the carbofuran.
A sandy loam soil with a moisture content of approximately 15% by weight was mixed in a small cement mixer with sufficient technical carbofuran to provide a carbofuran content of 2.0 parts per million by weight (ppm). Separately, an aqueous suspension of eggs of the western spotted cucumber beetle (Diabrotica undecimpunctata undecimpunctata Mann.) was prepared, containing approximately 250 eggs per cc, held in suspension by 0.2% (by weight, relative to the water) of the commercial suspending agent Dacagin® (Diamond Alkali Company, Cleveland, Ohio).
A ten-gram soil sample was then infested with 0.2 cc of the suspension (containing approximately 50 eggs), and the remainder of the soil was placed in constant temperature storage at 85° F. (29° C.) while water was added as needed to maintain the moisture level (determined by periodic weighings). Several days later the infested soil sample was observed for the emergence of larvae (none was detected). Further soil samples were similarly infested and observed after multiples of one week of storage. The four week sample was the first to show larval emergence, indicating that the insecticidal effectiveness of the carbofuran lasted over three weeks.
The soil remaining in storage was then re-treated with carbofuran at 2.0 ppm, and a series of samples were infested one week apart as before. This time the second-week sample showed the emergence of larvae. The remaining soil was then given a third treatment at 2.0 ppm and the initial sample showed the emergence of larvae. This soil was labeled "problem soil."
To test the restorative capabilities of the organophosphorus compound, several ten-gram samples of problem soil were placed in one-ounce plastic containers and treated with 2.5 ppm of O,O-diethyl-O-phenyl phosphorothioate (in acetone solution) plus varying amounts of carbofuran ranging from 10.0 ppm down to 0.1 ppm. A second series was similarly treated using 5.0 ppm of O,O-diethyl-O-phenyl phosphorothioate, and a third series was treated using 10.0 ppm. Additional series were treated with carbofuran alone and O,O-diethyl-O-phenyl phosphorothioate alone (at varying dosages). A final series consisted of carbofuran treatments on non-problem soil (i.e., soil never before treated with carbofuran). All samples were thoroughly mixed, then infested with approximately fifty Diabrotica eggs as described above. A piece of Romaine lettuce leaf was placed in each container. Seven to ten days later, the leaves were examined for evidence of larval feeding.
In samples where the carbofuran had destroyed the insect population, the leaves were intact. In samples where the carbofuran was ineffective, much of the leaf tissue had been eaten away. The break-point dosage in each series, i.e., the point above which the insecticidal activity was evident and below which it was not, was designated the LD-50 (lethal dose with 50% kill), and is listed in Table I. It is clear from the table that a substantial restoration of carbofuran insecticidal activity took place at each of the three application rates of organophosphorus compound, and that the 5.0 and 10.0 ppm applications completely restored the carbofuran activity. It is also evident that the organophosphorus compound itself has no insecticidal activity (the designation ">10" signifies that no insecticidal activity was observed at a dosage of 10 ppm).
TABLE I______________________________________RESTORATION OF CARBOFURAN ACTIVITYIN PROBLEM SOILAdditive: ##STR5## LD-50 Values onTest Chemicals Diabrotica Larvae (ppm)______________________________________Non-problem soil:Carbofuran alone 0.2Problem soil:Carbofuran alone 2.0Carbofuran plus additive 0.5.sup.(a)(at 2.5 ppm)Carbofuran plus additive 0.2.sup.(a)(at 5.0 ppm)Carbofuran plus additive 0.2.sup.(a)(at 10.0 ppm)Additive alone >10.0.sup.(b)______________________________________ Notes: .sup.(a) Measured in terms of carbofuran. .sup.(b) Measured in terms of additive.
EXAMPLE 2
This example demonstrates the restorative capabilities of three organophosphorus compounds, each applied in a 1:1 weight ratio with carbofuran. The three compounds were as follows:
O,O-Diethyl-O-phenyl phosphorothioate
O,O-Diethyl-O-benzyl phosphorothioate
O-Ethyl-S-ethyl-O-phenyl phosphorodithioate
The test procedure was the same as that described in Example 1 above, except that the weight ratio of carbofuran to the organophosphorus additive was held constant at 1:1, and two replications of each test were run.
The results are shown in Table II, where it is clear that each additive served to restore a substantial amount of the insecticidal activity of carbofuran. While the use of a constant weight ratio precluded the determination of the amount required to completely restore the carbofuran activity, the benefit obtained from the inclusion of each additive is clear. Two of the three additives showed no insecticidal activity of their own, while the third showed very little. Differences between the activities reported in this table and those reported in Table I reflect the fact that different potting soils were used and the tests were run at different times of the year. Again, the ">" signs indicate that no insecticidal activity was observed at the dosages indicated.
TABLE II______________________________________RESTORATION OF CARBOFURAN ACTIVITYIN PROBLEM SOILAdditive: ##STR6## ##STR7## ##STR8## LD-50 Values on Diabrotica Larvae (ppm)Test Chemicals (Average of Two Replications)______________________________________Non-problem soil:Carbofuran alone 0.75Problem soil:Carbofuran alone >20.0Carbofuran plus Additive A (1:1) 7.5.sup.(a)Carbofuran plus Additive B (1:1) 7.5.sup.(a)Carbofuran plus Additive C (1:1) 5.0.sup.(a)Additive A alone >20.0.sup.(b)Additive B alone >20.0.sup.(b)Additive C alone 15.0.sup.(b)______________________________________ Notes: .sup.(a) Measured in terms of carbofuran. .sup.(b) Measured in terms of additives.
METHODS OF APPLICATION
The compositions of the present invention are most useful in controlling soil insects when applied directly to the soil. Both carbofuran and the organophosphorus additive can be combined in a single formulation, or each can be applied in a separate formulation. Common agricultural formulations can be used, the most appropriate types being determined by the physical properties of the active ingredients, the environmental conditions, the types of crop to be protected, and other such factors. Such formulations typically contain additional, usually inert ingredients, such as diluents, carriers, wetting agents, dispersing agents, emulsifiers, suspending agents, etc. The most likely formulations for these compositions are wettable powders, flowable pastes, and granules.
Wettable powders are water-dispersable powders containing the active ingredient(s), an inert solid filler, and one or more surface-active agents to enhance wetting and prevent heavy flocculation when suspended in water. Typical solid fillers include natural clays, talcs, diatomaceous earth, and synthetic mineral fillers derived from silica and silicates. Typical surface-active agents include alkylbenzene and alkylnaphthalene sulfonates, sulfated fatty alcohols, amines or acid amides, long chain acid esters of sodium isothionate, esters of sodium sulfosuccinate, sulfated or sulfonated fatty acid esters, petroleum sulfonates, sulfonated vegetable oils, and ditertiary acetylenic glycols.
Flowable pastes are concentrated suspensions of a solid active ingredient in an aqueous system. The solid particles are typically under 5 mm in diameter, and are kept in suspension by suspending agents. Typical suspending agents include low-viscosity methyl cellulose, water-soluble low-viscosity partially hydrolyzed polyvinyl alcohols, polyoxyethylene sorbitan esters of mixed fatty acid rosin acids, purified sodium lignin sulfonates, sodium salts of polymerized alkaryl and aryl alkyl sulfonic acids, methyl hydroxyethyl cellulose, and carboxymethyl cellulose.
Granules are particulate compositions with the active ingredients adhering to or distributed throughout an inert carrier about 1 to 2 millimeters in diameter. The carrier is generally of mineral origin, and falls within one of two types. The first are porous, absorptive preformed particles, such as attapulgite or heat expanded vermiculite, upon which a solution of the active ingredient is sprayed. The second are powdered materials to which the active ingredient is added prior to formation of the granule. Such materials include kaolin clays, hydrated attapulgite, or bentonite clays in the form of sodium, calcium, or magnesium bentonites. Water-soluble salts may also be present to help the granules disintegrate in water when such is desired. Surface-active agents are sometimes included to aid in the leaching of the active ingredient from the granule to the surrounding soil.
Soil application can be accomplished by any conventional technique, such as discing, dragging, or mixing operations, or spraying or sprinkling over the surface of the soil. The compositions can also be added to irrigation water so that they will accompany the water as it penetrates the soil. In-furrow application prior to the planting of seeds, however, is preferred.
Amounts required for insecticidal effectiveness will depend on the nature of the insects to be controlled as well as the prevailing conditions. Insect control is usually achieved at application rates ranging from about 0.01 to about 50 pounds of carbofuran per acre, preferably from about 0.1 to about 25 pounds per acre.
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The insecticide carbofuran (2,3-dihydro-2,2-dimethyl-7-benzofuranyl methylcarbamate) is combined with an organophosphorus additive of the formula ##STR1## in which R 1 is C 1 -C 4 alkyl,
R 2 is C 1 -C 4 alkyl,
R 3 is C 1 -C 4 alkylene,
X is oxygen or sulfur, and
n is zero or one,
for application to soil where previous applications of carbofuran have resulted in successive decreases in the insecticidal activity of carbofuran. The lost activity of the carbofuran is thereby restored.
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BACKGROUND OF THE INVENTION
The invention is a jackpot game involving matching symbols to determine a win. There are no set sequences of plays to determine jackpots based on number of plays made previously. Any play made can determine a win. Pairs of facing discs with identical symbols on them rotate at random with no gears to control the rotation. Any symbol on a disc can match any symbol on a facing disc on every play made on the machine and determine a win. Adjoining sections can be attached separately to other identical operating sections to increase the odds in any play of the machine. Odds can be increased also by addition of identical symbols to the edges of facing discs.
Other jackpot machines operate with rotation controlled by gears. Wins are determined by set sequences. Wins only occur when a predetermined number of plays are made to allow a win. There is no random rotation to allow a win without a predetermined number of plays made previously to allow a win. They operate on a principle similar to lottery rub off cards where a predetermined number of winning cards are printed. A predetermined winning card has to be purchased to win. Other jackpot machines and lottery rub off cards allow no random chance wins when each win is predetermined by either the number of plays made previously or by purchase of a printed card that is predetermined to be a winning card.
SUMMARY OF THE INVENTION
The double match jackpot machine has two (2) identical operating mechanisms that operate independently of each other. The machine operates without a predetermined number of plays made previously to allow a win. Every play made is a random play and allows a win without any predetermined number of plays made previously to allow a win.
Pairs of facing discs with identical symbols on their edges rotate and determine a win when two (2) symbols match. There are no gears to regulate the rotation of the discs. The discs are attached to discs bars through holes in the centers of the discs. The discs rotate on the discs bars at random with no restraint.
Pairs of facing discs have discs levers attached to their facing surfaces that are engaged by the coin slots elevator springs and braces during the withdrawal of the coin slots during play. This engagement during withdrawal of the coin slots during play causes random rotation of the discs in a clockwise direction. The rotation of pairs of facing discs aligns two (2) symbols. The alignment of two (2) symbols that match on pairs of facing discs determine a win.
There are two (2) methods to increase odds in the machine, Attachment rods can be attached through coin slots handles hollows to allow more than one coin slot to operate in a play. The increase in odds depends upon how many identical sections are attached together for a play. Identical symbols can be added also to the edges of pairs of facing discs to increase odds. The increase in odds depends upon how many symbols are added to the edges of the facing discs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective top view of the double match jackpot with the top of the machine removed to show the double operating mechanisms that operate independently of each other from the front side and from the rear side. Shown in each mechanism are the discs and discs bars that the discs rotate on. Discs bars are supported by discs bars supports attached to the left side and to the right side. The discs bars pins are attached to the discs bars on each side of pairs of facing discs to hold them in alignment with each other. Shown are the coin slots containers that extend through the coin slots containers entryways into the machine. The coin slots are contained in the coin slots containers. The coin slots containers holders that are attached to the inside of the front side and to the inside of the rear side of the machine hold the coin slots containers.
FIG. 2 is a perspective view of the left side, right side, front side, rear side, bottom side and top side of the machine.
FIG. 3 is a view of the front side showing the front side coin slots containers entryways and front side symbols viewing ports.
FIG. 4 is a view of the rear side showing the rear side coin slots containers entryways and rear side symbols viewing ports.
FIG. 5 is a view of the discs bars supports showing the grooves in the top that support the discs bars.
FIGS. 6 and 6A are a view of the attachment rods that are attached to identical operating sections to increase odds.
FIGS. 7 and 7A are a perspective view of the attachment of the attachment rods attached through the hollows in the coin slots handles.
FIG. 8 is a perspective view of the coin slots showing the coin slots handles and coin slots handles hollows. Shown are the coin slots cutouts with the elevated coin slots elevator springs and braces attached to the bottoms of the coin slots coin placements.
FIG. 9 is a view of the coin slots as shown in FIG. 8 with coins placed in the coin slots coin placements to depress the coin slots elevator springs and braces from the elevated positions.
FIG. 10 is a view of the coin slots containers.
FIG. 11 is a perspective view showing the coin slots contained inside the coin slots containers.
FIG. 12 is a view of pairs of facing discs with the arrangement of identical symbols on the discs edges.
FIG. 13 is a view of the discs levers that are attached to the inside surfaces of pairs of facing discs. Shown are the discs levers pivots that attach the discs levers to the discs. Shown are the discs levers stops that are attached to the discs to control the pivoting of the discs levers during play of the machine.
FIG. 14 is a perspective view of the facing sides of pairs of facing discs and shows the attachment of the discs levers, discs levers pivots and discs levers stops to the facing surfaces of the discs.
FIG. 15 is a perspective side view of pairs of facing discs combined with a top view of coin slots contained in coin slot containers. This is a view of a section of the machine that is engaged to play the machine.
FIG. 16 is the same view as shown in FIG. 15 with one of the pairs of facing discs removed to clarify the engagement of the coin slots with the discs. Shown in the coin slots coin placements are coins placed to depress the coin slots elevator springs and braces from the elevated positions.
FIG. 17 is the same view as shown in FIG. 16 with the coin slots advanced to positions of engagement of the coins with the discs levers at the bottoms of the discs.
FIG. 18 is the same view as shown in FIG. 17 with the coin slots advanced farther until the coins engagement with the discs levers pivots the discs levers on the discs levers pivots to positions parallel to the coin slots.
FIG. 19 is the same view as shown in FIG. 18 with the coin slots advanced farther until the coins in the coin slots coin placements go beyond the ends of the coin slots containers. The coins then drop out the bottoms of the coin slots coin placements. The discs levers upon release of the pressure from the coins drop from the parallel positions back to the original perpendicular positions inside the coin slots cutouts. The coin slots elevator springs and braces upon release from being depressed by the coins resume the elevated positions.
FIG. 20 is the same view as shown in FIG. 19 with the coin slots being withdrawn. The elevated coin slots elevator springs and braces engage the discs levers at the bottoms of the discs and force the discs levers against the discs levers stops attached to the discs and cause rotation of the discs in a clockwise direction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 there is illustrated a top view of the machine with the top of the machine removed. Shown are the front side 3 and rear side 4 with identical mechanisms that operate independently of each other. Each side has six (6) separate sections that can be played individually or can be attached to one or more adjoining sections to be played together as one unit in a play. Increased odds are attained according to how many sections are attached together in a play. There are twenty-four (24) discs 13-26 attached to two (2) discs bars 7-8 through holes in the centers of the discs. The discs bars are held in place by grooves in the four (4) discs bars supports 9-12 as shown in FIG. 5. The discs bars supports are attached to the inside of the left side and to the inside of the right side. The discs are held in pairs of facing discs by twenty-four (24) discs bars pins 61-84 that are attached to the discs bars. The pairs of facing discs have identical symbols on the edges of the discs as shown in FIG. 12. Increased odds are attained according to how many symbols are added to the edges of pairs of facing discs. There are twelve (12) coin slots containers 109-120 attached to the front side and to the rear side to hold the coin slots. The twelve (12) coin slots containers enter the machine through twelve (12) coin slots containers entryways 85-96. The twelve (12) coin slots containers are supported inside the machine by twelve (12) coin slots container supports 121-132 attached to the inside of the front side and to the inside of the rear side.
Referring to FIG. 8 there is illustrated the coin slots that are advanced inside the machine and withdrawn in movements to play the machine. These movements of the coin slots cause rotations in pairs of facing discs. The rotated symbols on pairs of facing discs are shown in symbols viewing ports 143-154 for the front side shown in FIG. 3. FIG. 3 shows the coin slots containers entryways 85-90 for the front side. The rotated symbols on pairs of facing discs are shown in symbols viewing ports 155-166 for the rear side as shown in FIG. 4. FIG. 4 shows the coin slots containers entryways 91-96 for the rear side. FIG. 8 shows the coin slots coin placements 221-232 without coins placed in them. The coin slots elevator springs and braces 233-244 attached to the bottoms of the coin slots coin placements are shown in elevated positions. Shown are the coin slots handles 185-196 and coin slots handles hollows 197-208 through which are attached the attachment rods 133-142 shown in FIG. 6A. The attachment rods are attached as shown in FIG. 7A. Front side sections on the left side show front coin slots 97-99 attached by front attachment end rod 133 and front attachment inner rod 134 to join these three (3) sections together. They are illustrated without coins inserted to play these three (3) sections. Front attachment inner rod 135 is removed to prevent attachment of the three (3) sections on the left side to the three (3) sections on the right side. Front side sections on the right side show front coin slots 100-102 attached by front attachment end rod 137 and front attachment inner rod 136 to join these three (3) sections together. They are illustrated in play inside the machine together. Rear side sections on the left side show rear coin slots 103-105 attached by rear attachment end rod 138 and rear attachment inner rod 139 to join these three (3) sections together. They are illustrated without coins inserted to play these three (3) sections. Rear attachment inner rod 140 is removed to prevent attachment of the three (3) sections on the left side to the three (3) sections on the right side. Rear side sections on the right side show rear coin slots 106-108 attached by rear attachment end rod 142 and rear attachment inner rod 141 to join these three (3) sections together. They are illustrated in play inside the machine together. The odds are increased depending upon how many attachment rods are attached during play of the machine.
Referring to FIG. 9 there is illustrated the coin slots as shown in FIG. 8. In FIG. 9 the coin slots coin placements are shown with coins placed in them to depress the coin slots elevators and braces. The coin slots elevator springs and braces have to be depressed by coins to allow the coin slots to enter the machine. FIG. 10 shows the coin slots containers. The coin slots contained in the coin slots containers through which they enter the machine are shown in FIG. 11.
Referring to FIG. 12 there is illustrated pairs of facing discs with identical symbols on their edges. Pairs of facing discs have attached to their facing surfaces the discs levers 167-172 shown in FIG. 13. The discs levers are attached to facing surfaces of pairs of facing discs by discs levers pivots 173-178 as shown in FIG. 14. FIG. 14 shows the discs levers stops 179-184 that control the pivoting of the discs during play of the machine.
Referring to FIG. 15 there is illustrated a side view of pairs of facing discs combined with a top view of coin slots contained in coin slots containers. Shown are pairs of facing discs with the discs levers attached to their facing surfaces. This is a view of a section of the machine that is engaged to play the machine.
Referring to FIG. 16 there is illustrated the same view of an operating section as shown in FIG. 15 with one of the pairs of facing discs removed to clarify the engagement of the coin slots with the discs. The advancement and withdrawal of the coin slots during engagement with the discs levers rotate the pairs of facing discs and play the machine. The discs rotate and symbols on their edges appear in the symbols viewing ports. Two (2) matching symbols on pairs of facing discs appearing in the symbols viewing ports determine a win. Shown are coins placed in the coin slots coin placements to depress the elevator springs and braces so the coin slots can enter into the machine.
Referring to FIG. 17 there is illustrated the same view as shown in FIG. 16 with the coin slots advanced into the machine to engage the discs levers.
Referring to FIG. 18 there is illustrated the same view as shown in FIG. 17 with the coin slots advanced farther into the machine. The coins in the coin slots coin placements engage the discs levers and pivot them parallel to the coin slots.
Referring to FIG. 19 there is illustrated the same view as shown in FIG. 18 with the coin slots advanced farther until the coins in the coin slots coin placements go beyond the ends of the coin slots containers. The coins then drop out the bottoms of the coin slots coin placements. The discs levers upon release of the pressure from the coins drop from the parallel positions back to the original perpendicular positions inside the coin slots cutouts. The coin slots elevator springs and braces upon release from being depressed by the coins resume the elevated positions.
Referring to FIG. 20 there is illustrated the same view as shown in FIG. 19 with the coin slots being withdrawn. The elevated coin slots elevator springs and braces engage the discs levers at the bottoms of the discs and force the discs levers against the discs levers stops attached to the discs and cause rotation of the discs in a clockwise direction. This rotation in the clockwise direction of the discs causes the rotation of symbols on the edges of pairs of facing discs. Two (2) matching symbols appearing in the symbols viewing ports of pairs of facing discs determine a win.
Referring to FIG. 2 there is illustrated the machine showing the left side 1, right side 2, front side 3, rear side 4, bottom side 5 and top side 6.
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A double match jackpot with (2) separate identical operating mechanisms in the machine is the invention. The two (2) identical mechanisms operate independently with no set combinations of play. Each play is with random results. A winning play is not determined by the number of plays made previously. The matching of two (2) identical symbols on pairs of facing discs determines a win. Operating sections can be attached separately to other identical operating sections to increase the odds in any play of the machine. Odds can be increased also by addition of identical symbols to the edges of facing discs.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application hereby claims priority under 35 U.S.C. Section 119 to Swiss Patent Application Number No. 00768/11, filed May 5, 2011, the entire contents of which are hereby incorporated by reference.
FIELD OF INVENTION
[0002] The present invention relates to a novel diaphragm of the type used in axial flow turbomachines and methods of assembling the same. It is particularly, but not exclusively, relevant to steam turbine diaphragms.
BACKGROUND
[0003] A traditional way of constructing a turbine diaphragm is to mount an annulus of aerofoil blades between an inner ring and an outer ring. Each blade is formed as part of a blade unit in which the blade extends between an inner platform and an outer platform, the blade unit being machined as a single component. Each platform is in the form of a segment of a cylinder so that when the annulus of blade units is assembled the inner platforms combine to create an inner cylinder and the outer platforms combine to create an outer cylinder. The outer platforms are welded to an outer ring that provides support and rigidity to the diaphragm.
[0004] The inner platforms are welded to an inner ring that prevents axial deflection of the turbine blades. In some known variants, the inner and outer rings are each divided into two semicircular halves along a plane that contains the axis of the diaphragm and passes between blade units so that the entire diaphragm can be separated into two parts for assembly around the rotor of the turbo-machine. The two halves of the outer ring can be bolted together when the diaphragm is assembled. The two halves of the inner ring are typically held in place by being welded to the blade units, which in turn are welded to the outer ring.
[0005] U.S. Patent Application Publication No. 2008/0170939 and published International Patent Application WO 2011/018413 disclose a compact turbine diaphragm that does away with the inner ring, thereby saving the cost of manufacturing that component and the cost of welding it to the blade units. The inner platforms are made to interlock in such a manner that the inner cylinder created by them serves the purpose of the inner ring. During assembly, the blade units become subject to a torque that pre-stresses them and helps to increase the rigidity of the diaphragm.
[0006] Though the diaphragms assembled, according to the '939 publication, require no welding operation at the inner ring the outer ring is still welded against the outer diaphragm ring. The welding of a diaphragm is a complex and expensive process, which additionally requires a post-welding heat-treatment and final machining process to correct distortions. In addition only a small number of factories are qualified to manufacture these diaphragms. A mechanical assembly would reduce cost by dispensing with the weld process and in addition would permit sourcing of the assembly from a wider range of suppliers.
[0007] Such problems are for example partly addressed in U.S. Patent Application Publication No. 2007/0292266. In the method disclosed, the high heat input welding is replaced by a low heat input type or shallow weld. A proposal for assembling a diaphragm without welding is also described for example in U.S. Pat. No. 7,179,052.
[0008] Given the state of the art, there can be seen a constant demand for the industry to facilitate the assembly of turbine diaphragms, avoiding welding as far as possible while maintaining the required mechanical stability of the assembled turbine and its parts.
SUMMARY
[0009] The present disclosure is directed to a turbine diaphragm assembly including an annulus of static blades. Each static blade includes at least an airfoil and an outer platform; and an outer diaphragm ring or segments of a ring for holding the annulus of static blades. Facing edges of the outer platforms and the ring are held by an interference fit configured to withstand the forces on the diaphragm during operation of the assembled turbine.
[0010] The present disclosure is also directed to a method of assembling a turbine diaphragm assembly including an annulus of static blades, each static blade having at least an airfoil and an outer platform. The method includes providing an outer diaphragm ring or segments of a ring for holding the annulus of static blades and assembling the diaphragm through a relative motion in an axial direction between the outer diaphragm ring or segments of a ring and the static blades. The motion forces facing edges of the outer platforms and the ring into contact such that the assembled diaphragm is held by an interference fit configured to withstand forces on the diaphragm during operation of the assembled turbine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Exemplary embodiments of the invention will now be described, with reference to the accompanying drawings, in which:
[0012] FIG. 1 presents a schematic cross-section of a (known) steam turbine to illustrate the environment, in which the present invention is placed;
[0013] FIG. 2 shows details of an airfoil or blade unit of FIG. 1 ;
[0014] FIGS. 3A-C show variants of airfoil or blade units in accordance with examples of the invention;
[0015] FIG. 4 illustrates a variant of the invention using pins to provides additional protection against a movement of the blade units; and
[0016] FIGS. 5A-D show steps of assembling a diaphragm in accordance with an example of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS INTRODUCTION TO THE EMBODIMENTS
[0017] According to an aspect of the present invention, there is provided a turbine diaphragm including an annulus of static blades, each static blade comprising an inner platform, an aerofoil, and an outer platform. The outer platforms have edges designed to interference fit with edges on segments of an outer diaphragm ring such that the blades are locked into position by a relative axial motion of the outer diaphragm ring and a ring formed by the outer platforms of the blades. The interference fit is sufficient to maintain the integrity of the diaphragm under operating conditions. In other words, the interface between the edges can remain essentially weld-free even under operating conditions.
[0018] In a first embodiment of the above aspect of the invention the edges have a radial taper along at least part of the interface line.
[0019] In a second embodiment of the above aspect of the invention, the edges have a matching step or flange part.
[0020] In a third embodiment of the above aspect of the invention, the edges have a radial taper along at least part of the interface line and a matching step or flange part.
[0021] In a forth embodiment of the above aspect of the invention, at least some blades have additional mechanical fixing element to prevent a motion in radial direction. These elements can be for example bolts or dowel pins extending when in position across the interface line between the edges, and which are preferably releasable by exerting a force in axial direction.
[0022] These and further aspects of the invention will be apparent from the following detailed description and drawings as listed below.
DETAILED DESCRIPTION
[0023] Aspects and details of examples of the present invention are described in further details in the following description referring first to a so-called “compact diaphragm” design as illustrated by FIG. 1 , which reproduces the relevant features of FIG. 2 of U.S. Patent Application Publication No. 2008/0170939, which is assigned to the same Assignee as the present application. FIG. 1 is partial radial sectional sketch of axial flow turbine, showing a fully assembled diaphragm located between successive annular rows of moving blades 12 , 13 in a steam turbine.
[0024] The moving blades are each provided with radially inner “T-root” portions 14 , 15 located in corresponding slots 16 , 17 machined in the rim of a rotor drum 18 . They are also provided with radially outer shrouds 19 , 20 that seal with seals 23 , 24 against circumscribing segmented rings 21 , 22 .
[0025] The inner casing 10 of the turbine comprises an annular row of static blades, each having an airfoil part 30 , 31 whose radially inner and outer ends are integral with radially inner and outer platforms 32 , 33 , respectively. During manufacture the radially outer surfaces of platforms 33 are welded onto the inner diameter of massive outer diaphragm rings 34 , which stiffens the diaphragm and controls its thermal expansion and contraction during operation of the turbine. In preparation for the welding, two circumferential grooves or steps 341 , 342 are machined into the outer diaphragm to be filled during the welding by a metal filler.
[0026] An enlarged cross-section of this part of the diaphragm ring with the single airfoil unit 30 is shown in FIG. 2 . In FIG. 2 as throughout the drawings, like elements or elements having the like functions are designated, when possible, by the same numerals.
[0027] A first example in accordance with the invention is shown in FIG. 3A . In the example the airfoil unit 30 is secured to the outer diaphragm ring 34 by a mechanical fixing. In the example of FIG. 3A , the mechanical fixing is achieved by an interference fit along the tapered or canted edge 330 where the outer platform 33 meets the outer diaphragm ring 34 . In the example the outer edge of the platform reduces its diameter or radial position with respect to the main axis of the turbine in the axial direction of the flow (as indicated by an arrow). In this way, a force in axial direction on the blades has a component pressing the faces of the outer platform 33 and outer diaphragm ring 34 into closer contact.
[0028] Whilst the interference fit along the edge 330 may be regarded as sufficient for some application, it is seen as advantageous to secure the inference fit by further means. In the example of FIG. 3B , a radially extending circumferential shoulder 331 is added as integral part to the outer platform 33 , thus forming an inverted L shape. During assembly the shoulder 331 hooks into a corresponding groove or recess 343 in the outer diaphragm ring 34 .
[0029] A further variant of the example of FIG. 3B is illustrated in FIG. 3C , where the shoulder 331 and the corresponding groove 343 are machined as a flange-type connection having an additional rim 344 further securing the outer platform 33 against radial movement.
[0030] In cases where the assembled or partly assembled diaphragm structure has to be moved during manufacturing or assembly, it has been found to be advantageous to provide further means to prevent the assembled from coming apart again. Various such means are feasible, including bolts, screws or spot-welds. The example of FIG. 4 shows a bore through the rim or shoulder 331 . The bore extends across the interface with the outer diaphragm ring 34 . During assembly dowel pins 346 are inserted into the bore 345 . The pins 346 of this example are also fixed through an interference fit and hence the whole structure retains its advantage of being capable of disassembly without machining or cutting steps.
[0031] A part-illustration of the assembly of a complete diaphragm using the variant of FIG. 4 above is shown in FIGS. 5A-5C .
[0032] After having prepared the sub-parts, a ring of blades are placed on a flat surface 51 on the flat outer platform face D and flat inner platform face E. The segments of outer diaphragm ring 34 are clamped or screwed together to form the complete ring, which in turn is pushed in axial direction with respect to the central turbine axis over the ring of blades as indicated by the arrow in FIG. 5B . As the outer diaphragm ring 34 slips over the blades along the tapered or canted edge 330 an interference is created by forcing the inner platforms into contact.
[0033] The dowel holes 345 are drilled after assembly using holes in the platform upstand 51 as a guide and the retaining dowel pins 346 are introduced into the holes after the assembly plate is removed. With the added stability of the dowel pins the assembled ring is split into segments. Additional stop plates may be used at the joints between the segments of the ring, in addition to the pins, to ensure that the blades do not come loose during this step. The segments can then be moved to their location inside the turbine casing, e.g. into its top and bottom half, respectively, before being clamped together again.
[0034] The exploded view of a turbine stage in FIG. 5D illustrates the latter step with the diaphragm structure split into a top and a bottom half 53 , 54 after removal of the diaphragm clamping bolts 55 . With the stop the pins 346 preventing a movement of the blades, the bottom half of the diaphragm is slotted into the bottom half 51 of the inner casing 10 . The top half diaphragm 54 is bolted to the bottom half and is slotted into the top half 52 of the inner casing 10 as the turbine is fully assembled.
[0035] It is worth noting that the assembly of a diaphragm in accordance with the present invention can thus be performed without a welding step. In particular, when using the present invention with blades having inner platforms such as described in the '939 application, a completely weld-free construction of a nozzle diaphragm is possible where all components are essentially held in position by interference fit and a pre-twist on the blades.
[0036] The present invention has been described above purely by way of example, and modifications can be made within the scope of the invention. The invention also consists in any individual features described or implicit herein or shown or implicit in the drawings or any combination of any such features or any generalization of any such features or combination, which extends to equivalents thereof. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments. Alternative features serving the same, equivalent or similar purposes may replace each feature disclosed in the specification, including the drawings, unless expressly stated otherwise.
[0037] Unless explicitly stated herein, any discussion of the prior art throughout the specification is not an admission that such prior art is widely known or forms part of the common general knowledge in the field.
LIST OF REFERENCE SIGNS AND NUMERALS
[0038] casing 10
[0039] moving blades 12 , 13
[0040] radially inner “T-root” portions 14 , 15
[0041] rotor drum slots 16 , 17
[0042] rotor drum 18
[0043] shrouds 19 , 20
[0044] stator seal support ring 21 , 22
[0045] seal/seal fins 23 , 24 stationary blades units 30 , 31
[0046] upstream and downstream diaphragm rings 33 , 34
[0047] tapered edge 330
[0048] circumferential shoulder 331
[0049] circumferential grooves 341 , 342
[0050] groove 343
[0051] additional rim 344
[0052] bore 345
[0053] dowel pins 346
[0054] flat assembly surface 50
[0055] casing bottom and top half 51 , 52
[0056] diaphragm bottom and top half 53 , 54
[0057] clamping bolts 55
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A turbine diaphragm assembly is described having an annulus of static blades, each static blade including at least an aerofoil and an outer platform; and an outer diaphragm ring or segments of a ring for holding the annulus of static blades; with confronting edges of the outer platforms and the ring are held by an interference fit when pushed in axial direction into contact with the interference fit designed to withstand the forces on the diaphragm during operation of the assembled turbine.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to microwave antennas.
2. Description of the Related Art
There is a growing commercial denhand for low-cost radar systems. For example, investigators around the world are working on the development of collision-avoidance radar systems for use in automobiles, trucks, boats and small aircraft. A key element of these radar systems is an antenna that can radiate a scanned microwave beam. Obstacles that are interrogated by the scanned beam cause an echo which is received by the antenna and sent to an electronic portion of the radar for processing.
If a collision-avoidance radar is to be commercially viable, its elements, such as the scanned antenna, must be light weight, low cost, spatially compact and offer good performance with low maintenance costs over a long lifetime (e.g., >10 years). In addition, the scanned antenna should preferably be based on technologies that are well developed so as to reduce technical and schedule risks.
Apparatus for scanning a microwave antenna beam have generally fallen into two groups, mechanically-scanned antennas and electronically-scanned antennas. Gimbal systems have been extensively used in aircraft to facilitate the mechanical scanning of fixed-beam antennas. However, gimbal systems are typically heavy and costly to ihbricate and usually require considerable maintenance.
Electronic scanning has often achieved high peribrmance but at the cost of complexity, weight and cost. For example, antennas have incorporated movable waveguide vanes which vary the phase of radiation through waveguide slots (e.g., see Markus, John, et al., McGraw-Hill Electroncis Dictionary, McGraw-Hill, New York, 5th Edition, 1994, p. 390). These systems involve a large number of moving parts so that both fabrication and maintenance costs tend to be high. Phased array antennas typically employ a plurality of phase shifters, e.g., ferrite and electronic, to provide beam steering (e.g., see Stimson, George W., Introduction to Airborne Radar, Hughes Aircraft Company, El Segundo, 1983, pp. 577-580). Phased arrays can achieve high-speed scanning but the phase shifters and associated parts, e.g., waveguide networks and amplifiers, result in complex fabrication and high parts count.
SUMMARY OF THE INVENTION
The present invention is directed to a simple, light-weight, compact, low-cost scanned antenna which offers the prospect of low maintenance over a long lifetime.
The antenna includes a radiator which is preferably formed with plating on a shaped dielectric to define a parallel-plate waveguide and a plurality of transverse stubs that issue from the waveguide. One edge of the waveguide forms an input port and the transverse stubs form an output aperture. A microwave signal inserted into the input port is converted to an antenna beam at the output aperture wherein the wavefront orientation of the antenna beam is a function of the wavefront orientation of the microwave signal at the input port. Changing the angular relationship between the path of the microwave signal and the input port changes the wavefront orientation of the antenna beam and, therefore, its beam axis.
The parallel-plate waveguide is extended to contain a reflector which preferably has a parabolic shape to reflect a collimated microwave signal with a transverse wavefront. Pivoting the reflector realizes the desired changes in the microwave signal path. Alternatively, the reflector can be fixed and a pivoted mirror is used to vary the orientation of the microwave signal path.
In accordance with a feature of the invention, the wavefront produced by the reflector is a continuous wavefront whose energy density approximates a cosine function. This wavefront is especially suited for illuminating the radiator because it will produce an antenna beam that has low side-lobe power.
In an antenna embodiment, the parallel-plate waveguide is folded to place the antenna elements back-to-back and, thereby, reduce the spatial volume of the antenna.
Antenna embodiments can be physically realized with a single moving part, the shaped dielectric is easy to form and when the antenna is configured to operate at a high frequency, e.g., 77 GHz, it is small enough to fit behind an automobile license plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a vehicle with a scanned antenna in accordance with the present invention;
FIG. 2 is an elevation view of the vehicle and scanned antenna of FIG. 1;
FIG. 3 is an enlarged view along the plane 3--3 of FIG. 2 which illustrates a front elevation of the scanned antenna of FIGS. 1 and 2; in this view, one side of a parallel plate waveguide is partially removed to show a mirror in a first position;
FIG. 4 is a top plan view of the scanned antenna of FIG. 3; this view shows a radiation wavefront with the antenna mirror in the first position of FIG. 3;
FIG. 5 is a view similar to FIG. 3 showing the antenna mirror in a second position;
FIG. 6 is a view similar to FIG. 4 showing the radiation wavefront with the antenna mirror in the second position;
FIG. 7A is a front elevation view of a radiator in the scanned antenna of FIG. 3;
FIG. 7B is a side elevation view of the radiator of FIG. 7A;
FIG. 7C is an enlarged view of the structure within the curved line 7C of FIG. 7B;
FIG. 7D is an enlarged view of the structure within the curved line 7D of FIG. 7B;
FIG. 8 is a graph of a preferred energy density distribution for illuminating an input port of the radiator of FIGS. 7A-7D;
FIG. 9A is a front elevation view of a reflector in the scanned antenna of FIG. 3;
FIG. 9B is a side elevation view of the reflector of FIG. 9A;
FIG. 9C is a bottom plan view of the reflector of FIG. 9A;
FIG. 10A is a side elevation view of a mirror in the scanned antenna of FIG. 3;
FIG. 10B is a front elevation view of the mirror of FIG. 10A;
FIG. 11A is a side elevation view of a feed horn in the scanned antenna of FIG. 3;
FIG. 11B is a top plan view of the feed horn of FIG. 11A;
FIG. 12 is a view, similar to FIG. 3, illustrating another scanned antenna embodiment;
FIG. 13 is a side elevation view of the scanned antenna of FIG. 12;
FIG. 14 is a rear elevation view of the scanned antenna of FIG. 12;
FIG. 15 is an enlarged view along the plane 15--15 of FIG. 12;
FIG. 16 is an enlarged view of the structure within the curved line 16 of FIG. 13;
FIG. 17 is an enlarged view of the structure within the curved line 17 of FIG. 13;
FIG. 18 is a view, similar to FIG. 3, illustrating another scanned antenna embodiment;
FIG. 19 is a side elevation view of the scanned antenna of FIG. 18;
FIG. 20 is a rear elevation view of the scanned antenna of FIG. 18;
FIG. 21A is front elevation view of a reflector in the scanned antenna of FIG. 18;
FIG. 21B is a top plan view of the reflector of FIG. 21A;
FIG. 21C is a side elevation view of the reflector of FIG. 21A;
FIG. 22A is a front elevation view of another reflector embodiment;
FIG. 22B is a side elevation view of the reflector of FIG. 22A; and
FIG. 22C is a bottom plan view of the reflector of FIG. 22A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate a motor vehicle 38 which has a scanned, antenna 40 in accordance with the present invention. The scanned antenna 40 is mounted approximately in the region of the vehicle's front license plate and radiates an antenna beam 42 forward from the vehicle 38. The scanned antenna 40 has a mechanical boresight 44 (an axis which is substantially orthogonal with the radiating face of the antenna).
In operation of the scanned antenna 40, the beam 42 is scanned in the antenna's azimuth plane (a plane through the boresight 44 which is parallel with the road surface 46) over a scan angle 48, e.g., 15°. Preferably, the beam 42 does not move in the antenna's elevation plane (a plane through the boresight 44 which is orthogonal to the road surface 46). The angular beam width in the elevation plane is preferably restricted to reduce echoes from the road surface 46. On the other hand, the elevation beam width is preferably sufficient to produce echoes from objects that could strike the roof 49 of the vehicle 38.
FIG. 3 shows the scanned antenna 40 as it would appear along the plane 3--3 of FIG. 2 and FIG. 4 is a top plan view of the scanned antenna 40. The antenna 40 includes a parabolic reflector 50, a pivotable mirror 52 and a radiator 54. The reflector 50 and radiator 54 are integrated within the structure of a parallel-plate waveguide 56 which has a lower plate 57 and an upper plate 58. In FIG. 3, the upper plate 58 is partially removed for clarity of illustration. Between the reflector 50 and the radiator 54, the parallel-plate waveguide 56 guides and contains microwave radiation that is redirected by the mirror 52.
A description of the structure and operation of the scanned antenna 40 is facilitated if the detailed structure of the reflector 50, mirror 52 and radiator 54 are understood. Accordingly, these elements will first be described with reference to FIGS. 7A-D, 8, 9A-9C, 10A-10B and 11A-11B. After this description of antenna elements, attention will be returned to the scanned antenna 40 of FIGS. 3 and 4 and its operation.
The radiator 54 is illustrated in FIGS. 7A-7D. The radiator 54 has a core 62 which is formed of a low-loss dielectric (e.g., Rexolite which has a loss tangent of ˜0.0003). The core 62 includes a rectangular panel 64 that has a height 66 and a width 68. As detailed in FIG. 7C, the core 62 also includes a plurality of parallel ribs 70 which extend orthogonally from one side of the panel 64. The ribs 70 have sides 72 which terminate at a face 74.
The broad sides of the panel 64 are plated with a metal, e.g., copper, which forms a pair of spaced, parallel plate portions 57A and 58A. The plate portions 57A and 58A are parts of the lower and upper plates 57 and 58 of FIG. 3. A variety of fabrication techniques can be employed to form the complete plates 57 and 58. For example, the portion of these plates that extends over the mirror 52 and the reflector 50 in FIG. 3 can be formed separately and then joined, e.g., by brazing, to the plate portions 57A and 58A that are plated onto the panel 64.
The sides 72 of the ribs 70 are also metallically plated as is the top edge 76 of the panel 64. The face 74 of the ribs 70 and the panel's side edges 77 and bottom edge 78 are not plated. The exposed, unplated surfaces of the core 62 (which are the faces 74, the panel side edges 76 and the panel bottom edge 78) are cross-hatched for clarity of illustration. The panel 64 and its plates 57A and 58A form a parallel-plate waveguide (a portion of the parallel-plate waveguide 56 of FIG. 3). The ribs 70 and their plated sides 72 form transverse stubs 79 which protrude outward from the plate portion 58A. As seen in FIG. 7A, the transverse stubs 79 extend between the panel's side edges 77.
The structure of the radiator 54 forms an input port 80 and an output aperture 82. The input port 80 is the lower panel edge 78 which is confined between the lower and upper plate portions 57A and 58A and which extends across the panel 64 from one port side 83 to another port side 84 (shown in FIG. 7A). The output aperture 82 is formed by the plurality of transverse stubs 79. An aperture is the radiating area of an antenna and the aperture 82, therefore, has, in FIG. 7A, a width 68 and a height 85. The mechanical boresight 44 that is indicated in FIGS. 1 and 2 is an axis that extends orthogonally from the center of the radiator's aperture, i.e., it extends orthogonally from a point on the panel 64 that is centered in the aperture width 68 and height 85.
In operation of the radiator 54, a microwave signal 90 is inserted into the input port 80 as shown in FIG. 7C. The microwave energy travels up the waveguide formed between the parallel plates 57A and 58A. At each transverse stub 79, a portion 92 of the energy is conducted between the plated rib sides 72 and radiated outward (across the rib face 74) orthogonally from the panel 64. The microwave energy continues upward in the panel 64 until it supplies the last transverse stub 79 (the stub that is adjacent the top panel edge 76). To reduce energy reflections from the top edge 76 of the radiator, the end of the parallel-plate waveguide is preferably filled with a load 94 which is formed from an energy-absorbent material. The energy portions 92 combine to form the antenna beam 42 that is illustrated in FIGS. 1 and 2. The height 95 of the ribs 70 can be adjusted to enhance the impedance match between free space and the parallel-plate waveguide that is formed by the plates 57A and 58A.
The guide wavelength λ g of the microwave energy within the radiator 54 is a function of the dielectric constant of the core 62 and the physical guide dimensions. If the spacing 96 (shown in FIG. 7D) of the transverse stubs 79 is an integer number of wavelengths λ g , then the energy issuing from each transverse stub 79 is in phase and the wavefront 98 (a wavefront is a radiation surface of constant phase; it is indicated in FIGS. 7C and 7D) of the antenna beam will be parallel with the panel 64. Because an antenna beam (42 in FIGS. 1 and 2) is always orthogonal with its microwave wavefront, the beam's axis will then be parallel with the antenna's mechanical boresight (44 in FIGS. 1 and 2) in the elevation plane.
The wavefront can be tilted, in the radiator's elevation plane, by fabricating the radiator with other spacings 96. For example, if the spacing 96 is fabricated to be greater than an integer number of wavelengths λ g , a tilted wavefront 99 will be realized as indicated in FIG. 7C. The tilted wavefront will cause the beam axis to tilt upward in the elevation plane, e.g., to the axis 100 that is shown in FIG. 2. This elevation tilting can be used to adjust the vertical orientation of the beam 42 to reduce reflections from the road surface 46 and to insure detection of overhead objects that might damage the vehicle roof 49.
The radiated power distribution along the radiator's elevation plane can be controlled by adjusting the width 104 (shown in FIG. 7D) of each transverse stub 79. The energy of the input signal 90 (in FIG. 7C) declines as it flows upward past the transverse stubs 79 because a portion of it is radiated from each stub. To cause the power of the radiation 92 from each stub 79 to be substantially constant, the width 104 preferably increases monotonically from the stub nearest the input port 80 to the stub nearest the panel top edge 76.
Thus, the radiator 54 radiates, in response to a microwave signal 90 that is received at its input port 80, an antenna beam from its output aperture 82 which has a wavefront 98. The movement of the beam's wavefront in the radiator's azimuth plane will be described as part of the operational description of the scanned antenna 40.
The radiator 54 belongs to a type of microwave structure generally known as continuous transverse stubs (CTS). CTS structures are described in detail in U.S. Pat. No. 5,266,961 which issued Nov. 30, 1993 and was assigned to Hughes Aircraft Company, the assignee of the present invention.
To enhance the formation of a well-shaped antenna beam (e.g., low side-lobe energy), the input signal energy at the input port 80 is preferably distributed in accordance with a cosine function. In particular, the energy density along the azimuth plane of the port 80 should approximate the density distribution 102 in FIG. 8. The distribution 102 is shown in this figure to have a peak energy density at the center of the input port 80 and a density which falls away to zero at the port sides 83 and 84. Because the structure of the radiator 54 is open at the side edges 76 of the panel 64, this distribution also reduces the amount of energy that leaks from the open panel edges 77 in FIG. 3. A microwave absorbent material can be positioned along the panel edges 77 to further reduce this microwave leakage.
The input port 80 of FIGS. 7A-7D has a narrow aspect ratio which is defined by the spacing between the plates 57A and 58A and the lateral extent between the port sides 83 and 84. Microwave sources that can form a signal whose shape corresponds to such a narrow input port are typically known as "line sources". Therefore, the port 80 is preferably illuminated by a line source which generates a microwave energy distribution that approximates the distribution 102 of FIG. 8.
FIGS. 9A-9C illustrate a reflector 50 which is particularly suited for forming a microwave, line source signal which can illuminate the input port 80 of the radiator 54. The reflector 50 includes portions 57B and 58B of the parallel-plate waveguide 56 of FIG. 3. These portions are terminated in an end wall 120 which is shaped as a thin, parabolic cylinder which has a focus 122.
Because of the properties of a parabolic surface, microwave energy that is directed at the end wall 120 from its focus 122 will be reflected as collimated energy, i.e., energy in which the reflected rays are parallel. In addition, the reflected energy from the parabolic surface will decline towards each side edge 123. If the distance between the side edges 123 is designated as d and the focal length of the parabolic wall 120 (distance from the wall to the focus 122) is designated as f, then the reflected energy at the edges 123 can be controlled by a suitable selection of the ratio f/d. For example, in practice the ratio f/d is often set at 0.4. With this ratio, the energy density at the reflector edges 123 will be 10-20% of the power density at the center of the parabola. Thus, the reflected energy distribution can be shaped to approximate the desired energy distribution of FIG. 8. Microwave structures similar to that of the reflector 50 are typically referred to as a "pillbox antennas" (e.g., see Silver, Samuel, Microwave Antenna Theory, McGraw-Hill Publishing, New York, 2nd Edition, 1984, pp. 457-464).
FIGS. 10A-10C illustrate a mirror 130 having a face 132 and a pivot bore 134. The mirror 130 has a thickness 136 that allows it to be closely received within the parallel-plate waveguide 56 of FIG. 3. If the gap between the long edges 138 of the mirror 130 and the waveguide plates 57 and 58 is small relative to the wavelength of the microwave energy, this gap will appear to be substantially a short circuit and only a small amount of radiation will leak past the edges. To further reduce energy leakage between the parallel-plate waveguide 56 and the mirror edges 138, the edges preferably define a choke groove in accordance with well-known microwave design practices.
FIGS. 11A-11B illustrate a conventional waveguide feed horn 140 that includes a horn section 141 at the end of a 90° bend waveguide section 142. The horn 141 is flared to enhance its impedance match with free space. The width 143 of the horn is preferably chosen to aid in achieving a cosine shaped energy density from the reflector 50 of FIGS. 9A-9C. In particular, it should be wide enough to illuminate the end wall 120.
With a description of the reflector 50, the mirror 52 and the radiator 54 in hand, attention is now redirected to the scanned antenna 40 of FIGS. 3 and 4. In the antenna 40, the reflector 50 is positioned at one end of the parallel-plate waveguide 56 and the radiator 54 is positioned at the other end. Between these elements, the mirror 52 is pivotably mounted at its pivot bore 134, e.g., with a pin that extends through the waveguide plates 57 and 58. The mirror 52 can be pivoted by any of various, well-known mechanical structures, e.g., by the urging of a cam 146 against a ball 147 that is mounted to the back of the mirror. The feed horn 140 protrudes through the waveguide plate 57 and is positioned at the focal point 123 of the reflector.
In operation of the antenna 40, a microwave signal is directed through the feed horn 140 and radiated (indicated by incidence ray paths 150) at the parabolically-shaped end wall 120 of the reflector 50. The signal is reflected as collimated microwave energy along reflected ray paths 152. Because of the properties of a parabolic surface, a reflected wavefront 153 will lie in a plane which is orthogonal with the reflected rays 152, i.e., the path distance along each set of rays 150, 152 between the focus 122 and the wavefront 153 is constant.
In FIG. 3, the mirror 52 is set at a 45° angle. Because the angle of incidence α must equal the angle of reflection β, the relation α=β=45° results. Therefore, the microwave energy is redirected along a vertical path 154 and with a redirected wavefront 155 that is horizontal, i.e., the path distance along each ray 152, 154 is constant between the wavefronts 153 and 155. The redirected microwave energy is received into the input port 80 of the radiator 54. It travels upward in the radiator 54 and is radiated from the output aperture 82 as indicated by the radiated rays 156 in FIG. 4. Because the transverse stubs 79 of the aperture 82 are substantially parallel with the input port 80, the wavefront 157 of the radiated rays 156 will be parallel with the stubs 79, i.e., the path distance along any set of rays 154, 156 and through any selected one of the transverse stubs 79 is equal between the wavefronts 155 and 157.
The antenna beam that results from the wavefront 157 is orthogonal to that wavefront. Therefore, as a result of the mirror 52 being positioned at 45°, the antenna beam will be directed along the mechanical boresight 44 in FIG. 1.
In FIG. 5, the mirror 52 has been pivoted counterclockwise by an angle δ=3.75° from its former 45° position of FIG. 3. The former position is indicated by the broken line 159. The angle of incidence α must now be 48.75°. Because the angle of reflection β is also 48.75° and the mirror surface 132 has been rotated 3.75°, the redirected rays 154 and the redirected wavefront 155 are rotated 7.5° from their positions in FIG. 3. Because the path distances along the ray paths 156 between the wavefronts 155 and 157 must be equal (to preserve phase equality), the wavefront 157 is also tilted 7.5°. This will cause the beam radiated from the radiator 54 to be rotated 7.5° from the mechanical boresight 44 in FIG. 1. In FIG. 1, this is indicated by the beam position 42A.
Thus, when the mirror 52 is pivoted back and forth from a median position by an angle δ, the radiated antenna beam 42 (in FIG. 1) will scan back and forth in azimuth by 2δ. In the specific case in which δ=3.75°, the scan angle 48 of the antenna beam 42 in FIG. 1 is 15°. The wavefront 157 of the antenna beam rotates because the wavefront 155 is rotated in reference to the input port 80.
Each wavefront 155 and 157 is related to an equivalent phase distribution across its respective port or aperture. For example, the wavefront 155 in FIG. 5 causes a phase distribution across the input port 80 (from one side 83 to the opposite side 84). In response, the radiator 54 generates a phase distribution across the aperture 82 (from one side 77 of the radiator 54 to an opposite side 77). The radiator 54 is configured to cause the phase distribution across its output aperture 82 to be a function, e.g., a linear one-to-one function, of the phase distribution across its input port 80. Therefore, if the phase distribution across the input port 80 is varied, e.g., by pivoting the mirror 52, the antenna beam is scanned.
In accordance with a feature of the invention, the wavefront 155 in FIGS. 3 and 5 is a continuous wavefront whose energy density approximates a cosine function. This wavefront is especially suitable for producing an antenna beam from the radiator 54 that has low side-lobe power. The continuous wavefront can better approximate a cosine function than a wavefront from structures, e.g., a slot array, that form an array of discrete sources.
It should be understood that the direction of microwave energy will be altered by diffraction as it crosses the air-dielectric interface of the input port 80 and the dielectric-air interface of each transverse stub face 74 (shown in FIG. 7C). However, the alteration is equal and opposite across these two interfaces and may, therefore, generally be ignored.
The thickness of the panel 64, as shown in FIGS. 7C-7D, is preferably less than λ g /2. This sets the spacing between the plate portions 57A and 58A of the radiator 54. At higher frequencies, this spacing narrows and may cause fabrication and assembly problems if it is maintained in the area of the reflector 50, the feed horn 140 and the mirror 52 (see FIG. 3). Accordingly, the waveguide plate spacing can be greater over these elements and then tapered to the narrower spacing of the portions 57A and 58A as the waveguide 56 approaches the input port 80.
FIGS. 12-17 illustrate another scanned antenna embodiment 160 in which the parallel-plate waveguide 56 of the scanned antenna 40 (shown in FIGS. 3-6) is folded twice to reduce the spatial volume of the antenna. This folding produces three waveguide portions 164, 166 and 168. The portions 164 and 166 are connected by a 180° waveguide bend 170 and the portions 166 and 168 are connected by another 180° waveguide bend 172. The portion 168 is substantially formed by the parallel-plates of the radiator 54.
FIGS. 12-14 indicate that the reflector 50 is positioned on the rear side of the scanned antenna 160. The parallel-plate waveguide portion 164 connects the reflector 50 with the 180° bend 170 that is positioned at the side 174 of the antenna. As shown in FIG. 15, the feed horn 140 is inserted through this bend 170 to illuminate the reflector 50. The reflected, collimated microwave energy from the reflector 50 flows around the bend 170 as indicated by the radiation ray 176. The ray 176 is then in the waveguide portion 166 which, as shown in FIG. 13, is positioned between the portions 164 and 168. The reflected ray strikes the mirror surface 132 and is redirected along ray paths 184. The reflecting surface 132 of the mirror is visible in FIG. 15 and the back side 180 of the mirror is visible in FIG. 13. The mirror 52 is pivotably mounted in the waveguide portion 166.
The redirected energy from the mirror 52 proceeds upward along the paths 184 through the waveguide portion 166 to the 180° bend 172 which is positioned at the top side 182 of the antenna 160. FIG. 16 illustrates that the redirected energy then flows around the bend 172 as indicated by the radiation arrow 184, and enters the input port 80 of the radiator 54. Relative to its orientation in FIGS. 3 and 5, the radiator 54 has been inverted in the scanned antenna 160 so that the input port 80 is at the top of the antenna. As shown in FIGS. 16 and 17, the radiation 184 then is radiated as radiation portions 186 out of each of the transverse stubs 79. FIG. 17 shows that an absorptive load 94 is positioned at the end 188 of the radiator 54 to reduce reflections that might otherwise alter the magnitude of the radiated portions 186.
A waveguide plate 190 is positioned between, and forms a part of, waveguide portions 164 and 166. The lower part 192 of this plate is shown to be unsupported in FIG. 13. Accordingly, structure can be placed between it and the rear plate of the radiator 54 to physically stabilize the plate 190. An exemplary structure is a dielectric block 196 that is shown in FIG. 17.
The operation of the scanned antenna 160 is similar to that of the scanned antenna 40 of FIGS. 3-11. Pivoting the reflector 52 causes a wavefront which enters the input port 80 and a wavefront that exits the transverse stubs 79 to pivot in response. Consequently, the antenna beam that is formed by the radiation portions 186 of FIGS. 16 and 17, is scanned back and forth.
Another scanned antenna embodiment 200 is shown in FIGS. 18-21. The antenna 200 includes a parallel-plate wave guide that is folded once to reduce the antenna's spatial volume. The folding produces two waveguide portions 202 and 204 which are connected by a 180° waveguide bend 206. The waveguide bend 206 is positioned at the upper edge 207 of the antenna. The waveguide portion 204 is substantially formed by the parallel-plates of a radiator 54.
The scanned antenna 200 also includes a reflector 210 which is illustrated in FIGS. 21A-21C. The reflector 210 is similar to the reflector 52 of FIGS. 9A-9C with like elements indicated by like reference numbers. However, the reflector's parabolic face 120 is carried on a single side plate 212. A pivot bore 214 is formed in the plate 206 at the focus of the parabolic face 120. Another pivot bore 215 is formed at the apex 216 of the parabolic face 120. Thus, the reflector 210 can be pivoted about either its parabolic focus or about the parabolic apex. Alternatively, the reflector need only define one pivot bore if the desired pivot point has been predetermined.
FIGS. 18-20 show that the reflector 210 is pivotably mounted in the waveguide portion 202. A feed horn 140 protrudes through a wall 218 of the waveguide portion 202 to illuminate the reflector 210 from its focus. The wall 218 is partially removed in FIG. 20 for clarity of illustration. The reflected energy travels upward along reflected rays 220 to the 180° waveguide bend 206. The waveguide bend 206 redirects the energy into the input port 80 of the radiator 54. The energy flows within the radiator and exits the transverse stubs 79 in a manner described hereinbefore relative to FIGS. 3-6 and 12-14.
The reflector 210 is preferably pivotably mounted about its focus, e.g., by a pin through its pivot bore 214. It can also be pivotably mounted by a pin through the pivot bore 215 at its parabolic apex 216. The latter pivotable mounting will cause a certain amount of aberration with consequent increase in side-lobe energy of the antenna beam. In either case, the feed horn 140 can remain in a fixed arrangement, or alternatively, can be pivoted with the reflector 210. The latter arrangement can be realized by bringing the microwave signal into the feed horn 140 through a rotary waveguide structure.
In the antenna embodiments 40, 160 and 200, a small amount of microwave energy will be lost because reflected energy from the parabolic surface of the reflector (50 or 210) is intercepted by the feed horn 140, e.g., see FIG. 3. Accordingly, the reflector structure may be replaced with a folded reflector such as the reflector 230 that is shown in FIGS. 22A-22C. The reflector 230 is similar to the reflector 50 of FIGS. 9A-9C with like elements indicated by like reference numbers.
However, the reflector 230 is widened so as to receive a septum 232 between its parallel plates 57B and 58B. The septum 232 is spaced from the parabolic wall 120 and divides the interior of the reflector 230 into a lower and an upper chamber 234 and 236 as shown in FIG. 22C. The feed horn 140 (shown in FIG. 3) can now be positioned to illuminate the lower chamber 234. The reflected radiation from the parabolic wall 120 will "wrap around" the septurn 232 and exit the upper chamber 236. Thus, the feed horn 140 is removed from the path of the reflected radiation.
As shown in FIG. 7A, the radiator 54 has an output aperture 82 with a width 68 and a height 85. The illustrated aspect ratio is only for illustrative purposes. The actual aspect ratio must be adjusted appropriately for each application of the teachings of the invention. For example, an exemplary scanned antenna realized as part of a collision-avoidance radar for the motor vehicle 38 of FIGS. 1 and 2, preferably has an antenna beam 42 that is narrower in its azimuth plane than in its elevation plane.
Because beam width is inversely proportional to aperture dimension, an aperture directed to this application would have a width 68 that is greater than its height 85. If the collision-avoidance radar were designed for a radiated frequency in the range of 77 GHz, exemplary dimensions 68 and 85 in FIG. 7A would be 20 and 10 centimeters respectively. This aperture could conveniently fit behind a license plate which would be preferably made of a low-loss material, e.g., plastic. Alternatively, the aperture and license plate could be positioned along side each other.
Scanned antennas in accordance with the present invention have few parts, require only a single moving part and can be fabricated with simple techniques. For example, the radiator 54 can be fabricated by shaping its core 62 from a low-loss dielectric and then metallically plating appropriate core portions to realize the parallel-plate waveguide and its transverse stubs. Due to the absence of interior details, this fabrication technique requires metallization only on exterior surfaces with an absence of stringent requirements on metallization thickness, uniformity or masking. Mirrors and reflectors taught by the invention may also be fabricated by this method. The mirror 52 which is illustrated in FIG. 3 is light weight with a low inertia that facilitates its pivoting action. It can be pivoted about its center as shown or about other portions, e.g., either end.
Although scanned antenna beams have been realized, in illustrated embodiments, with rotation of mirrors and reflectors with reference to a fixed radiator, it should be realized that such rotation is relative, and other embodiments can be realized in an opposite manner, i.e., rotation of the radiator with respect to other fixed antenna elements.
While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims.
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Compact, microwave scanned antennas include combinations of a radiator, a reflector and a mirror. The radiator is formed by plating a shaped dielectric core. It generates an antenna beam at an output aperture in response to a microwave signal at an input port. The wavefront orientation of the antenna beam is a function of the wavefront orientation of the microwave signal at the input port. Changing the angular relationship between the path of the microwave signal and the input port changes the wavefront orentation of the antenna beam and, therefore, its beam axis. Pivoting the reflector realizes the desired angular change in the microwave signal path. Alternatively, the reflector can be fixed and the mirror pivoted to vary the microwave signal path. Antenna embodiments can be physically realized with a single moving part, the shaped dielectric is easy to form and when configured to operate at a high frequency, e.g., 77 GHz, the antenna is small enough to fit behind an automobile license plate.
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FIELD OF THE INVENTION
This invention concerns a sleeve for medical instruments such as endoscopes. The invention is especially useful for dental and other procedures in which it is desirable to stabilize an endoscope while allowing repeated positional adjustment.
BACKGROUND OF THE INVENTION
An endoscope is a long, thin instrument used in medical procedures to view or operate inside a patient's body with minimal intrusiveness. Rather than opening a large cavity to reach a location in a patient's body, a doctor can create a small opening and reach the location by inserting and guiding the endoscope. To view inside a body, the distal end of the endoscope is mounted with a camera lens that transmits a video image of the surrounding tissue. The lens is often cut at an angle to yield an image of the tissue that is more or less (depending on the angle) to the side of, rather than directly in front of, the end of the endoscope.
Endoscopes can be rigid or flexible. A rigid endoscope is in the form of a long, thin tube connected to a base joint, which in turn is typically mounted on a handle. A flexible endoscope is in the form of a long, thin cable. The present invention is for use with rigid endoscopes.
A rigid endoscope is usually fitted with a sleeve: a hollow, rigid tube into which the endoscope is inserted, of a length slightly less than that of the endoscope. The shorter length of the sleeve permits the distal end of the endoscope to protrude slightly from the distal end of the sleeve, thus enabling the imaging or other function of the endoscope. Particularly when the endoscope has an angled lens for viewing sideways, the sleeve may end in an angled cut or an irregular cutaway shape to cover the endoscope as much as possible while permitting the lens to view its object. Prior sleeves connect to the endoscope at the proximal end (i.e., the end nearer to the base joint) and are immovably fixed in relation to the endoscope.
An endoscope sleeve may perform various purposes. One purpose is to protect the endoscope as it is pushed, pulled, and angled within a patient. Another purpose is to introduce irrigation or suction to the area surrounding the distal end, thus either flushing the area with an externally supplied fluid or removing internal matter from the area. For either purpose, the inner diameter of the sleeve is of sufficiently greater diameter than the outer diameter of the endoscope to form a space, or channel, between the two tubes. Irrigation or suction is introduced through that space or channel.
Another purpose of an endoscope sleeve can be to spread bodily tissue away from the distal end of the endoscope, thus clearing a space for the imaging or other function. To this end, the distal end of the sleeve may terminate in a flared tip that angles outwardly from the tubular sleeve. The flared tip pushes or lifts tissue away from the axis of the sleeved endoscope, sheltering the distal end of the endoscope in an umbrella-like space.
Prior sleeves for rigid endoscopes pose several problems for their users. First, the sleeves are sometimes difficult to stabilize in the area to be viewed or treated. Instability compromises the quality and accuracy of the imaging or other function being performed. It is sometimes possible to anchor the endoscope sleeve on nearby tissue; because the endoscope is fixed to the sleeve, the endoscope is stabilized. But such a technique depends on coincidence. Anchoring the sleeve in a convenient spot will not necessarily leave the distal end of the endoscope in its required location.
Second, even if the sleeve could be anchored in a spot that placed the distal end of the endoscope in a favorable position, it would usually be necessary to move the endoscope in various directions--pushing, pulling, rotating, angling--with the result that the anchoring spot for the sleeve would soon be lost. The sleeve simply cannot remain anchored while the endoscope is moved, because the two are fixed relative to one another.
Third, an endoscope fixed to a sleeve is bulkier than an endoscope alone, which limits the spaces into which the endoscope may reach. This is of particular concern where the instrument must pass through a small opening in solid material like bone.
It is therefore an object of this invention to provide an endoscope sleeve that facilitates stabilization of an endoscope to which the sleeve is attached.
It is another object of this invention to provide an endoscope sleeve that permits axial and rotational movement of the endoscope relative to the sleeve.
It is a further object of this invention to provide an endoscope sleeve that can be fixed to an endoscope selectively along the endoscope's length and circumference.
It is yet another object of this invention to provide an endoscope sleeve that operates as an effective anchor when positioned against a stable surface.
It is still another object of this invention to provide an endoscope sleeve that permits extension of the distal end of the endoscope substantially beyond the distal end of the sleeve, thus facilitating the examination of spaces unreachable by a combined endoscope and sleeve.
SUMMARY OF THE INVENTION
The present invention provides an endoscope sleeve that can be fixed at any point along the length of, and in any radial orientation around the circumference of, an endoscope. A clamp-like locking means at the proximal end of the sleeve engages the outer surface of the endoscope and holds the two parts together. This is preferably accomplished by means of a screw that threads through a collar around the proximal end of the sleeve and tightens a portion of the sleeve against the endoscope. The sleeve tube is preferably slotted to permit displacement of a section of the tube wall toward and away from the endoscope. The greater the surface area of the displaced section of the tube wall, the more widely distributed the pressure on the endoscope will be. A wider distribution of pressure reduces the possibility of damage to the endoscope.
If the length of the sleeve is shorter than the endoscope, then the endoscope can be extended beyond the end of the sleeve and reach locations that could not be reached if the sleeve, which is wider than the endoscope, covered the entire length of the endoscope.
The sleeve has a flared extension at its distal end to facilitate stabilizing the sleeve and endoscope during a medical procedure. The flared extension could be a separate element attached to the sleeve but preferably is a contiguous extension of part of the circumference of the tube portion of the sleeve. The extension is anchored on a surface near the area where the endoscope is to be used. Although it is not necessary that the extension flare outwardly from the sleeve tube, a flared construction puts a small distance between the extension and the endoscope and provides greater flexibility in anchoring the sleeve.
The flared extension is particularly useful when the sleeve is shorter than the endoscope. In dental procedures, for example, such a sleeve can be anchored on the top or side of a tooth while the endoscope extends into a drilled opening. Not only is the instrument thus more stable, the drilling or incision need not be as wide as if the sleeve covered the length of the endoscope.
The clamp lock between the sleeve and endoscope can be loosened at any time for adjustment of the endoscope's position without disturbing the anchored position of the sleeve. Alternatively, the clamp lock on the sleeve can be left disengaged from the endoscope, with the sleeve used simply to guide the position of the endoscope. This would be particularly useful if the sleeve were anchored in a favorable spot but considerable movement of the endoscope were required.
Many endoscope sleeves facilitate irrigation or suction through a channel between the endoscope and the sleeve. Those functions are possible with the present sleeve invention, provided that it is equipped with certain additional features. Because the proximal end of the sleeve does not connect to the base joint of the endoscope but instead is selectively fixed along the length of the endoscope, it is necessary to provide a conduit between the base joint of the endoscope and the proximal end of the sleeve, and further necessary to provide a seal around the proximal end of the sleeve to prevent leakage from the irrigation or suction channel. The conduit is preferably a flexible tubing of sufficient length and flexibility to allow the full range of axial and rotational adjustment that the sleeve enables. The seal is preferably of sufficient quality and construction to provide effective protection against leakage but not impair the ability of a user to smoothly adjust the sleeve's axial or rotational position.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings which form a part of this specification:
FIG. 1A is a perspective side view of the endoscope sleeve of the invention, having a forked stabilizer extension;
FIG. 1B is a perspective side view of the endoscope sleeve of the invention, having a serrated stabilizer extension;
FIG. 1C is a cut-off side view of the endoscope sleeve of the invention, showing the flared construction of the stabilizer extension;
FIG. 2 is a cut-away view of the clamp-like locking means at the proximal end of the endoscope sleeve of the invention;
FIG. 3A is an elevation end view of the proximal end of the endoscope sleeve of the invention, mounted on an endoscope (shown in cross-section), with the sleeve's clamp-like locking means disengaged;
FIG. 3B is an elevation end view of the proximal end of the endoscope sleeve of the invention, mounted on an endoscope (shown in cross-section), with the sleeve's clamp-like locking means engaged;
FIG. 4A is an elevation side view of the endoscope sleeve of the invention, mounted on an endoscope and positioned with the distal end of the sleeve aligned with the distal end of the endoscope;
FIG. 4B is an elevation side view of the endoscope sleeve of the invention, mounted on an endoscope and positioned with the proximal end of the sleeve aligned with the proximal end of the endoscope;
FIG. 4C is an elevation top view of the endoscope sleeve of the invention, mounted on an endoscope and positioned with the proximal end of the sleeve aligned with the proximal end of the endoscope.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the accompanying drawing FIG. 1A, the endoscope sleeve 2 of the present invention is shown unattached to an endoscope. The sleeve 2 has a sleeve tube 4 with clamp-like locking means 6 at the sleeve's proximal end 8. Clamp lock 6 comprises a collar 10 into which a locking screw 12 is threaded. Locking screw 12, when tightened into the collar 10, engages the outside of the sleeve tube 4 at the proximal end 8. The sleeve tube 4 is slotted at that end, and the engagement of locking screw 12 forces the slotted sections of sleeve tube 4 together, enabling them to lock the sleeve to an endoscope on which the invention has been mounted.
The distal end 14 of sleeve 2 has a flared extension 16 for stabilization. The preferred design of extension 16 depends on the surface on which the extension is to be anchored. In FIG. 1A, the extension 16 has a forked design that is especially useful for dental applications. Tines 18 of the extension 16 are easily and effectively positioned across, or on top of, a dental patient's teeth. In FIG. 1B, the extension 16 has a serrated design. Other designs may be desirable as well, depending on the location and manner in which an endoscope is to be used.
In FIG. 1C, extension 16 is shown to have a flared structure in relation to the sleeve tube 4. Extension 16 nonetheless extends contiguously from part of the circumference of sleeve tube 4. Extension 16 comprises an angled segment 16a that flares extension 16 outwardly from the axis and circumference of sleeve tube 4, and a stabilizing extension segment 16b that extends parallel to sleeve tube 4 and beyond the distal end 14 of sleeve tube 4. The structure of extension 16 thus provides a stabilizer or anchor that, relative to the axis of sleeve tube 4, is positioned outside the circumference of sleeve tube 4, thereby facilitating not only stabilization of the endoscope and sleeve but ample work space and freedom of movement for the endoscope beyond distal end 14 of the sleeve. This structure is further depicted in, and described in connection with, FIG. 4C.
In FIG. 2, clamp lock 6 at the proximal end 8 of the sleeve 2 is shown to comprise collar 10 mounted on sleeve tube 4, with locking screw 12 threaded through collar 10. Sleeve tube 4 is slotted at proximal end 8 of sleeve 2, thus defining slotted sections 20 and 22. Collar 10 is welded to slotted section 22, and may also be welded to sleeve tube 4 beyond slotted sections 20 and 22. Collar 10 is not, however, welded to slotted section 20, which leaves slotted section 20 free to be displaced toward and away from slotted section 22. Tightening locking screw 12 into engagement with slotted section 20 forces that section toward slotted section 22. An endoscope passed through sleeve tube 4 would be locked between the compressed slotted sections 20 and 22, which act as pressure plates against the endoscope.
The operation of clamp lock 6 is further depicted in FIGS. 3A and 3B. In FIG. 3A, the sleeve 2 is mounted on an endoscope tube 24. Locking screw 12, through collar 10, just barely engages slotted section 20 opposite slotted section 22. In such a state, endoscope tube 24 is free to move axially or rotationally within sleeve 2. This state may be preferred when substantial or frequent adjustment of the position of endoscope tube 24 will be necessary. In such instances, sleeve 2 functions as a guide to the movements of the endoscope and as a shield protecting the endoscope's surface.
In FIG. 3B, locking screw 12, in collar 10, is fully engaged with slotted section 20 opposite slotted section 22, and slotted sections 20 and 22 are compressed against endoscope tube 24. Sleeve 2 is thus fixed to endoscope tube 24. Although a rigid endoscope is a fragile instrument because of its long, thin tube, and although the present invention is locked to that fragile section of an endoscope, the preferred structure of the present invention as shown in the accompanying drawings assures that damage to an endoscope will be avoided. Specifically, the pressure of sections 20 and 22 against endoscope tube 24 is spread over the surface area of sections 20 and 22, thus preventing concentrated forces from damaging endoscope tube 24.
In FIG. 4A, the sleeve 2 is mounted on an endoscope tube 24, with the sleeve 2 positioned just about as far toward the distal end 26 of the endoscope tube 24 as would be practicable without impeding the function of the endoscope. (If the sleeve were positioned much further toward the distal end of the endoscope tube, the sleeve tube 4 of the sleeve would cover the distal end 26 of the endoscope tube and block the endoscope from functioning.) Likewise, the distance between the proximal end 8 of the sleeve 2 and the proximal end 28 of the endoscope tube is just about the greatest it can be without impeding the function of the endoscope. Tines 18 of flared extension 16 are visible behind distal end 26 of the endoseope. Base joint 30 connects the endoscope tube 24 to remote equipment for such purposes as video display or recording.
In FIG. 4B, the sleeve 2 is positioned just about as far toward the proximal end 28 of the endoscope tube 24 as possible, with proximal end 8 of the sleeve 2 nearly abutting proximal end 28 of the endoscope tube 24. With the sleeve in this position, the distal end 26 of the endoscope tube 24 extends substantially beyond the distal end 14 of the sleeve tube 4. The endoscope tube 24, which of course is thinner than the sleeve tube 4, can therefore reach spaces that could not be reached if the sleeve tube 4 covered the entire length of endoscope tube 24. Tines 18 of flared extension 16 are visible behind the endoscope tube 24.
In FIG. 4C, the sleeve 2 is in the same position as in FIG. 4B, but is seen from above instead of from the side. As in FIG. 4B, the distal end 26 of the endoscope tube 24 extends substantially beyond the distal end 14 of the sleeve tube 4. Tines 18 of flared extension 16 are spaced from the endoscope tube 24 and are available to be anchored on any accessible, stable surface.
The endoscope sleeve of the present invention, as it is depicted in FIGS. 4A through 4C, may be either locked in place by engagement of clamp lock 6 or unlocked by disengagement of clamp lock 6. Whether the endoscope sleeve is locked depends on the medical application at hand. Some applications require substantial and frequent adjustment of the endoscope, in which case it may be preferable to leave the device unlocked and simply use the sleeve as a guide and anchor. Separate manipulation of the sleeve and endoscope would then be required to maintain positional control of each. If the endoscope were to be held steady, the locked state would usually be preferable because separate manipulation would be unnecessary. Often a successive combination of unlocked and locked states will be most desirable. Thus, a user may wish to: introduce the sleeve and endoscope to an area in the unlocked state; position the endoscope where it is to operate; anchor the sleeve's flared extension on the most stable accessible surface that the flared extension can contact; finally adjust the endoscope's position; lock the sleeve and endoscope; and if and when necessary, loosen the lock, adjust the endoscope's position, and re-tighten the lock.
According to an alternative embodiment of the invention, it is possible to introduce irrigation or suction through a channel between the endoscope tube 24 and the sleeve tube 4. Base joint 30 would be provided with a socket that is in communication with an external source of irrigation or suction. Proximal end 8 of the sleeve would be provided with a socket that is in communication with the channel between the endoscope tube 24 and the sleeve tube 4. A flexible tube would connect each of the sockets. A seal at proximal end 8 of the sleeve would prevent leakage while permitting axial and rotational movement of the sleeve relative to the endoscope tube 24.
The invention is preferably constructed entirely of surgical stainless steel, but various other materials, including but not limited to plastic or chrome-plated brass, could be used.
While the invention has been described by reference to illustrative embodiments, it is not intended that the novel device be limited thereby, but that modifications thereof are intended to be included as falling within the broad spirit and scope of the foregoing disclosure, the following claims and the appended drawings.
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A sleeve for medical instruments such as endoscopes is disclosed. The sleeve is attachable in any axial or rotational orientation on the endoscope tube. A clamp-like locking means holds the sleeve securely to the endoscope tube without causing damage, while a locking screw permits easy locking, releasing or adjustment. A flared extension at the distal end of the sleeve facilitates stabilization during medical procedures.
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TECHNICAL FIELD OF THE INVENTION
The present invention is comprised within the technical field of microencapsulation, particularly, in the coating of droplets of particles with sizes comprised within the nanometric range, using biodegradable and bio-compatible polymers of different nature. The thus obtained products have important applications in pharmacy, medicine, cosmetics, veterinary, chemical industry, agriculture etc.
BACKGROUND OF THE ART
The obtention of a fine suspension of particles formed by a biodegradable polymer, polycaprolactone, by means of precipitation due to a change of solvent, has been described in the scientific work "Mechanism of the biodegradable of polycaprolactone" (1983), Jarret, P. et al. Polym Prep. (Am. Chem. Soc. Div. Polym. Chem.) Vol. 24 No. 1, page 32-33.
EP Patent 0274961B1 (which corresponds to U.S. Pat. No. 5,049,322) describes a method for the obtention of vesicular type, spherical particles having a size less than 500 nm. The method comprises the preparation of a phase containing a polymer, an oil and a substance to be encapsulated in a solution or dispersion. The phase is added, under agitation, to another phase formed by a non solvent of the polymer and of the oil, producing the precipitation of the polymer and subsequently the removal of the solvents by lyophilization. On incorporation of one phase over another, the size of the reactor which contains the mixture is increased depending on the final volume desired. This implies the necessity of a scaling to adapt the manufacturing conditions. There exists the difficulty in large volumes in that, once the mixture is formed, the polymer solvent must be in contact with the nanocapsules for a long period, with the possibility of producing the re-dissolution of the same, or the extraction of the active substance to the external phase. On the other hand, the removal of solvents by means of lyophilization is a slow and expensive process, with the additional disadvantage that when inflammable solvents are involved, it is highly dangerous.
The present invention relates to the coating of already formed droplets or particles, so that it is not necessary to agitate the mixture, which is effected by incorporation of the two phases in a device in which the mixture flows continuously, with the immediate production of the evaporation of the solvents. The elaboration and facility conditions (reaction volume) is always the same, independent of the final volume to be obtained, so that it does not require scaling for the obtention of industrial quantities. The solvent remains in contact with the recently coated vesicules during a very short period, so that the re-dissolution of the coating and the possible extraction of the active principle to the external phase is avoided, whatever the volume to be prepared.
The process described in FR A2 515960 allows the obtention of poly alkyl-cyanoacrylate biodegradable nanocapsules, which separate from the polymerization of the corresponding monomer. These nanocapsules contain a biologically active substance. The disadvantage of this method is that it requires a polymerization stage, so that it can only be used with specific polymers. Besides this important limitation, it involves the difficulty of controlling the polymerization and the possible existence of residual monomers which may, in some cases, be toxic. The present invention has the advantage that it does not require a polymerization, being a more rapid process and being applicable to a great number of polymers of diverse nature.
The process described in EP 0480 729 A1 consists of the coating of droplets in oil, containing active principles for oral administration, with a polysaccharide with chelator capacity (sodium alginate) which hardens on the addition of multivalent cations, resulting in micro-capsules with sizes over 1 μm. Finally, it is lyophilized to obtain a product in powder form. This method is limited to the employment of polysaccharides with chelator capacity. Likewise, sonication is necessary, not being applicable for those active substances which are degraded by ultrasonic action. Additionally, the use of a multivalent cation solution makes difficult its employment in any form other than oral. The present invention provides coated droplets with sizes appreciably below 1 μm, does not require hardening agents, does not use sonication, and the product obtained may be administered orally, parenterally, or through the nose, eyes, skin, lungs or any other form of administration.
In the process described in EP 0462003 A1, microcapsules, with sizes between 25 and 100 μm with oil inside, are obtained when dried by atomization and oil/water emulsion formed by the active principle and a gastroresistant polymer aqueous solution, producing a fine powder, by means of the use of an atomizer at a temperature of 140° C. The use of high temperatures is a disadvantage since it limits the use of this method when the encapsulated substance is thermosensitive. This method is only usable for water-soluble polymers, and additionally differs from the object of the present invention in that the sizes obtained are much greater.
The process described in EP 0556917 Al allows the obtention of biodegradable microcapsules containing
an active substance separating from the ultrasonic atomization of a solution or suspension, over a non solvent, in such a way that the coagulated droplets are transferred to a second non solvent. This method, besides being complicated and requiring various solvents and a special atomizer by sonication, results in microcapsules with sizes over 10 μm.
Unlike all previously mentioned patents, the present invention is a method which allows the obtention of large quantities of the product without changing the conditions or facilities, and consequently, is easily industrialized. This method allows the rapid and continuous coating of temperature or sonication-sensitive active substances, resulting in a final product which is usable in any field, and especially in the pharmacy and veterinary field.
DESCRIPTION OF THE INVENTION
The present invention concerns to a new process for the coating of droplets or particles with sizes below a micrometer, which contain, or are formed, of one or various chemical or biologically active substances. Consequentially, the present invention allows the obtention of particles or droplets coated by one or various biodegradable and/or bio-compatible polymers with diameters comprised within 100 and 100 nm, preferably within 200 and 500 nm.
For the performance of the present invention, a fine dispersion of droplets or particles is prepared. When dealing with droplets, the active substance is dissolved in a lipidic substance (generally an oil) or in a substance at fusion point below the temperature of the dispersing means. The droplets may also be consist of the actual active substance. When dealing with solid particles, these may be the actual active substance or have the active substance dispersed inside. They may also be part of a microorganism or integral microorganisms with sizes below one micrometer. The dispersing phase is constituted by a solvent and a non solvent of the polymer which forms the coating and, optionally, contains one or more surfactant or suspending agents (PHASE 1). The relationship between the solvent and the non solvent in PHASE 1 must be the adequate one, so that the coat-forming polymer does not precipitate when mixed with the phase which contains the polymer. The phase which contains the coat-forming polymer (PHASE 2) is prepared by dissolving the coat-forming polymer in a solvent equal to the one used as part of PHASE 1, or any other which is miscible in a high relationship with the solvent of the polymer used in PHASE 1.
Once PHASE 1 and PHASE 2 have been separately prepared, they are lead through separate tubes to a mixing zone, where they continuously contact without agitation or ultra-sonication, keeping their relationship constant (which avoids the instantaneous precipitation of the polymer) and the volume of the mixture. During the mixing, the polymer does not deposit on the droplets or particles, though the deposition process may be initiated, which occurs instantaneously when the mixture is pulverized in an evaporation system with temperature and vacuum conditions allowing the rapid evaporation of the polymer solvent, which provides for the immediate deposition of the polymer around the droplets or particles. Optionally, part of the non solvent, or the totality of the same, may be eliminated until a concentrated or dry product is obtained.
The conduction of the phases towards the mixture device zone, may be carried out be means of any pumping system, or with the help of pressure or vacuum.
It is a characteristic of this process that, once PHASE 1 and PHASE 2 have been prepared, the formation of the mixture, the pulverization of the mixture and the deposition of the polymer are carried out in a totally continuous and simultaneous manner in time.
The relation between the solvent and the non solvent of the coat-forming polymer in the initial dispersion must be adequate so that when in contact with the phase which contains the polymer in the solution, the immediate deposition of the polymer tends to precipitate in the mixture of the phases, the small dimensions of the mixing zone allows the entrance of the phases in the mixing zone, and their exit in the form of powder through the other end is so rapid that the polymer has no time to precipitate. In this way, an uncontrolled precipitation is avoided which would produce the formation of aggregates, and it ensures that the coating is produced at the amount of pulverization or nebulization.
The selection of the solvent and the non solvent of the polymer in the initial dispersion is carried out depending on the chemical and physicochemical characteristics of the polymer, or the oil or lipidic substance, and of the active substance to be incorporated.
If the coat-formed polymer is non soluble in water, the non solvent may be a more or less complex aqueous solution, and the solvent may be any organic solvent which is miscible with a high relationship in water, capable of dissolving the polymer. The solvent of the polymer may be for instance, an alcohol such as ethanol, methanol, isopropanol, a ketone of low molecular weight such as acetone or methyl ethyl ketone or any other solvent such as acetonitrile or tetrahydrofuran. Normally, the solvent of the polymer has a dielectric constant over 15.
In the case that the polymer is soluble in an organic solvent and water soluble depending on the pH or temperature, the aqueous solution of the initial dispersion must be adjusted to a pH and/or temperature at which said polymer is insoluble to ensure the deposition of the polymer when the solvent is evaporated during the pulverization.
The lipidic substance to be dispersed in the water may be a natural oil such as coconut oil, soya oil, olive oil, castor-oil, a mixture of capric acid tristearates and capric acid with glycerol, a mixture of saturated and unsaturated acid fats C 12 -C 18 where the main constituent is the linolenic acid (48%), a mixture of unsaturated poly-glycosided glycols consisting of glycerols and polyethylene glycol esters, a mixture of saturated poly-glycosided C 8 -C 10 glycerols, a palmitate ester of glycerol formed by mono, di and triglycerols of natural C 16 and C 18 fatty acids, or a mixture of the same, a mineral oil or a phospholipid.
Generally, the concentration of the lipidic substance in the final product is comprised within 0.1 and 10% (w/V), preferably within 0.5 and 5% (w/V).
The surfactant or emulgent agent of PHASE 1 may be amphoteric such as soya or egg lecithin, anionic such as sodium laurysulfate, cationic such as benzalkonium chloride or non ionic such as sorbitan monoleate, sorbitan monestearate, a polysorbate or a copolymer of polyoxyethylene-polyoxypropylene or a mixture of the same.
The suspending agent may be a dextran, poly-vinylic alcohol, a cellulosic derivative, or a natural rubber such as xanthene rubber. Any of these may be used in combination with a surfactant agent enumerated above.
The surfactant or suspending agent concentration in the final formula is comprised between 0.01 and 10% (w/V).
In PHASE 2, the polymer used may be a synthetic polymer such as the glycols derived from propiolactone, butyrolactone and the epsilocaprolactone; a hemisynthetic polymer such as cellulose acetobutyrate, ethylcellulose, hydroxpropylmethylcellulose acetophtalate; the acrylic acid copolymers and the acrylic polymer, lactic acid copolymers with the glycol acid or the polycaprolactone. Other polymers which may be employed are the cellulose acetophtalate, the polyanhydrides, the polyalphahydroxy-acids and the natural polymers.
The concentration of the coat-forming polymer in the organic phase is comprised between 0.01 and 5% (w/V).
Different forms of mixing the two phases exist. It may be performed through two parallel tubes, producing the union in a concentric or "Y" shaped zone, in such a way that the two phases are joined simultaneously. The volumes of the phases may be equal or the volume of one phase may be greater with respect to the other. The mixing zone has, on the extreme end at which the phases are incorporated, a suitable device, so that the mixture exists in powder form towards an evaporation system in which the solvent of the polymer is totally eliminated and, optionally, part of, or the whole of, the non solvent under reduced pressure and at a temperature below 50° C. The degree of vacuum and the temperature must be adjusted depending on the solvent and the immediate deposition of the polymer around the droplets or particles is ensured, and the formation of aggregates or the appearance of uncoated particles is avoided.
The product thus obtained may be used in suspension or dry powder form, be extruded, compressed or granulated and be used alone or as part of a more complex blend.
An analysis has been made of the experimental results obtained in some specific tests performed according to the process of the present invention.
1. Nanoemulsion coating tests without drugs
In order to study the suitability of the process for coating droplets, which is the object of the present invention, various formulations were prepared with the purpose of checking that the polymer is mainly deposited around the oil droplets instead of individually precipitating in the form of nanospheres, the greater part of the oil droplets remaining uncoated. For this, the three types of products which could be formed were separately prepared: nanocapsules, nanoemulsions and nanospheres.
a) A nanoemulsion of a mixture of caprylic acid and caprynic acid triesters with polyepsiloncaprolactone-coated glycol, was prepared according to the process specified in the description of the present invention.
b) A nanoemulsion mixture of the caprylic acid and caprynic acid triester with glycol was prepared in the same manner as in the previous section (a), but without adding polymer in the organic solution (PHASE 2) of the description of the present invention.
c) For the obtention of nanospheres, the process detailed in the description of the present invention was followed, but using only the mixture of solvents and non solvents of the coat-forming polymer (polyepsiloncaprolactone), without oil, as PHASE 1.
A determination was made of the particle size, the polydispersity and the Z potential of the resultant products of (a), (b) and (c) with the Zetasizer 3 (Malvern Instruments England).
As is shown in Table 1, the values of the average size and the polydispersity of the uncoated oil droplets are greater than those of the coated oil droplets, and these, in turn, are greater than the nanosphere.
The Z potential (parameter which indicates of the electric load on the surface of the droplets and particles), is -18 mV for coated droplets, while for the free oil droplets, it is -8 mV and for the nanosphere it is -14 mV.
TABLE I______________________________________Non ionic PolySurfactant caprolactone Oil Average Zfinal % final % Final % size Poly- potential(w/V) (w/V) (w/V) (nm) dispersity (mV)______________________________________NC 2.5 1.25 2.5 192 0.150 -18NE 2.5 -- 2.5 307 0.302 -8NS 2.5 1.25 -- 149 0.022 -14______________________________________ NC: coated nanoemulsion; NE: nanoemulsion; NS: nanospheres.
The values of size, polydispersity and Z potential correspond to the average of 10 measurements.
An evaluation was conducted, by means of electronic microscopy, at transmission of 66,000 magnification on diverse samples of the resultant products of (a) and (b) which were previously tinted with uranyl acetate at 1%.
As can be observed in FIG. 1, the uncoated oil droplets (A), appear as uniform particles which adapt with one another, while coated oil droplets (B) appear as particles with a less dense core, surrounded by a transparent zone limited by a dark edge (polymeric coating).
2. Nanoemulsion coating test with drug
The proceedings were similar to the previous section for the formulations without active principle, and a mixture of nanoemulsion and nanosphere was additionally prepared.
a) A nanoemulsion of a mixture of caprylic acid and caprynic acid triesters was prepared with polycaprolactone-coated glycol, containing indomethacin at 0.1% (w/V) according to the process detailed in the description of the present invention.
b) A nanoemulsion of a mixture of caprylic acid and caprynic acid triesters was prepared with glycol containing indomethacin at 0.1% (w/V) in the same manner as in previous section (a) but without adding polyepsiloncaprolactone of the present invention.
c) For the obtention of indomethacin nanospheres at 0.1% (w/V), the process detailed in the description of the present invention was followed, but using only a mixture of solvent and non solvent of the coat-forming polymer (polyepsiloncaprolactone), without oil, as in PHASE 1,
Additionally, a dispersion of oil droplets, and nanoparticles was prepared, mixing at equal parts, the resultant products of previous sections (b) and (c).
A determination was made of the size of the particle, the polydispersity and the Z potential with a Zetasizer 3 (Malvern Instruments, England), and 5 ml of each one of the products was centrifuged during 2 cycles of 1 h at 4000 rpm in a centrifugal Selecta model Centromix.
The results are represented in Table II and in FIG. 2. As may be observed in Table II, the average size values and the polydispersity values of the uncoated oil droplets are greater than those of the coated oil droplets and these, in turn, are greater than those of the nanospheres. The average size and the polydispersity of the nanosphere mixture and the uncoated oil droplets give intermediate values to those corresponding to the separate products and greater than those obtained for the coated droplets. Likewise, the nanaosphere and nanoemulsion mixture showed a bimodal distribution (two populations of particle sizes). As regards to the Z potential, the values obtained for the mixture of the nanospheres and the uncoated oil droplets are within the values corresponding to each product separately.
The Z potential of the coated droplets is greater (in absolute values) than those of the nanospheres, the uncoated droplets and their mixture. Consequently, the product obtained by the process of the present invention is not the result of a mixture of precipitated polymer particles (nanospheres) and of uncoated oil droplets.
TABLE II______________________________________ Poly capro- Indo-Non-ionic lactone Oil metacine Averagesurfactant final % final % final % size Poli- Pot.final % (w/V) (w/V) (p/V) (nm) dis. (mV)______________________________________NC 2.5 1.25 2.5 0.1 419 0.157 -38NE 2.5 -- 2.5 0.1 1026 0.319 -24NS 2.5 1.25 -- 0.1 345 0.121 -36NS + 2.5 1.25 2.5 0.1 511 0.199 -31NE______________________________________ NC: coated nanoemulsion; NE: nanoemulsion; NS: nanospheres; NS + NE: mixture at equal parts of nanospheres and nanoemulsions.
The values of size, polydispersity and Z potential correspond to the average of 10 measurements.
As may be observed in FIG. 2, the nanospheres (NS) show a white sediment at the bottom of the tube, while the nanoemulsion (NE) shows a whitish float. The nanosphere and nanoemulsion mixture (NS+NE) presents both a sediment and a floating, as well as a practically transparent intermediate liquid. On the other hand, the coated oil droplets (NC) show a minimum sediment and floating but the intermediate liquid is much cloudier (whitish). This intermediate coat, which is wider and cloudier, corresponds to the coated oil droplets with an intermediate density between that of the oil droplets (less dense) and that of the nanospheres (denser).
BRIEF DESCRIPTION OF THE FIGURES
In FIG. 1:(A) represents uncoated oil droplets which appear as uniform particles which adapt with one another; and 1(B) represents the coated oil droplets which appear as particles with a denser core, surrounded by a transparent zone limited by a dark edge (polymeric coat).
FIG. 2 shows a comparison of the appearance of the intermediate liquid in test 2, between the nanospheres (NS), the nanoemulsion (NE), the mixture of nanospheres and nanoemulsion (NS+NE) and the coated oil droplets (NC).
EXAMPLES OF THE INVENTION
The present invention is additionally illustrated by means of the following examples, which must not be considered as limiting the scope of the same, and which is defined by the attached note of the claims:
For the description of the examples, the commercial names of the products are used, which must be understood to be any product with the same characteristics, commercialized by any other company. The products are as follows:
Miglyol 812® (Dynamit Nobel, Sweden): is a mixture of caprylic acid triesters and caprynic acid with glycol.
Commercial linolenic acid (Henkel, Dusseldorf): is a mixture of saturated and unsaturated fatty acids C 12 -C 18 where the main constituent is linolenic acid (48%).
Eudragit L 12 5 (Rohm Pharma, Darmstadt): is a polymerized anionic of methacrylic acid and methyl methacrylate.
Lutrol F68 (BASF, Germany): is Poloxamer 188 which is a copolymer of polyoxyethylene and polyoxypropylene.
EXAMPLE 1
Nanoemulsion of Miglyol 812® Coated With Polyepsilon Caprolactone
0.625 g of Lutrol F 68® is dissolved, under agitation, in 62 ml of deionized water and filtered through 0.22 μm. 0.625 g of Miglyol 812® dissolved in 62 ml of acetone. The acetonic solution is incorporated to the initial acqeous solution under magnetic agitation, so that a dispersion of droplets with average size below 1 μm is obtained (PHASE 1), 0.312 g of polyepsiloncaprolactone is dissolved in 125 ml of acetone with the help of ultrasonication (PHASE 2). The two phases are continuously mixed through the two parallel tubes, maintaining the relation of the phase constant in the mixing zone and pulverizing the resultant mixture towards the evaporation system simultaneously to the formation of the mixture. The evaporation system removes under reduced pressure and at a maximum temperature of 45° C., the acetone (polymer solvent) so that the deposition of the polymer around the oil droplets is produced and part of the water (non-solvent of the polymer) is eliminated until a final volume of 25 ml is reached. The average size of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments, England) was 192±0.1 nm.
EXAMPLE 2
Nanoemulsion of Miglyol 812® Coated With Polyepsiloncaprolactone
Follow the technique described in Example 1, but the ratio of solvents in the initial dispersion is of 2:3 water/acetone expressed in volumes, instead of 1:1 water/acetone. The average size of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments, England) was 307±0.5 nm.
EXAMPLE 3
Nanoemulsion of Miglyon 812® Coated With Polylacticglycolic Copolymer 75:25
The technique described in Example 1 is followed, but using 0.830 g of Lutrol F68®, 0.207 g of polylactic-glycolic copolymer instead of polyepsiloncaprolactone and 0.415 g of Miglyol 812®. The average size of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments, England) was 197±5 nm.
EXAMPLE 4
Nanoemulsion of Carteolol Base at 0.2% Coated With Polyepsiloncaprolactone
0.375 g Lutrol F68® was dissolved in 40 ml of deionized water and filtered through 0.22 μm under agitation. 0.030 g of carteolol base was dissolved in 0.375 g of commercial linolenic acid, and the resultant solution is added to 60 ml of acetone. The acetonic solution was incorporated into the initial aqueous solution under magnetic agitation to obtain a dispersion of droplets with average size below 1 μm (PHASE 1). 0.187 g of polyepsiloncaprolactone was dissolved in 100 ml of acetone with the help of ultrasonication (PHASE 2). The two phases were continuously mixed through two parallel tubes, while maintaining the ratio of the phases constant in the mixing zone, and pulverizing the resultant mixture the evaporation system simultaneously with the formation of the mixture. Using an evaporation system, the acetone was removed (solvent of the polymer), under reduced pressure and at a maximum temperature of 45° C., so that the deposition of the polymer around the oil droplets was produced and part of the water was removed (non-solvent of the polymer) until a final volume of 25 ml is reached. The average size of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments, England) was 375±3 nm.
For separating the coated droplets of the external aqueous phase, the ultrafiltering-centrifugal technique was used, determining, by means of HPLC, the concentration of carteolol in the total formula and in the filtration. The percentage of the encapsulation of the carteolol was calculated by the difference between the concentration in the total formula and that of the filtration. The percentage of encapsulation was of 70%
EXAMPLE 5
Nanoemulsion of Indomethacin at 0.1% Coated With Polyepsiloncaprolactone
1.66 g of Lutrol F68® was dissolved in 100 ml of deionized water and filtered through 0.22 μm under agitation, 0.050 g of indomethacin was dissolved in 0.83 g of Miglyol 812® with the application of heat, and the resultant solution added to 100 ml of acetone. The acetonic solution was incorporated into the initial aqueous solution under magnetic agitation, so as to obtain a dispersion of droplets with average size below 1 μm (PHASE 1), and 0.415 g of polyepsiloncaprolactone was dissolved in 200 ml of acetone with the help of ultrasonication (PHASE 2). The two phases were mixed continuously through the two parallel tubes, maintaining the ratio of the phases constant in the mixing zone and pulverizing the resultant mixture towards the evaporation system simultaneously with the formation of the mixture. Using an evaporation system, the acetone was removed (solvent of the polymer), under reduced pressure and at a maximum temperature of 45° C., so that the deposition of the polymer around the oil droplets was produced and part of the water was removed (non solvent of the polymer) until a final volume of 50 ml was reached. The final pH was adjusted to 5.5 with HCl 0.1M. The average size of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments) was 551±15 nm.
For the separation of the coated droplets of the external aqueous phase, the ultrafiltering-centrigal technique was used, determining by means of HPLC, the concentration of indomethacin in the total formula and in the filtration. The percentage of encapsulation of the indomethacin was calculated by the difference between the concentration in the total formula and that of the filtrate. The percentage of encapsulation was 99%
EXAMPLE 6
Nanoemulsion of Miglyol 840® Coated With Eudragit 12.5 p®
0.375 G of Lutrol F68° was dissolved, under agitation in 40 ml of deionized water and filtered through 0.22 μm. The pH was adjusted to 4.5 with HC 0.1M. 0.37 g of Miglyol 840® was dissolved in 60 ml of acetone. The acetonic solution was incorporated into the acetone. The acetone solution was incorporated into the initial aqueous solution under magnetic agitation, so that a dispersion of droplets with average size below 1 μm was obtained. (Phase 1). 0.150 g of Eudragit L 12.5 p® was dissolved in 100 ml of acetone (Phase 2). The two phases were continuously mixed through the two parallel tubes constantly maintaining the ratio of phases in the mixing zone and pulverizing the resultant mixture towards the evaporation system simultaneously with the formation of the mixture. Using an evaporation system, the acetone (solvent of the polymer) was removed under reduced pressure and at a maximum temperature of 45° C., so that the deposition of the polymer around the oil droplets was produced and part of the water (non solvent of the polymer) was removed until a final volume of 15 ml is reached. The average size of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments) was of 832±nm.
EXAMPLE 7
Nanoemulsion of Carteolol at 0.1% Coated With Eudragit L 12.5 P®
The technique described in Example 6 was followed, but substituting the Miglyol 840® commercial linolenic acid for the Miglyol 840®, and 0.030 g of carteolol base was included in the oil. The average size of the coated droplets measured in a Zetasizer 3 (Malvern Instruments) was of 290±12 nm.
For the separation of the coated droplets of the external aqueous phase, the ultra-filtering-centrifugal technique was used, determining, by means of HPLC, the carteolol concentration in the total formula and in the filtration. The percentage of encapsulation of the carteolol was calculated by the difference between the concentration in the total formula and that of the filtration. The percentage of encapsulation was 66%.
EXAMPLE 8
Polystyrene Latex Coated With Polyepsiloncaprolactone
0.125 g of Lutrol F68® was dissolved, under agitation, in 40 ml of deionized water and filtered through 0.22 μm. To this solution was added 100 μm of polystyrene latex with an average particle size of 200 nm and a Z potential of -30.81 mV measured in a Zetasizer 3 (Malvern Instruments) and subsequently 20 ml of acetone was added, to obtain a dispersion of droplets with average size below 1 μm (Phase 1). 0.01 g of polyepsiloncaprolactone was dissolved, by means of ultra-sonication in 25 ml of acetone (Phase 2). The two phases were continuously mixed through the two parallel tubes, maintaining the relationship of the phases constant in the mixing zone and pulverized the resultant mixture towards the evaporation system simultaneously with the formation of the mixture. Using an evaporation system, the acetone (solvent of the polymer) was removed under reduced pressure and at a maximum temperature of 45° C., in order to produce the deposition of the polymer around the latex particles and part of the water (not the solvent of the polymer) was removed until a final volume of 7 ml is reached. The average Z potential of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments) was 28 6±1.5 mV.
EXAMPLE 9
Polystrene Latex Coated With Eudragit I 12.5 p
The same procedure for Example 8 is followed, but replacing the polyepsiloncaprolaotone with Eudragit L 12.5 P. The initial solution of water and Lutrol F68 was adjusted to approximately pH4. The average size of the coated droplets, measured in a Zetasizer 3 (Malvern Instruments), was 270±12 nm and the Z potential of 17.39±1.5 mV.
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The process comprises: (1) preparing a fine dispersion of droplets or particles which contain, or are formed, of a chemical or biologically active substance in a phase comprised of a solvent and a non solvent of the polymer forming the coating and, optionally, a surfactant or suspending agent; (2) preparing a phase which contains the coat-forming polymer dissolved in a miscible solvent in any relationship with the prior dispersion, (3) mixing both phases continuously while maintaining constant the relationship between the phases and the mixture volume, and simultaneously spraying the resultant mixture in an evaporation system with temperature and vacuum conditions which provide for the instantaneous evaporation of the solvent from the polymer, causing the deposition of the polymer around the particles or droplets. Applications to pharmacy, medicine, cosmetics, veterinary, chemical industry, agriculture are discussed.
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BACKGROUND OF THE INVENTION
The invention relates to a method of clearing mispicks in rapier looms as set out in the preamble of claim 1 and to a loom having means for the practice of the method.
A known method of this kind (EP-PS 332,257) discloses the clearance of a weft breakage in the shed by detaching the weft yarn from the fell and drawing out the faulty yarn parts by means of the loom rapiers and an extractor. The disclosure is silent about how the fault is detected while the loom is running and how weaving resumes after clearance of the fault, nor is anything said about the numerous other faults which may occur in the picking of a weft yarn and how they could be cleared.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide a method of the kind defined enabling all or at least most of the mispicks which can occur to be detected by the loom itself, whereupon the loom itself clears the fault, depending upon the nature thereof, and whereafter the loom resumes weaving.
It is another object of the invention to provide a loom of the kind defined which has means for the practice of the respective fault-clearing method.
In the method of clearing mispicks in the shed of a rapier loom, the loom itself determines the nature of the fault in the time slot allocated to faults of this nature in the continuously produced signals corresponding to the angular position of the loom on the basis of the combination of such signals arising in such slots and of the weft movement and weft presence signals produced in the slot by the nature of the fault, whereafter the loom automatically acts to clear the fault and resumes weaving after the clearance thereof.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front elevational view of a rapier loom constructed according to the present invention and shows the clearing of "drive faults";
FIGS. 2 to 4 are front elevational views and show the clearing of "giver mispicks" by the "clamping" solution;
FIGS. 5 and 6 are front elevational views and show the clearing of "giver mispicks" by the "clamping" solution;
FIGS. 7 to 9 are front elevational views and show the clearing of "taker mispicks" by the "clamping" solution;
FIGS. 10 to 14 are front elevational views and show the clearing of "taker mispicks" by the "slipping" solution;
FIGS. 15 to 18 are front elevational views and show the clearing of "transfer faults" by the "clamping" solution;
FIGS. 19 and 20 are front elevational views and show the clearing of "transfer faults" by the "slipping" solution;
FIGS. 21 to 23 are front elevational views and show the clearing of "transfer faults" by the "clamping variant" solution;
FIG. 24 is a front elevational view and shows "breakage before transfer" faults in which substantially equally long yarn pieces are disposed one on the giver side and one on the taker side;
FIG. 25 is a front elevational view and shows the same kind of fault as FIG. 24 but with a longer yarn piece on the giver side than on the taker side;
FIG. 26 is a front elevational view and shows the same kind of fault as shown in FIGS. 24 and 25 but with a yarn piece outside the shed on the giver side;
FIGS. 27 and 28 are front elevational views and show clearing of the kinds of fault shown in FIGS. 24 to 26;
FIG. 29 is a front elevational view and shows the "breakage after transfer" fault, the breakage being on the taker side;
FIG. 30 is a front elevational view and shows the same kind of fault as FIG. 29 but with the breakage on the giver side;
FIG. 31 is a front elevational view and shows the same kind of fault as in FIGS. 29 and 30 but with the breakage on the giver side outside the shed;
FIGS. 32 and 33 are perspective, side elevational views and show the cooperation between a slipping element on the giver rapier and a slipping element on the taker rapier; and
FIGS. 34a, 34b and 34c are perspective, side elevational views and show a second embodiment of slipping elements for the rapiers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. Drive faults (FIG. 1)
The term "drive faults" denotes a fault in which the giver has entered the shed without a weft yarn in its rapier. This kind of fault will be described with reference to FIG. 1. The short description used in this case of the arrangement around the shed applies to all the subsequent figures of the drawings (facilities mentioned hereinafter will be described in connection with the associated figures of the drawings).
Referring to FIG. 1, a weft yarn giver 3 having a giver rapier 4 is disposed on side 1 of a shed 2 of a rapier loom and a weft yarn taker 6 having a taker rapier 7 is disposed on the other side 5 of the shed. Also disposed on side 1 of the shed are a yarn supply bobbin 8, a yarn thrower 9, shears 10 and a weft yarn monitor 11. The same monitors the weft yarn 12 coming off the bobbin 8. The weft yarn 12 goes through a yarn guide 13 of thrower 9. There can be seen a reed 14 (14' denoting the reed shown in chain-dotted lines during beating-up) and cloth 15. The cloth has a fell 16--i.e., the weft yarn last picked and beaten up by the reed. The shears 10 have not yet severed the latter weft yarn. A chain-dotted line 18 denotes the weft yarn which should have been picked but which was not introduced into the shed by the giver. To pick the weft yarn the giver rapier 4 and taker rapier 7 were moved to the center 19 of the shed into respective positions 4' and 7'. Cams 27, 48 for the two rapiers 27, 48 respectively are disposed outside the shed. A second weft yarn monitor 25 is disposed on the reed 12 on the taker side.
The phase of loom operation is referred in conventional manner to the angular position of the loom main shaft, such position being referred to as the angular position of the main shaft of the loom in degrees and abbreviated "MGR". The start of the loom cycle or the 0° position=reference position, is, for example, the beating-up position of the reed on the cloth and the rapier reversal position in its initial position. The 0° position can of course be chosen in some other way.
The absence of weft yarn is detected by the monitor 11 in the MGR slot disposed within 10 MGR after the start of picking, e.g. between 60 to 70 MGR. The monitor 11 transmits a corresponding signal to the loom control, the same receiving from an angle sensor (not shown) a signal for each degree of angular position of the loom main shaft. The control is programmed to stop the loom upon detection of a drive fault, the stoppage occurring after the rapiers have left the shed and after beating-up and shed-changing. The control also moves the pattern program back by one cycle and initiates a weft search in which the shed opens. The control clears the fault quite simply by a normal loom restart, the previously accidentally unpicked weft yarn, recognized as a "drive fault", being re-presented to the giver. After clearance of the cause of the fault the loom restarts. The fact that there is a drive fault is read off by the loom operator from the display of the corresponding angular position on the display screen indicating the operative position of the loom. The control can be so programmed that in the event of an unsuccessful effort to re-pick the missing weft yarn, after several stoppages of the loom and after several weft searches there is a further loom restart. The searches can be repeated until after a predetermined number of unsuccessful searches a warning signal is given for manual clearance of the fault by the loom operator.
2. "Giver mispick" fault
The term "giver mispick" denotes the fault wherein the giver rapier loses the weft yarn on its way to the center of the shed. There are two solutions according to the invention for clearing this fault and these two solutions are referred to here as "clamping" and "slipping".
2.1 "Clamping" solution (FIGS. 2-4)
In the first solution the loom detects the fault in a fault-associated slot of the MGR position signals, the same being supplied continuously to the control during a loom cycle. This slot extends over approximately 10 MGR after the start of picking somewhere between approximately 60 and 140 MGR. The control detects from the combination of these signals with the missing yarn movement signal of the yarn detector 11 and the missing yarn presence signal of the yarn detector 25--which latter is operative between 300 and 340 MGR--that the giver rapier 4 has lost the weft yarn 2. By means of the missing yarn presence signal from the monitor 25 the control distinguishes this fault from the kinds of fault to be discussed hereinafter. A weft yarn piece 12a remains in the shed after beating-up (FIG. 2).
The control stops the loom, moves the rapiers back out of the shed, moves the loom program back by one cycle and initiates a weft search with "asynchronous shed adjustment", a term denoting that the shed is being opened and kept open for weft breakage clearance by means of a shedding mechanism adapted to be brought into operation independently of normal weaving. The shears 10 are rendered inoperative. The thrower 9 transfers the same weft yarn 12 to the giver rapier 4 again. During the entry of the giver into the shed yarn is additionally drawn off the bobbin 8, the yarn piece 12a simultaneously being peeled off the fell 16. FIG. 3 shows two intermediate positions 12b, 12c of the weft piece. At the center of the shed the taker rapier 7 takes over the weft yarn from the giver rapier 4. After both rapiers have moved back out of the shed the yarn end 12d (FIG. 4) is disposed loosely in the taker rapier 7 since the same opened upon striking the cam 27. Two yarn draw-back rollers 28 move towards one another and are rotated and draw the complete weft yarn out of the taker rapier and the shed, whereafter the loom restarts to resume weaving.
The aim of the asynchronous weft search is to have the shed open very wide when the rapiers move thereinto in order that the beaten-up weft yarn residues may be detached readily from the fell of the cloth. If the rapiers are still outside the shed the shedding unit, which is driven by the loom main shaft by way of a clutch, is declutched from the loom. The shedding unit is then rotated further by the inching motor of the loom to open the shed, whereafter the clutch is reengaged and the inching motor inches the rapiers into the shed. This occurs backwards--i.e., the main crank drive of the rapiers is turned backwards by the inching motor through approximately 280°. Consequently, at the restart after clearance of the fault the loom is once again in its programmed timing. The shedding movement during this operation is slight. At the center of the shed--i.e., at yarn transfer between the rapiers--the movement of the shedding unit stops and then reverses to prevent the shed closing in this position with the rapiers in it.
During the weft-searching step described the shears 10 move back and therefore make no severing movement. The events described apply to every kind of fault to be described hereinafter.
2.2 "Slipping" solution (FIGS. 5 and 6)
The procedure for this solution is the same as for the first "clamping" solution described in 2.1 as far as and inclusive of the asynchronous weft-searching step. In contrast to the first solution, however, in the "slipping" solution a slipping element 30, to be described hereinafter with reference to embodiments (FIGS. 33 and 34c, where the slipping element 30 is embodied by elements 65 and 80 respectively), is pushed on to the giver rapier 40 outside the shed. The element 30 is pushed on to the giver rapier automatically by means of a push-on device 31. While the draw-back rollers 28 are in the braking position, the thrower 9 re-presents the weft yarn 12 to the giver rapier 4. When the same moves into the shed the weft yarn piece 12a disengages from the fell 16 and slips through the slipping element 30. The presence thereof on the rapier prevents the yarn piece 12a from being caught by the clamp of the rapier 4. The taker rapier therefore cannot take over the yarn piece 12a since the same does not extend as far as the center of the shed. The draw-back rollers 28 move towards one another and rotate and draw the yarn piece 12a out of the shed 2. The yarn piece 12a is shown in two intermediate positions 12b and 12c during the draw-back. The loom restarts.
3. "Taker mispick" fault
The term "taker mispick" denotes the fault wherein after taking over the weft yarn from the giver rapier the taker rapier loses the weft yarn in its return movement. There are two solutions according to the invention, called "clamping" and "slipping", in the method of clearing this fault.
3.1 "Clamping" solution (FIGS. 7-9)
The procedure for this solution is as described in 2.1 for the "clamping" solution of the "giver mispick" fault. However, the MGR slot allocated to this particular fault lies within 130 to 160 MGR after the start of picking or between 190 and 320 MGR referred to the loom cycle if the 0° position is defined as hereinbefore described in connection with the "drive fault". A yarn piece 12a remains which extends as far as the taker side. After the return of the rapiers an asynchronous weft search operation is made, the shears 10 being inoperative. The thrower 9 re-presents the weft yarn 12 to the giver rapier 4. When the same enters the shed yarn is additionally drawn off the bobbin 8 and the yarn piece 12a peeled off the fell 16. The taker rapier 7 takes the yarn piece over from the giver rapier and continues to release it from the fell 16. When the taker rapier 7 strikes its cam 27 it opens and the now operative draw-back rollers 28 draw the complete weft yarn out of the taker rapier and out of the shed (FIG. 9), whereafter the loom restarts. The only difference from the "clamping" solution for clearing the "giver mispick" fault is, therefore, that a longer yarn must be drawn back by way of the taker rapier 7.
3.2 "Slipping" solution (FIGS. 10-14)
The procedure in the second solution up to and including the pushing-on of the slipping element 30 is as described in 2.2 for the "giver mispick" fault. However, the MGR signal slot associated with this kind of fault lies within 130 to 260 MGR after the start of picking, corresponding to between 190 and 320 MGR of the loom cycle. In contrast to this solution, however, a slipping element 35 is pushed on to the taker rapier 7 by means of a push-on device 36 immediately after the taker rapier 7 is outside the shed 2. The element 35, which will be described hereinafter with reference to an embodiment, has a transfer function and a slipping function. The transfer function resides in the transfer by the taker rapier 7 of the weft yarn piece 12a from the giver rapier 4 without such yarn piece being caught by the clamp of the taker rapier 7. The same cannot therefore itself take over the yarn piece. The slipping function will be discussed in section 5. FIG. 11 shows the position of the giver rapier 4 and taker rapier 7 in the shed. The weft yarn 12 has been re-presented to the slipping element 30 and is now guided by way thereof with disengagement of the yarn piece 12a from the fell 16. The draw-back rollers 28 were in the braking position. The shears 10 are inoperative. After the slipping element 35 has taken over the yarn piece 12a from the slipping element 30 in the manner shown in FIG. 12, during the return of the taker 6 the yarn piece 12a slips over the slipping element 35 while the still unreleased part 12a' of the yarn piece 12a is disengaging from the fell 16. FIG. 13 illustrates the operation. As will be apparent in FIG. 13 the slipping element 35 prevents the weft yarn piece 12a from entering the clamp 37 of the taker rapier 7 so that the piece 12a can slip over the slipping element 35. Near the end of the return movement of the taker 6 (FIG. 14) the yarn piece 12a has already disengaged completely from the fell 16. The draw-back rollers 28 on the giver side are now started and the withdrawal of the mispicked weft yarn from the shed 2 begins. After the weft yarn has been fully withdrawn and extracted by a nozzle 38, the loom restarts.
4. Transfer faults
The term "transfer fault" denotes mistransfer of the weft yarn between the giver and the taker. For example, a loop 40 forms in the weft yarn piece near the fell. There are three solutions according to the invention for clearing the faults and they are known respectively as "clamping", "slipping" and "clamping variant".
4.1 "Clamping" solution (FIGS. 15-18)
The procedure for this solution is the same as described in 2.1 for the "clamping-solution" of the "giver mispick" fault--i.e. transfer of the weft yarn back to the giver rapier 4 and picking of the weft yarn, the weft yarn piece 12a being detached from the fell simultaneously with the loop 40 (FIG. 16). After takeover of the yarn piece by the taker rapier and the return thereof from the shed, the yarn piece remains loosely in the open taker rapier 7 (FIG. 17). As is apparent in FIG. 18, a single opening movement of the taker rapier clamp 41 suffices to guide the yarn piece 12a into the yarn guide 42 of the rapier so that the yarn piece 12a experiences no clamping, whereafter the yarn is drawn by the draw-back rollers 28.
4.2 "Slipping" solution (FIGS. 19 and 20)
The procedure for this solution is the same as described in 2.2 for the "slipping" solution of the "giver mispick" fault. The yarn piece 12a is completely detached from the fell 16 even before the two rapiers 4, 7 meet. Since the weft length is approximately halved, the taker rapier 7 cannot engage the yarn piece (FIG. 20). Finally, the rollers 28 draw the yarn out of the shed.
4.3 "Clamping variant" solution (FIGS. 21-23)
It may occur with a transfer fault that when the two rapiers meet at the center 19 of the shed the tip of the weft yarn 12 remains in the giver rapier 4 and, when the same returns, is pulled to some extent out of the shed and forms a loop 45. The MGR position signals associated with this kind of fault lie within approximately 130 to 160 MGR after the start of picking (between approximately 190 and approximately 320 MGR of the loom cycle). According to FIG. 21, to clear this fault a suction tube 46 is provided on the giver side, the inlet of the tube 46 being disposed near the giver rapier 4. A weft yarn monitor 47 is disposed in such inlet. The tube 46 sucks in the loop 45 in the yarn piece 12a as initiated by the monitor 47 for detecting this kind of transfer fault. Since the monitor 11 has previously detected absence of yarn movement, a signal from the monitor 11 has already initiated stoppage of the loom. The signal from the monitor 47 to the loom control initiates the following fault clearance operation.
The thrower 9 re-presents the weft yarn 12 to the giver rapier 4. The shears 10 are inoperative. The giver 3 moves backwards into the shed; as previously explained the rapier main crank drive is turned backwards in order to be in the programmed timing when the loom restarts after clearance of the fault. The control now so acts on giver movement that the giver does not reach the taker rapier 7 but reverses before reaching the center 19 of the shed, e.g. at 175 MGR, and moves out of the shed (see FIG. 22, although the rapiers therein are shown on their way to the reversal position). There can therefore be no transfer of yarn from the giver to the taker. Conventionally the yarn is transferred at approximately 180 MGR. Consequently, during the return of the giver the yarn remains engaged by the giver rapier 4. When the giver leaves the shed the giver yarn clamp is opened by the giver 4 striking its cam 48 (see FIG. 1). The draw-back rollers 28 are started, extend the yarn with the multiple loop 49 (FIG. 23) and draw the yarn piece 12a out of the shed. The loom restarts after clearance of the reason for the fault.
5. "Breakage before transfer" fault (FIGS. 24-28)
This fault occurs in three forms (as shown in FIGS. 24-26) which have the following common features:
The entire faulty length of weft yarn corresponds approximately to half the cloth width;
This half of the weft yarn length is divided into two parts 12a (or 12d) and 12b.
A relatively long weft yarn piece 12b was transferred to the taker rapier 7 from the giver rapier 4 and woven into the cloth by subsequent beating-up and shed changing. Also, the relatively long yarn piece 12a was woven into the cloth on the giver side (FIGS. 24 and 25) or a piece 12d remained unwoven outside the shed (FIG. 26).
The faults described are recognized as such first by the absence of yarn movement signal from the monitor 11 prior to yarn transfer at the center of the shed and second by the detection of yarn presence by the detector 25 on the taker side. In this case the monitor 11 is operative in the slot extending from 62° to 170° of the MGR position signals of a loom cycle (picking starts at 60° ) and the taker-side monitor 25 is operative in the slot extending from 300 to 340 MGR.
5.1 Solution for the giver side
To remove the yarn piece on the giver side the procedure is the same for all three kinds of fault as for the "giver mispick" fault described in the "clamping" section 2.1 or "slipping" section 2.2.
Advantageously, for the sake of consistency the same fault clearance program is gone through for the three kinds of fault--i.e., e.g. for the kind of fault according to claim 26 in which the yarn end 12d on the giver side has not been woven in at all, the program step for detaching the yarn from the fell is performed nevertheless.
5.2 Solution for the taker side
To remove the yarn piece 12b on the taker side the slipping element 35 of FIG. 13 is first pushed on to the taker rapier 7 by means of the push-on device 36, as shown in FIG. 27. There is a yarn clamp 51 on the taker side to catch the weft yarn piece 12b on the fell and then transfer it to the taker rapier. Also, a pair of draw-back rollers 52 are disposed on the taker side. To this end, the clamp 51 is moved from its position 51' into a position 51" so that the yarn piece 12b crosses the path of the taker. When the same enters the shed its rapier 7 engages the yarn piece 12b by way of the slipping element 35 and detaches such piece from the fell 16. When the taker rapier is outside the shed again after its return movement the yarn clamp transfers in its position 51" the yarn piece 12b to the draw-back rollers 52 which draw the yarn piece out of the shed (FIG. 28). In addition to or instead of the rollers 52 the yarn clamp 51 can transfer the yarn piece 12b to a suction nozzle 53.
6. "Breakage after transfer" fault (FIGS. 29-31)
The term "breakage after transfer" denotes a fault wherein the weft yarn breaks after the taker has taken it over from the giver.
The MGR position slot allocated to this kind of fault extends over 130 to 250 MGR after the start of picking, corresponding to 190 to 320 MGR of the loom cycle. From the combination of these signals, viz. the missing yarn movement signal of the monitor 11 on the giver side and the yarn presence signal of the monitor 25 on the taker side, the control ascertains that the weft yarn broke after transfer. This fault can take three forms.
6.1 Solution for faults according to FIG. 29
Because of the breakage a weft yarn piece 12a is present in the shed 2 on the giver side and a yarn piece 12b on the taker side. The two pieces are separated from one another by the break 55. The same is on the taker side in FIG. 29. Consequently, the yarn piece 12b must be detached from the fell 16 on the taker side and drawn out of the shed. The requirement on the giver side is to detach the yarn piece 12a and draw it out of the shed.
The procedure for clearing this fault is the same as described for the "slipping" solution in section 3.2 for the "giver mispick" fault--i.e., pushing the slipping elements 30, 35 on to the giver rapier 4 and taker rapier 7 respectively, re-supply of the weft yarn 12 to the giver by the thrower 9, movement of the giver into the shed while the draw-back rollers 28 are in the braking position with detachment of the yarn piece 12a from the fell 16, and transfer of the yarn piece 12a to the slipping element 35 of the taker.
The yarn piece 12a residue remaining on the fell is detached therefrom by means of the slipping element of the taker 3 when the same moves out of the shed. The yarn piece 12b (FIG. 29) on the taker side is removed by means of the clamp 51 (FIG. 27) as described in section 5 for the "breakage before transfer" fault-- i.e., the clamp 51 presents the yarn piece 12b to the taker rapier 4. When the taker enters the shed it detaches the yarn piece from the fell. After the return of the taker the clamp 51 transfers the yarn piece to draw-back rollers and/or an extraction nozzle for removal of the yarn piece.
6.2 Solution for faults according to FIG. 30
In FIG. 30 the break 56 is disposed substantially at the center of the shed and the two weft yarn pieces 12a, 12b are of approximately the same length.
The procedure for clearing this fault is the same as the fault clearance procedure described in section 6.1 for otherwise this fault cannot be distinguished from these two without great complexity.
6.3 Solution for faults according to FIG. 31
In FIG. 31 the break 57 is disposed on the fell on the giver side and the yarn piece 12a is outside the shed while the other yarn piece 12b is disposed substantially completely in the shed.
To clear this fault, for example, a slipping element 65 is pushed on to the giver rapier 4 and a slipping element 66 on to the taker rapier 7 (see FIGS. 32 and 33). When the giver 3 enters the shed the slipping element 65 is devoid of weft yarn. The weft yarn piece 12b was presented to the slipping element 65 by the clamp 51. Upon entering the shed the taker detaches the weft yarn from the fell 16 on the taker side. At the center of the shed the yarn is transferred from the taker rapier 7 to the giver rapier 4 by a yarn hook 70. In the return movement the yarn hook 70 detaches the weft yarn from the fell on the giver side.
FIGS. 32 and 33 show two cooperating slipping elements, viz. a slipping element 65 on the giver rapier 4 and a slipping element 66 on the taker rapier 7. The two slipping elements are shown shortly before their stationary position 65', 66' respectively in the shed at approximately 175 MGR. The giver slipping element 65 is pushed on to the giver rapier 4 and retained thereon by means of a snap fastening 67. The end face of the slipping element 68 is formed with a yarn-guiding groove 68. A yarn transfer hook 70 which extends in the forward direction is secured to the element 65 on the side near the cloth 15. The other slipping element 66 is pushed on to the taker rapier 7 and secured thereon by means of two snap fastenings 71, 72. The end face of the element 66 is formed with a groove 73. A yarn transfer hook 75 which extends in the forward direction is secured to the element 66 on the side near the cloth.
The operation of the slipping elements will be described for clearing the "taker mispick" fault by the "slipping" solution of section 3.2. Upon entry into the shed the slipping element 65 of the giver rapier 4 engages the yarn piece 12a, the latter being shown in chain-dotted line. While the giver is entering the shed the yarn piece 12a slips through the groove 68 in the slipping element 65 and is detached from the fell 16. When the slipping elements have reached their respective end positions 65', 66', the yarn hook 70 of the element 65 is in a position 70' indicated in chain-dotted line and the yarn hook 75 of the element 66 is in a position 75' indicated by a chain-dotted line. When the giver and the taker move apart from one another the yarn hook 75' catches the still unreleased yarn piece 12a and detaches it from the fell, the yarn piece 12a slipping through the yarn hook 75, 75' of the element 66.
FIG. 32 also shows the converse case in which the yarn hook 70, 70' of the giver rapier 4 would catch a yarn piece 12b, shown in solid line, presented by the taker rapier 7.
FIGS. 34a, 34b and 34c, which show variants of FIG. 33, illustrate the cooperation between transfer element 80 (snap fastening 88) pushed on to the giver rapier 4 and a slipping element 81 (snap fastening 84) pushed on to the taker rapier 7 for clearing the "break after transfer" fault in accordance with section 6.3, the break position 57 being disposed outside the shed on the giver side. Upon entry into the shed the transfer element 80 carries no weft yarn for the giver rapier. The slipping element 81 on the taker rapier has by way of its yarn hook 82 caught the yarn piece 12b presented by the yarn clamp 51. Upon entering the shed the taker rapier disengages the yarn piece 12b from the fell 16 on the taker side, the yarn slipping through the hook 82. On its return movement from the stationary position at approximately 175 MGR of the rapier, a yarn hook 85 (FIG. 34c) of the transfer element 80 on the giver rapier takes over the yarn piece 12b from the taker rapier and detaches the yarn piece 12c left on the giver side from the fell, the yarn slipping out of the yarn hook 82 of the element 81.
The slipping element 81 also has a weft yarn slipping hook 83 (FIG. 34b) whose purpose was described with reference to FIGS. 12 and 13. The slipping element 80 (FIG. 34c) forms on the giver rapier 4 a trough 86 for the slipping function in the "slipping" solutions hereinbefore described, the yarn 12a slipping through the trough 86.
Although the invention has been described in the foregoing for a single-shed rapier loom having rapiers moving into the shed in opposite directions, it is of use for a double-shed rapier loom and a two-web rapier loom. Also, the invention is of use in looms in which the rapiers enter the shed on only one side.
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Weft yarn faults encountered during the operation of rapier looms are corrected by correlating the detection of the fault to the angular position of the rotating main shaft of the loom. The loom has a shed with a giver side and a taker side, a giver rapier at the giver side and a taker rapier at the taker side. Position signals are stored in an electronic storage device for weft yarn faults which can occur at predetermined angular positions of the main shaft during operation of the loom. The weft yarn is monitored and a signal is generated when a faulty weft yarn is detected. This signal is compared with the position signals in a logic circuit to thereby determine the nature of the fault. After the nature of the fault has been determined, the faulty weft yarn is appropriately removed and, thereafter, weaving continues.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dentifrice compositions containing stannous compounds.
2. Related Art
There have been many proposals in the prior art to incorporate stannous compounds into oral health care products for the purpose of achieving particular clinical benefits such as caries prevention, plaque control or the reduction of gingivitis. These stannous compounds are compounds which, upon association with water, are capable of yielding stannous ions, as it is actually the stannous ion which is active against oral bacteria.
However, the incorporation of stannous compounds into dentifrice compositions presents problems in that the stannous ions tend to react with other components of the dentifrice composition to form insoluble stannous compounds, which reduces the effective amount of stannous ions in the composition and thus renders the stannous compound less efficacious. In addition, the active stannous ion is particularly prone to oxidation, e.g. by air or an oxidizing agent, the stannous ion being converted thereby into the inactive stannic form.
In GB-A-804,486 it is proposed to overcome the problem that stannous ions react with other components of a dentifrice composition by using a slightly soluble stannous compound e.g. stannous pyrophosphate, thus maintaining a "reservoir" of stannous tin in the form of an undissociated stannous compound which replenishes stannous ions that have reacted with other components of the dentifrice composition.
We have found, however, that the inclusion of such slightly soluble stannous compounds, e.g. stannous pyrophosphate, still gives rise to the formation of inactive stannic compounds.
According to the present invention it has now been found that the conversion of stannous ions in a dentifrice composition into inactive stannic ions can be significantly reduced or prevented by the inclusion in the dentifrice composition of an antioxidant which is a radical inhibitor. Since dentifrice compositions do not normally contain an oxidizing agent and are usually packed in a closed container, it was quite unexpected that the use of an antioxidant of the radical inhibitortype did significantly reduce and prevent the conversion of stannous ions into stannic ions in such a dentifrice composition.
SUMMARY OF THE INVENTION
Consequently, in its broadest aspect, the present invention embraces a dentifrice composition which comprises an effective amount of a stannous compound capable of yielding stannous ions upon association with water, and an effective amount of an antioxidant which is a radical inhibitor capable of reducing or preventing the conversion of the stannous ions in the dentifrice composition into stannic ions.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will more fully be appreciated by reference to the drawing in which:
FIG. 1 is a graph depicting the oxidative stability of stannous ions in pastes containing antioxidants; and
FIG. 2 is a graph depicting the soluble stannous stability in pastes containing antioxidants.
DETAILED DESCRIPTION
The stannous compounds Which are suitable for inclusion in dentifrice compositions are known per se. Typical examples of suitable stannous compounds are stannous compounds with inorganic or organic counter-ions. It can be a highly soluble stannous salt, or it can be a sparingly soluble stannous salt. Highly soluble stannous salts are e.g. stannous fluoride, stannous chloride, stannous acetate, sodium stannous fluoride, potassium stannous fluoride, stannous hexafluorozirconate, stannous sulphate, stannous tartrate, stannous gluconate, etc. Of these highly soluble stannous salts, stannous fluoride is the preferred stannous salt.
Sparingly soluble stannous salts are e.g. stannous pyrophosphate, stannous metaphosphate, stannous oxalate, stannous phosphate, etc. Stannous pyrophosphate is a preferred sparingly soluble stannous salt. Mixtures of various highly soluble stannous salts may also be used, as well as mixtures of various sparingly soluble stannous salts and mixtures of highly and sparingly soluble stannous salts. A preferred mixture is the mixture of stannous fluoride and stannous pyrophosphate.
In general, the stannous salt is used in such an amount in the oral composition that there is an effective amount of active dissolved stannous ions available in the composition to achieve an anti-caries, antigingivitis or anti-plaque efficacy. For the highly soluble stannous salts, this amount will generally range from 0.01-10%, preferably from 0.02-5%, and particularly preferably from 0.1-3% by weight of the oral composition. As regards the sparingly soluble stannous salts, these ranges are 0.05-10%, preferably 0.1-5%, and particularly preferably 0.1-3% by weight of the oral composition.
Antioxidants which are radical inhibitors are known per se. Both synthetically made or naturally occurring antioxidants are suitable in the present invention. Typical examples of suitable antioxidants in the present invention are propyl gallate, butylated hydroxyanisole (BHA), butylated hydroxytoluene (BHT), ethyl vanillin, rosemary oil, lecithin, vitamin E, rutin, morin, fisetin and other bioflavonoids. Mixtures of various antioxidants can also be used.
The antioxidant is used in an effective amount to significantly reduce or prevent the conversion of stannous ions into stannic ions. In general, low amounts of the antioxidants are already sufficient. Thus, the amount may range from 0.001-2%, usually from 0.015-1.5%, and preferably from 0.02-1% by weight of the dentifrice composition. Naturally, within the above framework the type of antioxidant and the level thereof will also be governed by ecological and safety approval factors.
Preferred antioxidants are BHA, BHT, and ethyl vanillin.
The oral composition of the present invention may contain an orally acceptable medium which contains usual additional ingredients in conventional amounts, depending upon the final form of the composition, i.e. a dentifrice, a mouthwash, a gel and the like. Thus, as a dentifrice it will usually comprise an abrasive cleaning agent in an amount of from 3-75 % by weight. Suitable abrasive cleaning agents are milled or unmilled particulate aluminas; silica xerogels, hydrogels and aerogels and precipitated particulate silicas; calcium pyrophosphate; insoluble sodium metaphosphate; calcium carbonate; dicalcium orthophosphate; particulate hydroxyapatite and so on.
Furthermore, the dentifrice may contain a liquid phase comprising water and a humectant in various relative amounts, in an amount of 10-99% by weight. Typical humectants are glycerol, sorbitol, polyethylene glycol, polypropylene glycol, propylene glycol, hydrogenated partially hydrolyzed polysaccharides and so on.
Binders or thickening agents such as sodium carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, xanthan gums, Irish moss, gum tragacanth, finely divided silicas and hectorites may also be included in the dentifrice in an amount of 0.5-10% by weight.
Another conventional ingredient in a dentifrice is an organic surfactant such as soap, an anionic, nonionic, cationic, ampholytic and/or a zwitterionic synthetic surfactant in an amount of 0.2-5% by weight.
When the composition is in the form of a mouthwash, it will usually contain an alcohol, a solubilizer and no abrasive cleaning agent and when in the form of a gel, it will usually contain a thickening agent. Various other optional ingredients may be included in the compositions of the invention, such as flavouring agents, sweetening agents such as sodium saccharinate, whitening agents such as titanium dioxide or zinc oxide, preservatives, vitamins such as vitamin C and E, other anti-plaque agents such as zinc salts, e.g. zinc citrate, copper salts, sanguinarine, allantoin, p-aminobenzoic acid derivatives, hexetidine, chlorhexidine, 3-(4-propylheptyl) -4-(2 -hydroxyethyl) - morpholine, anti-bacterial agents such as Triclosan (2',4,4'-trichloro-2-hydroxy-diphenyl ether), anticalculus agents such as di- and/or tetra-alkali metal pyrophosphates, pH-adjusting agents, colouring agents, anti-caries agents such as casein, casein digests, urea, calcium glycerophosphates, sodium trimetaphosphate, sodium fluoride and monosodium fluorophosphate, anti-staining compounds such as silicone polymers, anti-inflammatory agents such as substituted salicylanilides, plant extracts, desensitizing agents for sensitive teeth such as potassium nitrate and potassium citrate, polymers such as polyvinyl methyl ether-maleic anhydride co-polymers and so on.
The present invention will now be further illustrated by the following Examples.
EXAMPLE 1
Five aqueous solutions of stannous fluoride, sodium lauryl sulphate and propyl gallate were prepared. The levels are listed below :
______________________________________Solution SnF2 SLS Propyl Gallate______________________________________1 0.5% 1.5% 0% (Control)2 0.5% 1.5% 0.25%3 0.5% 1.5% 0.5%4 0.5% 1.5% 0.75%5 0.5% 1.5% 1.00%______________________________________ *All quantities are % w/v.
The solutions were made up in distilled water that had been purged with dry nitrogen gas for 1 hour prior to use. The SLS was added to solubilize the propyl gallate.
The solutions were left at 20° C. for 5 days. After this period, the solutions contained varying amounts of a white precipitate. Small aliquots of the whole solution were taken and analyzed, using Mossbauer Spectroscopy. After 10 days, solutions 1 and 5 were analyzed by Mossbauer Spectroscopy again.
In addition to Mossbauer Spectroscopy, the solutions were analyzed after 5 days for soluble stannous content by polarography. However, unlike the samples taken for Mossbauer analysis, the samples for polarographic analysis were centrifuged first (3000 rpm, 30 minutes) to remove the flocculent white precipitate.
______________________________________Polarographic Analysis:Solution Soluble Stannous Levels/ppm______________________________________1 9052 12713 16914 17865 1861______________________________________Mossbauer Analysis: Sn (II) Sn (IV) Area of Sn (IV)Solution I.S. Q.S. I.S. Peak %______________________________________5 DAYS1 3.15 1.88 -0.32 352 3.16 1.79 -0.52 63 3.16 1.80 -0.57 44 3.19 1.77 -0.53 45 3.14 1.98 -0.58 510 DAYS1 3.11 1.98 -0.32 545 3.14 1.80 -0.57 6______________________________________ *All figures given in mmsec1 *Mossbauer errors +/- 0.05 mmsec1 *I.S. = Isomer Shift; Q.S. = Quadrupole Split.
It is clear from the polarographic analysis that increasing levels of propyl gallate inhibited the loss of soluble stannous from solution. The polarograph, however, only tests the stannous components in solution. The Mossbauer spectra showed that with no propyl gallate present (solution 1), at least 34 of the total tin was Sn(IV) after 5 days and 54% Sn(IV) at 10 days. Even with only 0.25% of propyl gallate, after 5 days, there was only approximately 6% of Sn(IV) and this level of Sn(IV) contamination was present in the starting materials anyway.
These data showed that the propyl gallate was inhibiting the oxidation of Sn(Il) to Sn(IV).
EXAMPLE 2
A series of 6 toothpastes have been formulated, containing different antioxidants. The formulations are listed below. The pastes were stored at 50° C. for 1.7 monts and analyzed, using Mossbauer Spectroscopy.
______________________________________Paste 1 2 3 4 5 6______________________________________Silica xerogel 14.67 14.67 14.67 14.67 14.67 14.67Silica aerogel 9.43 9.43 9.43 9.43 9.43 9.43Sorbitol 46.98 46.98 46.98 46.98 46.98 46.98(70%)Polyethylene 5.24 5.24 5.24 5.24 5.24 5.24glycol(MW 1500)Xanthan gum 0.63 0.63 0.63 0.63 0.63 0.63Saccharin 0.24 0.24 0.24 0.24 0.24 0.24Sodium 0.34 0.34 0.34 0.34 0.34 0.34fluorideBenzoic acid 0.1965 0.1965 0.1965 0.1965 0.1965 0.1965Titanium 1.04 1.04 1.04 1.04 1.04 1.04dioxideSodium 1.5 1.5 1.5 1.5 1.5 1.5lauryl sul-phateStannous 1.0 1.0 1.0 1.0 1.0 1.0pyrophos-phateZinc citrate 0.5 0.5 0.5 0.5 0.5 0.5Flavour 1.0 1.0 1.0 1.0 1.0 1.0Special 0.05 -- -- -- -- --progallinPropyl -- 0.05 -- -- -- --gallateBHA -- -- 0.07 -- -- --Rosemary oil -- -- -- 1.00 -- --extractEthyl vanillin -- -- -- -- 1.00 --BHT -- -- -- -- -- 0.03Water 17.24 17.24 17.23 17.14 17.14 17.24Total 100.00 100.00 100.00 100.00 100.00 100.00______________________________________Results:Antioxidant Sn (II) Sn (IV) Area of Sn (IV)in Paste I.S. Q.S. I.S. Peak %______________________________________Progallin 2.95 2.13 -0.15 5(0.05%) 3.14 1.75Propyl 2.93 2.11 -0.18 6Gallate 3.17 1.81(0.05%)Butylated 2.94 2.10 -0.24 3Hydroxyanisole 3.14 1.77(0.07%)Rosemary Oil 2.95 2.09 -0.21 4Extract 3.14 1.77Ethyl Vanillin 2.94 2.09 -0.19 6(1%) 3.15 1.79Butylated 2.94 2.10 -0.22 4HydroxyToluene 3.15 1.78(0.03%)______________________________________
Again, these data showed that the antioxidants inhibited the oxidation of Sn(Il) to Sn(IV).
EXAMPLE 3
A series of nine toothpastes having the following formulations were stored for nine months at 37° C, and the amount of Sn (IV) was determined using Mossbauer spectroscopy. The amount of soluble Sn (II) was determined by polarographic analysis. Figures I and II show the results.
These results show, that the inclusion of antioxidants have a beneficial effect on the stability of Sn (II), even in the presence of an additional 0.5% citrate, of which it is known that it can exert a solubilizing effect on stannous ions in certain formulations.
__________________________________________________________________________Paste Control BT/CIT BT EV EV/CIT BA/CIT BA/BT/CIT BA BA/BT__________________________________________________________________________Silica xerogel 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00Silica aerogel 9.00 9.00 9.00 9.00 9.00 9.00 9.00 9.00 9.00Sorbitol (70%) 45.00 45.00 45.00 45.00 45.00 45.00 45.00 45.00 45.00Polyethyleneglycol 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00(MW 1,500)Xanthan gum 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20Titanium doxide 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00Saccharin 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13Sodium fluoride 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25Sodium laurylsulphate 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50Stannous pyrophosphate 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00Zinc citrate 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50Flavour 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00BHA -- -- -- -- -- 0.07 0.07 0.07 0.07BHT -- 0.03 0.03 -- -- -- 0.03 -- 0.03Ethyl vanillin -- -- -- 0.80 0.80 -- -- -- --Sodium citrate -- 0.325 -- -- 0.325 0.325 0.325 -- --Citric acid -- 0.175 -- -- 0.175 0.175 0.175 -- --Water 24.42 23.890 24.39 23.62 23.120 23.850 23.820 24.35 24.32__________________________________________________________________________
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The present invention relates to a dentifrice composition comprising a stannous compound that releases stannous ions in the composition such as stannous fluoride or stannous pyrophosphate. These stannous ions can be converted in the composition into the inactive stannic ions, and to prevent such conversion according to the present invention an antioxidant is incorporated into the composition, such as butylated hydroxyanisole, butylated hydroxytoluene and ethyl vanillin.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for initially inserting a strand of a textile material into a drafting device of a textile machine and, more particularly, a method and apparatus for aligning an initial strand inserting device and a strand guide of a drafting device in an alignment position at which a strand can be initially inserted into the strand guide.
In German Offenlegungsschrift No. 36 26 268, a device is disclosed for initially inserting a roving end into the yarn guide and the first pair of rollers of a drafting device of a textile machine. The roving end inserting device is operable to insert the roving through a side slot in the roving guide of the drafting device to thereby dispose the roving within the roving guide. The side slot extends along the entire extent of the roving guide to permit lateral insertion of the roving into the roving guide.
The roving guide of a drafting device is typically reciprocally moved along a path extending generally transverse to the direction of feed of roving through the rollers of the drafting device. This reciprocating movement tends to lessen the risk that the roving guide will wear excessively on one portion as the roving is guided therethrough since the reciprocating action of the roving guide continuously varies the portion of the inner surface of the roving guide over which the roving travels thereby spreading the wear on the inner surface of the roving guide more uniformly. However, the reciprocating movement of the roving guide complicates the process of initially inserting the roving end into the roving guide since the roving guide may be located at any one of a number of positions along its reciprocating travel path when the need arises to initially insert a strand therein. Moreover, the initial insertion process is further complicated if the roving guide is not provided with a side slot for introducing the roving into the roving guide. Accordingly, the need exists for a method and apparatus for insuring the reliable insertion of a strand into the strand guide of a drafting device.
SUMMARY OF THE INVENTION
Briefly described, the present invention provides an apparatus for a textile machine of the type having a supply of a strand of textile material, a device for drafting the strand of textile material, a reciprocable member, a strand guide mounted on the reciprocable member for guiding the strand from the strand supply to the drafting device, a device for reciprocating the reciprocable member transversely with respect to the strand during operation of the drafting device to effect reciprocating movement of the strand guide relative to the drafting device during the feed of the strand through the strand guide to the drafting device, and a device for initially inserting the strand into the strand guide. The apparatus includes a device for aligning the initial strand inserting device and the strand guide with respect to one another in an alignment position at which the strand is initially inserted into the strand guide.
According to one aspect of the present invention, the aligning apparatus includes a device for uncoupling the reciprocable member from the device for reciprocating the reciprocable members and a device for selectively securing the reciprocable member at a predetermined position in alignment for initial insertion of a strand in the strand guide by the initial strand inserting device.
According to another aspect of the present invention, the aligning apparatus includes a device for sensing the position of the strand guide and device, operatively connected to the sensing device, for moving the initial strand inserting device relative to the strand guide to align the initial strand inserting device and the strand guide with one another at the alignment position. According to a further aspect of the present invention, the aligning apparatus includes a device for sensing the position of the strand guide and a device, operatively connected to the sensing device, for moving the reciprocable member in response to the sensed position of the strand guide to position the strand guide at the alignment position. The aligning apparatus includes, in one aspect, a first component disposed on the initial strand inserting device and a second component disposed on the reciprocable member adjacent the strand guide, the first and second components cooperating together to form a passage for travel of the strand therethrough from the initial strand inserting device to the strand guide at the alignment position.
According to one aspect of the present invention, the aligning apparatus includes a first component disposed on the initial strand inserting device and a second component disposed on the reciprocable member adjacent the strand guide, the first and second components cooperating together to form a passage for travel of the strand therethrough from the initial strand inserting device to the strand guide at the alignment position. Additionally, the aligning apparatus includes a laterally projecting member mounted to the reciprocable member for movement therewith during the reciprocating movement, the projecting member being movable about the axis of reciprocation of the reciprocable member, and the uncoupling device includes a member formed in the device for reciprocating the reciprocable member for receiving the radially projecting member therein and a device for selectively moving the radially projecting member into and out of engagement with the receiving member. Moreover, the aligning apparatus includes a laterally projecting member mounted to the reciprocable member for movement therewith during the reciprocating movement, the projecting member being movable about the axis of reciprocation of the reciprocable member and the device for selectively securing the reciprocable member at a predetermined position includes a projection receiving member for receiving the radially projecting member therein when the reciprocable member is uncoupled from the device for reciprocating the reciprocable member and a device for selectively moving the radially projecting member into and out of engagement with the projection receiving member.
In one form of the present invention, the uncoupling device includes a receiving component formed in the device for reciprocating the reciprocable member for receiving the radially projecting member therein to effect coupling of the device for reciprocating the reciprocable member and the reciprocable member and the device for selectively moving the radially projecting member moves the radially projecting member alternately into engagement with one of the projection receiving members of the device for reciprocating the reciprocable member and the device for selectively securing the reciprocable member, and out of engagement with the other of the device for reciprocating the reciprocable member and the device for selectively securing the reciprocable member. Additionally, the aligning apparatus includes a device for sensing the positioning of the strand guide at the alignment location, the device for selectively moving the radially projecting member acting to move the radially projecting member in response to the sensing of the strand guide at the alignment location to uncouple the reciprocable member from the device for reciprocating the reciprocable member. The second component includes a pair of laterally projecting, axially spaced arms, each of the arms being axially displaced from the strand guide in a respective axial direction with respect to the reciprocable member, the initial strand inserting device includes a portion having a channel for feed of the strand therethrough and the first component of the initial strand inserting device is movable with respect to the channel portion and compatibly configured for receipt between the arms of the second component.
According to another aspect of the present invention, the second component includes a pair of laterally projecting, axially spaced arms, each of the arms being axially displaced from the strand guide in a respective axial direction with respect to the reciprocable member, the second device being axially movable with respect to the reciprocable device during receipt of the end portion in the arms and the initial strand inserting device includes an end portion for feed therethrough of the strand, the end portion being receivable between the arms.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of one embodiment of the aligning apparatus of the present invention;
FIG. 2 is a transverse vertical sectional view of a portion of the aligning apparatus shown in FIG. 1, taken along line II--II of FIG. 1;
FIG. 3 is a transverse vertical sectional view of a portion of the aligning apparatus shown in FIG. 1, taken along line III--III of FIG. 1;
FIG. 4 is a front elevational view of another embodiment of the aligning apparatus of the present invention;
FIG. 5 is an elevational view of a portion of an alternative embodiment of the aligning apparatus of the present invention;
FIG. 6 is a front elevational view of a modification of the aligning apparatus of the present invention; and
FIG. 7 is a front elevational view of a further modification of the aligning apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-3 illustrate one embodiment of the apparatus of the present invention for aligning a textile strand supply device and a strand guide of a drafting device of a textile machine for intial insertion of a strand into the strand guide. A textile machine such as, for example, a ring spinning machine, includes a drafting device for drafting roving or another strand of textile material therethrough. The ring spinning machine includes a plurality of strand guides 1 mounted to a reciprocable member such as, for example, a cylindrical shaft 2, extending transversely of the strand path and means for reciprocating the shaft 2. The cylindrical shaft 2 is movably mounted within the bearings 12 of a pair of mounting members 6', 6" spaced axially from one another along the shaft and supporting the shaft for reciprocating axial movement. The strand guides are identically configured and are positioned at spacings along the shaft in correspondence with the positions of the plurality of drafting devices along the machine.
The ring spinning machine additionally includes a conventional traveling service unit (not shown) having means for initially inserting a strand into a strand guide such as, for example, an insertion device 24. The insertion device 24 includes a clamping element 25 for clamping the strand of textile material 33 such as, for example, the end of a supply of roving, to insert the strand in one of the strand guides 1 of the ring spinning machine.
The means for reciprocating the shaft 2 includes a conventional drive motor (not shown) having a drive shaft 21 extending transversely with respect to the reciprocating shaft 2, as best seen in FIG. 2. A disk 18 is fixedly coaxially mounted to the free end of the drive shaft for rotation therewith. A cylindrical drive pin 16 is mounted at one end to the disk 18 at an offset from the axis of the drive shaft 21 for movement in a circular path upon rotation of the drive shaft. Each of the mounting members 6', 6" includes a downwardly opening horizontally extending guide channel extending parallel with the reciprocating shaft 2. A guide channel member 5 extends parallel with the reciprocating shaft 2 and has an upwardly opening guide channel vertically spaced from, and parallel with, the channels of the mounting members 6', 6". A generally rectangular drive plate 3 is disposed with vertically spaced horizontal edges disposed in the guide channels of the guide channel member 5 and the mounting member 6', 6" for guided sliding reciprocation. The drive plate 3 includes a vertically extending drive slot 15 for receiving the drive pin 16 therein to translate circular motion of the pin 16 into reciprocation of the drive plate 3.
As seen in FIGS. 2 and 3, a means for selectively coupling and uncoupling the shaft 2 and the drive plate 3 is provided. As seen in FIG. 2, the selective coupling and uncoupling means includes an arm 7 pivotally mounted on the shaft 2 and projecting radially therefrom, the arm 7 being constrained from movement along the axis of the shaft 2 by a pair of collars 8', 8" that are secured to the shaft 2 on each side of the arm 7. The collars 8', 8" are selectively fixedly adjustable along the shaft 2 to selectively adjust the axial position of the arm 7 with respect to the shaft 2. The drive plate 3 includes a drive plate notch 4 along its top edge for receiving the free end of the arm 7 therein so that the arm 7 can selectively interconnect the shaft 2 to the drive plate 3 for transmitting the reciprocating motion of the drive plate 3 to the shaft 2.
The aligning apparatus of the present invention additionally provides a means for selectively engaging and disengaging the arm 7 with the drive plate notch 4 on the drive plate 3. As seen in FIG. 1, the selective engagement and disengagement means includes a pair of counterweight arms 10', 10" each movably mounted to the shaft 2 at axially spaced positions thereon between the mounting members 6', 6". The selective engagement and disengaging means serves to move the arm 7 about the axis of the shaft 2 to move the free end of the arm into and out of engagement with the drive plate notch 4 and to move the free end of the arm into and out of engagement with a positioning notch member 9 located generally laterally opposite the shaft 2 from the drive plate 3. The positioning notch member 9 has a notch for receiving the free end of the arm 7.
In accordance with the present invention, means are provided for aligning the insertion device 24 and the strand guide 1 with respect to one another in an alignment position at which the strand is initially inserted into the strand guide.
Each counterweight arm 10', 10" includes a first portion extending laterally from the cylindrical shaft 2 and the first portions of the counterweight arms 10', 10" are interconnected by a cross shaft 11 extending therebetween and connected at one respective end thereof to each of the first portions. The counterweight arm 10' additionally includes a second portion projecting laterally from the cylindrical shaft 2 generally diametrically oppositely the first portion of the counterweight arm. As seen in FIG. 3, movement of the counterweight arms 10', 10" brings the cross shaft 11 into contact with the arm 7 to effect movement of the arm 7 about the shaft 2 from the solid line position to the broken line position shown in FIG. 3. The movement of the counterweight arms 10', 10" is driven by a conventional electromagnetic assembly including a stem 13 projecting therefrom. The free end of the stem 13 is pivotally mounted to the free end of the second portion of the counterweight arm 10'. The conventional electromagnetic assembly is of the type in which the counterweight 14 is magnetically active and configured to cooperate with a magnetically active bore for vertical movement within the bore in response to energization of the magnetic bore.
To control the operation of the aligning apparatus of the present invention, a conventional control device 23 is provided. The control device 23 is operatively connected to the electromagnetic assembly for selectively energizing and deenergizing the assembly to effect movement of the arm 7 about the shaft 2. Additionally, the control device 23 includes a conventional signal receiving means for receiving a signal from a conventional sensor 22 which is mounted to the shaft 2 at a predetermined axial position thereon. The sensor 22 moves in correspondence with the movement of the shaft 2 and emits a signal indicating when it is axially aligned with the signal receiving means of the control device 23.
The operation of the aligning apparatus of the present invention will now be described. The aligning apparatus is operable to initially insert a strand of textile material in the strand guide 1 following a break in the supply of the strand, the exhaustion of the strand supply or some other interruption in the feed of the strand through the strand guide 1. In normal operation, the strand of textile material is fed from a strand supply through the strand guide 1 for feed therethrough to the drafting device of the ring spinning machine while the cylindrical shaft 2 is driven in a reciprocal manner by the drive plate 3. The reciprocal movement of the shaft 2 insures that the strand traveling through the strand guide 1 travels over continuously varying portions of the inner bore of the strand guide such that the wear on the inner bore is advantageously spread over an arcuate extent thereof instead of occurring at a single location.
The reciprocal movement of the cylindrical shaft 2 is effected as follows. As the drive shaft 21 rotates, the drive pin 16 is rotated by the disk 18 around a circular path. The drive pin 16 imparts movement to the drive plate 3 as the pin travels around its circular path while being retained within the drive slot 15, thereby effecting reciprocating movement of the drive plate 3 within the guide channels of the mounting members 6', 6" and the longitudinal guide channel of the guide channel member 5.
The reciprocating movement of the drive plate 3 is transmitted to the cylindrical shaft 2 via the arm 7. Specifically, the free end of the arm 7, as shown in FIGS. 1 and 2, is received in the drive plate notch 4. Since the arm 7 is axially fixed relative to the cylindrical shaft 2 by the collars 8', 8", axial movement of the arm 7 by the drive plate 3 produces axially reciprocating movement of the cylindrical shaft 2 relative to the mounting members 6', 6". While the cylindrical shaft 2 moves relative to the counterweight arms during the axial movement of the shaft, the counterweight arms 10', 10" remain in position between the mounting members 6', 6".
When an interruption of the feed of the strand of textile material through the strand guide 1 occurs as a result of, for example, the exhaustion of the supply of the strand material or a break in the strand, the alignment apparatus of the present invention is operable to align the insertion device 24 and the strand guide 1 with respect to one another in an alignment position at which the strand is initially inserted into the strand guide. Specifically, the alignment apparatus operates to position the strand guide 1 in a predetermined axial position which is indicated by the axis 17. In conjunction with the positioning of the strand guide 1 at the axis 17, the movable service unit is controlled to effect positioning of the insertion device 24 at the axis 17 for inserting the strand 33 in the strand guide 1 when the strand guide 1 is also aligned with the axis 17.
The alignment of the strand guide 1 at the axis 17 is accomplished through the transmission of a signal from the sensor 22 to the control unit 23 upon alignment of the sensor 22 with the control unit 23. As can be understood, the sensor 22 is axially positioned on the shaft 2 relative to the strand guide 1 such that the sensor 22 is aligned with the control unit 23 when the strand guide 1 is positioned at the axis 17. Moreover, the notch of the positioning notch member 9 is axially located with respect to the shaft 2 such that, when the arm 7 is received in the notch, the strand guide 1 is positioned at the axis 17. Upon receipt of the signal from the sensor 22, the control unit 23 operates the electromagnetic assembly to cause the counterweight 14 to drop. The downward movement of the counterweight 14 effects pivoting of the counterweight arms 10', 10" about the cylindrical shaft 2. In turn, the pivoting of the counterweight arms 10', 10" effects counterclockwise movement (as viewed in FIG. 3) of the cross shaft 11 about the cylindrical shaft 2. As the cross shaft 11 rotates counterclockwise, it moves the arm 7 from the solid line position shown in FIG. 3 to the broken line position shown in FIG. 3. In the broken line position shown in FIG. 3, the arm 7 is received in the positioning notch 9 and the force of gravity acting on the counterweight 14 serves to continually urge the arm 7 into the positioning notch 9.
Accordingly, the movement of the arm 7 from the position in which is it is received in the drive plate notch 4 to the position in which it is received in the positioning notch 9 simultaneously acts to uncouple the cylindrical shaft 2 from the reciprocating movement of the drive plate 3 and to fixedly secure the cylindrical shaft 2 at the axial position in which the strand guide 1 is aligned with the axis 17.
When the strand guide 1 is aligned with the axis 17, the insertion device 24 of the movable service unit is operated to effect insertion of the strand 33 into the strand guide 1. Since the strand guide 1 is always positioned at the axis 17 when a strand is to be inserted in the strand guide, the movable service unit can be programmed to repetitively position the strand 33 at a ready position adjacent the axis 17 for insertion of the strand into the strand guide 1, thereby resulting in an efficient strand inserting operation. Once the strand 33 is inserted into the strand guide 1, the end of the strand can be engaged in conventional manner by the first pair of rollers of the drafting device.
Once the insertion of the strand 33 has been accomplished, the control unit 23 operates the electromagnetic assembly to effect upward movement of the counterweight 14. The upward movement of the counterweight 14 effects movement of the cross shaft 11 in a clockwise direction (as viewed in FIG. 3) and the arm 7 falls under its own weight from the broken line position in which it is received in the positioning notch 9 to the solid line position in which it is received in the drive plate notch 4. If the drive plate notch 4 is not aligned with the arm 7, the arm 7 rests on the top of the driven plate 3 until the driven plate notch 4 again comes into alignment with the arm 7.
In FIG. 4, another embodiment of the alignment apparatus of the present invention is illustrated. A reciprocal member such as, for example, a shaft 2 is reciprocated in conventional manner by reciprocating means (not shown) to effect reciprocating movement of a strand guide 1 mounted on the shaft. The strand guide 1 guides the feed of a strand of textile material 33 from a supply of the strand material to the first pair of rollers 26 of a drafting device of a textile machine. A sensor 32 is fixedly secured to the shaft 2. The sensor 32 can be, for example, a tachoalternator or an incremental transmitter, and is operable to transmit a signal to a control unit 31. A conventional movable service unit (not shown) includes an initial strand inserting means 24 having a strand clamping device 25 for clamping the strand 33. The strand clamping device 25 includes a housing having an inner threaded bore. A threaded drive member 27 has a plurality of external threads configured to threadably engage the threaded inner bore of the strand clamping device 25. A gear 28 is mounted adjacent one end of the drive member 27. A drive motor 30, which can be, for example, a conventional electric motor, includes a drive shaft having a gear 29 fixedly mounted to the end thereof. The gears 28, 29 are meshingly engaged with one another for transmitting driving rotation therebetween. The drive motor 30 is operatively connected to the control unit 31. The strand guide 1 includes an opening 1' defined between a pair of oppositely tapering arms.
In operation, the alignment apparatus illustrated in FIG. 4 is operable to insert the end of the strand 33 into the opening 1' of the strand guide 1. The sensor 32 and the control unit 31 are configured such that the control unit 31 receives a signal from the sensor 32 when the strand guide 1 is positioned in a predetermined position. Upon receipt by the control unit 31 of the signal from the sensor 32, the reciprocal movement of the shaft 2 is ceased. The control unit 31 then controls the operation of the motor 1 to effect rotation of the gears 28, 29 and, thus, rotation of the drive member 27. The rotation of the external threads of the drive member 27 relative to the inner threaded bore of the strand clamping device 25 causes axial movement of the initial strand inserting means 24 relative to the strand guide 1. The control unit 31 controls the operation of the motor 30 to effect centering of the strand clamping device 25 with respect to the opening 1' of the strand guide 1. Once the strand 33 is aligned with the opening 1', the strand is fed through the opening 1 to the first pair of rollers 26 for feeding to the drafting device.
In FIG. 5, another embodiment of the alignment apparatus of the present invention is illustrated. A reciprocal member such as, for example, a shaft 2, is coupled to a means (not shown) for reciprocating the shaft 2 during operation of a drafting device to effect reciprocating movement of a strand guide (not shown) secured to the shaft 2. The shaft 2 includes a positioning projection extending laterally therefrom. A member 35 is fixedly secured to the shaft 2 and extends radially therefrom. The member 35 is provided with an inner threaded bore. A cylindrical drive member 34 has a plurality of external threads compatibly configured for threading engagement with the inner threaded bore of the member 35. A gear 36 is fixedly mounted to one end of the cylindrical drive member 34. A drive motor 38 which can be, for example, a conventional electric motor, includes a shaft having a gear 37 fixedly mounted at the end thereof. The gears 36, 37 are configured for meshing engagement with one another and the gear 37 is selectively movable by a conventional means (not shown) for movement of the gear into and out of meshing engagement with the gear 36.
A target sensor 41 is operatively connected to a control unit 39. A left-hand sensor 40' and a right-hand sensor 40" are operatively connected to the control unit 39. The target sensor 41, the left-hand sensor 40', and the right-hand sensor 40" are each configured to transmit a signal to the control unit 39 in response to the positioning of the positioning projection on the cylindrical shaft 2 in alignment with the respective sensor. The sensors are each positioned at a different axial position with respect to the shaft 2.
The control unit 39 includes a reversing switch 42 operatively connected to the left-hand sensor 40' and the right-hand sensor 40". The reversing switch 42 is operatively connected to the connector extending between the motor 38 and its power source and is operable to control rotation of the drive shaft of the motor 38 in opposite directions in response to signals received from the left-hand sensor 40' and/or the right-hand sensor 40".
In operation, the alignment apparatus illustrated in FIG. 5 is operable to align the strand guide on the shaft 2 in a predetermined position for insertion therein of a strand. To effect insertion of a strand into the strand guide, the shaft 2 is uncoupled from the reciprocal movement means. The gear 37 is moved into meshing engagement with the gear 36. The control unit 39 then controls the operation of the motor 38 in response to the position of the sensing projection on the shaft 2 as sensed by the left-hand sensor 40', the target sensor 41 and/or the right-hand sensor 40". Specifically, if the positioning projection of the shaft 2 is aligned with the left-hand sensor 40', the left-hand sensor 40' signals the control unit 39 to control the motor 38 to effect rotation of the gear 37 such that the shaft 2 is axially moved in the axial direction from the left-hand sensor 40' to the target sensor 41. The rotation of the gear 37 effects rotation of the drive member 34 within the inner threaded bore of the member 35, thereby effecting movement of the member 35 relative to the drive member 34. Once the positioning projection on the shaft 2 is aligned with the target sensor 41, the target sensor 41 signals the control unit 39 to stop the operation of the motor 38 and the insertion of the strand into the strand guide by the initial strand inserting means is then performed.
Similarly, if the positioning projection of the shaft 2 is axially aligned with the right-hand sensor 40" when the aligning operating begins, the right-hand sensor 40" signals the control unit 39 to control the operation of the motor 38. The control unit 39 controls the reversing switch 42 to effect appropriate rotation of the drive shaft of the motor 38 such that the shaft 2 is moved in an axial direction from the right-hand sensor 40" toward the target sensor 41. Once the positioning projection on the shaft 2 is aligned with the target sensor 41, the strand insertion operation is performed. Upon completion of the strand insertion operation, the shaft 2 is again coupled to the reciprocal driving means for normal operation.
In FIG. 6, another embodiment of the alignment apparatus of the present invention is illustrated. A reciprocable member such as, for example, a shaft 2 is operatively coupled to a means (not shown) for reciprocating the shaft during operation of a drafting device to effect reciprocating movement of a strand guide 1 relative to the drafting device during the feed of a strand through the strand guide 1 to the drafting device. A means 24 for initially inserting the strand into the strand guide is operatively connected to a movable service unit (not shown) and is operable to insert a strand from a supply of a strand of textile material into the yarn guide 1. The initial strand inserting means 24 includes a main portion having a channel for the feed therethrough of the strand and a strand clamping device 25 pivotally mounted at a pivot 43 to the main portion. The strand clamping device 25 includes a coupling guide member 44 having a central channel for the passage of the strand 33 therethrough. The strand guide 1 includes a coupling receptacle 45 defined by a pair of arms projecting radially in the same direction from the shaft 2. The arms of the strand guide 1 define an opening 1' therebetween and the axial spacing between the free ends of the arms is greater than the side to side extent of the coupling guide member 44 of the strand clamping device 25.
In operation, the initial strand inserting means 24 and the strand guide 1 cooperate with one another to effect insertion of the strand 23 into the strand guide 1 during movement of the shaft 2 in its normal reciprocating operation or when the shaft 2 is stationary. To insert a strand, the initial strand inserting means 24 is moved in a radial direction with respect to the shaft 2 toward the shaft 2 while the initial strand inserting means 24 is axially aligned with the strand guide 1. The coupling guide member 44 of the strand clamping device 25 is eventually received between the free ends of the arms of the strand guide 1 as the inserting means 24 approaches the shaft 2. Once the coupling guide member 44 is inserted into the coupling receptacle 45 of the strand guide 1, the strand 33 is fed through the channel of the coupling guide member 44 and through the opening 1' of the strand guide 1 to the first pair of rollers 26 of the drafting device. As can be understood, the strand clamping device 25 pivots about the pivot 43 to accommodate relatively limited axial misalignment between the housing of the initial strand inserting means 24 and the strand guide 1.
In FIG. 7, a further embodiment of the alignment apparatus of the present invention is illustrated. A reciprocable member such as, for example, a shaft 2 has a plurality of strand guides 1 for guiding strands to a drafting device. A means (not shown) is provided for reciprocating the shaft 2 during operation of the drafting device to effect reciprocating movement of the strand guides 1 relative to the drafting device. Each strand guide 1 includes a pair of arms projecting radially in the same direction from the shaft 2, each pair of arms defining therebetween a coupling receptacle 45. Additionally, each strand guide 1 includes an opening 1' opening centrally into the coupling receptacle 45 of the strand guide. Each strand guide 1 is movably mounted to the shaft 2 for relative axial movement therewith. A spring 46' extends between the shaft 2 and one side of the strand guide 1. A spring 46" extends between the shaft 2 and a side of the strand guide 1 generally axially opposite to the side against which the spring 46' contacts. Accordingly, each stand guide 1 is maintained in an axial equilibrium position with respect to the shaft 2 due to the oppositely directed urgings of the springs 46', 46".
An initial strand inserting means 24 for initially feeding a strand 33 into the strand guides 1 includes a strand clamping device 25 having a central channel for clamping the strand 33. The strand clamping device 25 is centrally mounted in a coupling end portion 44 of the housing of the initial strand inserting means 24. The side to side extent of the coupling end portion 44 is less than the axial spacing between the free ends of the arms of the strand guide 1.
In operation, the initial strand inserting means 24 is moved in a radial direction with respect to the shaft 2 toward one of the strand guides 1 while the initial strand inserting means 24 is generally axially aligned with the strand guide 1. The coupling end portion 44 is eventually received between the arms of the strand guide in the coupling receptacle 45 as the inserting means 24 approaches the shaft 2. Once the coupling end portion 44 is received in the coupling receptacle 45, the strand 33 is fed through the strand clamping device 25 into the opening 1' of the strand guide 1 to the first pair of rollers 26 of the drafting device. If the central channel of the strand clamping device 25 is not axially aligned with the opening 1' of the strand guide 1 when the coupling end portion 44 is initially received in the coupling receptacle 45, the strand guide 1 moves axially relative to the shaft 2 to effect alignment of the opening 1' with the strand clamping device 25. During this relative axial movement of the strand guide 1, one of the springs 46', 46" contracts while the other of the springs expands to accommodate the axial movement of the strand guide 1. Once the initial strand inserting means 24 has been withdrawn from engagement with the strand guide 1, the springs 46' , 46" return the strand guide 1 to its axial equilibrium position relative to the shaft 2.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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An apparatus for aligning a textile strand supple device and a strand guide of a drafting device of a textile machine is provided for initially inserting a textile strand into the strand guide. The strand guide of the drafting device is typically reciprocally moved transversely to the direction of feed of the textile strand and the aligning apparatus of the present invention includes a device for securing the strand guide at a predetermined position along its reciprocating path at which a conventional movable service unit can be positioned for initially inserting a textile strand into the strand guide. According to another aspect of the present invention, the aligning apparatus includes a motor assembly for adjustably moving the textile strand supply device in response to the sensed position of the strand guide of the drafting device. According to another aspect of the present invention, the aligning apparatus includes a device for resiliently adjusting the strand guide of the drafting device in response to the position of the textile strand supply device.
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This application is a continuation of application Ser. No. 07/318,756, filed Mar. 3, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an aromatic polyisocyanate and a production process thereof. The polyisocyanate of the present invention is a polyisocyanate having a novel structure and used as raw materials for polyurethane resins and polyurea resins in a wide variety of fields such as foams, elastomers, synthetic leathers, adhesives and films.
2. Description of the Related Art
Among the aromatic polyisocyanates known in the art, polyphenylmethane-polyisocyanate (hereinafter referred to as P-MDI) represented by the following general formula: ##STR2## is widely-known and has been finding versatile uses as raw materials for polyurethane resins and polyurea resins.
SUMMARY OF THE INVENTION
The first object of the present invention is to provide a novel aromatic polyisocyanate which is entirely different in structure from P-MDI and expected to have new uses as raw materials for polyurethane resins and polyurea resins.
The second object of the present invention is to provide a novel production process of the above polyisocyanate.
In order to attain the above objects, the inventors have made intensive investigations, and finally found that the objects of the present invention can be attained by reacting an aromatic amine resin having a specific structure or a salt thereof with phosgene. The present invention has been completed on the basis of this finding.
Specifically, the novel polyisocyanate of the present invention is a polyisocyanate comprising a mixture of aromatic polyisocyanates represented by the general formula: ##STR3## wherein A represents a phenylene group, alkylene group, alkyl-substituted phenylene group, diphenylene group, diphenyl ether group, or naphthylenyl group, R 1 is a halogen atom, lower alkoxy group with a carbon number of 4 or less or lower alkyl group with a carbon number of 5 or less, R 1 s may be the same or different from each other and may form a ring, l means 1 or 2, m is an integer of 0-3, and n is an integer of 0-300.
Further, the novel production process of the present invention is a production process of a polyisocyanate comprising a mixture of aromatic polyisocyanates represented by the general formula (a), which process comprises reacting an aromatic amine resin comprising a mixture of aromatic amine compounds represented by the general formula: ##STR4## wherein A, R 1 , l, m and n have in the general formula (a), or a salt thereof, with phosgene.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the IR spectrum of polyparaxylylene-polyphenyl-polyisocyanate obtained in Example 1. FIG. 2 is the IR spectrum of paraxylylenediphenyl isocycanate obtained in Example 2.
DETAILED DESCRIPTION OF THE INVENTION
The aromatic amine resins represented by the general formula (b) are entirely novel compounds which have been developed recently, and their properties and production processes are described in detail in Japanese patent application Ser. Nos. 252517/1987 and 282048/1987 (see U.S. Pat. No. 4,937,318 at column 3, lines 8-43, and the disclosure therein extending from column 4, line 57 to column 10, line 21).
The aromatic polyisocyanate of the present invention is prepared by reacting the aromatic amine resin represented by the foregoing general formula (b) directly with phosgene or by synthesizing a salt of the aromatic amine resin such as its hydrochloride in advance and suspending the salt in an inert solvent so that it is reacted with phosgene.
The former process is called "cold-hot two stage phosgenation", and the embodiment of the reaction suffers from no particular restriction. In general, however, gaseous phosgene is introduced into an inert solvent in a reactor, in which the reaction system can fully be stirred and which is provided with a phosgene gas inlet, while cooling the reaction system at a temperature of 0°-5° C. Thus, the phosgene is dissolved in the inert solvent almost to the saturated solubility of phosgene to the solvent. Then, a solution formed separately by dissolving the above-described amine resin in the inert solvent is added thereto while introducing gaseous phosgene in an amount 1 to 2 times as much as its stoichiometric quantity. In the mean time, the temperature of the reaction liquid is maintained at not higher than 15° C., and the hydrogen chloride thus-evolved and excess phosgene are purged out through a reflux condenser to the outside of the system. The contents in the reactor form a slurry. The main reaction is the formation of carbamyl chloride and amine hydrochlorides. After the addition of the amine solution, the reaction is continued for 30 minutes to 2 hours. The above-described procedure is referred to as cold phosgenation.
Then, the reaction system is heated to a temperature of 130° C. to 160° C. for 30 minutes to 3 hours. Upon raising temperature, the phosgene dissolved in the solvent is liable to vaporize and foam, so that it is preferable to reduce the feed rate of phosgene to the order of its theoretical quantity, as opposed to the case of cold phosgenation. After the temperature has been raised, the reaction is continued for 1 to 3 hours. When the slurry is entirely dissolved, the reaction is assumed to be complete. The above procedure is called hot phosgenation. The principal reactions of the hot phosgenation are the decomposition of carbamyl chloride to isocyanate and the phosgenation of amine hydrochlorides into isocyanates.
After completion of the hot phosgenation, the reaction system is heated to a temperature of 150°-180° C. and gaseous nitrogen is blown into the reaction system at an appropriate rate, (i.g., not lower than 200 ml/min.; this value varies depending on the reaction scale) to remove dissolved gaseous components and decompose sufficiently unreacted carbamyl chloride. Then, following cooling, the inert solvent is removed under reduced pressure by distillation to obtain an aromatic polyisocyanate.
The latter process is referred to as "phosgenation of amine hydrochloride". The hydrochloride of the above-described aromatic amine resin is synthesized in advance. The synthesis of the hydrochloride is effected with ease by the well-known method of treating an aromatic amine resin with hydrogen chloride or conc. hydrochloric acid. The thus-formed aromatic amine hydrochloride, which has been fully dried and pulverized, is dispersed in an inert solvent in a reactor equipped similarly to that used in the "cold-hot two stage phosgenation" process as described above. The reaction system is maintained at a temperature of 80°-160° C., to which system gaseous phosgene is admitted for 3 to 10 hours so that the total phosgene introduction may amount to 2 to 10 times as much as its stoichiometric quantity, thus synthesizing an isocyanate. The progress of the reaction may be inferred by the amount of gaseous hydrogen chloride evolved, the dissipation of the aromatic amine hydrochloride used as the raw material and insoluble in the inert solvent, and the transparency and homogeneity of the reaction liquid. The hydrogen chloride evolved and excess phosgene are discharged through a reflux condenser to the outside of the reaction system. After the reaction has been completed, gaseous nitrogen is introduced into the reaction solvent to remove dissolved phosgene, and subsequent to cooling and filtration, the inert solvent is distilled out under reduced pressure to obtain an aromatic polyisocyanate.
It is sufficient to introduce phosgene in an amount 2 to 10 times as much as its stoichiometric quantity for the both processes of "cold-hot two stage phosgenation" and "phosgenation of amine hydrochloride". As the inert solvent may be mentioned aromatic hydrocarbons, fatty acid esters and chlorinated aromatic hydrocarbons. Of these, orthodichlorobenzene is preferred.
The present invention will be illustrated by reference to the following examples. These examples are intended to illustrate the invention and are not to be construed to limit the scope of the invention. In the examples, description will be made particularly with regard to polyparaxylylene-polyphenyl-polyisocyanate of the following formula (c): ##STR5## which is the compound of the general formula (a) wherein A is a p-phenylene group, m is 0, and l is 1.
EXAMPLE 1
Polyparaxylylene-polyaniline represented by the following formula: ##STR6## was used as a raw material for phosgenation. The molecular weight distribution of the polyaniline resin used as the raw material was determined with a high speed liquid chromatography using GPC column. The determination revealed that the distribution was 76.3 wt. % for the compound of the general formula (b') wherein n=0, 18.7 wt. % for the compound wherein n=1, 4.3 wt. % for the compound wherein n=2 and 0.7 wt. % for the compounds wherein n=3 or more. The mean molecular weight was about 350, while the amine equivalent of the resin was 0.653 eq/100 g according to the perchloric acid-glacial acetic acid method.
Into a 2-l reaction flask equipped with a stirrer, thermometor, phosgene inlet, cooling tube and dropping funnel, 682 g of orthodichlorobenzene (ODCB) were charged. The reaction flask was placed in a ice-water bath under stirring so that the inner temperature of the flask was kept at 1°-2° C. Then, gaseous phosgene was introduced therein at a rate of 100 g/hour for 2 hours. Subsequently, a solution of 100 g of the abovedescribed polyaniline resin in 704 g of orthodichlorobenzene was added dropwise over 45 minutes. Gaseous phosgene was also introduced therein at a rate of 100 g/ hour during the dropping. The temperature was 2°-8° C. at this moment. Then, with gaseous phosgene introducing at a rate of 100 g/hour, cold phosgenation was carried out at 4°-5° C. for 30 minutes. The cold phosgenation produced a yellowish-green slurry in the reaction flask due to the formation of carbamyl chloride and amine hydrochlorides. The reaction flask was heated with a mantle heater to raise the temperature to 140° C. over about 45 minutes. During the rise in temperature, gaseous phosgene was charged at a rate of 100 g/hour. In the course of raising temperature, the slurry was completely dissolved in orthodichlorobenzene with violent evolution of gaseous hydrogen chloride. Then, hot phosgenation was conducted at 140° C. for 75 minutes while introducing gaseous phosgene at a rate of 100 g/hour. A total of 525 g of gaseous phosgene was introduced by the cold-hot two state phosgenation. This amount was equivalent to 8.1 times as much as the theoretical value. Then, the reaction liquid was raised in temperature to 160° C., following which gaseous nitrogen was admitted thereto at a rate of 500 ml/min. for 2 hours to remove dissolved gaseous components and decompose fully unreacted carbamyl chloride. After cooling, a bit of undissolved matters by filtration and then orthodichlorobenzene by distillation under reduced pressure (about 1 mm Hg abs.) were removed from the reaction liquid. Thus, 119.8 g of polyparaxylylene-polyphenyl-polyisocyanate were obtained. Its analysis revealed that it had an NCO% of 23.5% by weight (theoretical value: 23.5% by weight), a hydrolyzable chlorine content of 0.28% by weight, an acid content of 0.063% by weight and a residual ODCB content of 47 ppm by weight.
The IR spectrum of the aromatic polyisocyanate is given in FIG. 1.
EXAMPLE 2
By the procedure of vacuum distillation, 30 g of the aromatic polyisocyanate obtained in Example 1 was purified. About 20 g of a yellowish transparent liquid were obtained under the conditions of boiling points of 210°-220° C./0.2 mmHg abs. and oil-bath temperatures for the distillation flask of 220°-240° C. The liquid product was rapidly solidified into a crystal with a melting point of 45°-48° C. As a result of the analyses described below, the liquid product was found to be paraxylylenediphenyl isocyanate, which is the compound represented by the formula (c) wherein n=0, the formula (c) representing the aromatic polyisocyanate obtained in Example 1.
______________________________________Elemental analysis (C.sub.22 H.sub.16 N.sub.2 O.sub.2): C H N______________________________________Calculated (%) 77.63 4.74 8.23Found (%) 77.86 4.35 8.25NCO % by weight: Found 24.65% (Calculated 24.69%)IR spectrum: shown in FIG. 2H-NMR (CDCl.sub.3, TMS) ppmδ 3.92 (4H --CH.sub.2 -- × 2) 7.10 (12H Ph--H.sub.4 × 3)______________________________________
EXAMPLE 3
Phosgenation was carried out in the same manner as in Example 1 by using polyparaxylylene-polyaniline represented by the formula (b') as a raw material. The molecular weight distribution of the polyaniline resin used as the raw material was determined according to the same analytical procedure as in Example 1. The determination revealed that the distribution was 56.5 wt. % for the compound of the formula (b') wherein n=0, 26.5 wt. % for the compound wherein n=1, 10.1 wt. % for the compound wherein n=2, 5.6 wt. % for the compound wherein n=3, and 1.3 wt. % for the compounds wherein n=>4. The mean molecular weight was about 423, while the amine equivalent of the resin was 0.633 eq/100 g according to the perchloric acid-glacial acetic acid method.
In 704 g of orthodichlorobenzene were dissolved 100 g of the polyaniline resin, following which phosgenation was conducted in the same manner as in Example 1. A total of 400 g of gaseous phosgene was introduced in the cold-hot two stage phosgenation. This amount corresponded to 6.4 times that of the theoretical value. Subsequently, dissolved gaseous components were removed from the reaction liquid, and carbamyl chloride was decomposed substantially. Following cooling and filtration, orthodichlorobenzene was removed under reduced pressure by distillation, thereby obtaining 103.5 g of polyparaxylylene-polyphenyl-polyisocyanate. Its analysis clarified that it had an NCO% of 23.1% by weight, a hydrolyzable chlorine content of 0.41% by weight and an acid content of 0.10% by weight.
The aromatic polyisocyanates obtained in accordance with the process of the present invention are entirely novel compounds which have never been known in the art and hence are anticipated to have novel uses as raw materials for polyurethane resins and polyurea resins. Further, from the aromatic polyisocyanates and by the procedure of high-vacuum distillation, etc., there are obtained relatively low molecular aromatic polyisocyanates, namely, the compounds of the general formula (a) wherein A is a p-phenylene group, m is 0, l is 1, and n is 0 (i.e., aromatic diisocyanates). These are also absolutely novel compounds and expected to have new uses.
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Disclosed herein are a polyiscoyanate comprising a mixture of aromatic polyisocyanates represented by the general formula: ##STR1## wherein A is a phenylene group, alkylene group, alkyl-substituted phenylene group, diphenylene group, diphenyl ether group or naphthylenyl group, R 1 is a halogen atom, lower alkoxy group with a carbon number of 4 or less or lower alkyl group with a carbon number of 5 or less, R 1 s may be the same or different from each other and may form a ring, l is 1 or 2, m is an integer of 0-3, and n is a integer of 0-300, and a production process thereof.
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TECHNICAL FIELD
[0001] The present invention relates to a circuit substrate and a display device. More specifically, the present invention relates to a circuit substrate and a display device that can be suitably used as components of a display device having a dual-gate structure, for example.
BACKGROUND ART
[0002] Circuit substrates, particularly active matrix substrates, are widely used in active matrix display devices such as EL (electroluminescence) display devices. Circuit substrates used in conventional liquid crystal display devices had TFT (thin film transistor) elements at respective intersections of a plurality of scan signal lines disposed so as to intersect with a plurality of data signal lines. Image signals are sent as appropriate to respective pixels (electrodes) that are connected to TFT elements due to the switching function of the TFT elements. Furthermore, there are circuit substrates having storage capacitance elements for respective pixels in order to prevent degradation of image signals due to electric discharge or OFF current of the TFT elements while the TFT elements are OFF, and also to use as a path or the like for applying various modulated signals during liquid crystal driving.
[0003] Below is an example of a conventional structure of a circuit substrate. Disclosed is a display device provided with an island shaped gate disconnection repairing conductive layer used for repairing disconnections, which includes: a plurality of gate wiring lines provided on a substrate; a first insulating layer provided on the gate wiring lines; a plurality of source wiring lines disposed so as to intersect with the gate wiring lines with the first insulating layer therebetween; an island shaped gate disconnection repairing conductive layer used to repair disconnections in the gate wiring lines disposed over the gate wiring lines with the first insulating layer therebetween; switching elements provided at the intersections of the gate wiring lines and the source wiring lines; a second insulating layer provided over the source wiring lines, the gate disconnection repairing conductive layer, and the switching elements; a contact hole provided in a portion of the second insulating layer; and pixel electrodes connected to the switching elements through the contact holes (see Patent Document 1, for example).
[0004] As a thin film transistor array by which it is possible to repair disconnections in a similar manner, a thin film transistor is disclosed, including: a plurality of scan signal lines formed of a first conductive film on a transparent insulating substrate; a plurality of signal lines formed of a second conductive film; pixel electrodes formed on a gate insulating film in an area surrounded by adjacent scan signal lines and adjacent signal lines; thin film transistors connected to the pixel electrodes; and a light-shielding film that is formed of the first conductive film and that forms a light-shielding overlapping portion through surrounding portions of the respective pixel electrodes and the gate insulating film, the surrounding portion facing the signal lines, wherein the light-shielding film has a prescribed area located near both edges thereof along the signal line, the area protruding towards so as to form an overlapping portion for repairing through the signal lines and the gate insulating film (see Patent Document 2, for example).
[0005] Furthermore, liquid crystal display devices that can electrically connect disconnected wiring lines or that can improve the yield of the connection is improved by electrically connecting the disconnected wiring lines and making the connection of the circuits and the panel terminal electrodes easy (see Patent Documents 3 to 5, for example.)
RELATED ART DOCUMENTS
Patent Documents
[0000]
Patent Document 1: Japanese Patent Application Laid-Open Publication No. 2004-054069
Patent Document 2: Japanese Patent Application Laid-Open Publication No. 2000-250436
Patent Document 3: Japanese Patent Application Laid-Open Publication No. H2-157828
Patent Document 4: Japanese Patent Application Laid-Open Publication No. H9-113930
Patent Document 5: Japanese Patent Application Laid-Open Publication No. H5-265045
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0011] Patent Document 1 discloses that disconnection can be repaired by disposing a repair wiring line (disconnection repairing conductive layer) on a scan signal line with an insulating layer therebetween. Patent Document 1 discloses a configuration in which a repair wiring line can be disposed anywhere on a scan signal line (gate wiring line, gate), source wiring line (source), and an auxiliary capacitance (Cs) and perform repair.
[0012] However, because in the invention disclosed in Patent Document 1, a repair wiring line is disposed over a scan signal line, even if repair is not performed, the capacitance of the scan signal line increases, the signal rounding increases, and power consumption increases. Therefore, there was room for improvement in terms of the difficulty in appropriately driving small display devices that require low power consumption, large display devices that have a low charging rate for each pixel, in devices with high resolution, or the like.
[0013] Furthermore, the pixels that are repaired have greater capacitance between adjacent scan signal lines and pixel electrodes, and thus a difference emerges in parasitic capacitance between normal pixels where repair has not been performed and pixels where repair has been performed. There is also a disadvantage that if the capacitance between the scan signal lines and the pixel electrodes becomes larger, a variation in stored potential occurs, causing a variation in luminance during halftone display leading to a decrease in display quality.
[0014] In other words, the capacitance increases, rounding takes place, and power consumption increases for pixels such as those shown in FIG. 1 of Patent Document 1 even before repair takes place. Furthermore, in the structure (repaired portion) such as those shown in FIG. 2 of Patent Document 1, the pixel capacitance also changes and a decrease in display quality occurs.
[0015] In this manner, in a conventional circuit substrate, if a scan signal line is repaired using a repair wiring line when disconnection occurs, then the subpixel where the repair took place becomes easier to perceive than the rest of the display during halftone display. Furthermore, as the capacitance increases even without repair, the signal rounding becomes greater, causing insufficient charging of each pixel (decrease in voltage applied to liquid crystal), and unevenness in halftone display becomes easier to perceive, especially in low temperature. Furthermore, as the rounding becomes greater, varied color tones can be perceived in both edges of large/high resolution devices.
[0016] Furthermore, as repair wiring lines are disposed on a gate insulating film, at the portions of the pixels in which repair was performed, the scan signal line and the repair wiring line in which the same signal is inputted comes closer to the pixel electrode. Therefore, the capacitance between the scan signal line and the pixel electrode increases. Thus, during halftone display, a change in luminance can be seen at the pixel electrode at the repaired portion caused by a load (capacitance) due to difference in potential during writing. Furthermore, even if the capacitances of the respective scan signal lines are compared, only the scan signal line in which repair was performed has a different capacitance from others, and thus a change in luminance can easily take place for one line due to signal rounding.
[0017] Furthermore, there is a risk that the display quality decreases in a non-transmissive region of the display region where wiring lines are not disposed, because pin holes are being formed in the light-shielding film such as an active matrix due to defects. The patent document mentioned above has room for improvement in suppressing signal rounding resulting from capacitance increase and in decreasing pin holes.
[0018] The present invention takes into consideration the above-mentioned situation, and an object thereof is to provide a circuit substrate and a display device having a patterned film that can sufficiently reduce the capacitance increase, sufficiently suppress a decrease in display quality due to signal rounding, and sufficiently block light at a portion where a light-shielding member is damaged.
Means for Solving the Problems
[0019] The inventor of the present invention conducted research on a circuit substrate and a display device in which a capacitance increase is reduced, a decrease in display quality due to signal rounding is sufficiently suppressed, and an occurrence of a transparent portion due to a damage of the light-shielding member is reduced, and focused on providing a patterned film between two wiring lines in a circuit substrate having two wiring lines between pixels. The inventor of the present invention found that by providing a patterned film between two wiring lines disposed between pixels, the decrease in aperture ratio is sufficiently suppressed, the increase in capacitance is sufficiently reduced, and the occurrence of the transparent portion due to the damage of the light-shielding member is sufficiently reduced. It was found that the pixel defects can be suitably repaired.
[0020] Furthermore, as disclosed in the respective patent documents above, if a repair wiring line is used as a countermeasure to disconnections of scan signal lines, if the repair wiring lines are disposed on the scan signal lines with an insulating layer therebetween, then the capacitance increases, and signal rounding can easily occur. On the other hand, if the repair wiring line is disposed so as to not overlap the scan signal line to not increase the capacitance, then the aperture ratio decreases. In this situation, the inventor of the present invention found that a display device that has excellent quality after repair can be formed by providing a plurality of projections on at least one side of the patterned film, the plurality of projections having overlapping portions with the first wiring line, and at least one of the overlapping portions has a wiring line structure in which an insulating film is between the overlapping portion and the first wiring line. This way, the projections can function as a repair wiring line and significantly reduce the capacitance change in the pixel electrode of the repaired portion. Furthermore, it was found that a similar effect can be achieved by providing a plurality of projections in the first wiring line instead of a patterned film. Because there is no repair wiring line that overlaps a wide area of the scan signal line, the power consumption is small, and the present invention is advantageous for use in small devices requiring low power consumption. Specifically, it was found that the effect on the capacitance on scan signal lines is small and decrease in display quality resulting from signal rounding and capacitance change does not occur due to a circuit substrate having a dual gate structure or the like with two wiring lines between adjacent pixels being provided with a repair wiring line (without melt connection portion) disposed between adjacent wiring lines (scan signal lines, for example). Furthermore, as mentioned above, the present invention was conceived when the present inventor found that the problem above can be solved as the portion between adjacent scan signal lines does not affect the aperture ratio, and thus, the problem of the aperture ratio does not occur.
[0021] As for the problem of signal rounding, in the conventional structure, it was evaluated that a signal rounding exists before and after repair. On the other hand, the present invention is acknowledged for having almost no signal rounding before and after repair. However, because only the projection for laser correction overlaps the scan signal line, there is a risk that signal rounding will occur more in the present invention than in a structure without a repair wiring line. Furthermore, because the main portion thereof (not the projection, but the line-shaped portions along two wiring lines adjacent to each other) is usually disposed so as to be separated by several micrometers from the adjacent two wiring lines, the effect of signal rounding is negligible compared to a structure in which repair wiring lines are disposed on the scan signal lines.
[0022] In this manner, the difference between the present invention and conventional technology is that, in a dual gate structure, a patterned film is disposed (without a melt connecting portion) between adjacent scan signal lines, for example. In this type of structure, the effect to the capacitance of scan signal lines is small, and thus signal rounding and a decrease in display quality due to change in capacitance do not occur. In other words, this structure is different from that disclosed in Patent Document 1 in which the repair wiring line overlaps a large area of the signal line, for example, and thus, adverse effects caused by an increase in the parasitic capacitance can be suppressed. The area between adjacent scan signal lines does not affect the aperture ratio, and therefore, there are no disadvantages regarding the aperture ratio decreasing. The patterned film with this type of effect can be used as a repair wiring line by having the patterned film at least include a plurality of projections on one side thereof, the plurality of projections having an overlapping portion that overlaps the first wiring line, at least one overlapping portion overlapping via an insulating film.
[0023] If a repair wiring line is disposed so as to overlap a large area of a scan signal line or the like, then in a normal state, the signal rounding in the signal line increases, thus causing a decrease in charging rate, a difference in quality towards the edge of the display, and in particular, the difference in signal rounding can be obvious for a two layer wiring line structure that selectively uses two types of wiring lines as lead-out lines (wiring lines to connect to drivers) of scan signal lines. In this case, there are disadvantages such as a stripe-shaped display anomaly being perceived, but these types of problems do not occur in the present invention.
[0024] Recently, the dual-gate structure is often adopted in mid-sized devices to lower the cost. The number of scan signal lines increase in a dual-gate structure and thus there is demand to narrow the scan signal lines. However, this increases instances of disconnection. If a repair wiring line is disposed at a normal location such as the location disclosed in Patent Document 1, then because the repair wiring line overlaps a wide area of the signal line, the capacitance increases, causing greater signal rounding that leads to adverse effects on the display quality and an increase in power consumption. These disadvantages are resolved in the present invention.
[0025] Usually, in order to avoid leaks between the scan signal lines, the area between two scan signal lines has a gap of a size sufficient to not decrease the yield. This gap is approximately 10 μm, for example. The width of the scan signal line is usually approximately 5 μm. While it is not be a problem even if the probability of disconnection in the repair wiring line is greater than in the scan signal line, if the width of the repair wiring line is 5 μm as in the scan signal line, then the space between the repair wiring line and the scan signal line can be set to be 2.5 μm, and thus, decrease in aperture ratio does not occur.
[0026] In the present invention, a circuit substrate included in a display device that displays an image by using pixels includes: a plurality of first wiring lines and a plurality of second wiring lines that intersect with the first wiring lines; thin film transistor elements; a plurality of pixel electrodes that are electrically connected to drain electrodes of the thin film transistor elements; and a patterned film, wherein two first wiring lines extend alongside each other between pixels when a main surface of the substrate is viewed in a plan view, and the patterned film has a line-shaped portion extending along and between the two first wiring lines extending alongside each other. The plurality of first wiring lines are usually provided in the same layer. The same can be the for the plurality of the second wiring lines.
[0027] There should be at least two of the plurality of first wiring lines extending between rows of pixels or columns of pixels. The structure may have at least two of the first wiring lines disposed between the row of pixels or the column of pixels for alternating pixel rows or alternating pixel columns and not for other pixel rows or columns, but it is preferable that at least two of the first wiring lines be disposed for each pixel row or each pixel column. It is preferable that the two wiring lines extending alongside each other be substantially parallel to each other. The intersection mentioned above can be substantially perpendicular, for example
[0028] At least two of the first wiring lines should extend alongside each other between pixels when the main surface of the substrate is seen in a plan view, but it is preferable that two first wiring lines extend alongside each other between pixels. A portion of a wiring line may be branched in order to achieve two wiring lines extending alongside each other between pixels, but it is preferable that two separate wiring lines be disposed adjacent to each other.
[0029] A dual-gate structure is one preferable configuration of the present invention. By having a dual-gate structure, the number of gate wiring lines doubles and the number of source wiring lines halves. As a result, the number of gate drivers doubles and the number of source drivers halves. The source drivers are more expensive than the gate drivers, and thus the cost of the drivers as a whole decreases. By applying the present invention to a circuit substrate with a dual-gate structure, the effect of the present invention can be sufficiently achieved in a configuration in which the cost can be reduced by decreasing the number of drivers.
[0030] There is a reference document showing a structure in which two source wiring lines are adjacent to each other (Japanese Patent Application Laid-Open Publication No. H10-197894). This structure is used in X ray sensors and the like. The present invention can be applied to a structure in which two wiring lines are adjacent to each other, and can be applied not only to a configuration in which a patterned film is disposed between two scan signal lines, but also in a configuration in which other two wiring lines such as two source wiring lines are disposed between the row of pixels or column of pixels.
[0031] In terms of the range of the width (maximum and minimum value) regarding the line-shaped portion of the patterned film, the scan signal line usually is approximately 5 μm in width, but the repair wiring line can be designed to be narrower because it does not affect the quality even if it disconnects. In other words, the repair wiring line can be designed to be 5 μm or less. If the width of the repair wiring line is 8 μm, then the probability of disconnection is extremely low. In this case, if the space between the scan signal lines is 10 μm, then the space between the repair wiring line and the scan signal line is only 1 μm, but the two can still be separated. On the other hand, if the width is less than 3 μm, then the possibility of disconnection increases, and therefore, it is preferable that the maximum width be 8 μm and the minimum be 3 μm.
[0032] The circuit substrate of the present invention has a plurality of gate wiring lines and a plurality of data wiring lines provided on the substrate, a thin film transistor in which a gate electrode is connected to a gate wiring line and a source electrode is connected to a source wiring line, and a pixel electrode to which the drain electrode or the drain lead-out wiring line of the thin film transistor is connected. It is preferable that the first wiring line be the gate wiring line and that the second wiring line be the source wiring line, for example.
[0033] By the circuit substrate of the present invention having this type of structure, the current (gate signal) flowing in the gate wiring line controls the driving of the thin film transistor and the driving of the pixel electrode can be controlled by the current (data signal) flowing in the data signal line when the thin film transistor is ON.
[0034] It is preferable that the circuit substrate further include an insulating film, the patterned film and one of the first wiring lines having a plurality of projections on one side thereof in the widthwise direction of the line-shaped portion, the plurality of projections having the patterned film and having an overlapping portion that overlaps another of the first wiring lines via an insulating film. The first wiring line mentioned above should be at least one of the two first wiring lines above. According to the circuit substrate, if a first wiring line disconnects during the manufacturing process of the circuit substrate, the two portions that are separated by the disconnection can be reconnected by forming an alternate route by using the patterned film having projections or by using the first wiring line having projections, and therefore the first wiring line can be repaired. In the present invention, a decrease in aperture ratio can be prevented by disposing a patterned film between two wiring lines provided between pixels. If the circuit substrate of the present invention has a patterned film or a first wiring line having the projections, then the wiring lines can be repaired, and if the circuit substrate is used for a panel substrate of a liquid crystal display device, then the circuit substrate can contribute to improving the yield of the liquid crystal display device.
[0035] A gate insulating film, a protective film of a thin film transistor, or the like can be used as the insulating film that insulates the overlapping portion of the wiring line structure. There is no special limitation on the thickness of the insulating film, but in order to electrically connect the overlapping portion of the wiring line structure with ease by laser radiation or the like, it is preferable that the thickness be 5000 Å or less.
[0036] It is more preferable that the patterned film have a plurality of projections on both sides in the widthwise direction of the line-shaped portion, and that the plurality of projections have an overlapping portion that overlaps the two first wiring lines via an insulating film.
[0037] The widthwise direction of the line-shaped portion usually refers to a direction that is not the longer side direction (that is, the shorter side direction). The widthwise direction of the line-shaped portion of the patterned film is usually the same as the widthwise direction of the first wiring line. A portion of the projection of the patterned film is an overlapping portion that overlaps the first wiring line.
[0038] It is preferable that the two first wiring lines respectively have a plurality of projections on the patterned film side thereof in the widthwise direction of the line-shaped portion, the plurality of projections having overlapping portions that overlap the patterned film across the insulating film.
[0039] As long as the effect of the present invention is preserved, not all of the overlapping portions need to overlap via the insulating film, but it is preferable that all of the plurality of projections that overlap the patterned film or the first wiring line overlap across the insulating film.
[0040] It is preferable that one of the first wiring line or the second wiring line be a gate wiring line and that the other one be a source wiring line.
[0041] The thin film transistor elements usually has a gate electrode connected to a gate wiring line and a source electrode connected to a data signal line. The circuit substrate is usually also referred to as an active matrix substrate. The members such as a wiring line, a patterned film, a thin film transistor element, an insulating film, and the like are usually disposed on a transparent substrate such as a glass substrate.
[0042] It is preferable that the patterned film be provided in the same layer as the second wiring line, for example. With this configuration, it is not necessary to form a new insulating film to form the patterned film, and thus, the circuit substrate of the present invention can be manufactured at ease.
[0043] It is preferable that the circuit substrate further include a storage capacitance wiring line, and that the storage capacitance wiring line overlap the projections when seeing the main surface of the substrate in a plan view.
[0044] As long as the circuit substrate and the display device of the present invention is configured to have these components, there is no special limitation regarding the circuit substrate and the display device including or not including other components.
[0045] It is preferable that the wiring line structure or the connecting electrode for repair be provided in the layer including the signal line (layer including source wiring lines, for example). With this configuration, the wiring line structure or the connecting electrode for repair can easily be formed without adding another step to form a film. In the present invention, a “layer including source wiring lines” refers to the layer in which the source wiring lines are formed in the circuit substrate having a multilayer structure. Usually, when the patterned film and the source wiring line are formed in the same layer, the patterned film and the source wiring line are formed in the same step. It is preferable that the patterned film be formed using the same conductive material as the source wiring line and the thin film transistor element of the source electrode in the same process as the source wiring line and the source electrode.
[0046] It is preferable that the storage capacitance wiring line be formed using the same conductive material as the gate wiring line and the gate electrode in the same process as the gate wiring line and the gate electrode. It is also preferable that the storage capacitance electrode be formed using the same conductive material as the source wiring line and the drain lead-out wiring line in the same process as the source wiring line and the drain lead-out wiring line.
[0047] It is preferable that the patterned film is formed of a material including at least one of Al, Cr, Ta, Ti, W, Mo, and Cu. With this configuration, the patterned film (repair wiring line) is formed of a material including a high melting point metal before performing melt processing using a laser or the like, but if compared to a transparent conductive film such as ITO or the like, the patterned film and the first wiring line can be electrically connected more easily and reliably.
[0048] Next, the respective components of the active matrix substrate of the present invention are described.
[0049] The material of the substrate can be a transparent insulating material such as glass or plastic.
[0050] The material for the signal lines (gate wiring line, source wiring line), gate electrode, and drain lead-out wiring line can be a metal film, an alloy film, a multilayer film, or the like of titanium (Ti), chromium (Cr), aluminum (Al), molybdenum (Mo), tantalum (Ta), tungsten (W), copper (Cu), or the like. The method of forming the signal lines, the gate electrodes, and the drain lead-out wiring lines includes patterning or the like after photoetching or the like once the film is formed by sputtering the material or the like.
[0051] The material for the source electrode and the drain electrode can be an n + amorphous silicon doped with phosphorus or the like. The source electrode and the drain electrode can be formed by separating the source and the drain through dry etching or the like after the film is formed by plasma CVD using the material mentioned above.
[0052] In order to reduce the manufacturing steps and the manufacturing cost, it is preferable that the gate wiring line, the gate electrode, the source wiring line, the drain lead-out wiring line, the source electrode, and the drain electrode respectively be formed using the same material during the same process. There is no special limitation on the thickness of the signal line, the gate electrode and the drain lead-out wiring line, but it is preferable that the minimum is substantially 1000 Å, and that the maximum is substantially 3000 Å. It is preferable that the thickness of the source electrode and the drain electrode be 500 Å.
[0053] The material for the pixel electrode can be a transparent conductive material such as ITO, IZO, tin oxide, or zinc oxide. The method of forming the pixel electrode includes pattering or the like after photoetching or the like once the film is formed by sputtering the material or the like. The pixel electrode can have a rectangular shape or the like. There is no special limitation on the thickness of the pixel electrode, but it is preferable that the minimum thereof be substantially 1000 Å and that the maximum thereof be substantially 3000 Å. It is preferable that the pixel electrode and the drain electrode or the drain lead-out wiring line be connected through a contact hole or the like formed in the interlayer insulating film.
[0054] A preferable structure of the active matrix substrate of the present invention can include a structure having (1) a substrate, (2) a gate wiring line, a gate electrode, and an auxiliary capacitance wiring line, (3) a (gate) insulating film, (4) a high resistance semiconductor layer, (5) a source wiring line, a source electrode, a drain electrode, a drain lead-out wiring line, and an auxiliary capacitance electrode, (6) an interlayer insulating film (including a contact hole), and (7) a pixel electrode in that order from the bottom layer.
[0055] It is preferable that the thin film transistor element of the circuit substrate of the present invention include an oxide semiconductor.
[0056] The present invention also includes a display device having the circuit substrate of the present invention. According to the display device of the present invention, during the manufacturing process of the circuit substrate, when a pixel defect occurs, the repair can be performed reliably and with ease, and thus the pixel defect can be sufficiently reduced to obtain high display quality and the manufacturing yield can be increased. A liquid crystal display device of the present invention can be suitably used in large liquid crystal TVs or the like that require point defects in particular to be suppressed from occurring.
[0057] The display device of the present invention can be an EL (electroluminescence) display device or the like, but it is preferable that the display device of the present invention be a liquid crystal display device, for example.
[0058] The present invention is also a method to repair pixel defects occurring in the pixel substrate of the present invention, the pixel defect repairing method of the circuit substrate also being a method to repair a pixel defect by electrically connecting a disconnected first wiring line through a patterned film.
[0059] It is preferable that the electrically connecting process above be performed by at least two areas where the patterned film and the first wiring line overlap be melted by laser irradiation.
[0060] It is preferable that the method of repairing a pixel defect of the circuit substrate include a step in which the patterned film that is electrically reconnected to the first wiring line is separated from the other patterned films.
[0061] The present invention is also a method of manufacturing the circuit substrate including a step to repair a pixel defect by using the method of repairing a pixel defect of the present invention.
[0062] The present invention is also a method of manufacturing the display device in which the process of manufacturing the circuit substrate uses the method or repairing a pixel substrate of the present invention.
[0063] The respective configurations mentioned above may be appropriately combined within a scope that does not depart from the gist of the present invention.
Effects of the Invention
[0064] According to the circuit substrate of the present invention, a patterned film is disposed in a manner that can sufficiently reduce the increase in capacitance and sufficiently minimize the degradation of display quality due to signal delay, while sufficiently shielding the part where the a light shielding member damaged with the patterned film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 is a schematic plan view of Working Example 1-1 showing a structure of a pixel of a circuit substrate.
[0066] FIG. 2 is a schematic cross-sectional view showing the circuit substrate in FIG. 1 along the line A-B.
[0067] FIG. 3 is a schematic plan view of Working Example 1-2 showing a structure of a pixel of a circuit substrate.
[0068] FIG. 4 is a schematic plan view of Working Example 1-3 showing a structure of a pixel of a circuit substrate.
[0069] FIG. 5 is a schematic plan view of Working Example 1-4 showing a structure of a pixel of a circuit substrate.
[0070] FIG. 6 is a schematic plan view of Working Example 1-5 showing a structure of a pixel of a circuit substrate.
[0071] FIG. 7 is a schematic plan view of Working Example 2-1 showing a structure of a pixel of a circuit substrate.
[0072] FIG. 8 is a schematic plan view of Working Example 2-2 showing a structure of a pixel of a circuit substrate.
[0073] FIG. 9 is a schematic plan view of Working Example 3-1 showing a structure of a pixel of a circuit substrate.
[0074] FIG. 10 is a schematic cross-sectional view showing the circuit substrate in FIG. 9 along the line C-D.
[0075] FIG. 11 is a schematic plan view of Working Example 3-2 showing a structure of a pixel of a circuit substrate.
[0076] FIG. 12 is a schematic plan view of Working Example 3-3 showing a structure of a pixel of a circuit substrate.
[0077] FIG. 13 is a schematic plan view of Working Example 3-4 showing a structure of a pixel of a circuit substrate.
[0078] FIG. 14 is a schematic plan view of Working Example 4-1 showing a structure of a pixel of a circuit substrate.
[0079] FIG. 15 is a schematic plan view of Working Example 4-2 showing a structure of a pixel of a circuit substrate.
[0080] FIG. 16 is a schematic plan view of Working Example 4-3 showing a structure of a pixel of a circuit substrate.
[0081] FIG. 17 is a schematic plan view of Working Example 4-4 showing a structure of a pixel of a circuit substrate.
[0082] FIG. 18 is a schematic plan view of Working Example 5-1 showing a structure of a pixel of a circuit substrate.
[0083] FIG. 19 is a schematic plan view of Working Example 6-1 showing a structure of a pixel of a circuit substrate.
[0084] FIG. 20 is a schematic plan view of Working Example 6-2 showing a structure of a pixel of a circuit substrate.
[0085] FIG. 21 is a schematic cross-sectional view of a liquid crystal display device showing light from a black light being reflected by a black matrix and then entering a metal channel.
[0086] FIG. 22 is a schematic plan view showing a pixel of a circuit substrate provided in an active matrix liquid crystal display device.
[0087] FIG. 23 is a schematic plan view showing a pixel having a delta pattern.
[0088] FIG. 24 is a schematic plan view showing a suitable form of intersection between a signal line and a patterned film.
[0089] FIG. 25 is a schematic plan view of a modification example of Working Example 1-1 showing a structure of a pixel of a circuit substrate.
[0090] FIG. 26 is a schematic plan view of a Comparison Example 1 showing a structure of a pixel of a circuit substrate.
[0091] FIG. 27 is a schematic cross-sectional view showing the circuit substrate in FIG. 26 along a line E-F.
DETAILED DESCRIPTION OF EMBODIMENTS
[0092] Embodiments are described below and the present invention is described in further detail with reference to the drawings, but the present invention is not limited to these embodiments. In the present specification, pixels may refer to sub pixels unless stated otherwise. Furthermore, the circuit substrate (first substrate) of the present embodiment is also referred to as a TFT substrate or array substrate, because the circuit substrate has thin film transistor elements (TFTs).
[0093] In the present embodiment, a circuit substrate is an active matrix circuit substrate.
[0094] In the present specification, if it is mentioned that a patterned film or the like is provided in the same layer as another member, then it means that the patterned film and the other member is in contact with a common member (insulating layer, liquid crystal layer, or the like, for example) on the liquid crystal layer side thereof and/or on the side opposite to the liquid crystal layer side thereof. Furthermore, in the figures, even if the digit of the reference numbers in the hundred's place and the thousand's place are different, if the digit in the one's place and in the ten's place are the same, then the reference number refer to the same member unless otherwise stated. In the figures, characteristic portions of the respective embodiments are surrounded by dotted lines.
[0095] Embodiments are described below and the present invention is described in further detail with reference to the drawings, but the present invention is not limited to these embodiments.
Embodiment 1
Patterned Film Disposed on Source Wiring Line (for Each Subpixel)
[0096] On a circuit substrate having a dual-gate structure, a patterned film (or, repair wiring line) is disposed between adjacent scan signal lines.
[0097] A basic structure of a liquid crystal display device of Embodiment 1 includes a TFT substrate (active matrix substrate) that is a circuit substrate, a color filter substrate (opposite substrate), and a display medium (liquid crystal) sandwiched between these two substrates. There is no special limitation on the alignment mode, alignment method, and driving method of liquid crystals, and TN (twisted nematic) mode, MVA (multi-domain vertical alignment) mode, IPS (in-plane switching) mode, FFS (fringe field switching) mode, or TBA (transverse bend alignment) mode can be adopted. Furthermore, the present embodiment can be suitably used in PSA (polymer sustained alignment) technology, photoalignment technology, and multi-pixel structure technology. A multi-pixel structure is a structure in which each subpixel electrode is driven by respective individual TFTs. Furthermore, there is no limit to the shape of the pixel, the pixel can be a vertically long pixel as shown, a horizontally long pixel, or in a delta pattern.
[0098] In Embodiment 1, a circuit substrate having a dual gate structure is disposed with a patterned film as a repair wiring line between adjacent gate wiring lines in the source layer. The patterned film is disposed between the pixel electrodes and between the gate wiring lines (an advantage is that a light-shielding effect can be obtained in case a light shielding member is damaged).
[0099] In Embodiment 1, a patterned film can be formed for a layer forming conventional TFTs. As a result, a process of forming a new layer (photolithography process) is not needed, and therefore, there are no additional steps. Furthermore, a new mask is not needed, and thus, cost does not increase. Furthermore, in a configuration of Embodiment 1, a projection is provided on the top and bottom of the line-shaped portion of a patterned film, and repair can be performed for both top and bottom gate wiring lines. It is preferable that a projection be provided on the top and bottom of the line-shaped portion of the patterned film, but the effect of the present invention can be achieved by having a plurality of similar projections on one side of the line-shaped portion of the patter film. Furthermore, in Embodiment 1, the effect of the electric field of the gate wiring line upon a pixel can be made smaller. As a result, a change in pixel potential due to an electric field of the gate wiring line becomes small, and thus a desirable color can be displayed.
Working Example 1-1
[0100] FIG. 1 is a schematic plan view of Working Example 1-1 showing a structure of a pixel of a circuit substrate. FIG. 2 is a schematic cross-sectional view showing the circuit substrate in FIG. 1 along the line A-B. Working Example 1-1 is a configuration in which two projections each for repairing are provided on the top and the bottom of the patterned film (portion surrounded by dotted lines in FIG. 1 .) Working Example 1-1 has the smallest capacitance out of all the working examples of Embodiment 1.
[0101] In a circuit substrate of Working Example 1-1, the patterned film 28 has a plurality of projections on both sides in the widthwise directions of the line-shaped portion such that a plurality of projections have an overlapping portion that overlaps the two first wiring lines across a first insulating film 31 . It is preferable that the thickness of the first insulating film 31 be 3000 Å or greater. Furthermore, it is preferable that the upper limit be less than or equal to 5000 Å.
[0102] As for a circuit substrate of Working Example 1-1, light-shielding of the damaged part of the light-shielding member can be sufficiently performed using the patterned film in the location surrounded by a two-dot chain line. This is the same for embodiments mentioned later.
[0103] The pixel electrodes 21 are formed of a transparent conductive film such as ITO (indium tin oxide), IZO (indium zinc oxide), tin oxide, zinc oxide, or the like. An insulating film such as the first insulating film 31 or the like can be formed of a material such as an acrylic resin, silicon nitride, or silicon oxide.
[0104] In the active matrix substrate having the above-mentioned configuration, it is possible to form the patterned film 28 of the same material and in the same step as the source wiring line (data signal line) 23 in order to simplify the manufacturing process and reduce the manufacturing cost. However, the patterned film 28 does not need to be formed with the same material as the source wiring line 23 nor be formed during the same step.
Working Example 1-2
[0105] FIG. 3 is a schematic plan view of Working Example 1-2 showing a structure of a pixel of a circuit substrate. In Working Example 1-2, the patterned film 128 has two or more projections for repairing (under Cs light shielding portion) on both the top and the bottom of the patterned film 128 . This can act as a countermeasure against pin holes in a black matrix (BM), and also acts as a countermeasure against a gate electric field (the effect is relatively small compared to other examples of Embodiment 1). Furthermore, the capacitance between pixel electrodes can be reduced (effect is small).
[0106] In Working Example 1-2, the portion of a display device that should be shielded from light can be shielded from light with the patterned film 128 (portion where neither the pixel electrode nor the light-shielding film are present). Also, a portion between pixel electrodes (location where storage capacitance wiring light-shielding layer is disposed) can be shielded from light and mitigate the formation of pinholes. These effects are the same in Working Examples 1-3 and 1-4 as mentioned later.
[0107] As for a circuit substrate in Working Example 1-2, in the location surrounded by a two-dot chain line, light-shielding can be performed sufficiently at the damaged part of the light-shielding member using the patterned film. This is the same for embodiments mentioned later.
Working Example 1-3
[0108] FIG. 4 is a schematic plan view of Working Example 1-3 showing a structure of a pixel of a circuit substrate.
[0109] The structure has projections for repairing in two or more locations on the top and the bottom of a patterned film 228 (under light shielding portion of Cs/near storage capacitance wiring line (auxiliary electrode portion) Cs) (acts as a countermeasure against pinholes in the BM/gate electric field (medium effectiveness) (also acts as a countermeasure against capacitance between pixel electrodes (medium effectiveness). The third projection is disposed between the pixel electrodes.
Working Example 1-4
[0110] FIG. 5 is a schematic plan view of Working Example 1-4 showing a structure of a pixel of a circuit substrate.
[0111] The structure has projections for repairing in two or more locations on the top and the bottom of a repair wiring line (under Cs light shielding portion/ near storage capacitance wiring line (auxiliary electrode portion) Cs (acts as a countermeasure against pinholes in the BM pinhole/gate electric field (highly effective) (also acts as a countermeasure against capacitance between pixel electrodes (highly effective). In an area surrounded by a dotted line, the structure in FIG. 5 has the third projections disposed between pixel electrodes where the storage capacitance wiring line Cs is, such that the third projections overlap the auxiliary electrode portion.
[0112] Unwanted portions of the patterned film can be cut out. When performing repair in a structure such as that of Working Example 1-4 in which the extending portion of the storage capacitance wiring line Cs overlaps a projection of the patterned film, it is preferable that the portion where the extending portion of the storage capacitance wiring line Cs and the projection of the patterned film overlap, or in other words, that the root of the projection of the patterned film (CUT1 or CUT2 shown in FIG. 5 , for example) be cut, for example. The location to be cut may be either CUT1 or CUT2.
[0113] The effect of performing the cut is described below. The gate wiring line repeatedly switches between high potential Vgh and low potential Vgl, and the storage capacitance wiring line Cs has a fixed Cs potential in dot inversion driving, but repeatedly switches between a high Cs potential and a low Cs potential in line inversion driving.
[0114] The extending portion of the storage capacitance wiring line Cs and the projection of the patterned film have an insulating film therebetween, and thus there are no crucial disadvantages in terms of quality, but if wiring lines with different voltages are nearby, both are affected by the voltage of the other wiring line to a certain degree.
[0115] Thus, if repair is performed in a structure in which the extending portion of the storage capacitance wiring line Cs and the projection of the patterned film overlap, it is preferable that the portion where the extending portion of the storage capacitance wiring line Cs and the projection of the patterned film overlaps, or in other words, the root of the projection of the patterned film be cut, and thus removing the projection of the patterned film. The removal of a projection of the patterned film is similarly effective in other embodiments in which the extending portion of the Cs and the projection of the patterned film overlaps.
Working Example 1-5
[0116] FIG. 6 is a schematic plan view of Working Example 1-5 showing a structure of a pixel of a circuit substrate.
[0117] The tip of the projection for repairing may protrude outside a gate wiring line as in Working Example 1-1/Working Example 1-2, or not protrude outside a gate wiring line as in Working Example 1-5, respectively.
[0118] If the projections protrude outside, then the repair rate improves and repair becomes easier. If the projections do not protrude outside, then the capacitance decreases, and the panel has less capacitance. As a result, lower power consumption can be attained.
[0119] It is preferable that the distance in micrometers, for example, between a patterned film (repair wiring line) and a pixel electrode be 7 and 25 μm.
[0120] The following details are assumed. In a normal design, it can be assumed that the distance between the pixel electrode and the repair wiring line is approximately 15 μm.
[0121] In other words, usually the distance between the pixel electrode and the gate wiring line is 8 μm, but it is preferable that the distance be 2 μm to 10 μm. Usually, the width of the gate wiring line is 5 μm, but it is preferable that the distance be 4 μm to 10 μm. Furthermore, the distance between the gate wiring line and the repair wiring line is usually assumed to be 2 μm, but it is preferable that the distance be 1 μm to 5 μm. The sum of these is usually approximately 15 μm, for example, but it is preferable that the sum be 7 μm to 25 μm.
[0122] In the present embodiment, a gate electrode that is connected to a gate wiring line is disposed on a transparent insulating substrate such as glass or plastic. The gate wiring line and the gate electrode are formed by first forming a metal film, an alloy film, or a multilayer film of titanium, chromium, aluminum, molybdenum, tantalum, tungsten, copper, or the like having a thickness of 1000 Å to 3000 Å by sputtering or the like, and then patterned into a desired shape by photoetching or the like.
[0123] In the present embodiment, the patterned film and the gate wiring line can be electrically connected to each other by irradiating the patterned film by a laser or the like at the projection thereof.
[0124] Therefore, in the active matrix substrate of the present embodiment, even if a disconnection occurs in a wiring line, the wiring line can be repaired by electrically connecting at least two locations in the patterned film and the gate wiring line.
[0125] As shown in FIG. 1 , in the present embodiment, the pattern of the patterned film is in a quadrilateral shape (four sided shape), but the pattern of the patterned film 28 is not limited to this, and may be in a triangular shape, semicircular shape, a trapezoid shape, or the like. In other words, it is preferable that the structure of the projection of the patterned film 28 be provided so as to overlap the gate wiring line with an insulating film therebetween such that a region for irradiating a laser is secured.
Embodiment 2
Disposing Patterned Film in Source Wiring Line Layer
[0126] In Embodiment 2, a patterned film is disposed between adjacent scan signal lines on a circuit substrate having a dual-gate structure.
[0127] A basic structure of a display device of Embodiment 2 includes a TFT substrate (active matrix substrate) that is a circuit substrate, a color filter substrate (opposite substrate), and a display medium (liquid crystals) sandwiched between these two substrates. There is no limitation regarding the alignment mode, alignment method, and the driving method of the liquid crystals (TN, MVA, IPS, FFS, TBA, PSA, photoalignment, multi-pixel). Furthermore, there are no limitations regarding pixel shape, the pixels may be vertically long pixels, horizontally long pixels, or in a delta pattern.
[0128] In a circuit substrate having a dual-gate structure, a patterned film is disposed in the source wiring line layer and between gate wiring lines. In a manner similar to Embodiment 1, a repair wiring line can be formed in a conventional TFT layer (manufacturing process). As a result, a process of forming a new layer (photolithography process) is not needed, and therefore there are no additional steps. Furthermore, a new mask is not needed, and thus, the cost does not increase. Both top and bottom gate wiring lines can be repaired. Also, the gate wiring lines can be repaired regardless of where the disconnection occurs.
Working Example 2-1
[0129] FIG. 7 is a schematic plan view of Working Example 2-1 showing a structure of a pixel of a circuit substrate.
[0130] A pixel electrode 521 and a transparent film 529 of the same film (location surrounded by a dotted line in FIG. 7 , for example) are disposed between patterned films (repair wiring lines) as a countermeasure against complete disconnection in the gate wiring lines 522 a and 522 b . When repair is being performed, an extra step of radiating a laser is needed, but the increase in capacitance is small. In Working Example 2-1, a transparent film 529 that is the same as the pixel electrode is provided in the same layer as the pixel electrode, but instead of the transparent film 529 that is the same material as the pixel electrode, a conductive film that is formed of a different material from that of the pixel electrode can be provided.
Working Example 2-2
[0131] FIG. 8 is a schematic plan view of Working Example 2-2 showing a structure of a pixel of a circuit substrate.
[0132] A transparent film 629 that is the same film as a pixel electrode 621 is formed between patterned films (repair wiring lines), and the patterned film and the transparent film are connected in advance through a hole CHpas formed in an insulating film (countermeasure against complete disconnection in the gate wiring lines). When repair takes place, the laser does not need to be radiated to connect the repair wiring line and the transparent film as in Embodiment 2-1, but the capacitance increases.
[0133] However, to connect the patterned film and the gate wiring line, a laser must be radiated. In Working Example 2-2, a transparent film 629 that is the same as the pixel electrode is provided in the same layer as the pixel electrode, but instead of the transparent film 629 that is the same as the pixel electrode, a different conductive film may be provided. The other structures of the present embodiment are the same as described above in Embodiment 1.
Embodiment 3
Patterned Film is Formed in a New Layer (Patterned Film can be Disposed Over Pixel and Thus Gate Wiring Line can be Repaired Regardless of where a Disconnection is Present)
[0134] In a circuit substrate with a dual-gate structure, a new layer that is not conventionally provided is disposed between adjacent scan signal lines, and a repair wiring line is provided thereon.
[0135] A basic structure of a display device of Embodiment 3 includes a TFT substrate (active matrix substrate), a color filter substrate (opposite substrate), and a display medium (liquid crystals) sandwiched between these two substrates.
[0136] There is no limitation regarding the alignment mode, alignment method, and the driving method of the liquid crystals (TN, MVA, IPS, FFS, TBA, PSA, photoalignment, multi-pixel). Furthermore, there are no limitations regarding pixel shape, the pixels may be vertically long pixels, horizontally long pixels, or in a delta pattern.
[0137] A patterned film is disposed between pixel electrodes (advantage in obtaining a light-shielding effect). Repair can be performed regardless of where the gate wiring line is disconnected. Both top and bottom gate wiring lines can be repaired. Also, in Embodiment 3, because the number of projections for repairing is reduced, the capacitance of the gate wiring line can be decreased.
Working Example 3-1
[0138] FIG. 9 is a schematic plan view of Working Example 3-1 showing a structure of a pixel of a circuit substrate. FIG. 10 is a schematic cross-sectional view showing the circuit substrate in FIG. 9 cut along a line C-D. In FIG. 10 , a repair wiring line 728 and a third insulating film 733 are provided as a new layer.
[0139] The structure has a patterned film (repair wiring line) with a projection for repairing on both the top and the bottom thereof (below the Cs light-shielding portion). This acts as a countermeasure for BM pinholes and gate electric fields (low effectiveness). Furthermore, this acts as a countermeasure for the capacitance between pixel electrodes (low effectiveness).
[0140] Out of the three embodiments, the capacitance of Working Example 3-1 is the smallest (because only the repairing portion of the repair wiring line overlaps the gate wiring line).
Working Example 3-2
[0141] FIG. 11 is a schematic plan view of Working Example 3-2 showing a structure of a pixel of a circuit substrate.
[0142] The structure thereof is provided with one projection for repairing on the top and the bottom of the patterned film 828 respectively. In this configuration, the projection for repairing is disposed between the pixel electrodes, and does not overlap the auxiliary electrode portion (below Cs light-shielding portion/to a vicinity of Cs). This acts as a countermeasure against pinholes in the BM and gate electric fields (medium effectiveness). It is also a countermeasure against the capacitance between pixel electrodes (medium effectiveness).
[0143] The portion that should be shielded from light can be shielded from light. The influence of the electric field of the gate wiring line on a pixel can also be reduced. As a result, a change in pixel potential due to an electric field of the gate wiring line becomes small, and thus, a desirable color can be displayed. The gap between pixel electrodes can also be shielded from light. Thus, the desired color can be displayed because the potentials of adjacent pixels do not influence each other. A similar effect can also be obtained in Working Example 3-3 that is described later.
Working Example 3-3
[0144] FIG. 12 is a schematic plan view of Working Example 3-3 showing a structure of a pixel of a circuit substrate.
[0145] The structure thereof is provided with one projection for repairing the top and the bottom of the patterned film 928 respectively. In this configuration, the projection for repairing is disposed between the pixel electrodes, and overlaps the auxiliary electrode portion (below Cs light-shielding portion/overlap Cs). This acts as a countermeasure against pinholes in the BM and gate electric fields (high effectiveness). It is also a countermeasure against the capacitance between pixel electrodes (high effectiveness).
[0146] It is preferable that the area in which the storage capacitance wiring line and the projection overlaps is 7 μm 2 to 39 μm 2 . Details of the value can be seen in table 1 below. In table 1 below, “overlap of Cs and projection” refers to the vertical length of the overlapping area of the projection of a patterned film 928 and an auxiliary capacitance wiring line in FIG. 12 . In table 1, “length in horizontal direction (width of light-shielding portion of Cs portion)” refers to the horizontal length of an area in which the projection of the patterned film 928 and the auxiliary capacitance wiring line overlap, and the “pixel electrode-Cs edge” thereof refers to where the pixel electrode and an edge of the auxiliary capacitance wiring line overlap and the “pixel electrode gap” refers to the length between the two pixel electrodes.
[0000]
TABLE 1
Length in Horizontal Direction
(Width of Light-Shielding
Portion of Cs Portion)
Overlap of Cs
Pixel Electrode-
Pixel
and Projection
Cs Edge
Electrode Gap
Calculating
1 μm ×
{(1 μm × 2
5 μm} =
1 × 7 = 7
Minimum Value
locations) +
Calculating
3 μm ×
{(2.5 μm × 2
8 μm} =
3 × 13 = 39
Maximum Value
locations) +
Working Example 3-4
[0147] FIG. 13 is a schematic plan view of Working Example 3-4 showing a structure of a pixel of a circuit substrate.
[0148] The tip of a projection for repairing may protrude outside the gate wiring line or not protrude outside as shown in FIG. 13 in the area surrounded by a dotted line. If the projections protrude outside, then the repair rate improves and repair becomes easier. If the projections do not protrude outside, then the capacitance decreases, and the panel has less capacitance. As a result, lower power consumption can be attained.
[0149] The other structures of the present embodiment are the same as described above in Embodiment 1.
Embodiment 4
Forming Patterned Film in New Layer
[0150] On a circuit substrate having a dual-gate structure, a patterned film is disposed between adjacent scan signal lines in a new layer different from a conventional layer.
[0151] A basic structure of a display device of Embodiment 4 includes a TFT substrate (active matrix substrate), a color filter substrate (opposite substrate), and a display medium (liquid crystals) sandwiched between these two substrates.
[0152] There is no limitation regarding the alignment mode, alignment method, and the driving method of the liquid crystals (TN, MVA, IPS, FFS, TBA, PSA, photoalignment, multi-pixel). There are no limitations regarding pixel shape, the pixels may be vertically long pixels, horizontally long pixels, or in a delta pattern. A patterned film is disposed between pixel electrodes in a location where the storage capacitance wiring line light-shielding layer is disposed (advantage of obtaining light-shielding effect).
Working Example 4-1
[0153] FIG. 14 is a schematic plan view of Working Example 4-1 showing a structure of a pixel of a circuit substrate.
[0154] As shown in the location surrounded by a dotted line, the number of the top and the bottom projections for revision is halved (½). The capacitance when the panel is not repaired is small. The top and bottom disposed location is shifted. The structure is not limited to having one projection for four pixels.
Working Example 4-2
[0155] FIG. 15 is a schematic plan view of Working Example 4-2 showing a structure of a pixel of a circuit substrate.
[0156] The number of the top and the bottom projections for repairing is halved (½). The positions of the bottom and the top projections are not shifted, but may be shifted (if shifted, it is similar to Working Example 4-1). The capacitance of the panel if not repaired is small (position of top and bottom may be the same). The structure is not limited to having one projection for four pixels.
Working Example 4-3
[0157] FIG. 16 is a schematic plan view of Working Example 4-3 showing a structure of a pixel of a circuit substrate.
[0158] In Working Example 4-3, a source wiring line (data signal line) 1323 and a repair wiring line (patterned film) 1328 reduce the overlapping area by half (see area surrounded by dotted line). The cross capacitance between the source wiring line 1323 and the repair wiring line (patterned film) 1328 can be halved (½). If the overlapping area is shifted by two subpixels towards the gate wiring line (2 picture element shift), then the capacitances of all of the signal lines are the same. An embodiment such as in Embodiment 4-3 is especially suitable for making the capacitance the same for all signal lines. The structure is not limited to having one projection for four pixels.
Embodiment 4-4
[0159] FIG. 17 is a schematic plan view of Embodiment 4-4 showing a structure of a pixel of a circuit substrate.
[0160] In Embodiment 4-4, the cross capacitance between a source wiring line (data signal line) 1423 and a repair wiring line (patterned film) 1428 is halved. There are no shifts towards the gate wiring line. The structure is not limited to having one projection for four pixels.
[0161] In the structure in Embodiment 4-4, in a circuit substrate in which the lead-out wiring line of the source wiring line is alternately disposed on the two layers, the gate wiring line layer and the source wiring line layer, the load can be matched, and thus the structure can be suitably applied. In case the lead-out wiring line of the source wiring line has a different sheet resistance from the gate wiring line layer and the source wiring line layer, conventionally, in order to eliminate the difference in resistance of the lead-out wiring line, one of the two layers needed to be designed to be narrow, and thus, there was a risk of lower yield due to disconnection of the narrow wiring line, but as the load of the source wiring line in the active area is different, this difference may be canceled out by the lead-out wiring line, and therefore, there is no longer a need to design one of the lead-out wiring line to be narrow. As a result, an advantage that the yield for the peripheral lead-out line improves can be obtained.
Effects
Whole Configuration
Working Examples 4-1 and 4-2
[0162] Repair can be performed wherever a gate wiring line gets disconnected. Both top and bottom gate wiring lines can be repaired. Also, the capacitance can be reduced because the number of projections for repairing can be reduced.
Working Examples 4-3 and 4-4
[0163] Both top and bottom gate wiring lines can be repaired. Also, the capacitance can be reduced because the number of projections for repairing can be reduced.
[0164] Embodiment 4 is especially advantageous for small devices that require low power consumption, because the load of the source wiring line is halved, and thus, the power consumption is small.
[0165] (Details)
[0166] Working Example 4-1: capacitance is small when repair is not performed.
[0167] Working Example 4-2: capacitance is small when repair is not performed.
[0168] Working Example 4-3: capacitance of the source wiring line is reduced. This is a modified version of Working Example 4-4, and because the position is shifted for each gate wiring line, no difference in lag occurs for all signal lines.
[0169] Working Example 4-4: capacitance of the source wiring line is reduced.
[0170] The other structures of the present embodiment are the same as described above in Embodiment 1.
Embodiment 5
Forming Repair Wiring Line in New Layer
[0171] In a circuit substrate having a dual-gate structure, a new layer that is different from a layer that is conventionally provided between gate wiring lines (between adjacent scan signal lines) is provided, and a repair wiring line is disposed thereon.
[0172] A basic structure of a display device of Embodiment 5 includes a TFT substrate (active matrix substrate), a color filter substrate (opposite substrate), and a display medium (liquid crystals) sandwiched between these two substrates.
[0173] There is no limitation regarding the alignment mode, alignment method, and the driving method of the liquid crystals (TN, MVA, IPS, FFS, TBA, PSA, photoalignment, multi-pixel). There are no limitations regarding pixel shape, the pixels may be vertically long pixels, horizontally long pixels, or in a delta pattern. Also, repair can be performed wherever a gate wiring line gets disconnected. It is disposed between pixel electrodes (advantage in obtaining a light-shielding effect).
[0174] FIG. 18 is a schematic plan view of Working Example 5-1 showing a structure of a pixel of a circuit substrate.
[0175] Projections for repair are not limited to a Cs shielding portion between pixel electrodes (Working Example 1-1-1 is formed on a new layer, and the structure has all lines connected). The number of projections for repairing is not limited and can be two or more for the top and the bottom of one picture element.
[0176] The position of the top and the bottom projections for repairing may be offset (can be selected as appropriate such as locations having an advantage in aperture ratio).
Working Examples 5-1 and 5-2
[0177] Repair can be performed wherever a gate wiring line is disconnected. Both top and bottom gate wiring lines can be repaired.
[0178] The other structures of the present embodiment are the same as described above in Embodiment 1.
Embodiment 6
Working Example 6-1
[0179] FIG. 19 is a schematic plan view of Working Example 6-1 showing a structure of a pixel of a circuit substrate. A patterned film 1628 is provided on a source wiring line in a manner similar to Embodiments 1 and 2.
Working Example 6-2
[0180] FIG. 20 is a schematic plan view of Embodiment 6-2 showing a structure of a pixel of a circuit substrate. In a manner similar to Embodiments 3 to 5, a patterned film 1728 is formed on a new layer that is different from where the patterned film 1728 was conventionally provided. A configuration of a circuit substrate of the present invention can be confirmed by viewing the panel (or circuit substrate) or the like through a microscope.
[0181] The patterned film of Embodiment 6 does not function as a repair wiring line, but has a configuration in which the patterned film is disposed such that the capacitance increase can be sufficiently reduced, the decrease in display quality based on signal rounding be sufficiently suppressed, and light-shielding can be performed sufficiently in the damaged part of the light-shielding member by the patterned film. As in Embodiment 6, the entire patterned film may be a line-shaped portion.
[0182] To dispose a patterned film such that capacitance increase can be sufficiently reduced means that a patterned film is disposed in an area including the area surrounded by a two-dot chain line in FIGS. 1 and 4 , for example. For example, in a display device with pixels arranged in a striped pattern, it is preferable that the location shown as reference number 51 in FIG. 22 have no color filter and that the patterned film be provided in order to prevent damage to the BM. In a display device with pixels arranged in a delta pattern, it is preferable that a patterned film be provided in order to prevent damage to the BM at the location shown as reference number 53 in FIG. 23 where a top and bottom color boundary separating top and bottom occurs with ease.
Modification Example of Embodiment 1
Modification Example of Working Example 1-1
[0183] FIG. 25 is a schematic plan view of a modification example of Embodiment 1-1 showing a structure of a pixel of a circuit substrate. The respective working examples were provided with a projection on the patterned film such that the patterned film functions as a repair wiring line, but the modification example of the embodiment 1-1 has projections on the gate wiring lines 22 a ′ and 22 b ′ instead of the patterned film, and when the main surface of the substrate is seen in a plan view, the projections of the gate wiring lines 22 a ′ and 22 b ′ and the patterned film 28 ′ overlap. Even this type of configuration allows the patterned film 28 ′ to desirably function as a repair wiring line and the effect of the present invention can also be achieved in a similar manner.
Comparison Example 1
[0184] FIG. 26 is a schematic plan view of a Comparison Example 1 showing a structure of a pixel of a circuit substrate. FIG. 27 is a schematic cross-sectional view showing the circuit substrate in FIG. 26 cut along a line E-F. The circuit substrate in Comparison Example 1 does not have a patterned film between two adjacent gate wiring lines (signal lines) 1922 a and 1922 b and light-shielding cannot be sufficiently performed at the damaged part of the light-shielding member.
Other Suitable Embodiments
[0185] In the respective embodiments of the present invention, an oxide semiconductor TFT (IGZO, In—Ga—Zn—O semiconductor, is especially preferable) is preferably used. The effect of combining an oxide semiconductor TFT and a dual-gate structure is described in detail below.
[0186] (1) An oxide semiconductor TFT has a higher ON current than an a-Si (amorphous silicon) TFT. Thus, even if the number of gate wiring lines doubles due to the dual-gate structure, higher resolution can be achieved.
[0187] (2) An oxide semiconductor TFT has a higher ON current than an a-Si TFT, and the OFF current thereof is lower. Thus, even if the number of gate wiring lines double due to a dual gate structure, a down period (stop driving after one frame ends) for driving can be set, and lower power consumption can be achieved.
[0188] If a touch panel sensing period occurs during the down period, noise in the touch panel decreases, or in other words, the accuracy of the touch panel improves.
[0189] It is preferable that a patterned film is disposed near the TFT as in Working Example 1-1. As a result, the OFF leakage of a TFT can be sufficiently prevented (for example, as shown in FIG. 21 , by providing a patterned film (light-shielding film) 28 on the bottom substrate, the light shown as an arrow can be blocked, and OFF leakage of the TFT can be prevented). A configuration that can be suitably applied to the respective embodiments above is mentioned below.
[0190] The tip of the projection of the patterned film may be completely separated from the pixel electrode or have a portion overlap, and is not limited in this sense.
[0191] The patterned film may perform cuts on unnecessary wiring lines in order to decrease capacitance or the like (cut is possible as a patterned film that overlaps a large area of the scan signal line is not provided).
[0192] Furthermore, it is preferable that a metal with high reflectance (aluminum, aluminum alloy, or the like, for example) be used in order to improve the efficiency of transmittance. The repair wiring line that crosses the signal line may be designed such that only the crossing portion is narrow and the capacitance of the panel be decreased ( FIG. 24 , for example).
[0193] In the respective embodiments above, configurations in which two gate signal lines are provided between pixels were shown, but as long as the effect of the present invention is preserved, another gate signal line may be provided. The wiring line that has the patterned film therebetween may be other wiring lines such as two adjacent data signal lines between pixels instead of two adjacent gate signal lines between pixels.
[0194] Instead of ITO, know materials such as IZO (indium zinc oxide) can be used as the electrode material.
[0195] The present invention can be applied to display devices other than liquid crystal display devices such as EL devices.
[0196] The respective configurations of the embodiments mentioned above may be appropriately combined within a scope that does not depart from the gist of the present invention.
DESCRIPTION OF REFERENCE CHARACTERS
[0000]
21 , 521 , 621 , 721 , 1121 , 1221 , 1321 , 1421 , 1521 , 1621 , 1721 , 1921 : pixel electrode
22 a , 22 b , 522 a , 522 b , 622 a , 622 b , 722 a , 722 b , 1122 a , 1122 b , 1222 a , 1222 b , 1322 a , 1322 b , 1422 a , 1422 b , 1522 a , 1522 b , 1622 a , 1622 b , 1722 a , 1722 b , 1922 a , 1922 b gate signal line
23 , 523 , 623 , 723 , 1123 , 1223 , 1323 , 1423 , 1523 , 1623 , 1723 , 1823 , 1923 data signal line
24 , 524 , 624 , 724 , 1124 , 1224 , 1324 , 1424 , 1524 , 1624 , 1724 , 1924 thin film transistor (TFT)
25 , 525 , 625 , 725 , 1125 , 1225 , 1325 , 1425 , 1525 , 1625 , 1725 , 1925 drain lead-out wiring line
26 , 526 , 626 , 726 , 1126 , 1226 , 1326 , 1426 , 1526 , 1626 , 1726 , 1926 contact hole
28 , 128 , 528 , 628 , 728 , 828 , 928 , 1028 , 1128 , 1228 , 1328 , 1428 , 1528 , 1628 , 1728 , 1828 repair wiring line (patterned film)
31 , 731 , 1931 first insulating film
32 , 732 , 1932 second insulating film
35 , 45 , 735 , 745 , 1935 , 1945 alignment film
529 , 629 same transparent film as pixel electrode
51 area without colored layer
53 area where top and bottom color boundary forms at ease
60 , 760 , 1960 liquid crystal layer
733 third insulating film
1628 , 1728 , 1828 patterned film
1823 signal line
B blue colored layer
G green colored layer
R red colored layer
BM black matrix (outside bold line
CF color filter
Cs, CSS storage capacitance wiring line
CHpas hole formed in insulating film
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The purpose of the present invention is to provide a circuit board and a display device wherein a patterned film is disposed in a manner that can sufficiently reduce the increase in capacitance and sufficiently minimize the degradation of display quality due to signal delay, while sufficiently shielding the lost part of a light shielding member with the patterned film. The present invention provides a circuit board used for a display device in which pixels are used to make an image. The circuit board comprises: a plurality of first wires and a plurality of second wires intersecting with the first wires; a thin-film transistor element; a plurality of pixel electrodes electrically connected to the drain electrodes of the thin-film transistor element; and a patterned film. In a planar view of the principal surface of the circuit board, two of the plurality of first wires extend parallel to each other between pixels, and the patterned film has a linear portion extending along the first wires between the mutually extending two first wires.
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FIELD OF THE INVENTION
[0001] The present invention relates to a novel construction of positive displacement pump for fluids, and more particularly to a rotary piston pump.
BACKGROUND OF THE INVENTION
[0002] Rotary pistons, in the nature of encased rotors with radially extending vanes which move in and out of the rotors, depending upon their location within the casing used, for example, as pumps or turbines, are known. One such device is described in U.S. Pat. No. 6,554,596 of Albert and David Patterson issued Apr. 29, 2003, in which the vane movement, in and out of the rotor, is achieved by cam surfaces within the casing which act on both inner and outer edges of the vanes.
[0003] In my co-pending U.S. patent application Ser. No. 10/680,236 entitled “Rotary Pistons”, the outward movement of the vanes is achieved by upward extensions of shoulders at the sides of each vane, which upward extensions contain pins which are seated in races continuously extending in portions of the interior wall of the casing and positioned so that as the pins move about the races, they draw their respective vanes outwardly.
[0004] Other known constructions of such vane pumps require centrifugal force, through rotation of the rotor, to force the vanes out.
[0005] Problems with such arrangements, if applied to pumps, include leakage of fluid between the vanes and consequent inability to effectively and efficiently handle fluids under high pressure. Of necessity, such devices have conventionally been of relatively small size, and, while they have been able to operate at fast speeds, they have been able to move only relatively low volumes of fluid.
[0006] Traditionally, positive displacement pumps have been of relatively complex construction and have been limited in their applications.
[0007] It is an object of the present invention to provide a positive displacement pump which is relatively economical to construct and efficient in its operation, which will be able to withstand high pressures and which will have a variety of applications.
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention there is provided a positive displacement pump for fluids which pump comprises a housing defining a chamber having opposed, interior end walls and an interior side wall. A fluid inlet port and a fluid outlet port are located at spaced locations in the interior side wall. A rotor to rotate about a longitudinal axis extending through the end walls is mounted within the housing chamber, the rotor having ends and a cylindrical side wall confronting respectively the interior end walls and side wall of the chamber. A rotor disk is provided at each end of the rotor secured to the rotor, the diameter of the rotor disks being greater than the diameter of the rotor. A slot extends diametrically completely through the rotor, longitudinally between the rotor ends. The slot has openings in opposite portions of the rotor side wall.
[0009] A pair of similar, planar vanes are provided, one vane slidably mounted in one opening of this slot and the other mounted in the other opening of the slot. Each vane extends from end to end in the rotor and has inner and outer edges extending parallel to the axis rotation of the rotor. Each vane is mounted so as to slide within the slot between an extended position protruding upwardly from a surface of the rotor side wall and a retracted position wherein the vane is entirely withdrawn into the rotor below that surface. Each vane is provided with opposite shoulders at their sides, which shoulders slide in corresponding slots in the rotor disks.
[0010] A first portion of the interior side wall of the housing is cylindrical and curved with constant radius over an angle of approximately 180°. This portion is spaced a constant distance from corresponding portions of the side wall of the rotor. A second portion of the interior side wall of the housing, in the vicinity of the outlet port, extends from an extremity of the first portion so as to be progressively closer to the rotor side wall until it is immediately adjacent to that side wall at a point beyond the outlet port intermediate between the outlet port and inlet port. A third portion of the interior side wall of the housing, in the vicinity of the inlet port, extends from the midpoint to the other extremity of the first portion of the interior end wall. The distance between the third portion and the side wall of the rotor progressively increases between the midpoint and the other extremity of the first portion.
[0011] The rotor, housing and vanes are constructed so that, during operation of the pump, fluid entering the housing through the inlet port is carried by the rotor in compartments formed between adjacent vanes, the rotor side wall between those vanes, the rotor disks and the interior side wall of the housing, until the compartments communicate with the outlet port, whereby the fluid is moved from the chamber through the outlet port. The vanes, during this operation, are urged outwardly so that their outer edges are in constant contact with the interior side wall of the housing and being urged inwardly by the housing side wall acting as a cam surface on said outer edges.
[0012] In a preferred embodiment of the present invention, the outer edges of the vanes are enlarged to form heads which provide additional weight to the vanes. The vanes' outward movement is caused by centrifugal force during operation of the pump. The opening of the slot, on each side of the rotor, is enlarged to receive the enlarged head of the corresponding vane when the vane is in retracted position.
[0013] In another embodiment, biasing means are provided between the inner edges of the vanes within the vane slot to provide outward biasing of the vanes during operation of the device and to ensure constant contact of the outer edges of the vanes with the inner side wall of the housing.
[0014] The pump according to the present invention, while providing many of the same advantages of applicant's previously developed rotary pistons, is simpler and more economical to construct, since the extending vane movement does not require end cams or races to activate and guide that movement. The present invention has a wide range of applications including pumping waste water or well water, and as a hydraulic pump.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:—
[0016] FIGS. 1 a , 1 b and 1 c are schematic side section views of an example embodiment of a positive displacement rotary piston pump according to the present invention;
[0017] FIG. 2 is a perspective view of the rotor and end disk construction of the pump according to FIG. 1 ;
[0018] FIGS. 3 and 4 are perspective views of example embodiments of vanes usable in association with the rotor and end disk, in accordance with the present invention;
[0019] FIG. 5 is a perspective view of a further embodiment of vane in accordance with the present invention; and
[0020] FIG. 6 is a perspective view, in section, of the rotor and end disk of the pump of FIG. 1 .
[0021] While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] In the following description, similar features in the drawings have been given similar reference numerals.
[0023] Turning to FIGS. 1 a , 1 b , 1 c , there is illustrated a pump 2 in accordance with the present invention, at sequential stages of its operation. Pump 2 has a housing 4 with an inlet port 6 and outlet port 8 spaced to one side of it and communicating with an interior chamber 10 defined by a side wall 12 extending between opposite end walls 14 . Mounted within housing 4 , for rotation about a longitudinal axis extending between end walls 14 (phantom, FIG. 2 ) is a rotor 16 and associated end disks 18 . End disks 18 may be secured to rotor 16 or may be integral therewith. The diameters of end disks 18 , as can be seen, are greater than the diameter of rotor 16 . Rotor 16 has a side wall 20 of elongated, cylindrical configuration. Diametrically positioned within rotor 16 is a vane slot 22 which passes through rotor 16 and extends from end to end. Corresponding slots 24 are provided in end disks 18 , aligned with vane slot 22 and extending beyond that slot, as illustrated. Mounted within vane slot 22 , for cooperative sliding movement on opposite sides of rotor 16 , is a pair of vanes 26 .
[0024] Interior side wall 12 of housing 4 , as can be seen in FIGS. 1 a , 1 b and 1 c is carefully configured so as to act as a cam surface guiding vanes 26 , for proper operation of pump 2 . In particular, a cylindrical first portion 28 of side wall 12 , over about 180°, is provided. Rotor 16 is positioned within interior chamber 10 so that the surface of its side wall 20 is the same distance from this first portion 28 of housing interior side wall 12 . A second portion 30 of interior side wall 12 extends from one extremity of first portion 28 to a midpoint 32 between inlet and outlet port 6 and 8 , this portion being contoured so that its surface progressively approaches the surface of side wall 20 of rotor 16 until, at midpoint 32 , those two surfaces are contiguous or immediately adjacent to each other. This second portion 30 extends across outlet port 8 .
[0025] A third portion 34 of interior side wall 12 extends from this midpoint 32 to the other extremity of first portion 28 in a manner such that the distance between third portion 34 and corresponding portions of the rotor surface progressively increase. Portion 34 extends across inlet port 6 .
[0026] The rate at which this distance to the surface of rotor 16 progressively increases and decreases for portions 30 and 34 may be adjusted for specific applications and desired efficiencies of the pump.
[0027] Passing through rotor 16 , preferably at a 90° angle to vane slot 22 , are one or more vent slots 36 , communicating with the interior chamber 10 of housing 4 and with vane slot 22 . A pair check valves 38 are provided in vent slot 36 as illustrated, to enable one way passage of fluid, outwardly, from vent slot 36 , to the surface of rotor 16 .
[0028] Vanes 26 have a planar body 40 , upper edges 42 and lower edges 44 . The height of the vanes, between upper and lower edges 42 and 44 , is such that, during operation of the pump, the movement of one vane does not obstruct the movement of the other. Vanes 22 extend from end to end of rotor 16 , and beyond with their shoulders 46 slidably received in end disk slots 24 . Vanes 26 slide within vane slot 22 between retracted and extended positions, upper edges 42 being at all times in contact with side wall 12 . Each of the vanes 22 is provided with enlarged head 48 , the surface of which is rounded to conform with the cylindrical surface of side wall 12 of rotor 16 when the vane is in retracted position. A suitable cavity 50 is provided at each entrance to vane slot 22 , as illustrated, to flushly receive head 48 when vane 26 is in retracted position. It is preferred that a resilient seat 52 be provided over the sides of cavity 50 , so as to provide a sealing function to reduce the amount of fluid which would enter vane slot 22 from contacting surfaces of vane 26 , and to act as a shock absorber to cushion the impact of head 48 against rotor 16 as vane 26 reaches its retracted position. The enlarged head 48 of vanes 26 provides additional weight to ensure that centrifugal force, as rotor 16 rotates during operation of the device, keeps the upper edge 42 of each vane 26 bearing against side wall 12 of housing 4 .
[0029] Different configurations of vanes 26 in accordance with the invention are illustrated in FIGS. 3, 4 and 5 . While the enlarged head vane of FIG. 5 has been described previously herein, the vanes 26 of FIGS. 3 and 4 are constructed so as to provide an outward, spring induced bias to supplement the outward centrifugal force acting on the vanes during operation of the pump. In particular, each vane 26 cooperates with a shoe plate 54 at its lower edge 44 , the shoe plate being provided with spring loaded pins 56 ( FIG. 3 ) or a spring loaded plate 58 ( FIG. 4 ), these pins and plates slidably movable within corresponding apertures in the lower edge 44 of the corresponding vane 26 . The pins and plates also further assist in guiding the vanes in their reciprocating movement within vane slot 22 .
[0030] A removable panel 60 may be provided in housing 4 to provide servicing access to chamber 10 and the pump components within chamber 10 .
[0031] In operation, as can be seen in FIGS. 1 a , 1 b and 1 c , as rotor 16 is driven in clockwise fashion, centrifugal force (in combination with the outward spring urged bias on vanes 26 , if the vane embodiment of FIG. 3 or 4 is used) ensures that the upper edges 42 of vanes 26 constantly bear against the relevant first, second and third portions 28 , 30 and 34 respectively, of side wall 12 of housing 4 . The inlet and outlet ports 6 and 8 are on opposite sides of midpoint 32 . Side wall 20 of rotor 16 is in contact with side wall 12 of housing 4 , at midpoint 32 , ensuring that fluid from inlet port 4 does not escape directly to outlet port 8 . Instead, fluid from inlet port 6 is drawn into chamber 62 ( FIG. 1 a ) as one of the vanes 26 passes over inlet port 6 and progresses to first portion 28 of side wall 12 of housing 4 . Side wall 12 at all times acts as a cam surface on upper edges 42 of the vanes 26 . As the rotor 16 continues in clockwise fashion, the other vane 26 passes over inlet port 6 . Chamber 62 then becomes sealed off and is at maximum volume ( FIG. 1 a ). With further clockwise movement of rotor 16 , as the first vane 26 passes outlet port 8 ( FIG. 1 b ), that chamber 62 then communicates with outlet port 8 and, as the volume of chamber 62 decreases with further clockwise movement of rotor 16 (with the decreasing distance of second portion 30 of side wall 12 of housing 4 with respect to the surface of side wall 20 of rotor 16 ), fluid is forced with the diminishing volume of that chamber 62 through outlet port 8 .
[0032] Fluid which enters vane slot 22 is not permitted to build up there as it is passed back to the surface of rotor 16 through check valves 38 in vent slots 36 .
[0033] Because of the relatively simple construction of the pump according to the present invention, with only two vanes and few moving parts, a pump which is inexpensive to construct and easy to repair is provided. The construction of the pump according to the present invention permits high torque on the rotor and high volume fluid movement since the shaft which drives the rotor can be the same diameter as that of the rotor.
[0034] The pump of the present invention is particularly suited to waste water, well water, hydraulics and other applications. If solids are entrapped in fluid being pumped, and get into interior chamber 10 , the enlarged heads 48 of vanes 26 will tend to crush the solids to smaller sizes so that those solids will pass through the pump 2 .
[0035] The pump according to the present invention withstands high pressure, since the shoulders 46 of the vanes 26 are supported by the end disks 18 . The simple construction of the pump according to the present invention permits it to be easily serviced and repaired in the field.
[0036] Thus, it is apparent that there has been provided in accordance with the invention a rotary piston device that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with illustrated embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention.
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A rotary piston pump comprising a rotor mounted within a housing, the rotor having a pair of slidably mounted vanes on opposite surfaces. The inner wall of the housing acts as a cam surface to move the vanes inwardly, and centrifugal force or a combination of centrifugal force and biasing causes the vanes to move outwardly. The rotor is eccentrically mounted within the housing and the housing interior walls are of irregular configuration, whereby fluid from an inlet is moved by the vanes through the housing to an outlet. This rotary piston pump is of economic construction, serves a variety of applications and is easy to service.
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CROSS REFERENCE TO RELATED APPLICATION
This invention is based on and claims priority of Japanese patent application 2001-329687, filed on Oct. 26, 2001, the whole contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor apparatus having plural parts packaged in one module, particularly a semiconductor apparatus having capacitors connected outside semiconductor elements for improving high frequency characteristics. It also relates to a production process thereof.
In this specification, in the case where plural semiconductor devices are arranged as a module to constitute a semiconductor apparatus, the respective semiconductor devices are called semiconductor elements. LSIs such as CPU are also called semiconductor elements.
2. Description of the Related Art
In recent years, the system-in-packages, in which existing chips are combined and connected at high densities to realize desired functions, are increasingly used. Compared with the case of integrating all functions on one chip, the development period can be shortened, and the cost performance can be improved.
Furthermore, semiconductor elements such as digital LSIs are advancing to be higher in speed and lower in power consumption. Because of the lower power consumption, the supply voltage declines. For example when the load impedance changes suddenly, the supply voltage is likely to vary. If the supply voltage varies, the semiconductor element is functionally disordered. So, the role of the decoupling capacitors for inhibiting the variation of supply voltage is important.
Since semiconductor elements are growing to be higher in speed, the influence of high frequency ripple is increasing. It is desired that the decoupling capacitors can also efficiently absorb the high frequency ripple component.
Because of the above, it is desired to lower the equivalent series resistance (ESR) and equivalent series inductance (ESL) of the capacitors. For this purpose, it is desired to minimize the wiring lengths between the semiconductor chips and the capacitors.
In the system-in-package, for connecting decoupling capacitors or the like to semiconductor chips or circuit substrate, there are known such techniques as (1) resin buildup technique, (2) thick ceramic film technique and (3) thin film multilayer technique.
(1) In the resin buildup technique, with a printed board used as the substrate, an insulation layer, passive element layer and wiring layer are built up on it, and capacitors are formed immediately below semiconductor chips and are connected by means of through wires. If an organic insulation layer is used as the insulation layer, the cost can be reduced, and the process can be carried out at low temperature. Furthermore, the thermal stress caused by heat cycles after mounting can be decreased, if the difference between the passive elements and the insulation layer in thermal expansion coefficient is kept small.
If capacitors are disposed immediately below semiconductor chips, ESL can be lowered, but the pitch of through wires in the capacitor support is as relatively large as 50 to 200 μm. The obtained capacitances of the capacitors are hundreds of picofarads per square centimeter, and this is insufficient as decoupling capacitors at high frequency.
(2) In the thick ceramic film technique, a low loss ceramic material is used as a substrate and an insulation layer, and a dielectric layer and a resistance layer are burned integrally. Capacitors can be formed immediately below semiconductor chips, and can be connected by means of through wires. The structure is excellent in parts-accommodating capability and low in dielectric loss (tan δ). So, the transmission loss at high frequency is small.
The obtained capacitance is tens of nanofarads per square centimeter, and the function as decoupling capacitors at high frequency is insufficient. Since the ceramics shrink in volume when burned, the dimensional dispersion becomes large. So, the through wire pitch in the capacitor support is as large as about 100 to 200 μm.
(3) In the thin film multilayer technique, a low dielectric constant resin is used as an insulation layer, and silicon or glass is used as a substrate. Resistances and capacitors can be formed in the layer, and the capacitors can be connected immediately below semiconductor chips by means of through wires. If the process is carried out at high temperature, capacitors having large capacitance of hundreds of nanofarads per square centimeter can be obtained.
If a semiconductor process is used, the through wire pitch in the support can be made as small as about 20 to 50 μm. The thermal stress caused by heat cycles after mounting can be decreased if the difference between passive elements and the insulation layer in thermal expansion coefficient is kept small.
Semiconductor elements are growing further higher in operation speed, lower in power consumption and larger in area. The transistors and wires in each semiconductor element become finer and finer. The number of terminals of a semiconductor element is also increasing, and the pitch between terminals is diminishing. There is a limit in narrowing the through wire pitch in the support of decoupling capacitors in accompany with the pitch of terminals of a semiconductor element.
If capacitors are mounted near, not immediately below, semiconductor elements, capacitors with large capacitance can be realized at low cost. However, since the wires must be routed longer, the high frequency characteristics become worse. It becomes difficult to install decoupling capacitors suitable for semiconductor elements acting at high speed at a frequency of more than GHz.
As described above, the system-in-package encounters a restriction in suitably connecting semiconductor elements, electronic parts such as capacitors, and a circuit substrate.
SUMMARY OF THE INVENTION
An object of this invention is to provide a semiconductor apparatus, in which semiconductor elements having a narrow terminal pitch, a support having through wires at a wider pitch, and capacitors are suitably electrically connected to realize a decoupling function with lowered inductance and large capacitance.
Another object of this invention is to provide a system-in-package that can be adapted to finer semiconductor elements.
A further object of this invention is to provide a semiconductor apparatus containing plural semiconductor elements to be used in such a system-in-package.
From one aspect of this invention, there is provided a semiconductor apparatus, comprising a support substrate having through holes filles with conductor in conformity with a first pitch, capacitors formed on or above said support substrate, a wiring layer formed on or above said support, leading some of said through wires upwards via said capacitors, having branches and having wires in conformity with a second pitch, and plural semiconductor elements disposed on or above said wiring layer, having terminals in conformity with the second pitch and connected with the wiring layer via said terminals.
From another aspect of this invention, there is provided a process for producing a semiconductor apparatus, comprising the steps of (a) forming through holes at a first pitch in a support substrate, (b) forming an insulation layer on side walls of said through holes, (c) filling through holes filled with conductor in the through holes provided with said insulation film, (d) forming capacitors connected with at least some of said through holes filled with conductor, and wires connected with said through holes filled with conductor or said capacitors and having a second pitch, on said support substrate, and (e) connecting plural semiconductor elements having terminals in conformity with said second pitch, with said wires.
In this way, a system-in-package having decoupling capacitors with good performance can be formed.
The wires on or above the support substrate of the capacitors can be used to connect the semiconductor elements with each other. It becomes easy to directly connect terminals disposed at a narrow pitch with each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A through 1T are sectional views showing a process for producing an intermediate laminate according to an embodiment of the present invention.
FIGS. 2A and 2B are a plan view and a partial sectional view schematically showing the constitution of a system-in-package.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of this invention is described below in reference to the drawings.
FIG. 2A shows a constitution example of a system-in-package SiP. A circuit substrate 50 is mounted with circuit parts 52 - 1 through 52 - 5 including plural semiconductor elements.
The semiconductor elements are, for example, an arithmetic processing unit, digital signal processor, memory, high frequency IC, input/output interface, etc. Another circuit part 53 is, for example, a SAW filter.
On the circuit substrate 50 , wires are formed, and between the circuit substrate 50 and the semiconductor elements 52 - 1 through 52 - 5 (and circuit part 53 ), an intermediate laminate 51 containing capacitors and wires is connected. A process for producing the intermediate laminate 51 containing capacitors and wires is described below.
As shown in FIG. 1A , for example, a 6-inch Si wafer 11 is mirror-ground to have a thickness of 300 μm, and about 0.5 μm thick silicon oxide layers 12 and 13 are formed on both sides of the wafer by thermal oxidation.
Insulation layers such as silicon oxide layers can also be formed by means of low-pressure chemical vapor deposition or sputtering instead of thermal oxidation. The insulation layer should act as an etching stopper when the Si substrate is dry-etched, and is not limited to silicon oxide in material. For example, the insulating layer can be, an oxynitride layer, or a laminate of an oxide layer and a nitride layer.
As shown in FIG. 1B , a resist mask PR 1 made of a photo resist material is formed on the silicon oxide layer 12 . Using the resist mask PR 1 as an etching mask and CF 4 as a main etching gas, the silicon oxide layer 12 is etched to form openings 14 . The openings 14 are formed according to the pattern of through wires to be formed. At this stage, the resist mask PR 1 may be removed.
Then, using the resist mask PR 1 or the patterned silicon oxide layer 12 a as an etching mask, and using SF 6 and C 4 F 8 as main etching gases, dry etching is carried out for anisotropic etching of the Si substrate 11 . This etching automatically stops at the lower silicon oxide layer 13 . As a result, via holes 14 through the silicone oxide layer 12 a and the Si substrate 11 a are formed. If the resist mask PR 1 has not been removed, it is removed after completion of etching.
As shown in FIG. 1C , the Si substrate 11 a is thermally oxidized to form a silicon oxide layer 15 a of about 1 μm thick in the regions where the Si surface is exposed. The portions of the silicon oxide layer 13 remaining at the bottoms of the via holes, remain to have the original thickness (about 0.5 μm). The upper and lower silicon oxide layers on the Si substrate 11 a are further oxidized to become silicon oxide layers 15 b and 15 c having a thickness of more than about 1 μm.
As shown in FIG. 1D , a Ti layer 16 of about 0.2 μm thick and a Pt layer 17 of about 1.0 μm thick are formed on the back surface of the substrate by sputtering. The Pt layer 17 is a seed layer for the plating to be carried out later. The Ti layer 16 is an adhesive layer for promoting the adhesion of the Pt layer 17 to the Si substrate. In the case where the seed layer has good adhesiveness, the adhesive layer may be omitted. The seed layer (and the adhesive layer) can also be formed by, for example, CVD or printing instead of sputtering.
Wet etching using a buffered hydrofluoric acid solution as an etchant is carried out to remove the portions of the silicon oxide layer 13 at the bottoms of the via holes. In this case, the other silicon oxide layers are also etched, but they are not removed entirely but partially remain due to the difference of thickness.
The etching with a buffered hydrofluoric acid solution is followed by wet etching using a diluted hydrofluoric acid nitric acid mixed solution as an etchant, to etch the portions of the Ti layer 16 exposed at the bottoms of the via holes. As a result, the Pt layer 17 is exposed at the bottoms of the via holes. The portions of the Ti layer are molten instantaneously when the etching starts. Even if the etchant has a nature of etching also the silicon oxide layers, the thickness of the silicon oxide layers removed while the Ti layer is etched is very limited. The silicon substrate 11 a remains covered with the silicon oxide layers.
Dry etching may also be carried out instead of wet etching. Also in this case, even if the portions of the silicon oxide layer 13 at the bottoms of the via holes, are completely removed by etching, other silicon oxide layers 15 a, 15 b and 15 c remain at least partially.
As a result, plural through holes can be formed in the Si substrate. At the bottoms of the through holes, the seed layer for plating is exposed, and the side walls of the through holes are covered with the insulation layer. The upper surface of the Si substrate is also covered with the insulation layer.
As shown in FIG. 1E , electroplating is carried out to form a Pt plating layer on the Pt layer 17 in the via holes 14 , for forming via conductors 18 filling or packing the via holes.
In the case where the via holes are small in diameter, the through holes filled with conductor can also be formed by CVD instead of plating. In this case, the seed layer is not especially necessary, and for example, CVD can be carried out in the state of FIG. 1B or 1 C.
As shown in FIG. 1F , the upper surface of the Si substrate is flattened or planarized by chemical mechanical polishing(CMP). The upper surfaces of the through holes filled with conductor 18 become flush with the upper surface of the surrounding insulation layer 15 b . Similarly, CMP is carried out also for the lower surface of the Si substrate, to expose the insulation layer 15 c and the through holes filled with conductor 18 . As a result, a support substrate S having through holes filled with conductor 18 can be obtained.
As shown in FIG. 1G , a Ti layer of about 0.1 μm thick and a Pt layer of about 0.2 μm thick are formed in this order as a lower electrode layer 20 on the surface of the support substrate S by sputtering at a substrate temperature of 400° C. A resist mask PR 2 is formed on the lower electrode layer 20 , and using the resist mask PR 2 as a mask, the lower electrode layer 20 is patterned by milling using Ar ions. The milling can also be combined with etching. Then, the resist mask PR 2 is removed.
Each of the lower electrodes 20 includes a first portion 20 a having a wide-area and a cut-away portion and a second portion 20 b within the cut-away portion. The second portion 20 b is formed of the same electrode layer and destined to be an extracting electrode for wire leading in the cut-away portion, while being separated from the first portion.
As shown in FIG. 1H , a (Ba, Sr)TiO 3 (BST) thin film 21 is formed on the substrate to cover the lower electrode 20 , for example, at a substrate temperature of 550° C., at an Ar gas flow rate of 80 sccm, at an O 2 gas flow rate of 10 sccm, at a vacuum degree of 30 mTorr, with 300 W power applied for a processing time of 1 hour. Under these conditions, a 0.2 μm thick BST dielectric film having a dielectric constant of 500 and a dielectric loss of 2% can be obtained.
As the material having a high dielectric constant, for example, SrTiO 3 or BaTiO 3 can also be used. It is preferred to use an oxide dielectric containing at least one of Ba, Sr and Ti and having a high dielectric constant. The dielectric film can be formed by sputtering, or also sol-gel method or CVD.
On the dielectric film 21 , a resist pattern PR 3 is formed, and a buffered hydrofluoric acid solution (NH 4 F:HF=6:1) is used for etching, to expose the surfaces of the leading electrodes and connection areas of the capacitor electrodes. Then, the resist pattern PR 3 is removed.
As shown in FIG. 1I , a Pt layer 22 of about 0.2 μm thick is formed by sputtering at a substrate temperature of 400° C. On the Pt layer 22 , a resist pattern PR 4 is formed. The Pt layer 22 is selectively removed by milling using Ar ions. As a result, an upper electrode pattern and a through conductor pattern are formed. Then, the resist pattern PR 4 is removed.
As a result, the lower electrode and the upper electrode sandwiching a BST dielectric layer form a capacitor. Furthermore, in the region free from the dielectric layer, the lower electrodes and the upper electrodes form through holes filled with conductor. It is preferred that the capacitor electrodes in contact with the oxide dielectric film are made of oxidation resistant material such as Au or Pt, or such material as Pt, Ir, Ru, Pd which keep conductivity even if oxidized, or their oxides.
As shown in FIG. 1J , a photosensitive polyimide resin layer 23 is coated to cover the upper electrodes 22 . It is desirable that the polyimide has a thermal expansion coefficient of 10 ppm/° C. or less in the in-plane direction. Then, the thermal stress by heat cycles after mounting can be decreased.
The photosensitive polyimide layer 23 is selectively exposed using, for example, a reticle and developed, to remove the polyimide layer in the wire-forming regions. The polyimide layer can also be patterned by any other method.
As shown in FIG. 1K , a Cu layer 25 is formed by electroplating on the surface of the Pt layer exposed within the openings of the polyimide layer 23 . After capacitors using an oxide dielectric layer are formed, it is preferred to use Cu as wires. Then, as required, CMP is carried out to flatten or planarize the surface of the Cu layer 25 and the polyimide layer 23 .
As shown in FIG. 1L , a Cu layer of about 0.2 μm thick is formed as a first wiring layer 26 on the polyimide layer 23 and the leading electrodes 25 by sputtering. The sputtering can be replaced with electroless plating or a combination of electroless plating and electroplating. A resist mask is formed, and ion milling is carried out to pattern the first wiring layer 26 .
As shown in 1 M, the pattern of the first wiring layer has a pitch and line width corresponding to, for example, one halves of the pitch and line width of the through holes filled with conductor 18 . For example, if the through holes filled with conductor have a pitch of 50 mm and a line width of 20 mm, the pattern of the first wiring layer has a pitch of 25 mm and a line width of 10 mm.
After patterning the first wiring layer 26 , a photosensitive polyimide resin is applied to form an insulation layer 28 for insulating the first wires 26 from each other. It is preferred that the polyimide resin has a thermal expansion coefficient of 10 ppm/° C. or less in the in-plane direction, like the aforesaid polyimide. In the case where the first wiring layer 26 is not flush with the polyimide layer 28 , it is preferred to flatten them by CMP, etc. As a result, the first wiring layer pattern is formed.
As shown in FIG. 1N , a connection wiring pattern 29 is formed according to the same method as described before.
As shown in FIG. 1O , the spaces in the connection wiring pattern are filled with a polyimide layer 30 according to the same method as described before.
As shown in FIG. 1P , a Cu layer of about 0.2 μm thick is formed as a second wiring layer 31 according to the same method as described before.
As shown in FIG. 1Q , the second wiring layer 31 is patterned according to the same method as described before, and the spaces in the pattern is filled with a polyimide insulation layer 32 as described before. As a result, a second wiring pattern is formed.
By repeating similar steps, a desired number of wiring layers can be formed.
As shown in FIG. 1R , a polyimide layer is formed as a protective film 33 on the surface of the wiring layer according to the same method as described before. Openings are selectively formed in the photosensitive polyimide protective film 33 according to the same method as described before, for forming electrode-leading regions.
As shown in FIG. 1S , a Cr layer of about 0.05 μm thick, a Ni layer of about 2 μm thick and a Au layer of about 0.2 μm thick, in this order from the bottom, are laminated on the upper surface of the substrate, to cover the protective layer 33 . The laminate is patterned to form electrode pads 35 .
A protective film 34 and electrode pads 36 are formed also on the lower surface of the substrate according to the same method described before.
For example, Pb-5 wt % Sn solder is vapor-deposited through a metal mask on the formed electrode pads 35 and 36 , and a flux is applied. They are heated and molten at 350° C., to form solder bumps 37 and 38 for connection. As a result, an intermediate laminate 51 having capacitors and wiring layers is formed.
As shown in FIG. 1T , semiconductor elements 52 are overlaid on the intermediate laminate 51 , and the bumps are molten for mounting them, to form a module. Only one semiconductor element is shown in the drawing, but as shown in FIG. 2A , plural semiconductor elements 52 are connected on the intermediate laminate 51 . Then, the intermediate laminate 51 is connected on the circuit board 50 . Alternatively, a module having plural circuit parts mounted on the intermediate laminate can also be offered as a product, and the user can mount it on a circuit board.
FIG. 2B schematically shows a portion of wires in a module. On the circuit board 50 , the intermediate laminate 51 is disposed, and on the intermediate laminate 51 , circuit parts 54 including plural semiconductor elements IC 1 and IC 2 are disposed. In the intermediate laminate 51 , there are formed through holes filled with conductor PC formed in the support substrate S, vertical wires WV connected to the through holes filled with conductor PC, electrodes C 1 and C 2 of a capacitor connected to the vertical wires WV, and local wires LI 1 and LI 2 for connecting the semiconductor elements with each other.
The terminal pitch of the semiconductor elements IC 1 and IC 2 is narrower than the terminal pitch of the circuit board 50 . If it is attempted to connect the terminals of the semiconductor elements IC 1 and IC 2 with each other via the wires on the circuit board 50 , the wire pitch must be once expanded. If the wires in the intermediate laminate 51 are used, the semiconductor elements IC 1 and IC 2 can be connected with each other using shorter wires without changing the wire pitch or suppressing the expansion of the wire pitch small.
In the constitution shown in FIG. 1T , signal wire TS is arranged vertically from the semiconductor element 52 to the circuit board 50 . Therefore, the wire length is short. Power wires V and G are connected to the semiconductor 52 from the circuit board 50 via each one electrode of a capacitor. The power wires respectively have a branch in the portion above the capacitor, to form a wire pitch adapted to the terminal pitch of the semiconductor element 52 . The opposing capacitor electrodes form a decoupling capacitance between power wires.
With the above constitution, semiconductor elements having a narrow terminal pitch can be efficiently connected with a circuit board having a wide wire pitch. Furthermore, local wires for connecting the semiconductor elements with each other without passing through the circuit board can also be formed. Capacitors having sufficient capacitances can be formed to achieve the function of decoupling capacitors.
The present invention has been described along one embodiment, but is not limited thereto. For example, it will be obvious for a those skilled in the art, to make various modifications, improvements and combinations.
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A semiconductor apparatus comprises a support substrate having through holes filles with conductor adapted to a first pitch; a capacitor formed on or above said support substrate; a wiring layer formed on or above said support substrate, leading some of said through holes filles with conductor upwards through said capacitor, having branches, and having wires of a second pitch different from said first pitch; and plural semiconductor elements disposed on or above said wiring layer, having terminals adapted to the second pitch, and connected with said wiring layer via said terminals. A semiconductor apparatus, in which semiconductor elements having a narrow terminal pitch, a support having through wires at a wider pitch, and a capacitor are suitably electrically connected to realize the decoupling function with reduced inductance and large capacitance.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 61/656,972, filed Jun. 7, 2012, the disclosure of which is incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to video games, and more particularly to distributed video game data modification.
Video games are enjoyed by many, often allowing video game players to virtually participate in otherwise unavailable activities, whether due to requirements of skill, experience, or equipment availability, or simply due to inherent dangers of the activities.
In many games a video game player may control a video game character, who may have various skills and powers, and who may be equipped with various items, whether for use in the video game or merely for purposes of visual appearance in a virtual world of the game. Some games may allow for personalization of equipping of video game characters. The personalization may relate to clothing worn by a video game character, whether for function or fashion, and what may be broadly termed accessories. The accessories may be items tradable by a video game character for value within a game, or tools or other useable equipment carried by the video game character for the video game character's use. The personalization may also, in some embodiments, relate to the video game character's skills or capabilities.
Unfortunately, while many video game players may find great enjoyment in equipping or otherwise personalizing their video game characters, the process of doing so may be laborious, and detract from the joys of video game play, particularly when the video game player is situated at a game console and ready to play.
BRIEF SUMMARY OF THE INVENTION
Aspects of the invention provide for remote and/or distributed equipping of video game characters.
In some aspects the invention provides a method for equipping a video game character, comprising: providing information regarding equipment for a video game character; receiving a personalization selection for the video game character from a first compute device, the first compute device being a device other than a compute device configured for video game play including the video game character; checking validity of the personalization selection for the video game character; storing the personalization selection for the video game character; and transmitting the personalization selection for the video game character to a second compute device, the second compute device being a device configured for video game play including the video game character. In some aspects of the invention the personalization selection is equipment associated with the video game character. In some aspects of the invention the personalization selection is capabilities of the video game character. In some aspects the invention the personalization selection is equipment and capabilities of the video game character. In some aspects of the invention, the first compute device is a smartphone. In some aspects of the invention, the first compute device is a tablet computer. In some aspects of the invention, the second compute device is a game console. In some aspects of the invention, the information regarding equipment comprises a list of equipment. In some aspects of the invention, the information regarding equipment further comprises information regarding effectiveness of the equipment within the video game. In some aspects of the invention, the video game character has available different sets of equipment, and aspects of the invention further comprise receiving an identification of a set of equipment to which the selection of equipment applies.
In some aspects the invention provides a system for performing the above-mentioned method(s), the system having at least one processor configured by program instructions to command provision of information regarding personalization to the first compute device, check validity of personalization selection, command storing of personalization selection, and command transmission of the personalization selection to the second compute device.
In some aspects of the invention the information regarding personalization selection is transmitted to the first compute device over a combination of wired and wireless communication links. In some aspects of the invention the transmission of personal selection information to the second compute device is transmitted over elements of a broad area network. In some aspects of the invention the broad area network is the Internet.
In some aspects the invention provides a method for distributed equipping of video game characters comprising: receiving, over a network, a request regarding possible personalization selections for a video game character of a video game; transmitting, over the network, information regarding equipment for the video game character to a first compute device not configured for play of the video game; receiving a personalization selection for the video game character from the first compute device; checking validity of the personalization selection for the video game character; storing the personalization selection for the video game character in memory; and transmitting the personalization selection for the video game character to a second compute device configured for play of the video game.
In some aspects the invention provides a system for distributed equipping of video game characters of a video game comprising: a server including at least one processor, a first compute device not configured for play of the video game, and a second compute device configured for play of the video game, the server, the first compute device, and the second compute device coupled by a network; the at least one processor being configured by program instructions to command transmission of information regarding personalization of a video game character to the first compute device in response to a request from the first compute device for personalization information of the video game character, to check validity of a personalization selection requested by the first compute device, to command storing of the personalization selection, and to command transmission of the personalization selection to the second compute device; the first compute device being configured to request information regarding personalization of the video game character, to make personalization selections for the video game character, and to transmit the personalization selections; and the second compute device being configured to present, during game play, an option to accept the personalization selections and to modify information of the video game character to reflect the personalization selections upon selection of the option.
These and other aspects of the invention are more fully comprehended upon review of this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a block diagram of a system in accordance with aspects of the invention.
FIG. 2 is a flow diagram of a process for modifying video game character equipment in accordance with aspects of the invention.
FIG. 3 is a flow diagram of a process, for example performed by a mobile compute device, useful in modifying video game character equipment in accordance with aspects of the invention.
FIG. 4 is a flow diagram of a process, for example performed by a server, useful in modifying video game character equipment in accordance with aspects of the invention.
FIG. 5 is a flow diagram of a process, for example performed by a game console, useful in modifying video game character equipment in accordance with aspects of the invention.
FIG. 6 is a screen shot of a mobile compute device showing equipment for a video game character in accordance with aspects of the invention.
DETAILED DESCRIPTION
FIG. 1 illustrates a system in accordance with aspects of the invention. A game console 113 , with associated monitor and game controller, is configured for play of a video game. The game console may be considered a compute device. During game play the game console, which includes at least one processor, computer memory, communication circuitry, and associated other hardware, executes program instructions to provide for play of the video game, with a video game player providing game play inputs using the game controller and the monitor associated with the game console displaying game play events. In various embodiments the video game may be an action game, for example a fighting game or a first-person shooter game, a role playing game, or a vehicle simulator game. The video game includes a character, who has various skills and capabilities and is equipped with equipment for use and/or display in the video game. The equipment in various embodiments may be items of clothing, weapons or other gear, vehicles or vehicular components, or other items.
The game console is coupled to a network 115 . The network may be a broad area network, for example the Internet. Also coupled to the network is a server 111 , a mobile compute device, shown as a smartphone 117 , and a personal computer, shown in the fowl a laptop computer 119 . The server may be for example be part of a server farm, including multiple servers, some of which may provide similar functions, and the server farm may be located at a co-location facility or other facility providing security, environmental conditioning, and wired Internet connections. The laptop may have a wired or wireless connection to the Internet. In some embodiments the laptop may be located approximate the game console, at least at some times, but in many embodiments the laptop is located at locations different than the game console. The smartphone is generally coupled to the Internet by way of a wireless cellular communications system, which may include wired communications links in addition to wireless communication channels. The server, laptop, and smartphone, of course, each have one or more processors, memory, communication circuitry. and associated hardware.
Skills, capabilities, and/or equipment associated with a game character may be modified through use of the smartphone or laptop, both of which may be considered compute devices, with one or neither in various embodiments configured to provide for game play of the video game. In some embodiments, for example a smartphone, laptop, or other personal computer may be a compute device configured for game play, while in various embodiments some or all of them may not. In some embodiments, using the smartphone and personalization of game character equipment as an example, the smartphone executes an application displaying options for equipping a game character. receives equipment selections, and transmits the equipment selections to the server. The server transmits the equipment selections to the game console, for use during game play, with the game console providing for game play with the game character equipped as indicted by the equipment selections. In some embodiments the server may validate the availability of the equipment selections for the game character, and/or provide additional information regarding equipment to the smartphone, for example to allow a user to investigate properties associated with various items or equipment or otherwise perform research related to selection of equipment.
FIG. 2 is a flow diagram of a process for modifying video game character personalization in accordance with aspects of the invention. In various embodiments the process of FIG. 2 may be performed by the system of FIG. 1 , or elements of the system of FIG. 1 . In some embodiments the process of FIG. 2 may be performed and/or have performance commanded by processors of elements of the system of FIG. 1 .
In block 211 of the process. personalization information for a video game character of a video game is set or modified on a compute device which is not configured for providing game play. The personalization information may be termed character load out information or simply load out information. In some embodiments the personalization information is limited to particular categories of information, with only a limited predefined number of selections possible within each category. In some embodiments the personalization information comprises equipment associated with a game character. and in some embodiments the personalization information is limited to equipment associated with the game character or such equipment and capabilities related to use of such equipment and/or, in various embodiments, capabilities related to ability to use or call upon use of similar or related equipment.
The compute device which is not configured for game play may. in various embodiments, be a compute device which potentially may be able to execute game program instructions of the video game, but does not have associated hardware which would make the compute device suitable for play of the video game. For example, due to screen display limitations or lack of interface ability with a particular game controller, a particular device, for example a smartphone, may not be suitable for play of the video game. Similarly, in various embodiments the compute device which is not configured for game play may be a compute device for which an operable version of the game program instructions is not available, as may be the case if game program instructions for the video game are only available for use with one, or several, game consoles, but not for smartphones or personal computers.
In some embodiments the personalization information is set or modified by a processor of the compute device commanding display of possible personalization selections, receiving a personalization selection or selections by way of user inputs to the compute device. and setting information reflecting the personalization selections, generally by storing the information in memory of the compute device in most embodiments. In some embodiments the compute device may allow for setting of different sets of personalization selections, with for example the different sets of personalization selections later being available as alternatives during game play on another compute device.
In block 213 the compute device provides the information reflecting the personalization selections to a server. In various embodiments the compute device provides. along with the personalization selections. identification of a game character to which the personalization selections apply, identification of a game player with whom the game character is associated, and/or identification of a game console or game to which the personalization selections apply.
In block 215 the server provides the personalization information to another compute device. The other compute device is configurable and configured to execute game program instructions for the video game. In some embodiments the other compute device is a game console.
In block 217 the other compute device modifies the game character information to reflect the personalization selections indicated by the personalization information. In some embodiments a game player is presented an option to accept the personalization selections prior to modification of the game character information. In some embodiments the game player has an option, prior to or in some embodiments during game play, to accept the personalization selections for use with the game character.
In block 219 the other compute device provides for game play.
The process thereafter returns.
FIG. 3 is a flow diagram of a process, for example performed by a mobile compute device, useful in modifying video game character equipment in accordance with aspects of the invention. In various embodiments the process of FIG. 3 may be performed by a compute device such as the smartphone or the laptop of FIG. 1 , or elements of smartphone or laptop of FIG. 1 . In some embodiments the process of FIG. 3 may be performed and/or have performance commanded by processors of the smartphone or laptop of the system of FIG. 1 .
In block 311 the process requests information regarding possible personalization selections. In some embodiments the request for information is by way of transmission of the request to a server having access to memory storing such information.
In block 313 the process receives information regarding possible personalization selections. In some embodiments the information regarding the possible personalization selections comprises current personal selections for a game character and/or a range of possible personalization selections.
In block 315 the process makes or modifies personalization selections. The personalization selections may be made or modified, for example, based on user inputs to the compute device.
In block 317 the process transmits the personalization selections to the server.
The process thereafter returns.
FIG. 4 is a flow diagram of a process, for example performed by the server of FIG. 1 . useful in modifying video game character equipment in accordance with aspects of the invention.
In block 411 the process receives a request over a network for information regarding personalization of a video game character from a compute device.
In block 413 the process transmits over the network information regarding personalization options for the video game character to the other compute device.
In block 415 the process receives modified personalization selections for the video game character from the compute device. In some embodiments the process additionally compares the personalization selections against information stored in memory reflecting allowable personalization selections for the character, with the allowable personalization selections in some embodiments additionally based on rule sets utilizing the information stored in memory. In some embodiments the process does not allow for the personalization selections if the personalization selections are not allowed.
In block 417 the process transmits the personalization selections to a compute device configured to execute game program instructions.
FIG. 5 is a flow diagram of a process, for example performed by the game console of FIG. 1 , useful in modifying video game character equipment in accordance with aspects of the invention.
In block 511 the process receives personalization selections from a server.
In block 513 the process modifies game character information to reflect the personalization selections.
In block 515 the process provides for game play.
The process thereafter returns.
FIG. 6 is a screen shot of a mobile compute device showing selected equipment for a video game character in accordance with aspects of the invention, along with an option to update the selected equipment by transmitting the selection to a server.
In the screen shot of FIG. 6 , three different alternative sets, or classes, of personalizations for the video game character are available, each with a larger piece of equipment and a smaller piece of equipment. A Class 1 indicates personalization selections of equipment of a MK14 and a USP 45 caliber. A Class 2 indicates personalization selections of equipment of an M16 and a G17 handgun. A Class 3 indicates personalization selections of an XM29 and a M1911 handgun. Upon selection of the Update Selection option, the device showing the displayed information transmits the personalization selections to a server for further processing.
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Video game characters of a video game may have associated attributes, such as their equipment, modified using a device which may be both remote from a device used to play the video game and incapable of playing the video game. A server in communication with both devices may communicate video game character information to the device remote from the game play device, check validity of modifications to video game character equipment requested by the remote device, save information of the modifications, and provide the information of the modifications to the device used to play the video game. The device used to play the video game may allow for acceptance, and use thereafter, of the equipment modifications during game play.
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TECHNICAL FIELD
[0001] The present invention belongs to the field of energy transduction equipment, and is related to a fuel cell which directly transforms chemical energy that fuel gas contains into electricity. In particular, the present invention relates to an MCFC gas-turbine hybrid system that increases the power generation efficiency of molten carbonate fuel cells (MCFC), makes recovery of CO 2 easy, and further enables operations such as thermoelectric conversion, gives flexibility to a system so as to enable free adjustment of cathode gas composition, thereby contributing to effective use of energy resources and improvement of earth environment, and a method of operating the same.
[0002] Hereinafter, in this application, a MCFC-gas turbine hybrid system is simply described as “MCFC power generation system.”
BACKGROUND ART
[0003] FIG. 3 is a configuration diagram of conventional MCFC power generation system (MCFC-gas turbine hybrid system).
[0004] A fuel gas FG, such as urban gas, is led to a fuel humidifier 41 , following desulfurization by a desulfurization agent 2 in a desulfurizer 1 . Here, the fuel gas is heated by the cathode exhaust of MCFC12, during which treatment water PW is sprayed on and evaporated; the preheated mixed gas of the fuel gas and vapor is then led to a pre-converter 9 . The treatment water used here is supplied to a fuel humidifier 41 through a treatment tank 5 by a pump 6 , after supply water W is treated in a water treatment device 4 .
[0005] The pre-converter 9 is a type of reformer, which contains a reforming catalyst 10 , but does not include a heat source, and mainly modifies components heavier than ethane using its own sensible heat, and reforming of methane hardly occurs. The gas that outlets pre-converter 9 is heated to a temperature near working temperature of fuel cell by a fuel heater 11 , and is supplied to MCFC12. MCFC12 is of an internal reforming type and an internal reformer 38 is built into the fuel cell.
[0006] Although about 70% of the total amount of H 2 and CO reformed and generated at anode A is used in the power generation reaction (H 2 +CO 3 2− ->H 2 O+CO 2 +2e − ), the remainder is led to the catalytic combustor 14 as anode exhaust. Here, the anode exhaust is mixed with air, which is the gas turbine exhaust, and the flammable component in the anode exhaust is combusted by combustion catalyst 15 . The combustion gas with increased temperature is cooled by heat-exchanging with compressed air CA in a high temperature heat exchanger 16 , and is then supplied to cathode C.
[0007] At cathode C, CO 2 and oxygen are partly consumed in the power generation reaction (CO 2 +1/2O 2 +2e − ->CO 3 2− ) and discharged from cathode C. The cathode exhaust provides heat to the fuel side in fuel heater 11 , flows into a low-temperature regeneration heat exchanger 32 to preheat compressed air, then provides heat to the fuel side in fuel humidifier 41 , and is then emitted in the atmosphere.
[0008] On the other hand, gas turbine generator 27 comprises a compressor 28 , a turbine 29 , and an electric generator 30 connected by a single axis; air AIR is compressed by the compressor 28 through filter 31 , and the compressed air CA is preheated in the low-temperature regeneration heat exchanger 32 , is subsequently heated to a predetermined temperature in the high temperature heat exchanger 16 , and flows in to the turbine 29 . In turbine 29 , work is done in the process of expanding to near atmospheric pressure, and the exhaust is supplied to the cathode through catalytic combustor 14 and high temperature heat exchanger 16 . In gas turbine generator 27 , the shaft output obtained by subtracting power for compressor 28 and mechanical loss from the output of turbine 29 is transmitted to electric generator 30 , thereby obtaining alternate current by use of exhaust heat of fuel cell.
[0009] Although this system has high power generation efficiency, and thus reduces the amount of CO 2 discharge, in the end, CO 2 generated from fuel gas, such as urban gas, externally-supplied, is completely contained in the cathode exhaust, and emitted in the atmosphere. Moreover, since gas turbine generator 27 recovers the heat emitted from MCFC12, the temperature of the cathode exhaust becomes very low in the end, collection of steam from the exhaust is impossible.
[0010] FIG. 4 is a configuration diagram of the apparatus used for separation and recovery of CO 2 from combustion fuel gas.
[0011] Combustion fuel gas CG enters absorption tower 42 from the bottom part and contacts absorbent liquid LAB in the process until it is discharged from the top part, during which CO 2 in the combustion fuel gas is absorbed by absorbent liquid LAB. After absorbing CO 2 , absorbent liquid RAB is pressurized by pump 43 , preheated by heat exchanger 44 , and is then fed from the upper part of regeneration tower 45 . Absorbent liquid RAB is then heated by coming into contact with the hot gas arising from the lower part, while falling toward the lower part, thereby emitting the absorbed CO 2 . Re-boiler 46 is installed on the bottom part of regeneration tower 45 , which heats the absorbent liquid with a heat medium HM. CO 2 and vapor flow from the bottom part toward the upper part of the regeneration tower, and, finally CO 2 gas CO 2 G is collected from the top. After emitting CO 2 , absorbent liquid LAB is pressurized by pump 47 , cooled by heat exchanger 44 and cooler 48 , and once again supplied from the upper part of the absorption tower.
[0012] By using the above-described CO 2 separation recovery apparatus, CO 2 contained in combustion fuel gas can be separated and collected, but energy consumption such as a heat source for the re-boiler and power for the pump is large, and the facility cost is also expensive.
[0013] Moreover, prior art such as patent documents 1 and 2, related to the present invention, have already been disclosed.
[0014] FIG. 1 is FIG. 3 disclosed in patent document 1. This diagram indicates that by utilizing the fact that combustion of the flammable component in the anode exhaust of solid oxide form fuel cell under oxygen, converts the combustion gas to CO 2 and H 2 O, cooling and separating H 2 O, CO 2 can be easily recovered. Therefore, that CO 2 is recoverable by cooling the anode exhaust of a fuel cell after combustion under oxygen and separating moisture, has already been disclosed by patent document 1.
[0015] On the other hand, it is a simple principle of chemistry that theoretically, combustion of all hydrocarbons under oxygen produces CO 2 and H 2 O. A fuel cell is, in short, the oxidation process of fuel gas, and anode exhaust is fuel gas in the state of partial oxidation. If the fuel gas supplied to a fuel cell is a hydrocarbon fuel or a fuel gas obtained from it, the anode exhaust is a partial oxidation product of the hydrocarbon fuel. By combusting under oxygen and cooling to remove water, CO 2 can be recovered.
[0016] In the case of FIG. 1 , SOFC is used as a fuel cell. Since the electrolyte in SOFC has oxygen ion conductivity, oxygen alone migrates to the fuel pole (anode), even if air is supplied to the air pole (cathode), and reacts with hydrogen to generate electricity; thus, N 2 is never mixed into the anode exhaust. Therefore, since air and not just oxygen can be supplied to the cathode, oxygen is only necessary for combusting the anode exhaust under oxygen; thus the amount of oxygen consumption can be decreased. However, even in phosphoric acid form fuel cells (PAFC) and polymer electrolyte fuel cells (PEFC) that have hydrogen ion conductivity, nitrogen is not mixed in the anode exhaust when air is supplied to the cathode, and by combustion of the anode exhaust under oxygen, CO 2 and H 2 O is generated, and CO 2 is collected by cooling and removing moisture.
[0017] That is, in the case of FIG. 1 , SOFC is used as a fuel cell, preheating air 130 obtained by preheating air 120 using air preheater 110 is supplied to the cathode, and the heat source for the air preheater is the cathode exhaust. Further, as fuel, coal 340 and oxygen 350 is gasified in a coal gasification furnace 310 to obtain a gas, which is then desulfurized in a desulfurizer 320 , passed through a methanol synthesis catalyst layer 330 , meanwhile leading steam at its entrance and outlet; the gas exiting the catalyst layer is fed to anode A. The fuel gas fed causes an internal reforming reaction within the fuel cell, and power generation reaction occurs by the H 2 and CO produced. External oxygen is supplied to the resulting gas discharged from anode A, which is then led to burner 360 ; the combustion gas is further led to a heat exchanger 200 , whereby water 220 is evaporated, which steam is used as a fuel reforming steam. Furthermore, the combustion gas cooled by heat exchanger 200 is subsequently led to a cooler 230 , whereby water is separated, and the remaining gas is collected as CO 2 . Moreover, the collected water is used in order to generate steam.
[0018] In the above-mentioned patent document 1, the fuel cell is limited to SOFC in the scope, and MCFC is not mentioned at all. The reason may be that the power generation principles differ and the same process is not applicable to MCFC.
[0019] On the other hand, FIG. 2 is equivalent to FIG. 14 disclosed in patent document 2, and is a hybrid system of MCFC, a gas turbine, and a steam turbine. The system uses oxygen as the oxidizer instead of air to enabled CO 2 recovery.
[0020] The fuel cell of this system is MCFC, and methanol is supplied to the anode 407 from a tank, mixed with the recycled anode exhaust, and supplied to the anode. Moreover, a combustion gas obtained by combusting anode exhaust under oxygen and a gas turbine exhaust are mixed and supplied to the cathode 406 . The cathode exhaust is led to a steam generator 408 , and after generating steam, is led to a cooler 410 , whereby moisture is separated. The steam generated by the steam generator is led to a steam turbine 409 , and drives the steam turbine to generate electricity. Further, the cathode exhaust from which moisture was separated by the cooler 410 , i.e., mixed gas of CO 2 and O 2 , is led to a compressor 411 of the gas turbine, and the compressed gas is heated by the heat exchanger 413 , and led to a burner 403 . Methanol and oxygen are supplied to the burner 403 , and the combustion gas is supplied to the gas turbine, and work is generated during the process of expansion inside the gas turbine, thereby generating electricity. Exhaust from the gas turbine is supplied to the cathode. On the other hand, the anode exhaust is led to a burner 412 , into which oxygen is supplied, and the combustible component in the anode exhaust is combusted. After this combustion gas gives heat to compressed gas in the heat exchanger 413 , it is separated into two lines: in one line, moisture is separated by a cooler 414 and CO 2 gas is collected; the other line is supplied to the cathode.
RELATED ART DOCUMENTS
Patent Documents
[0000]
Patent document 1: JP-A-H04-000108, “COMBUSTION DEVICE”
Patent document 2: JP-A-H11-026004, “POWER GENERATING SYSTEM”
[0023] The system disclosed in patent document 2 is a combination of MCFC and gas turbine and is extremely complicated, difficult to operate and control since the subsystems affect each other, thus, making it impossible to freely change the composition of cathode gas.
[0024] Hereinafter, problems that are not solved by the system disclosed in patent document 2 are described in detail.
[0025] (1) The power generation reaction of MCFC is as follows. About half of the reaction heat from hydrogen in transformed to electricity, and the remainder turns to heat.
[0000] Cathode reaction: CO 2 +1/2O 2 +2 e − ->CO 3 2−
[0000] Anode reaction: H 2 +CO 3 2− ->H 2 O+CO 2 +2 e −
[0000] Whole reaction: H 2 +1/2O 2 ->H 2 O
[0026] Therefore, cooling of heat generated during power generation reaction is necessary for this fuel cell; for an external reforming type MCFC, sensible heat from cathode gas and anode gas is used for cooling, and for an internal reforming type, in addition to the sensible heat of cathode gas and anode gas, reforming reaction is also used for cooling.
[0027] Therefore, the flow rate of the gas which flows through the cathode and the temperature at the inlet and an outlet are decided by the heat balance of the fuel cell. Exhaust from gas turbine is supplied to the cathode, and the cathode exhaust is fed to a compressor in the gas turbine after separating moisture, methanol and oxygen are added and the combustion gas is fed to the gas turbine. That is, cathode and a gas turbine act as one and cannot be freely adjusted individually. It is quite difficult to control the rate of gas flow at the cathode and the temperature at the inlet and outlet so as to maintain heat balance.
[0028] On the other hand, the same amount of CO 2 and O 2 as those consumed in the power generation reaction at the cathode must be externally-supplied. Although CO 2 is supplied from methanol and by recycling exhaust obtained from combustion of anode exhaust under oxygen, the amount supplied by such means must be in exact agreement with the amount consumed in the power generation reaction. Since the quantity of methanol and oxygen determines the temperature at the inlet, while also determining CO 2 balance, it is quite difficult to satisfy this condition.
[0029] Furthermore, since there is no purge line in the cathode gas circulation system, the quantity of CO 2 generated from methanol cannot exceed the amount of power generation reactions, oxygen cannot be fed in a quantity above that consumed in the power generation reaction, and the total amount of CO 2 and O 2 that is fed from the combustion gas of anode exhaust, and the total amount of CO 2 and O 2 that is fed from the methanol and O 2 burner must be in exact agreement with the quantity of those consumed by the power generation reaction.
[0030] On the other hand, since the temperature at the outlet of the gas turbine, i.e. the cathode entrance, is determined by the inlet temperature, which is decided by the combustion of methanol, there is a factor, aside from CO 2 balance, that determines the flow rate of methanol. Thus, the fuel cell and gas turbine can only be operated simultaneously under conditions that satisfy these conditions.
[0031] Furthermore, if for example, power generation load were to be decrease from 100% to 50% of its rated value, heat generation by the fuel cell decreases to less than half, and if the inlet and outlet temperatures of the cathode were to be fixed, then the flow rate to the gas turbine must be controlled to less than half. Moreover, since the pressure ratio of the gas turbine also changes with the change in flow rate, in order to maintain the cathode inlet temperature uniformly, the amount of methanol, in other words, combustion temperature must be changed depending on the flow rate. On the other hand, since the amount of CO 2 consumed by the power generation reaction becomes less than half, the amount of methanol must also become less than half.
[0032] As has been described, it is very difficult to operate both gas turbine and fuel cell simultaneously, and further change its load freely, while maintaining circulation rate of cathode gas, the cathode inlet and outlet temperatures, and CO 2 balance, which determines the heat balance of fuel cell.
[0033] (2) Moreover, when using oxygen as an oxidizer at the cathode, not only is it possible to recover CO 2 , but by heightening the partial pressure of CO 2 and O 2 at the cathode, voltage of the fuel cell can be increased, which results in increased output of the fuel cell, and improvement of power generation efficiency. Such merit must be used to advantage. However, on the other hand, in MCFC, there is a problem of nickel short-circuit, and increasing CO 2 partial pressure at the cathode shortens the life of a fuel cell.
[0034] Nickel short-circuit is a fatal problem for a fuel cell, which occurs when nickel oxide constituting the cathode dissolves into the electrolyte as ions (NiO+CO 2 ->Ni 2+ +CO 3 2− ), which are then reduced by hydrogen and deposited in the electrolyte plate as metal nickel (Ni 2+ +H 2 +CO 3 2− ->Ni+H 2 O+CO 2 ), and increase in nickel deposition causes conduction between anode and cathode of the electrolyte plate, which should be insulated.
[0035] In order to increase voltage of the fuel cell while preventing such nickel short-circuit, gas composition at the cathode should be freely controllable; however, in the system disclosed in FIG. 2 , it is virtually impossible to change the CO 2 and O 2 concentrations at the cathode freely, while satisfying heat balance and CO 2 balance of the fuel cell.
[0036] (3) Moreover, although methanol is supplied to the anode as fuel, steam, which is required for reforming, is not externally-supplied, but is provided by recycling of the anode exhaust. Since the anode exhaust contains a large amount of CO 2 in addition to H 2 O, and CO 2 is also recycled, the hydrogen partial pressure at the anode decreases, leading to a decrease in voltage of the fuel cell, and decrease in power generation efficiency. Furthermore, in this system, methanol fuel must be supplied not only for MCFC, but for the gas turbine, as well, and in comparison to a system with the highest power generation efficiency, where fuel is only supplied for the MCFC, power generation efficiency becomes low.
[0037] Although there is no description in particular for the system indicated in FIG. 2 , an oxygen plant is required in order to supply oxygen, and the quantity of oxygen consumption is that necessary for the combustion of both methanol for the fuel cell and methanol for the gas turbine, thus leading to much larger consumption power, which then becomes a major factor in decreasing its power generation efficiency.
[0038] Although the use of oxygen can be a factor in increasing power generation efficiency in MCFC, since a gas turbine is decided by the flow rate, the entrance temperature, and the pressure ratio that flows through the gas turbine, there is no particular advantage in using oxygen, and the consumption power for the oxygen plant corresponding to the gas turbine becomes a factor that decreases power generation efficiency.
[0039] (4) Moreover, in the system disclosed in FIG. 2 , heat is not recovered; the system's aim seems to be to convert as much energy that fuel holds to electricity, and the system seems to be intended for use in large-scale business power generation facilities, and is thus not suitable for middle-to-small-size dispersed power source, which requires both heat and electric power.
[0040] Furthermore, change of load is also required in a dispersed power source, and the rate of heat and electricity needed is not constant, and so-called thermoelectric variable operation is also required. However, in FIG. 2 , the entire system is integrated, and lacks system flexibility for load change, thermoelectric variable operation, and adjustment of cathode gas composition, etc.
SUMMARY OF THE INVENTION
Technical Problem to be Solved by the Invention
[0041] The present invention has been originated in order to solve the above-mentioned conventional problems. That is, the purpose of the present invention is to provide an MCFC power generation system, which minimizes the facility added to usual power generation facilities, drastically reduces or eliminates atmosphere discharge of CO 2 while simultaneously acquiring high power generation efficiency and heat recollection efficiency, and method of operating the same. Furthermore, the purpose of the present invention is to provide a MCFC power generation system, which enables adjustment of voltage and output of fuel cell within a certain range by adjusting cathode gas composition, enables drastic change in the ratio of heat and electricity, and enables the so-called thermoelectric variable operation, and method of operating the same.
Means to Solve the Problem
[0042] According to the present invention, a MCFC power generation system comprising a fuel gas supply system for supplying fuel gas to a molten carbonate type fuel cell is provided, wherein said fuel gas supply system comprises: a fuel heater that connects to an anode outlet; two lines that divide anode exhaust from said fuel heater, of which one line is connected to an anode exhaust circulation blower, mixing outlet gas from said blower with fuel gas externally supplied to said fuel cell, then mixing with steam for reforming, and leading to catalyst layer in a pre-converter, whereby pretreatment of mixed gas is performed, followed by heating with a fuel heater, and supplying to said fuel cell.
[0043] According to a desirable embodiment of the present invention, amount of anode recycling is controlled so that the mixed temperature of the outlet gas from the anode exhaust circulation blower, the externally-supplied fuel gas, and the steam for reforming, is in the range of 250 to 400° C., thereby obtaining high methane concentration in pre-converter outlet gas.
[0044] Moreover, according to the present invention, a MCFC power generation system comprising a cathode gas circulation system for circulating cathode gas of a molten carbonate type fuel cell is provided, wherein said cathode gas circulation system comprises: a closed circulation loop, comprising a cathode gas circulation blower whose intake side connects to a cathode outlet and discharge side connects to a cathode inlet, wherein the cathode outlet side is separated in to two lines, one of which is connected to a purge line comprising a flow rate regulation valve, and the other line is connected to a check valve, and further, downstream to said check valve, there is connected an oxygen supplying line and a CO 2 supplying line, each of which comprise a control valve.
[0045] According to a desirable embodiment of the present invention, by building a heat exchanger with temperature control function for controlling temperature of CO 2 supply to the CO 2 supply line, cathode inlet temperature can be controlled by simply supplying and mixing oxygen and CO 2 to the cathode outlet gas which passes through the check valve.
[0046] Moreover, according to the present invention, a MCFC power generation system comprising an energy recovery system for recovering energy from anode exhaust of a molten carbonate type fuel cell is provided, wherein said energy recovery system: leads at least part of anode exhaust to a mixer, wherein said mixer comprises an oxygen supply line and a combustion gas recycle line; and mixed gas from the mixer outlet is led to a catalytic oxidizer, wherein combustible composition in said anode exhaust is combusted under oxygen; and combustion gas exiting said catalytic oxidizer first heats compressed air for a gas turbine that utilizes air as a working medium, then heats recycled CO 2 , and is led to an exhaust heat recovery boiler, thereby producing steam; and combustion gas exiting the evaporation side of the exhaust heat recovery boiler is separated into two lines, of which one is connected to a combustion gas recycling blower to recycle cooled combustion gas to the mixer, and the other line feeds to a water supply heater of the exhaust heat recycling boiler.
[0047] According to a desirable embodiment of the present invention, said system comprises a gas turbine that utilizes air as its operation medium, which receives heat from high temperature combustion gas from said catalytic oxidizer through an air heater, and air, which is the above-mentioned operation medium is independent and does not mix with any other fluids.
[0048] Moreover, as a means to collect heat energy from turbine exhaust, said system is constructed so that compressed air is first heated by a regenerated heat exchanger, and steam is produced by an exhaust heat recovery boiler, subsequently; and at the exhaust heat recovery boiler, temperature of regenerated heat exchanger outlet is controlled so as to enable constant production of steam necessary for reforming.
[0049] Moreover, rotation frequency of the combustion gas recycling blower is controlled so as to maintain a constant preset temperature at the outlet of the catalyst oxidization chamber.
[0050] Further, said system comprises a damper that enables switching of position of recycling combustion gas from a low temperature part to a high temperature part.
[0051] Moreover, according to the present invention, a method for operating the above-described MCFC power generation system is provided, wherein the amount of combustion gas passing through an air heater is increased by switching position of recycling combustion gas from a low temperature part to a high temperature part, thereby increasing gas turbine output by increasing amount of heat provided to compressed air, while, conversely decreasing amount of steam production at the exhaust heat recovery boiler.
[0052] Furthermore, according to the present invention, a method for operating the above-described MCFC power generation system is provided, wherein circulation flow rate of the combustion gas recycling blower is gradually increased by gradually reducing the set value for the outlet temperature of the catalytic oxidizer, thereby decreasing the outlet temperature of the catalytic oxidizer, and decreasing the amount of heat provided to the compressed air through the air heater, thereby decreasing output of gas turbine, and conversely increasing the amount of steam production at the exhaust heat recovery boiler.
[0053] According to a desirable embodiment of the present invention, the amount of steam production by the exhaust heat recovery boiler is at a maximum when the supply of steam for reforming is switched from the exhaust heat recovery boiler at the gas turbine side to that at the combustion gas side while gas turbine output is near zero, and then the gas turbine is turned off.
[0054] Moreover, according to the present invention, a method for operating the above-described MCFC power generation system is provided, wherein voltage of the fuel cell is maintained at a near constant throughout its life, by increasing the concentration of CO 2 and O 2 in the cathode circulation system in an amount that corresponds to voltage degradation, in correspondence with time-dependent voltage degradation of fuel cell.
Effect of Invention
[0055] (1) According to the composition of the above-described present invention, the system comprises a cathode gas circulation system, wherein cathode gas is circulated by a cathode gas circulation blower and forms a closed loop; oxygen consumed by the power generation reaction is supplied by the oxygen supplying plant, and CO 2 is supplied by recycled CO 2 , and thus, the necessary amount and composition of cathode circulation gas is maintained, and there is basically no exhaust from the cathode circulation system. Therefore, it may be said that the present power generation facility is a power generation facility with substantially no, or minimized, atmospheric release of CO 2 .
[0056] (2) On the other hand, since only CO 2 remains by combusting combustible components in the anode exhaust under oxygen, cooling and removing water, part of such CO 2 is recycled to the cathode, while the remainder is mostly collected as high concentration CO 2 gas, there is virtually no atmospheric release of CO 2 from the anode.
[0057] (3) Moreover, by recycling fuel gas in the anode exhaust, the amount of fuel gas externally-supplied can be reduced.
[0058] Also, in the present invention, by mixing with part of the high-temperature exhaust, the temperature of fuel gas and reforming steam can be raised to a temperature close to the working temperature of the pre-converter, thus the need for a fuel humidifier is eliminated.
[0059] Furthermore, since anode exhaust contains steam generated in the power generation reaction at the anode, the quantity of reforming steam to be freshly supplied is significantly reduced.
[0060] (4) Moreover, since the amount of reforming steam supplied can be reduced significantly, reforming steam supply can be fully provided simply by generating low-pressure steam from turbine exhaust exiting the low-temperature regeneration heat exchanger.
[0061] On the other hand, in the combustion gas system wherein the anode exhaust is combusted under oxygen, since fuel humidifier conventionally needed is made unnecessary, all excessive heat can be applied to the generation of high-pressure steam, and the amount of recycled steam significantly increases, thereby significantly increasing the comprehensive thermal efficiency.
[0062] (5) Furthermore, the MCFC of the present invention is of an internal reforming type; thus, by mixing part of the anode exhaust with fuel gas such as urban gas externally-supplied, adding reforming steam and passing through one reforming catalyst layer, reforming reaction and methanation reaction progress simultaneously; since an endothermic reaction and an exothermic reaction progress simultaneously, thermal change is mutually absorbed, making it easy to control reaction temperature to that desired.
[0063] (6) The medium for the gas turbine is air and its exhaust does not pollute the atmosphere. Moreover, variable heat and power operation is enabled since although electric output increases while the gas turbine is in operation, exhaust heat recovery becomes large when turned off.
[0064] (7) When oxygen instead of air is supplied to the cathode of MCFC as an oxidizer, not only is it possible to recover CO 2 , but the voltage of fuel cell can be increased by increasing the CO 2 and O 2 concentration at the cathode. Thus, fuel cell output is increased and power generation efficiency can be raised.
BRIEF DESCRIPTION OF DRAWINGS
[0065] FIG. 1 is a configuration diagram of the power generation system disclosed in patent document 1.
[0066] FIG. 2 is a configuration diagram of the power generation system disclosed in patent document 2.
[0067] FIG. 3 is a configuration diagram of a conventional MCFC power generation system.
[0068] FIG. 4 is a configuration diagram of an apparatus for separation and recovery of CO 2 from combustion exhaust.
[0069] FIG. 5 is a configuration diagram of the MCFC power generation system of the present invention.
[0070] FIG. 6 is a detailed drawing of the cathode gas circulation system of FIG. 5 .
[0071] FIG. 7 is a detailed drawing of the fuel gas supply system of FIG. 5 .
[0072] FIG. 8 is a detailed drawing of the energy recovery system of FIG. 5 .
[0073] FIG. 9 is a diagram that shows the relationship of the amount of combustion gas recycled, the entrance temperature of a gas turbine, and output.
[0074] FIG. 10 shows data for voltage fixed operation.
DESCRIPTION OF EMBODIMENTS
[0075] Hereinafter, favorable examples of embodiments of the present invention are described with reference to the accompanying drawings. The same or corresponding portions are denoted by the same reference numerals, and overlapping descriptions are omitted.
[0076] FIG. 5 is a configuration diagram of the entire MCFC power generation system of the present invention.
[0077] Although fuel gas FG, such as urban gas, externally-supplied, is desulfurized by a desulfurization agent 2 in a desulfurization facility 1 and supplied to a pre-converter 9 via a filter 3 , part of the anode exhaust is mixed in at a high temperature along the way. Subsequently, steam for reforming is mixed in an amount matching that of the externally-supplied fuel gas such as urban gas, and components heavier that ethane in the externally-supplied fuel gas such as urban gas is reformed in the course of passing through a reforming catalyst layer 10 in the pre-converter, while at the same time, H 2 , CO, and CO 2 in the recycled anode exhaust conversely initiate methanation reaction.
[0078] The order by which externally-supplied fuel gas such as urban gas, part of the anode exhaust, and steam for reforming are mixed, may be as indicated in FIG. 5 , or preferably, for preventing drain generation, urban gas may be added after mixing part of the anode exhaust with steam for reforming; although the site at which mixing occurs is indicated as a piping in FIG. 5 , methods such as mixing with a mixer built between the piping and mixing inside the pre-converter may also be applied, and FIG. 5 merely shows one example among such methods.
[0079] Gas exiting the pre-converter is led to a fuel heater 11 , is heated by anode exhaust to a temperature slightly lower than the working temperature of the fuel cell, and is supplied to the fuel cell 12 . The fuel cell is an internal reforming type MCFC, wherein reformer 38 is built inside the fuel cell, and fuel gas is reformed inside the fuel cell to generate H 2 and CO, which become fuel for MCFC.
[0080] About 70% of H 2 +CO generated by the conventional MCFC-gas turbine hybrid system of FIG. 3 is consumed by the power generation reaction (H 2 +CO 3 2− ->H 2 O+CO 2 +2e − ), while the remainder becomes anode exhaust and its combustible component is combusted; however, in the present invention, because part of the anode exhaust is recycled, utilization ratio of fuel is increased up to 80%, thereby reduces the amount of externally-supplied fuel gas such as urban gas and amount of steam for reforming supplied.
[0081] At any rate, part of H 2 and CO in fuel gas is consumed in the power generation reaction, and the remainder is discharged from the fuel cell as anode exhaust. In a fuel cell, since a direct current is generated, electricity is delivered after converting to alternate current by an inverter 37 .
[0082] After the anode exhaust provides heat to the pre-converter outlet gas at the fuel heater 11 , part of the exhaust is pressurized by an anode exhaust circulation blower 8 , and mixed with externally-supplied fuel gas such as urban gas. The remainder is mixed with oxygen and recycled combustion gas RCG by a mixer 13 , and led to a catalytic combustor 14 .
[0083] The catalytic combustor 14 comprises a combustion catalyst layer 15 , which combusts the combustible component in the anode exhaust. The combustion gas exiting the catalytic combustor 14 is led to a high temperature heat exchanger 16 , and heats the compressed air CA to a turbine inlet temperature. Subsequently, heat is provided to RCO 2 , which is recycled CO 2 , with a CO 2 heater 17 , and the gas is led to an exhaust heat recovery boiler 18 . The exhaust heat recovery boiler 18 comprises an evaporation part EVA and a feed-water heating part ECO, and although the heat source is the same combustion gas, since the recycled combustion gas RCG branches from the outlet of the evaporation part of the exhaust heat recovery boiler 18 , the flows rate of the combustion gas differ between the evaporation part and a feed-water heating part.
[0084] Meanwhile, although the position at which combustion gas is recycled is indicated as the outlet of the evaporation part of the exhaust heat recovery boiler in FIG. 5 , it may also be positioned at the outlet of the CO 2 heater 17 or the outlet of the high temperature heat exchanger 16 ; although power generation efficiency becomes higher as the position of recycling becomes higher in temperature, exhaust heat recovery efficiency decreases, and has both features.
[0085] The recycled combustion gas is pressurized by a combustion gas recycling blower 19 , and sent to a mixer 13 . Although FIG. 5 indicated that mixing occurs in the oxygen line, the mixing of anode exhaust, oxygen and recycled combustion gas, may be performed by a method that uses mixer 13 , and other such methods, and FIG. 5 is not intended to specify a method.
[0086] The combustion gas exiting the feed-water heating part of the exhaust heat recovery boiler 18 is cooled by a cooler 20 , and condensed water is separated by a KO drum 21 . Although the gas exiting the KO drum 21 is substantially CO 2 gas, if necessary, it may further be led to a dehumidification system 22 , which decreases temperature to remove moisture. The dehumidification system 22 comprises a freezer 23 , a heat exchanger 24 , and a KO drum 25 .
[0087] As for the CO 2 gas exiting the KO drum 25 , CO 2 concentration is raised to about 95%. Part of it is pressurized by a CO 2 recycling blower 26 , and after being preheated with a CO 2 warmer 17 , is supplied to the cathode gas circulation system. The remaining CO 2 gas is recovered by the high concentration CO 2 recovery apparatus 70 in high concentration, and discharge to the atmosphere is mostly lost.
[0088] On the other hand, the cathode gas circulation system forms a closed cycle in which circulation is induced by a cathode gas circulating blower 36 , and oxygen consumed by the power generation reaction (CO 2 +1/2O 2 +2e − ->CO 3 2− ) of the cathode is supplied by an oxygen supply plant 33 . Although the oxygen supply plant 33 is indicated in FIG. 5 as being composed of an air compressor 34 and a separator 35 , various systems, such as PSA (Pressure Swing Adsorber) and liquefaction separation are known for oxygen supply plant, and the present invention does not limit the specifics of the oxygen supply plant.
[0089] On the other hand, with regard to the CO 2 consumed by the power generation reaction, as has been previously described, recycled CO 2 , obtained by combustion of anode exhaust under oxygen, is supplied to the cathode gas circulation system after being cooled and dehumidified. The temperature of cathode gas is higher at the outlet than at the inlet, due to heat generation accompanying the power generation reaction in the fuel cell, but may be adjusted to a temperature close to that of the inlet temperature by mixing oxygen near normal temperature with recycled CO 2 preheated to 250-450° C. Such temperature control is performed by controlling the outlet temperature of CO 2 heater 17 .
[0090] The basic structure of the MCFC power generation facility part of the present invention, the present invention additionally comprises a gas turbine generator, which utilizes air as its operation medium.
[0091] Air is led to a compressor 28 in a gas turbine generator 27 via a filter 31 , and the compressed air CA is first heated by the exhaust from a turbine 29 in a regeneration heat exchanger 32 , followed by heat exchanging with combustion gas CG of anode exhaust in the high temperature heat exchanger 16 , whereby the compressed air heated to turbine inlet temperature is led to the turbine 29 . Works takes place in the process of expanding to a pressure near atmospheric pressure in the turbine 29 , and is extracted as alternating current output by an electric generator 30 . Furthermore, the turbine exhaust is led to the regeneration heat exchanger 32 , where it provides heat to compressed air, and subsequently to an exhaust heat recovery boiler 7 . At the exhaust heat recovery boiler 7 , low-pressure steam required for reforming is generated, and the turbine exhaust exiting the exhaust heat recovery boiler is emitted to the atmosphere.
[0092] Although the basic structure of the present invention is as described above, hereinafter, details on the constituents, use and effect, etc. of each subsystem will be further described with reference to FIG. 6-FIG . 10 .
[0093] The above-described MCFC power generation system of the present invention produces the following effects.
[0094] (1) Cathode gas is circulated by the cathode gas circulation blower, and forms a closed loop. Since the oxygen consumed by the power generation reaction (CO 2 +1/2O 2 +2e − ->CO 3 2− ) is supplied from an oxygen supply plant and CO 2 is supplied by recycled CO 2 , the required quantity and composition of the cathode circulating gas is maintained, and there is basically no exhaust from the cathode gas circulation system. However, a certain amount of purging would be needed if the oxygen and CO 2 supplied contain impurities. But, since the nitrogen content of oxygen and the H 2 O content of CO 2 are slight, and part of such CO 2 is recycled to the cathode while the remainder is mostly collected as high concentration CO 2 gas, atmospheric discharge of CO 2 from an anode is virtually lost.
[0095] (2) On the other hand, the carbonic acid ion (CO 3 2− ) generated at the cathode diffuses to the anode, and CO 2 is generated by the power generation reaction (CO 2 +1/2O 2 +2e − ->CO 3 2− ) at the anode. Although anode exhaust contain CH 4 , H 2 , CO, CO 2 , and H 2 O, these are converted to CO 2 and H 2 O by combusting the combustible component under oxygen, and by cooling and water removal, only CO 2 will remain. However, when oxygen contains nitrogen, a small amount of nitrogen is mixed in CO 2 , and when excessive oxygen is introduced, a small amount of oxygen may also be mixed. Furthermore, since CO 2 is cannot be completely removed by cooling and water removal, a small amount of nitrogen, oxygen, and vapor will be contained in CO 2 , but such impurities do not cause harm either at recycling or collection. Since a part of such CO 2 is collected and the remainder is recycled to the cathode, atmospheric discharge of CO 2 from the anode is zero.
[0096] (3) Moreover, in the conventional system of FIG. 3 , the anode exhaust contains about 30% of remaining fuel gas, and by combusting its entirety under air and using its heat as a heat source for the gas turbine for the purpose of power recovery, the overall power generation efficiency was improved.
[0097] In the present invention, fuel gas in the anode exhaust is recycled by recycling part of the anode exhaust and mixing with externally-supplied fuel gas, such as urban gas, and steam for reforming; thus, the amount of fuel gas to be supplied externally is reduced.
[0098] Moreover, although a fuel humidifier was needed in the conventional system of FIG. 3 for preheating externally-supplied fuel gas, such as urban gas, and for generating and preheating steam for reforming, the present invention does not require one, since the temperature of fuel gas and steam are raised to working temperature of the pre-converter by mixing with part of the hot anode exhaust.
[0099] Furthermore, since the anode exhaust contains steam generated by the power generation reaction at the anode, the quantity of steam for reforming that is freshly supplied can be significantly reduced. Also, that the amount of externally-supplied fuel gas, such as urban gas, is reduced is a factor for reducing the amount of steam for reforming.
[0100] (4) When considering a case where part of the anode exhaust is not recycled in the present invention shown in FIG. 5 , the temperature of the turbine exhaust exiting the low-temperature regeneration heat exchanger becomes low, and cannot be effectively utilized as a heat source; however, since the amount of steam for reforming that is supplied is significantly reduced by recycling part of the anode exhaust, when low-pressure vapor is generated from the turbine exhaust exiting the low-temperature regeneration heat exchanger, all necessary steam can be covered.
[0101] On the other hand, in the combustion gas system, wherein anode exhaust is combusted with oxygen, because a fuel humidifier that was conventionally needed is now unnecessary, all excessive heat can be used for the generation of high-pressure steam, and the amount of recycled steam increases significantly. Since this high-pressure vapor may be used outside the system of the present invention shown in FIG. 5 , the total thermal efficiency is significantly increased.
[0102] (5) Moreover, the MCFC of the present invention is an internal reforming type, and uses the reforming reaction (CH 4 +H 2 O->CO+3H 2 ), which is an endothermic reaction, to cool the fuel cell. Therefore, it is desirable that the methane concentration in the fuel gas supplied to the fuel cell is high. However, the main components in the anode exhaust are H 2 , CO, CO 2 , and H 2 O, and methane is virtually non-existent. Therefore, it is necessary to promote a methanation reaction (CO 2 +4H 2 ->CH 4 +2H 2 O), which is the reverse reaction of reforming reaction.
[0103] Although these reactions can be attained using the same reforming catalyst by adjusting temperature with the same reforming catalyst, methanation reaction is an exothermic reaction, and methanation of part of the anode exhaust alone cause excessive increase in temperature, which not only inhibits the increase of methane concentration due to equilibrium, but causes degradation of the catalyst. On the other hand, externally-supplied fuel gas, such as urban gas, contains ethane, propane, butane, etc. along with methane, that when reforming temperature is low, reforming of most components heavier than ethane proceeds, but reforming of methane hardly proceeds. Since reforming reaction is an endothermic reaction, in order for it to proceed on its own, preheating is necessary.
[0104] Therefore, the reforming reaction and methanation reaction can proceed simultaneously by mixing part of the anode gas with externally-supplied fuel gas, such as urban gas, adding steam for reforming, and passing through one reforming catalytic layer; since an endothermic and exothermic reaction proceed simultaneously, temperature change is mutually mitigated, and maintaining the reaction temperature to that intended becomes easy. Operations, such as preheating of gas and cooling of a reaction machine, are unnecessary in this process.
[0105] In addition, since externally-supplied fuel gas, such as urban gas, is at normal temperature, drain will occur if saturated steam is mixed; therefore, to prevent generation of drain at mixing, steam should be mixed after mixing part of the hot anode exhaust with fuel gas, or fuel gas should be mixed after mixing part of the hot anode exhaust with steam.
[0106] (6) The medium of the gas turbine is air and its exhaust does not pollute the atmosphere, and since heat is only received from the MCFC power generation system via the heat exchanger, operation of the MCFC power generation system can be continued even when the gas turbine is turned off. Therefore, the electric output increases while the gas turbine is in operation, and exhaust heat recovery increases when it is stopped, thereby enabling a variable heat and power operation. By increasing the amount of recycling of combustion gas and decreasing the temperature of the catalytic oxidizer outlet, the quantity of heat exchange at the high temperature heat exchanger is decreased, and the output of the gas turbine is reduced while the amount of steam generation in the exhaust heat recovery boiler is increased, and the final form is the shut-down of the gas turbine. Detailed descriptions are given in the example section.
[0107] (7) When supplying oxygen as an oxidizer for the MCFC cathode, instead of air, not only can CO 2 be recovered, but the voltage of the fuel cell can be raised by increasing the CO 2 and O 2 concentration at the cathode. This, in turn increases the output of the fuel cell and enhance power generation efficiency.
[0108] However, on the other hand, problems such as nickel short circuit, and shortening of cell life by increased cathode CO 2 partial pressure exist in MCFC. Nickel short-circuit is a fatal problem for a fuel cell, which occurs when nickel oxide constituting the cathode dissolves into the electrolyte as ions (NiO+CO 2 ->Ni 2+ +CO 3 2− ), which are then reduced by hydrogen and deposited as metal nickel in the electrolyte plate (Ni 2+ +H 2 +CO 3 2− ->Ni+H 2 O+CO 2 ), and increase in nickel deposition causes conduction between anode and cathode of the electrolyte plate, which should be insulated.
[0109] In order to increase the voltage of the fuel cell while preventing such problems, the gas composition of the cathode should be freely controllable; the cathode gas circulation system of the present invention is a closed loop completely independent of other subsystems, so that the gas composition of the cathode can be freely adjusted without the change in gas composition affecting other subsystems.
[0110] When the voltage of the fuel cell becomes high, heat generation in the fuel cell decreases, and the necessity to cool the fuel cell will decrease in accordance; however, since the amount of cathode gas circulation can be easily fluctuated by changing the rotation frequency of the blower, that even with the heat balance of the fuel cell in mind, the CO 2 and O 2 concentration in the cathode gas can be adjusted easily and accurately, while taking nickel short circuit into consideration. Detailed descriptions are given in the example section.
Example 1
[0111] FIG. 6 describes the cathode gas circulation system part of FIG. 5 in further detail.
[0112] It is necessary to supply CO 2 and O 2 which are consumed by the power generation reaction (CO 2 +1/2O 2 +2e − ->CO 3 2− ) at the cathode, and purged. The reaction amount may be calculated from the direct-current of the fuel cell, and the purged amount may be checked by flow control valve 53 . O 2 from the oxygen plant established in the exterior of the MCFC power generation plant, is controlled by the flow control valve 51 , and is supplied at a temperature near normal temperature. CO 2 is supplied to the cathode gas circulation system by controlling the flow rate of recycled CO 2 (RCO 2 ), obtained by combustion of anode exhaust under oxygen, cooling, and water-extraction, with a flow control valve 52 , and by controlling the temperature with a temperature control valve 40 built in a CO 2 heater 36 . Since the temperature of the gas passing through the cathode is higher at the outlet than the inlet due to heat generated by the power generation reaction, the temperature is controlled to recover the inlet temperature by supplying and mixing CO 2 and O 2 . The temperature of recycled CO 2 is adjusted by a CO 2 heater so that the temperature of the mixed gas after adiabatic compression by the cathode gas circulation blower matches the cathode inlet temperature. The circulation volume of the cathode gas circulation blower is controlled so that the cathode outlet gas temperature is kept constant.
[0113] On the other hand, since both CO 2 and O 2 supplied contain impure gas, purging is necessary; hence, the cathode outlet of the cathode circulation system is divided into two lines, of which one is connected to a purge line that is equipped with a flow control valve 53 , and the other is equipped with a check valve 54 and connects the supply line of CO 2 and O 2 downstream of the check valve 54 .
[0114] The cathode gas circulation system of the present invention enables free change of the gas composition, as well as free fluctuation of the amount of circulation depending on the degree of heat generation in the fuel cell. Moreover, such changes do not affect other subsystems.
[0115] Plant performance when the cathode gas composition in the present invention is changed, is shown in Table 1, as one example.
[0116] The CO 2 and O 2 concentrations in Table 1 are not meant to indicate the maximum concentration, but are rather concentrations with the influence of nickel short circuit taken in consideration; power generation efficiency is still improved by 5%. Further, operation at high concentration may be performed when high power generation efficiency is called for, and can easily be returned to standard operating condition.
[0000]
TABLE 1
Effect of Cathode Gas Composition on Plant Performance
Standard
High-Output
Operating
Operating
Condition
Condition
Cathode Inlet CO 2 [mol %]
12
30
O 2 [mol %]
10
20
Stack AC Output [kW]
2453
2557
Gas Turbine Output [kW]
370
360
Facility Power [kW]
470
474
including
oxygen plant
Transmission End Output [kW]
2353
2443
Fuel Flow Rate [Nm 3 /h]
422
395
Power Generation Efficiency
50
55
[LHV %]
Heat Recovery Rate [%]
13
6
Example 2
[0117] Voltage deteriorates with operation time in every fuel cell. In general, the life of a fuel cell is defined as the point at which cell voltage deteriorates 10%. If operation time per year is assumed to be 8000 hours and the cell life is five years, that is 40000 hours, deterioration occurs 1% each per half a year, and the output of fuel cell and power generation efficiency will fall 1% per half a year, as well, in proportion to the voltage. However, according to the present invention, CO 2 and O 2 concentration at the cathode can be gradually raised, in correspondence to the deterioration of the fuel cell, thereby keeping the voltage of the fuel cell constant.
[0118] FIG. 10 shows the data for voltage fixed operation. This figure is an example of CO 2 and O 2 concentration change for maintaining the same performance as that of standard operating conditions for five years; by applying such operation, the output and power generation efficiency of the fuel cell can be increased relatively by an average of 5% during cell life. In this method of operation, the time during which CO 2 partial pressure is extremely high is kept short, and therefore the total accumulation of metal nickel, which leads to nickel short circuit, can be suppressed; thus, this is one operating method that can enhance power generation efficiency while suppressing nickel short circuit.
Example 3
[0119] FIG. 7 is a detailed drawing that describes the fuel gas supply system in FIG. 5 ; the anode outlet is connected to a fuel heater 11 the temperature of the outlet gas from pre-convertor 9 is heated, utilizing the anode exhaust as a heat source, to a temperature close to the operation temperature of fuel gas. The anode exhaust, whose temperature then decreases, is divided into two lines, one of which is connected to an anode exhaust circulation blower, and the blower outlet gas is mixed with externally-supplied fuel gas, such as urban gas. Fuel gas, such as urban gas, is supplied by adjusting its flow rate with a flow control valve 56 . Subsequently, it is mixed with steam for reforming such urban gas, and the like. Steam is supplied by adjusting its flow rate with a flow control valve 57 .
[0120] Although FIG. 7 indicates that mixing occurs in the piping, mixing may be performed by methods such as one that uses a mixer, or one where mixing is performed inside a pre-convertor 9 , and the present invention does not specify a mixing method.
[0121] This mixed gas is then led to a reforming catalyst layer 10 in a pre-converter 9 . Here, reforming of components heavier than ethane in the urban gas occurs, and CO, CO 2 , and H 2 O in the anode recycle gas undergo methanation reaction. Reforming reaction is an endothermic reaction, while methanation reaction is an exothermic reaction; so, by these two reactions proceeding simultaneously, temperature changes are mutually suppressed, thereby making it easy to maintain the working temperature of the pre-converter to that desired.
[0122] Moreover, since MCFC of FIG. 7 is an internal reforming type and the reforming reaction (CH 4 +H 2 O->CO+3H 2 ), which is an endothermic reaction is used for cooling of the fuel cell, it is desirable that the methane concentration is high; by controlling the outlet temperature of the catalyst layer in the pre-converter to 250-450° C. using temperature controller 58 , and by controlling the flow rate of urban gas and the like and the flow rate of steam for reforming using rate controller 39 equipped in the anode exhaust circulation blower, the amount of recycling is controlled.
[0123] The constituent features of the fuel supplying system of the present invention is: to connect the anode outlet to a fuel heater to decrease the temperature of the anode exhaust; to divide the cooled anode exhaust line in to two systems, of which one is connected to an anode exhaust circulation blower; to mix outlet gas from anode exhaust circulation blower with fuel gas, such as urban gas, and steam for reforming, thereby raising the temperature to that of the gas supplied to the pre-converter without using a heat exchanger; subsequently leading mixed gas to reforming catalyst layer in the pre-converter, which does not have a heat source; to retain an operating temperature in the range of 250-450° C., so that the methane concentration of the pre-converter outlet gas is increased; and to retain a anode exhaust recycling rate in the range of about 20 to 40% for the same reason.
[0124] The performances of the present invention are compared for cases where anode exhaust is recycled and not recycled, and shown in Table 2. Although the power generation efficiency does not change, the heat recovery rate improves drastically.
[0125] Moreover, although changing the anode exhaust recycling rate does not change the power generation efficiency of the overall plant, individual factors vary. When the anode recycling rate is raised, the amount of urban gas supplied decreases, as does the amount of steam for reforming supplied, the voltage of the fuel cell drops, and therefore, the output of the fuel cell also drops; the output of the gas turbine decreases, as does the power within the facility. These varying factors are effective in changing the operating conditions of the plant; for example, by increasing the concentration of CO 2 and O 2 in the cathode, the voltage of the fuel cell increases, thereby decreasing heat generation in the fuel cell, which may cause too much cooling of the fuel cell depending on the conditions, but in such a case, by increasing the recycling rate of the anode, the voltage of the fuel cell can be dropped, which in turn leads to a decrease in the amount of urban gas supplied; thus, the heat balance of the fuel cell can be maintained while also maintaining power generation efficiency. In addition, it is also effective to adjust specification of the constitutive apparatus.
[0000]
TABLE 2
Effect of Anode Recycling on Performance
Without Recycling
20% Recycling
Stack AC Output [kW]
2538
2453
Gas Turbine Output [kW]
464
370
Facility Power [kW]
488
470
Transmission End Output
2514
2353
[kW]
Fuel Flow Rate [Nm 3 /h]
450
422
Power Generation
50
50
Efficiency [LHV %]
Heat Recovery Rate [%]
8
13
S/C
2
1.44
Pre-converter Inlet
375
257
Temperature [° C.]
Pre-converter Outlet
300
320
Temperature [° C.]
Compo-
Compo-
Flow Rate
sition
Flow Rate
sition
Pre-converter Outlet Gas
[kgmol/h]
[%]
[kgmol/h]
[%]
CH 4
21.10
29.49
21.77
24.18
H 2
5.92
8.28
3.19
3.54
CO
0.01
0.01
0.05
0.06
CO 2
2.30
3.22
21.21
23.56
H 2 O
42.20
59.00
43.80
48.65
Example 4
[0126] FIG. 8 describes the energy recovery system of FIG. 5 that effectively utilizes combustion heat obtained by the combustion of anode exhaust under oxygen via various heat exchangers.
[0127] The anode exhaust AEG is mixed with the oxygen OXG and the recycling combustion gas RCG in a mixer 13 . Since the amount of combustible components in anode exhaust is calculable from the amount of fuel supplied, fuel consumed, and the direct-current of the fuel cell, etc., the amount of oxygen required is calculated based on that value, and supplied by controlling with a flow control valve 59 . On the other hand, the once cooled combustion gas RCG is recycled to the mixer by a combustion gas recycling blower. Since the rise in temperature becomes excessive if the anode exhaust is simply combusted under oxygen, combustion gas of low-temperature is recycled so that the outlet temperature of the catalytic combustor can be adjusted.
[0128] As for the mixed gas of anode exhaust, oxygen, and recycled combustion gas, the combustible gas in the anode exhaust is combusted by the combustion catalyst in the catalytic combustor 14 , and the temperature rises. The rate controller 61 in the combustion gas recycling blower controls the flow rate to suit the preset outlet temperature of the catalytic combustor. This preset temperature may be changed as needed.
[0129] The combustion gas leaving the catalytic combustor 14 first provides heat to compressed air through a high temperature heat exchanger 16 , then provides heat to recycled CO 2 through the CO 2 warmer, and subsequently generates steam in the exhaust heat recovery boiler 18 .
[0130] In a standard operating condition, combustion gas is recycled when exiting the evaporation part EVA of the exhaust heat recovery boiler. The remaining combustion gas is sent to the water supply heater ECO of the exhaust heat recovery boiler.
[0131] On the other hand, in a high-output operation mode, the combustion gas is recycled at the outlet of the high temperature heat exchanger 16 . This change is performed by gradually switching the gate opening of the damper 62 from the low temperature side to the high temperature side. Simultaneously, the flow rate of combustion gas recycling blower increases so that the preset value for the outlet temperature of the catalytic combustor is maintained. Therefore, the quantity of the combustion gas, which passes through the high temperature heat exchanger 16 increases, increasing the amount of heat provided to compressed air. Here, the amount of air in the gas turbine is increased by speed controller 64 of the gas turbine generator. As a result, even though the gas turbine output increases, the amount of steam generation is reduced, since the amount of heat going to the exhaust heat recovery boiler decreases.
[0132] The standard operating condition and the high-output operating mode are compared in Table 3. By applying the high-output operating mode, power generation efficiency improves by 2 points, but conversely, the heat recovery rate falls by 6 points. Whichever operating mode is desirable is decided by the balance between thermal demand and power demand.
[0000]
TABLE 3
Comparison of Standard and High-Output Operation
Standard
High-Output
Operation
Operation
Stack AC Output [kW]
2453
2453
Gas Turbine Output [kW]
370
461
Facility Power [kW]
470
470
Transmission End Output [kW]
2353
2444
Fuel Flow Rate [Nm 3 /h]
422
422
Power Generation Efficiency
50
52
[LHV %]
Heat Recovery Rate [%]
13
7
[0133] On the other hand, at the gas turbine, which utilizes air as an operation medium, air is compressed with a compressor via a filter 31 , and heat exchange with turbine exhaust occurs at the regeneration heat exchanger 32 . The outlet temperature at the turbine exhaust side is controlled by this regeneration heat exchanger, and is controlled so that low-pressure steam required for reforming is constantly generated at the exhaust heat recovery boiler 7 . Therefore, the temperature of compressed air at the outlet of the regeneration heat exchanger is constant according to the operating condition, but is rather adjusted by the high temperature heat exchanger 16 in this system.
[0134] Compressed air heated by the high temperature heat exchanger is led to the turbine, where work is done in the process of expanding to near atmospheric pressure, whereby alternate current is obtained by an electric generator 30 . Since this gas turbine collects exhaust heat from fuel cell and generates electricity, and the quantity of exhaust heat changes according to the load of the MCFC side, the electric generator is to be a motor/generator, which is additionally rotation frequency-variable, and the amount of air flow is to be changeable according to the operational status of the fuel cell.
Example 5
[0135] Heat and electricity variable operation is made possible by using the energy recovery system of FIG. 8 . The conditions that maximize the electric output are, as described previously, the operation modes in which the position of combustion gas recycling is switched to the high temperature heat exchanger outlet. On the other hand, the operating method which maximizes heat recovery is as described below.
[0136] The position for recycling combustion gas is set to the exit of the evaporation part of the exhaust heat recovery boiler, and the preset value of the outlet temperature of the catalyst oxidizer is gradually lowered. This causes the flow rate of combustion gas recycling blower to increase. When the outlet temperature of the catalyst oxidizer decreases, the amount of heat provided to compressed air through high temperature heat exchanger 16 decreases, thereby causing the gas turbine entrance temperature to drop. Thus, the gas turbine output decreases. On the other hand, since the amount of heat that heats recycled CO 2 at the CO 2 heater, in the process, does not change, the amount of evaporation at the exhaust heat recovery boiler increases at an amount corresponding to the decrease in the amount of heat provided to the gas turbine.
[0137] The relationship among the amount of combustion gas recycled, the inlet temperature of the gas turbine and the output, are shown in FIG. 9 . If the outlet temperature of the catalytic combustor decreases below a certain temperature, the output of the gas turbine becomes zero. At this point, supply of steam for reforming is switched from the exhaust heat recovery boiler on the gas turbine side to the exhaust heat recovery boiler on the combustion gas side, and the gas turbine is turned off. Since all the heat that was contained in the gas turbine during standard operation goes into the exhaust heat recovery boiler on the combustion gas size when the gas turbine is stopped, the amount of heat recovery is at its maximum. Comparison between standard operation and maximum heat recovery is shown in Table 4.
[0000]
TABLE 4
Comparison of Standard and Maximum Heat Recovery Operation
Standard
Maximum Heat
Operation
Recovery
Stack AC Output [kW]
2453
2453
Gas Turbine Output [kW]
370
0
Facility Power [kW]
470
490
Transmission End Output [kW]
2353
1963
Fuel Flow Rate [Nm 3 /h]
422
422
Power Generation Efficiency
50
41
[LHV %]
Heat Recovery Rate [%]
13
31
[0138] The present invention is not limited to the above-described embodiments and various changes can be made without departing the scope of the present invention.
REFERENCE SIGNS LIST
[0000]
A anode, AEG anode exhaust, AIR air
C cathode, CA compressed air, CG combustion gas
CMP compressor, CO 2 G CO 2 gas, CO 2 R recovered CO 2
DR drain, ECO water supply heater, EVA evaporation part
EXG exhaust, FG fuel, G electric generator, HM heat medium
HPSTM high-pressure vapor, LAB absorbent liquid which emitted CO 2
LPSTM Low-pressure vapor, M motor, OXG Oxygen
PW treated water, RAB absorbent liquid which absorbed CO 2
RCG recycled combustion gas, RCO 2 recycled CO 2
SC rate control, T turbine, TC temperature control, W water supply
1 desulfurizer, 2 desulfurization agent, 3 Filter, 4 water treatment apparatus,
5 tank for treated water, 6 pump, 7 exhaust heat recovery boiler for low-pressure steam,
8 anode exhaust circulation blower, 9 pre-converter,
10 reforming catalyst, 11 fuel heater, 12 MCFC,
13 mixer, 14 catalytic combustor, 15 combustion catalyst,
16 high temperature heat exchanger, 17 CO 2 heater,
18 exhaust heat recovery boiler for generation of high-pressure steam,
19 combustion gas recycling blower,
20 cooler, 21 KO drum, 22 cooling and dehumidification system,
23 freezer, 24 heat exchanger, 25 KO drum,
26 CO 2 recycling blower, 27 gas turbine generator
28 compressor, 29 turbine, 30 electric generator,
31 filter, 32 low-temperature regeneration heat exchanger,
33 oxygen supply plant, 34 air compressor, 35 air separation plant,
36 cathode gas circulating blower, 37 inverter,
38 internal reformer, 39 rate controller,
40 temperature control valve, 41 fuel humidifier,
42 absorption tower, 43 pump, 44 heat exchanger,
45 regeneration tower, 46 reboiler, 47 pump, 48 cooler,
50 heater for startup, 51 flow control valve, 52 flow control valve,
53 flow control valve, 54 check valve, 55 rate control valve
56 flow control valve, 57 flow control valve, 58 temperature control valve
59 flow control valve, 60 temperature control valve
61 rate control valve, 62 damper, 63 temperature control valve,
70 high concentration CO 2 recovery subsystem
110 air preheater, 120 air, 130 preheated air, 150 SOFC,
200 heat exchanger, 220 water, 230 cooler, 240 drain,
310 coal gasification furnace, 320 desulfurization apparatus, 330 methanol synthesis apparatus,
340 coal, 350 oxygen,
401 fuel cell (MCFC), 402 gas turbine,
403 burner, 404 oxygen tank, 405 methanol tank,
406 cathode, 407 anode, 408 steam generator,
409 steam turbine, 410 cooler, 411 compressor,
412 burner, 413 heat exchanger, 414 cooler,
415 CO 2 recovery subsystem
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Disclosed is an MCFC power generation system and a method for operating the same enabling significant reduction of CO 2 emission or substantially zero CO 2 emission by minimizing the equipment added to a general power generation facility to a minimum, enabling both high power generation efficiency and high heat recovery efficiency, enabling adjustment of the voltage and output of the fuel cell in a certain range by adjusting the cathode gas composition, enabling great variation of the ratio between the heat and electricity, and thereby enabling variable thermoelectric operation. The MCFC generation system includes a cathode gas circulation system in which the cathode gas is circulated by a cathode gas recycle blower, and a closed loop is formed. Oxygen consumed by power generation is supplied from an oxygen supply plant, and CO 2 is supplied from recycled CO 2 . Combustible components in anode exhaust are burned with oxygen, the resultant gas is cooled, and water is removed. The fuel gases in the anode exhaust is recycled.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a solid state drive (SSD) tester, and more particularly to an SSD tester which divides the functions of generating and comparing test pattern data and Frame Information Structure (FIS) data with each other into each other to implement the functions as separate logics, so that entire test time is decreased by reducing load of a processor.
2. Description of the Related Art
Until now, hard disk drives (HDDs) have been most generally known and used as large capacity digital media storage devices. However, in recent years, as prices of NAND flash semiconductor devices, which can store the largest capacity among semiconductor devices having a memory function and data stored therein are not erased even when electric power is not supplied, are being lowered, large capacity digital medial storage apparatus such as solid state drives (SSDs) using a semiconductor having a memory function are newly appearing.
Writing and reading speeds of such an SSD are 3 to 5 times as fast as those of existing hard disks, and its performance of reading/writing a random address required by a database management system is several hundreds of times as excellent as those of existing hard disks. In addition, an SSD is operated in a silent way, so a noise problem of an existing hard disk can be solved. Further, since the SSD is operated with power consumption significantly lower than that of a hard disk, the SSD is known as to most suitable for a digital device, such as a laptop computer, which requires low power consumption.
In addition, the SSD has a higher durability against an external impact than an existing hard disk, and as the SSD can be manufactured to be smaller and more various in shape as compared with a hard disk having a fixed form in terms of an external design, an external shape of an electronic product employing the SSD can be made smaller, showing many excellent advantages in its applications.
Due to its advantages, it is expected that distributions of SSDs can be expanded rapidly to searches, home shopping, storage media of video service servers, storage media for storing various R&D materials, and special equipment, as well as existing desktop computers or laptop computers.
As a scheme of testing the above-described SSD, an SSD tester according to the related art is illustrated in FIG. 1 .
The SSD tester according to the related art shown in FIG. 1 includes a host terminal 10 , a network 20 , a communication interface unit 30 , a memory 40 , a micro processor 50 , a storage interface unit 60 , and a storage unit 70 . The storage interface unit 60 includes a plurality of storage interfaces 61 ˜ 60 +n. The storage unit 70 includes a plurality of storages 71 ˜ 70 +N, and respective storage interfaces perform the same function. Each unit in the above described SSD tester according to the related art is provided as a separate device.
The network 20 maintains a wired/wireless network connection with the host terminal 10 . The network 20 may be network-connected to the host terminal 10 through wired communication such as LAN, USB, or RS-232, and wireless local area communication such as Bluetooth, Zigbee, or UWB.
A user inputs a test condition through the host terminal 10 . The input test condition, which is received through the network 20 , is transferred to the micro processor 50 through the communication interface unit 30 of a next stage.
The micro processor 50 generates a test pattern for testing the storage 70 in connection with the memory 40 according to the transferred test condition. The test pattern may be implemented as various types of test patterns which are widely used for testing an SSD and various types of storages. In addition, the micro processor 50 performs a function of generating Frame Information Structure (FIS) data.
The micro processor 50 controls test of the storage 70 using the generated test pattern. For example, the micro processor 50 generates a test signal based on the test pattern and transmits the test signal to the storage 70 through the storage interface unit 60 so that test of the storage 70 may be controlled. The test control includes storing the test pattern generated for the test in the storage 70 , reading out the test pattern from the storage 70 , and comparing the stored test pattern (expectation data) with the read test pattern (readout data) to process a fail.
As well known in the related art, the micro processor 50 performs all functions related to the test, such as a function of generating the test pattern for testing the SSD, a function of generating the FIS data, a function of storing the test pattern in the storage 70 , a function of reading out data from the storage 70 , a function of comparing the stored data with the read data to determine whether a fail occurs.
The storage interface unit 60 maintains interface with the storage 70 . The storage interface unit 60 performs Serial-ATA (SATA) interface with the storage 70 .
However, in the related art as illustrated above, since the micro processor 50 completely performs all functions related to the SSD test, such as a function of generating the test pattern for testing the SSD, a function of generating the FIS data, a function of storing the test pattern in the storage 70 , a function of reading out data from the storage 70 , a function of comparing the stored data with the read data to determine whether a fail occurs, load of the micro processor is weighted so that a real-time test is impossible.
Specifically, as described above, since one micro processor completely performs entire functions for the SSD test, the real-time test is impossible, so since when plural SSDs are tested, the SSDs must be sequentially tested, the micro processor requires much time to test all SSDs.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide an SSD tester which divides the functions of generating and comparing test pattern data and Frame Information Structure (FIS) data with each other into each other to implement the functions as separate logics, so that entire test time is decreased by reducing load of a processor.
It is another object of the present invention to provide an SSD tester capable of randomly generating various pattern data.
According to an aspect of the present invention, there is provided a solid state drive tester which includes: a host terminal for receiving a test condition for testing a storage from a user; and a test control unit generating a test pattern corresponding to the test condition, and adaptively selecting an interface according to an interface type of the storage to be tested to test the storage using the test pattern, wherein the test control unit is divided into a control module for controlling the test of the storage and a test execution module for practically executing the test in hardware to test a plurality of storages in real time.
The test control unit includes: an embedded processor for controlling the test of the storage; and a test executing unit for generating a test pattern to test the storage, transmitting the test pattern to the storage, and determining whether a fail occurs by comparing the test pattern with a test pattern read out from the storage in cooperation with the embedded processor.
The test control unit includes: a communication interface unit connected with the host terminal through a network to receive information of the user and to transmit a test result to the host terminal; and a storage interface unit for interfacing the storage.
The test executing unit includes: a pattern data generator for generating pattern data by selecting one of pattern data generated corresponding to the test condition and random pattern data according to a pattern selection signal generated from the embedded processor; a fail processor for comparing the pattern data generated from the pattern data generator with test result data read out from the storage to determine whether the fail occurs and to generate fail information when the fail occurs; a fail memory for storing the fail information generated from the fail processor; and an instruction generator for transmitting a test instruction generated from the embedded processor to the storage interface unit.
The pattern data generator includes: a pattern data memory for storing the pattern data generated according to the test condition; a pattern data creating unit for randomly generating the pattern data to output the pattern data as the random pattern data; and a multiplexer for outputting the pattern data by selecting one of the pattern data output from the pattern data memory and the pattern data output from the pattern data creating unit according to the pattern data selection signal output from the embedded processor.
The pattern data creating unit includes a plurality of pattern data generators for randomly generating the pattern data.
The fail processor includes: a comparing unit for comparing writing data generated from the pattern data generator with reading data read out from the storage to generate a fail signal when the writing data are not equal to the reading data; a fail counter for counting a number of the fail signals generated from the comparing unit to output a fail count value; and a fail memory address generator for generating a storage address to store the fail signal when the fail signal is generated from the comparing unit.
The storage interface unit includes a plurality of multi-interfaces to simultaneously test a plurality of the storages, and the multi-interfaces comprise a plurality of interfaces corresponding to the interfaces of the storage, and interface with the storage by selecting one of the interfaces according to the interface selection signal generated from the embedded processor corresponding to the storage interface.
According to the present invention, the functions of generating and comparing test pattern data and Frame Information Structure (FIS) data with each other, which are performed by an embedded processor, are divided into each other to implement the functions as separate logics, so that entire test time is decreased by reducing load of a processor.
According to the present invention, since various pattern data can be randomly generated, a user can freely use desired pattern data.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic block diagram of a solid state drive test device according to the related art;
FIG. 2 is a block diagram illustrating a configuration of an SSD tester according to an embodiment of the present invention;
FIG. 3 is a block diagram illustrating an example of a test executing unit shown in FIG. 2 ;
FIG. 4 is a block diagram illustrating an example of a pattern data generator shown in FIG. 3 ;
FIG. 5 is a block diagram illustrating an example of a storage interface unit shown in FIG. 2 ; and
FIG. 6 is a block diagram illustrating an example of a fail processor shown in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings. A detailed description of known functions and configurations of the present invention will be omitted when it may make the subject of the present invention unclear.
FIG. 2 is a block diagram illustrating a configuration of an SSD tester according to an embodiment of the present invention. The SSD tester includes a host terminal 110 , a network 120 , a test control unit 130 , and a memory 140 . In FIG. 2 , reference numeral 200 denotes a storage unit 200 including a plurality of storages 201 to 200 +N which are test targets.
The host terminal 110 functions to receive a test condition for testing a storage from the user, and the network 120 is in charge of a data interface between the host terminal 110 and the test control unit 130 .
A program for testing an SSD is stored in the memory 140 , and performs the function of a data memory device for storing pattern data for generating a test pattern and data generated in an SSD test.
The test control unit 130 functions to generate a test pattern according to the test condition or to randomly generate a test pattern, and adaptively selects an interface according to a storage type of the storage to be tested to test the storage with the test pattern. Preferably, a plurality of devices installed in the test control unit 130 to test the SSD is implemented as one chip by using a field programmable gate array (FPGA).
Preferably, the test control unit 130 is divided into a control module for controlling the test of the storage and a test execution module for practically executing the test in hardware to test a plurality of storages in real time.
The test control unit 130 according to the related art includes a communication interface unit 131 connected to the host terminal 110 through the network 120 to receive information of the user and to transmit the test result to the host terminal 110 , a storage interface unit 132 for interfacing the storage unit 200 , an embedded processor 133 for controlling the storage test, and a test executing unit 160 in cooperation with the embedded processor 133 for generating a test pattern for testing the storage and transmitting the test pattern to the storage, and for comparing the generated test pattern with a test pattern stored in the storage to process whether a fail occurs. Further, as shown in FIG. 3 , the test executing unit 160 includes a pattern data generator 161 for selecting one of pattern data generated corresponding to the test condition according to a pattern selection signal generated from the embedded processor 133 and random pattern data to generate pattern data, a fail processor 162 for comparing the pattern data generated from the pattern data generator 161 with test result data read out from the storage to determining whether the fail occurs, such that fail information is generated when the fail occurs, a fail memory 163 for storing the fail information generated from the fail processor 162 , and an instruction generator 164 for transmitting a test instruction generated from the embedded processor to the storage interface unit 132 .
In addition, as shown in FIG. 4 , the pattern data generator 161 includes a pattern data memory 161 a for storing the pattern data generated according to the test condition, a pattern data creating unit 161 b for randomly generating pattern data to output the pattern data as random pattern data, and a multiplexer 161 c for selecting one of the pattern data output from the pattern data memory 161 a according to a pattern data selection signal output from the embedded processor 133 and the pattern data output from the pattern data creating unit 161 b to output the selected data as the pattern data.
Further, as shown in FIG. 6 , the fail processor 162 includes a comparing unit 162 a for comparing writing data generated from the pattern data generator 161 with reading data read out from the storage to generate a fail signal when the writing data is not equal to the reading data, a fail counter 162 b for counting a number of the fail signal generated from the comparing unit 162 a to output a fail count value, and a fail memory address generator 162 c for generating a storage address to store the fail signal when the fail signal is generated from the comparing unit 162 a.
Meanwhile, the storage interface unit 132 includes a plurality of multi-interfaces 151 to 151 +N. Here, internal configurations and operations of the plurality of multi-interfaces 151 to 151 +N are the same, and thus only one multi-interface 151 will be described below for convenience' sake.
As illustrated in FIG. 5 , the multi-interface 151 includes an advanced host controller interface (AHCI) 151 a for interfacing instruction data generated in the embedded processor 133 , a direct memory access (DMA) unit 151 b for interfacing writing data generated in the embedded processor 133 , a serial-ATA (SATA) interface 151 c for supporting an SATA interface between the advanced host controller interface 151 a and the storage 201 and between the direct memory access unit 151 b and the storage 201 , a serial attached SCSI (SAS) interface 151 d for supporting an SAS interface between the advanced host controller interface 151 a and the storage 201 and between the direct memory access unit 151 b and the storage 201 , a PCI express (PCIe) interface 151 e for supporting a PCIe interface between the advanced host controller interface 151 a and the storage 201 and between the direct memory access unit 151 b and the storage 201 , and a multiplexer (MUX) 151 f for selecting one of the SATA interface 151 c , the SAS interface 151 d , and the PCIe interface 151 e according to an interface selection signal generated in the embedded processor 133 to connect the storage 201 and the embedded processor 133 .
In the above-described SSD tester according to the present invention, a plurality of test devices for testing a storage are implemented as one chip on one board by using FPGA. In this state, after a user who wants to test an SSD allows the solid state drive tester to access a test target storage, the user inputs a test condition through the host terminal 110 . Here, the test condition may include an interface selection signal for interfacing the test target storage and a test pattern selection signal. The test pattern selection signal is a signal for determining whether predetermined pattern data are selected or a plurality of random patter data arbitrarily generated are selected.
The test condition of the user input through the host terminal 110 is transferred to the one-chipped test control unit 130 through the network 120 .
The communication interface unit 131 of the test control unit 130 receives the test condition input by the user through the network 120 , and transfers the received test condition to the embedded processor 133 . If the test condition is input by the user and a test is requested, the embedded processor 133 extracts a test program for the storage test from the memory 140 and starts to test the storage. Here, as an initial operation of the test, test pattern data corresponding to the test condition input by the user are extracted from the memory 140 and are transferred to the test executing unit 160 .
The test executing unit 160 is a separate logic for a module for executing a practical test separated from the embedded processor 133 . Thus, by separating the module (generating a test pattern data and confirming a fail) for executing the test from the embedded processor 133 , the burden of the embedded processor 133 may be reduced and the control and test for plural storages are performed at the same time, so that entire test time can be reduced.
In more detail, as shown in FIG. 3 , the pattern data generator 161 of the test executing unit 160 selects one of pattern data generated corresponding to the test condition according to the pattern data selection signal output from the embedded processor 133 and random pattern data to generate the pattern data.
For example, as shown in FIG. 4 , in the pattern data generator 161 , the pattern data generated corresponding to the test condition are stored in the pattern data memory 161 a and are output to the multiplexer 161 c . The pattern data creating unit 161 b randomly generates the pattern data (Psuedo Random Binary Sequence: PRBS) to transfer the pattern data to the multiplexer 161 c.
Preferably, the pattern data creating unit 161 b includes a plurality of pattern data creators 161 b - 1 to 161 b - 4 .
For example, the pattern data creator 161 b - 1 generates 8-bit pattern data, the pattern data creator 161 b - 2 generates 16-bit pattern data, the pattern data creator 161 b - 3 generates 24-bit pattern data, and the pattern data creator 161 b - 4 generates 32-bit pattern data.
The multiplexer 161 c selects one of the pattern data stored in the pattern data memory 161 a and the pattern data randomly generated from the pattern data creating unit 161 b according to the pattern data selection signal generated from the embedded processor 133 to transfer the selected data to the multi-interface 151 of the storage interface unit 132 . When plural storages are tested at the same time, the pattern data are applied to the plurality of multi-interfaces at the same time.
At this time, as illustrated in FIG. 5 , an interface selection signal is provided to the multi-interface 151 to select an interface corresponding to the storage 201 .
For example, an interface selection signal is applied from the embedded processor 133 to the multiplexer 151 f of the multi-interface 151 , the multiplexer 151 f selects one of the interfaces SATA, SAS, and PCIe according to the applied interface selection signal. That is, an interface corresponding to the interface of the storage 201 is selected.
Thereafter, instruction data output from the embedded processor 133 for the test are input to the SATA interface 151 c , the SAS interface 151 d , and the PCIe interface 151 e through the advanced host controller interface 151 a , respectively.
In addition, writing data output from the test executing unit 160 are input to the SATA interface 151 c , the SAS interface 151 d , and the PCIe interface 151 e , respectively, through the DMA unit 151 b.
When the instruction data output from the embedded processor 133 and the writing data output from the test executing unit 160 are input to the respective interfaces in this way, the multiplexer 151 f selects only one interface according to an interface selection signal. The test of the storage 201 is started by transferring the instruction data and writing data input to the selected interface to the storage 201 . For example, when the interface of the storage 201 uses the SATA interface, the SATA interface 151 c is selected, and the instruction data and writing data input to the SATA interface 151 c are converted into a format suitable for the SATA interface to be applied to the storage 201 .
Here, since standard interfaces are employed for the SATA interface, the SAS interface, and the PCIe interface, and protocols for interfaces, a detailed description of respective interfaces is omitted.
Next, after result data for testing the storage 201 are read out according to a reading instruction, they are transferred to the embedded processor 133 through the multiplexer 151 f , the SATA interface 151 c , and the DMA unit 151 b of the multi-interface 151 .
If the data obtained by reading out the storage test are transferred to the embedded processor 133 , the embedded processor 133 transmits the readout data to the test executing unit 160 .
As shown in FIG. 6 , a comparator 162 a of the fail processor 162 compares expectation data output from the pattern data generator 161 with the readout data (reading data) transferred from the embedded processor 133 , and does not generate a fail signal if they are the same and to the contrary, generates the fail signal if they are different.
According to the generated fail signal, the fail counter 162 b increases an internal count value by 1 to output a fail count value, and a fail memory address generator 162 c generates and transfers an address of a fail memory to the fail memory 163 .
The fail memory 163 stores expectation data and reading data inputted to the fail processor 162 as fail information by using the transferred address as a logical block address (LBA).
As described above, in another characteristic of the present invention, since the embedded processor 133 does not perform fail processing during testing a storage but a test executing unit 160 as a logic separated from the embedded processor 133 performs fail processing, burden of the embedded processor 133 can be reduced and accordingly an entire storage test time can be reduced by simultaneously testing the storages.
Further, the fail information stored in the fail memory 163 is transferred to the embedded processor 133 upon the request of the embedded processor 133 , and is transmitted to the host terminal 110 through the communication interface unit 131 and the network 120 .
Thus, the user can easily recognize the test result of the storage tested through the host terminal 110 .
As described above, the present invention separates the SSD test function performed in the embedded processor as a separate logic, so that burden of the embedded processor 133 can be reduced and accordingly an entire storage test time can be reduced.
The present invention designs interface of a storage using an FPGA which allows a user to easily use the interface if needed. Various interfaces are implemented by one chip using an FPGA which allows the user to selectively use interface corresponding to the interface of the storage without changing H/W.
The present invention is not limited to the above-described embodiment, and may be variously modified by those skilled in the art to which the present invention pertains without departing from the spirit of the present invention and the modification falls within the scope of the present invention.
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Disclosed is a solid state drive tester which divides the functions of generating and comparing test pattern data and Frame Information Structure (FIS) data with each other into each other to implement the functions as separate logics, so that entire test time is decreased by reducing load of a processor. The solid state drive tester includes a host terminal for receiving a test condition for testing a storage from a user, and a test control unit creating a test pattern corresponding to the test condition, and adaptively selecting an interface according to an interface type of the storage to be tested to test the storage using the test pattern, wherein the test control unit is divided into a control module for controlling the test of the storage and a test execution module for practically executing the test in hardware to test a plurality of storages in real time.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to inertial navigation systems and, more particularly, to such systems of the strap-down type.
2. Description of the Prior Art
All inertial navigation systems provide for the isolation of the accelerometers from rotations of the vehicle. Gyroscopes (gyros) are used for such isolation. In the inertial platform type of system, the gyros drive gimbals which physically isolate the platform-mounted accelerometers from vehicle rotations. In the strap-down type of system, the gyro outputs are coupled to a computer which computationally isolates the outputs of the vehicle-mounted accelerometers from the vehicle rotations to which the accelerometers are physically subjected. Strap-down systems place stringent requirements on the gyro dynamic range performance in maintaining a space fixed reference in a vehicle. A three-axis platform requires three single-degree-of-freedom gyros arranged orthogonally for proper operation. In the prior art, particularly as applied to space vehicles and others where extreme reliability over a considerable period of time is required, the need for redundancy for protection against component failure dictated using at least five gyros to achieve both failure detection and correction. This not only increases the number of gyros required to provide redundancy but it also increases the number of channels including the circuitry for processing the gyro signals.
Recently, a new type of gyro has been developed which provides two degrees of freedom, rather than one. This is a so-called dry tuned rotor gyro and it is possible, in embodiments of the invention shown and described herein, to arrange three two-degree-of-freedom dry tuned rotor gyros or their equivalent in a particular orientation so that both orthogonal and skewed rate data are available with complete redundancy, utilizing only the three units. This affords not only a saving in the number of gyros required, but also a corresponding reduction in the associated circuitry.
SUMMARY OF THE INVENTION
In brief, arrangements in accordance with the present invention comprise three two-degree-of-freedom dry tuned rotor gyros mounted on a specially shaped case on three differently-angled mounting surfaces which are so arranged that both an orthogonal and a 45° skewed set of axes can be achieved. If a cube having four vertical faces and two horizontal faces be considered, each of the three differently-angled mounting surfaces may be described as being at 45° with respect to a pair of faces of the cube. Two of the gyro mounting surfaces--those mounting the Z axis gyro and the Y axis gyro--are respectively inclined at 45° from first and second adjacent vertical faces and from a horizontal face of the cube. The third mounting surface--that for the X-axis gyro--is at 45° to the second and third vertical faces of the cube and itself is in a vertical plane.
Considered more generally, and with reference to any type of gyro having a pair of orthogonal axes (primary and secondary), three such gyros are mounted so that their primary axes are directed mutually orthogonally, say along arbitrarily designated X, Y and Z axes. Each gyro is then further oriented so that its remaining, secondary, axis is at 45° to the primary axes of the other two gyros. Thus the gyro having its primary axis aligned with the X axis, here designated the X gyro, has its secondary axis aligned at 45° to the Y and Z axes in the Y-Z plane. Similarly the Y gyro has its secondary axis aligned at 45° to the X and Z axes in the X-Z plane, and the Z gyro secondary axis is at 45° to the X and Y axes in the X-Y plane.
By mounting gyros of this particular type on the three respective mounting surfaces as defined, the gyros each have a first axis which combines with the other two gyro first axes to form an orthogonal triad and a second axis which, combined with the other two gyro second axes, forms a second set skewed at 45° to the first triad. The associated electronics utilize a common power source and clock which furnish raw power and timing to three identical gyro driving and data conversion circuits. Any one of these circuits can be lost, due to a failure, and the unit continues to accomplish its function based on the data provided by the other two channels. The data from this inertial measurement unit (IMU) is provided over six lines to an associated computer for processing. Because of the skewed axis data, it is possible to form three independent measurements of vehicle rates along each of the orthogonal axes of the IMU. The failure detection and selection process is provided by software logic which compares relative performance on these equivalent measurements.
Although the particular unit described herein is designed for special application to space booster launch vehicles, suitable selection of the instruments used and scaling of the electronics make it possible to utilize the same design in most applications where three-axis inertial reference is required. Applications of particular interest may be in aircraft and cruise missile type vehicles.
BRIEF DESCRIPTION OF THE DRAWING
A better understanding of the present invention may be had from a consideration of the following detailed description, taken in conjunction with the accompanying drawing, in which:
FIG. 1 is a perspective view of a redundant inertial measurement system in accordance with the present invention;
FIG. 2 is a schematic view of the sensor block of the system of FIG. 1; and
FIG. 3 is a functional block diagram of the system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a redundant inertial measurement system 10 in accordance with the invention principally comprises a sensor block 12 in which all of the sensing elements are mounted and an electronics section 13 comprising a plurality of circuit cards 14 which provide the processing of the sensor data into a digital pulse representation. The sensor block 12 carries the X gyro 16, the Y gyro 18 and the Z gyro 20 mounted on three respective orthogonally oriented mounting surfaces. Also shown mounted to the sensor block 12 are the X' accelerometer 22, the X accelerometer 24, the Y accelerometer 26 and the Z accelerometer 28. The sensor block connector 30 is also shown as a part of the sensor block in FIG. 1.
The orientation of the respective gyros and accelerometers may be better seen in FIG. 2 which shows the sensor block 12 rotated 180° and turned over on its back from the orientation shown in FIG. 1. In FIG. 2, which shows the sensor block 12 in its true orientation in the space vehicle, the directions X IMU , Y IMU , Z IMU represent the coordinate axes of the inertial measure unit (IMU). The X, Y and Z gyros 16, 18, and 20 are two-axis dry tuned gyros, specifically Teledyne Model SDG-5 gyros, which permit the orientation of the three gyros in combination to develop two completely redundant sets or triads of three axes each. From FIG. 2, it may be seen that if the sensor block 12 is viewed as a cube, the Y and Z gyros 18, 20 are mounted on surfaces which are angled at 45° from respective first and second sides of the cube. The X gyro is mounted on a surface in a vertical plane which is at 45° with respect to the second and third sides of the cube. Each of the three gyros has two orthogonal axes, referred to in FIG. 2 as X case and Y case . These respective axes directions are shown in FIG. 2 with the X case axes of the X and Y gyros and the Y case axis of the Z gyro parallel to the plane of the Y-Z axes of the IMU. In addition, the directions of the X, X', Y and Z accelerometers are also shown in FIG. 2. The X' accelerometer is oppositely directed from the X accelerometer and provides redundance for accelerometer measurements along the X (vertical) axis.
Other system components and their functional interrelationship are represented schematically in the block diagram of FIG. 3. Thus, the X gyro 16 is shown coupled to a capture loop stage 17, the combination of which provides a gyro caging loop system using cross feed shaping networks for gyro control. Similarly, the Y gyro 18 is shown coupled to a capture loop stage 19 and the Z gyro 20 is shown coupled to a capture loop stage 21. In each of these gyro caging loop systems, Y-pickoff signals are applied to a shaping network in the associated capture loop stage and shaped in a cross feed network for return to the X-torque element in the gyro. In similar fashion the X-pickoff signals are processed in a shaping network in the associated capture loop stage and returned in a cross feed network to the Y-torque element of the gyro.
IMU signals from each of the two axes of the three gyros and from the four accelerometers are applied to a set (10 in all) of analog-to-digital (A/D) converters 30. These A/D converters are of the integrating type, bi-polar in operation, and act to process the analog voltages from the gyro capture loops and accelerometers and convert them to digital output signals having a duration corresponding to the amplitude of the analog signal with an indication of the polarity thereof.
Coupled to the output of the A/D converters 30 is a plurality (six in number) of data combiners 32 which provide digital signals corresponding to the output of the A/D converters 30 to an associated guidance computer 34. Each of the data combiners 32 has two distinct inputs and is capable of processing and combining the signals from two A/D converters 30 for transmission as a multiplexed signal over its single data line to the guidance computer 34. Since the six data combiners 32 together have the capability of processing signals on 12 inputs, and there are only 10 A/D converters 30, the two unused inputs are coupled to receive a sync word from the system clock 40. The data combiners 32 make use of this sync word in the multiplexing process and pass it along to the guidance computer 34 as information used in demultiplexing the data.
It will be noted in FIG. 3 that the various components are organized by channels--the X gyro 16 and its associated capture loop stage 17, the X accelerometer 24, the three A/D converters 30 and the two data combiners 32 associated with these elements are shown in an X channel along the top of the figure; the Y accelerometer 26, the Y gyro 18 and its associated capture loop stage 19, the three A/D converters 30 associated with these elements in the corresponding two data combiners 32 are shown in a Y channel extending along the middle of the figure; and the Z gyro 20 and the associated capture loop stage 21, the X' accelerometer 22 and the Z acceleormeter 28, the four A/D converters 30 associated with these elements and the corresponding two data combiners 32 are shown in a Z channel along the bottom of FIG. 3. Each separate channel has its own power supply; the X power supply 42 in the X channel, and Y power supply 44 in the Y channel and the Z power supply 46 in the Z channel. Also provided separately for each channel is a buffer/filter 48 which is part of the gyro caging loop system of the corresponding channel. The clock 40 provides appropriate timing signals to all of the channels. The basic clock frequency is 32 KHz. Timing signals at 32 KHz, 64 KHz, and 256 KHz as well as a transmit phase signal are applied from the clock to the data combiners 32. A 400 Hz synchronizing signal is applied to the three power supplies 42, 44 and 46 for ultimate application to the gyros. A sync burst signal is sent from the clock 40 to the guidance computer 34 and is also the source of the sync words applied to the two data combiners 32. 1 KHz and 32 KHz timing signals are also provided by the clock to the A/D converters 30. The clock 40 also provides a 49 KHz signal to the three buffer/filter stages 48.
Voltage for the respective power supplies 42, 44 and 46 is received from the vehicle 28 volt DC primary system via a line filter 52. The power supply 54 for the clock 40 develops the desired 5 volts DC by gating ten volt DC outputs from the X and Y power supplies 42, 44. Each of the X, Y and Z power supplies 42, 44 and 46 develops ± 15 volt DC for its associated capture loop stage, buffer/filter, accelerometer, and A/D converters. Each power supply 42, 44 and 46 also provides a 400 Hz signal to spin its associated gyro and 5 volts DC for the logic circuitry of the data combiners 32 in the same gyro channel.
The system of the present invention as shown in FIGS. 1-3 is designed with precision, effectiveness, and realiability as primary considerations. The reliability objective depends in part on a simplification of circuitry and system components, and the judicious use of such to provide built-in redundancy wherever practical. Thus, the mounting of the three gyros, which are of the two-axis type, is arranged to provide two distinct sets of rate data, thereby achieving gyro signal redundancy protection for the system. Since only three gyros are employed, an independent three-channel electronic system for processing the gyro signals is sufficient to achieve the desired redundancy. If there is a failure in one of the gyros or its associated electronics channel, the information normally processaed by that channel can be derived from the other two gyros which provide information with respect to the one axis because of the cross coupling between axes which is inherent in the gyro.
If the signal from either the X or X' accelerometer is lost, the signal from the other accelerometer of the pair still provides the needed information, there being redundancy with respect to the X and X' accelerometers. Accelerometer information with respect to the X axis is the most important of the three axes. The accelerometers for the Y and Z (pitch and yaw) axes are not redundant, but this information is only weakly related to mission success. Generally, there is not very much acceleration with respect to those two axes. The only time this information is really critical is in approximately the first minute of launch. After that, with the vehicle out of the atmosphere, there is little data provided by these acceleration components. Redundancy is provided with respect to the power supplies for the three separate channels, there being a separate power supply for each channel. The clock timer for the system is common to all channels. However, the clock power supply is developed to provide redundancy for the clock. The X and Y and X and Z power supplies are gated together to provide the positive and negative 15 volts DC for the clock oscillator. (See the top of the block 40 in FIG. 3). Also, at the lower end of the block representing the X and Y power supplies in FIG. 3, 10 volts DC is picked off and gated together in the power supply 54 which provides five volts DC to the clock 40.
Since the 45° skewed set of gyro axes provides data which is independent of the orthogonal set of gyro axes, it is possible to form three independent measurements of vehicle rates along each of the orthogonal axes of the inertial measurement unit. Software logic in the guidance computer 34 compares relative performance with respect to these measurements and makes the decision as to which is to be selected when there is a discrepancy. This also involves the detection of failure in the system. For example, if there were a discrepancy between data provided by the X channel as contrasted with corresponding information received by the guidance computer over the Y and Z channels, this would be interpreted as a failure somewhere in the X channel and thereafter the data from that channel could be ignored, relative to data from the Y and Z channels.
Although there has been described above a particular arrangement of a redundant inertial measurement system in accordance with the invention for the purpose of illustrating the matter in which the invention may be used to advantage, it will be appreciated that the invention is not limited thereto. Accordingly, any and all modification, variations or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of the invention as defined in the appended claims.
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A system providing economical redundant strap-down inertial measurement capability in a space navigation system. By appropriate orientation of two-degree-of-freedom dry tuned rotor gyros, the system is able to achieve complete redundancy utilizing only three gyro units. With this orientation, both orthogonal and skewed rate data are available. Not only are the necessary computations materially simplified, but this system also provides the necessary conditions for failure detection and isolation.
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BACKGROUND OF THE INVENTION
[0001] The present invention is in the technical field of construction.
[0002] More particularly, the present invention is in the technical field of erosion and sediment control as it relates to construction.
BRIEF SUMMARY OF THE INVENTION
[0003] The present invention is a filtering device for storm water run off. Upon being placed in front of a storm drain (catch basin) sediment and debris are trapped in the filter fabric as the storm water passes through the entrance and exit holes of the device. Once the sediment and debris reach a reasonable level the filter fabric can be removed and cleaned or replaced.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0004] FIG. 1 is a top view of the housing component of the present invention;
[0005] FIG. 2 is a front view of the housing component of the present invention;
[0006] FIG. 3 is a side view of the housing component of the present invention;
[0007] FIG. 4 is a bottom view of the housing component of the present invention;
[0008] FIG. 5 is an isometric view of the housing and filter fabric of the present invention;
[0009] FIG. 6 is an isometric view of the housing and filter fabric of the present invention;
[0010] FIG. 7 is a perspective view of the curved version of the present invention;
DETAILED DESCRIPTION OF THE INVENTION
[0011] The outer housing consist of a HDPE (high-density polyethylene), LDPE (low-density polyethylene) or PVC (polyvinylchloride) cylinder. The cylinder (sleeve) may be formed to make various geometric shapes i.e., square, rectangular, triangle or circle. The cylinder may also be curved. The cylinder will have drilled holes or slots (of various diameters) front and back to accommodate water flow in and out of the cylinder. This outer housing also serves as a protective sleeve for the internal filtering components.
[0012] The internal components consist of a removable frame. The frame may be made of LDPE (low-density polyethylene), HDPE (high-density polyethylene), steel, aluminum or wood. This frame will conform to the same shape(s) as the housing unit; square, curved, etc.
[0013] The filtering component consists of a variety of filtering fabric materials that will be attached to the internal frame. This filter fabric may be cloth, woven cloth, fiberglass or plastic. This filter fabric will be attached to the above mentioned frame.
[0014] The invention works by allowing storm water to flow through openings (round or oblong) in a geometrically shaped cylinder that is placed in front of a storm water catch basin. A portion of the sediment that is traveling in the storm water will be trapped in the internal filter component. The filter component will also trap and stop sizeable debris particles from entering the storm drain structure. The opposite side of the cylinder also has openings (round or oblong) to allow the storm water to exit into the storm drain structure (catch basin). The cylinder's diameter and or geometric shape will allow the storm water to over flow into the storm drain structure (catch basin); therefore preventing the storm drain structure from being clogged during rain fall.
[0015] Referring now to the invention in more detail, in FIG. 5 to FIG. 6 there is shown the filtering device with the housing unit 10 . The housing unit 10 , is shown in this view with an elongated slot which is cut on opposite sides of the housing unit 10 . Also shown in this view is the filter fabric 12 , which can be rolled into a cylinder and attached to itself with Velcro or attached to a frame 14 .
[0016] In more detail, still referring to the invention of FIG. 7 the filtering device is shown with the housing unit 10 , in a curved shape with a cut-a-way section showing the filter fabric 12 , which conforms to the shape of the curved housing unit 10 .
[0017] The construction details of the invention as shown in FIG. 1 to FIG. 4 would have a diameter of 4 to 6″ this would be the housing unit 10 . The thickness of the housing unit 10 , will depend upon the type of material used i.e. PVC schedule 23 . 5 , 26 or 40 ; HDPE or LDPE. The length of the housing unit 10 , would range from 6′ to 16′ or any desired size smaller or greater. The filter fabric 12 , would be cut and rolled to fit the inside diameter of the housing unit 10 , which would make the filter fabric 12 ; when laid flat measure 11½″ to 13½″ (when used without the frame 14 ). The length of the filter fabric 14 , will match the length of the housing unit 10 . When the frame 14 , is used with the filter fabric 12 , (when flat) it shall be cut to fit the inside diameter of housing unit “snuggly” and match the length of the housing 10 , the attached filter fabric 12 , shall be the same height and length of the frame 14 , and housing unit 10 . When the frame 14 , is made round and cylinder shaped, it along with the filter fabric 12 , shall be made to fit the inside diameter of the housing unit 10 , “snuggly” and match the length of the housing unit 10 .
[0018] The advantages of the present invention, without limitation, are (1), when using a 4″ diameter device (straight or curved) an overflow space is created and in case there is severe rain fall and or the device becomes clogged the excessive water will be able to over flow into the storm structure avoiding significant street flooding. Secondly, the housing unit serves as a protective shell for the filter fabric as well a portal for the storm water to flow through. Thirdly, the curved design is especially helpful when placed in front of storm catch basins with narrow openings (4″ inches or less) because of the over flow space that is created. Next, one person can reasonably manage the weight of the device. Also, the portal design of the device will not allow it to float away. Finally, the removable filter fabric is a true benefit because it can be removed, cleaned or replaced on site.
[0019] While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.
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The objective of this invention is to filter storm water that drains into catch basins and drain inlets by trapping sediment and preventing sizeable objects from flowing into storm drain systems. The device can be made of durable material and with a removable inner filter it can cleaned and reused. This device can also be made in a verity of diameter sizes and geometric shapes to accommodate various types of applications.
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This application is a Continuation of PCT International Application No. PCT/AU01/00220, filed on Mar. 2, 2001.
TECHNICAL FIELD
The present invention relates to a weapon and in particular to a recoil control mechanism for a weapon. The invention will be described generally in relation to a firearm, however it is to be understood that the invention is applicable to other forms of weapons for firing a projectile. Thus the weapon may, for example, be a large calibre weapon which is supported on a mounting such as a stand or platform instead of a hand held portable weapon such as a firearm.
In this specification the term “projectile” is to be understood as encompassing one piece generally solid projectiles such as bullets, pellets, darts, flechettes, artillery warheads, projectiles as in for example WO 97/04281, mortar shells (eg. 120 mm) or rocket boosted artillary shells, plus multiple piece charges which are fired as one, such as the shot in a shotgun cartridge or a plurality of bullets fired as one.
BACKGROUND
A problem with all weapons which fire a projectile, particularly those that rely upon detonation of an explosive propellant, is recoil. That is, firing the weapon (for example by detonation of a charge of explosive propellant within the weapon) produces a forward propelling thrust on the projectile and an equal and opposite rearward force, or recoil. Recoil limits the accuracy and portability of weapons. First it produces a force which has the effect of rotating the weapon about the centre of gravity of the weapon and its support (which for a firearm would be the shooter), resulting in vertical climb and lateral drift of the muzzle end of the barrel for succeeding firings. Recoil forces also cause torque, which has the effect of ‘twisting’ the weapon. The muzzle is thrown off the target in an irregular half circular motion around the longitudinal axis of the barrel. Similar to the effect of muzzle climb, the time of reacquisition of the target is therefore increased for subsequent rounds and accuracy is therefore significantly affected.
During automatic firing recoil can significantly affect the accuracy of the succeeding rounds. Second, the force of recoil must be absorbed by the weapon, or the shooter if the weapon is a firearm, or transmitted to a support mounting and thus to ground for heavier weapons such as artillery pieces. Thus it may cause discomfort and fatigue or even injury to a shooter, or require heavier supporting structures, or complex “soft” mounting carriages for mobile artillery weapons. Large masses are sometimes used in firearms to absorb the recoil velocity, however this compromises portability.
Clearly, if the recoil of a weapon could be substantially reduced if not eliminated within the weapon itself, it would reduce the above problems.
There are many known recoil reducing mechanisms, including arrangements which are initiated by the rapidly expanding gases produced by the detonation and burning of an explosive propellant. Generally, however, the known arrangements effectively only reduce the recoil without cancelling or at least substantially eliminating it.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved recoil control mechanism.
The invention is characterised by the generation of a forward counterforce to the rearward recoil simultaneously with absorption of rearward recoil force momentarily after propulsion of the projectile is initiated.
Accordingly, in a first aspect the invention provides a recoil control mechanism for a weapon for firing a projectile in a forward direction which includes a first mass and a second mass which are driven in substantially opposite directions upon firing, wherein the first mass is driven in the forward direction to counter a rearward recoil of the weapon and the second mass is driven in the rearward direction for absorbing some of the recoil force.
The first mass and the second mass are solid inertial weights.
Preferably the mechanism includes a frame, the first mass and the second mass being associated with the frame for the frame to guide their respective forwards and rearwards movement, and including a force absorbing means which is operative between the second mass and the frame and a force transferring means which is operative between the first mass and the frame.
In a second aspect the invention provides a method of countering recoil of a weapon caused by the firing of a projectile, the method including providing a first mass to be driven forwardly in the same direction as the projectile to counter a rearwards recoil force and providing a second mass to be driven rearwardly against a force absorbing means for substantially simultaneously absorbing some of the rearwards recoil force.
The generation of a forward counterforce simultaneously with absorption of the residual recoil force over the time period of the recoil, allows the achievement of a resultant force-time characteristic which may be reasonably predetermined. For example, for a projectile which is fired by detonation of an explosive propellant, the recoil force of a weapon is reasonably calculable from, knowledge of the amount and type of propellant and the masses etc. that are involved, or it may be empirically determined experimentally, and from this appropriate parameters for the counterforce and recoil absorption sub mechanisms can be calculated (and possibly experimentally adjusted) to give a predetermined resultant force-time characteristic. Thus the invention gives an improved recoil control mechanism. It is envisaged that in some embodiments of the invention, the recoil of the weapon may be at least substantially eliminated if not fully cancelled (that is, the resultant force is substantially zero over the recoil time period). It is also considered that a resultant forward force could be generated.
Preferably the first mass is a barrel and the second mass is a breech block of the weapon and a means is provided associated with the barrel and a frame of the weapon for transferring a forwards force to the frame from the forward motion of the barrel. This means may include a compression spring or pneumatic or hydraulic piston and cylinder arrangement or electromagnetic means which is operative to return the barrel to its firing position.
The barrel and the breech block are also preferably biased towards each other relative to the frame of the weapon. This bias may be provided by a tension spring which is connected between the barrel and the breech block. Thus, as force from the forward momentum of the barrel is being transferred to the frame, the rearwards recoil force imparted to the breech block is being absorbed by the tension spring. Thus the tension spring provides a force absorbing means against which the breech block is driven. The tension spring may also be operative to restrain the breech block in its firing position momentarily upon detonation of the propellant to provide an adequate reaction surface for initiating the forward movement of the projectile and then to return it to its firing position after its rearward movement.
Alternatively the bias of the breech block and the barrel towards each other may be provided by means acting independently between the barrel and the frame and the breech block and the frame. Such means acting between the barrel and the frame may constitute the above described means for transferring a forwards force to the frame from the forward motion of the barrel. The independent means may each comprise a helical spring.
Although the preferred embodiment combines simultaneous “blow forward” of the barrel and “blow back” of the breech block to control recoil, as described above, it is to be understood that the invention may be realised in alternative embodiments. For example, it is envisaged that the first mass and the second mass may be additional components and that a gas for driving them apart may be tapped from the barrel or firing chamber. The recoil control mechanism may also be provided as an attachment per se for a weapon. Various of the foregoing or following features for biasing the breech block and barrel and providing gas reaction surfaces may be adapted to the masses of such alternative embodiments.
In the preferred arrangement wherein the first mass is a barrel and the second mass is a breech block of the weapon, a chamber for receiving a cartridge containing the projectile (such as a bullet) and explosive propellant is preferably provided at a loading end of the barrel. The chamber is associated with the barrel and the breech block to provide an interposed gas contact region therebetween for receiving expanding gases from the chamber upon firing of the projectile from the cartridge. Thus, upon firing of the cartridge, expanding gases from the propellant force the projectile from the cartridge and propel it through the barrel, and momentarily after initiation of the projectile's movement, the expanding gases following the projectile which emerge from the cartridge into the chamber expand into the interposed gas contact region to blow the barrel forward and simultaneously blow the breech block backwards to thereby reduce if not eliminate the recoil of the weapon. The chamber may be provided by the barrel, by the breech block, or the barrel and the breech block in combination, or by a separate chamber member. Preferably the component or components providing the chamber are in a structural relationship such that the interposed gas contact region is defined in part by at least two facing reaction surfaces, with each reaction surface being directly or indirectly associated with one of the barrel or the breech block. Preferably the reaction surfaces are substantially normally orientated relative to the forward and rearward directions to maximise the forces applied thereto in the forward and rearward directions by the gas pressure. The aforesaid structural relationship may be realised by a telescopic arrangement of one component relative to another, as will be described in more detail below.
It is to be understood that the weapon will include a firing mechanism for initiating detonation of the explosive propellant and in the preferred embodiment this may include a firing pin associated with the breech block which is operable via a trigger mechanism carried by the frame, as is known. The weapon may also provide for semi automatic or fully automatic operation utilising the energy stored during the blow back of the breech block, as is also known, in which case a magazine will need to be provided. A suitable firing mechanism and a mechanism for providing semi or fully automatic operation including a magazine for the cartridges will not be described in further detail herein as there are many such known mechanisms from which a person skilled in the art may choose to provide suitable such mechanisms for the weapon.
A weapon incorporating the invention, in its preferred form involving blow forward of the barrel, may include additional features associated with the barrel for increasing the forwards momentum thereof. Such additional features include, for example, the provision of a conical bore for the barrel and/or muzzle breaks for redirecting the gas from the barrel, as are known. The weapon in its preferred form may be a firearm such as a rifle, shotgun, pistol or revolver.
For a better understanding of the invention, the principle thereof for various embodiments, as well as a specific embodiment, which are given by way of non limiting example only, will now be described with reference to the accompanying drawings (which are not to scale).
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1 to 4 schematically illustrate the operating principle of the invention.
FIG. 5 schematically illustrates use of a barrel, chamber unit and breech block for the invention.
FIGS. 6A-D and 7 A-F illustrate further embodiments in principle.
FIG. 8 is a partially sectioned side view of an embodiment of the invention in the form of an automatic pistol, and
FIG. 9 is a partially sectioned view of a portion of the pistol of FIG. 8 showing the slide (that is breech block) in its rearmost position.
DETAILED DESCRIPTION
A recoil control mechanism 10 of a weapon as schematically shown in FIGS. 1 to 4 includes a first mass which is a barrel 12 of the weapon and a second mass which is a breech block 14 of the weapon. The barrel 12 is movable in a forward direction against a biasing means 16 relative to a frame 18 of the weapon and the breech block 14 is movable rearward against a biasing means 20 relative to the frame 18 . The biasing means 16 and 20 may be helical compression springs. The barrel defines a chamber 22 at its loading end, for receiving a cartridge 24 with a bullet 25 , and is telescopically received within a recess 26 in the breech block 14 .
The recess 26 of the breech block and the barrel 12 are shaped such that when in the ready to fire position (FIG. 1) they define an interposed gas contact region, namely an annular volume 28 . Ports 29 provide for gas flow from chamber 22 into volume 28 . The interposed gas contact region 28 is defined in part by a reaction surface 30 on the barrel 12 and a facing reaction surface 32 on the breech block 14 . The surfaces 30 and 32 lie substantially normally to the forward and rearward directions. A firing pin 34 is associated with the breech block 14 .
On firing, the rapidly expanding gases 36 from the explosive propellant in cartridge 24 propel bullet 25 into the bore of barrel 12 and also flow through ports 29 into the interposed gas contact region 28 (FIG. 2 ). The very high pressure gases entering region 28 act on reaction surfaces 30 and 32 and thus simultaneously force or “blow” the barrel 12 forwardly (arrow A, FIG. 3) and the breech block 14 rearwardly (arrow B, FIG. 3 ). Initiation of the blowing forward of the barrel 12 and blowing back of the breech block 14 occurs momentarily after firing because of the proximity of ports 29 and chamber 22 . The force of the rearward or recoil movement of the breech block 14 is absorbed by biasing means 20 which has a suitable characteristic relative to that of biasing means 16 to ensure it stores a significant portion of the force instead of immediately transferring it to frame 18 . Simultaneously, the force from the forward movement of barrel 12 is transferred to frame 18 via biasing means 16 , which has a relatively stiffer characteristic compared to that of biasing means 20 to ensure that the counter recoil force is quickly transferred to the frame 18 . Thus the rearward recoil which occurs upon detonation of the explosive in cartridge 24 and expansion of gases 36 therefrom to propel bullet 25 through barrel 12 is simultaneously both absorbed in biasing means 20 and countered by an oppositely directed force applied to frame 18 from barrel 12 . The resultant of this may be to totally or at least substantially eliminate recoil of the weapon. At the limit of the forward movement of barrel 12 and rearward movement of breech block 14 (FIG. 4) the cartridge 24 is ejected by ejector 35 and the biasing means 16 and 20 are operative to restore the parts to their ready to fire positions.
FIG. 5 schematically shows a modification wherein a chamber unit 40 is provided interposed between a breech block 14 and barrel 12 (the components of FIG. 5 which are equivalent to those in FIGS. 1 to 4 have been given the same reference numeral, but note that some features have been omitted from FIG. 5 for clarity). A forward cylindrical portion 42 of chamber unit 40 telescopically engages in a wider cylindrical recess 44 in barrel 12 to provide an interposed gas contact region 28 defined in part by facing reaction surfaces 30 and 32 of, respectively, the barrel 12 and the chamber unit 40 . With this construction, the ports 29 are eliminated, however it functions the same as the construction of FIGS. 1 to 4 .
The reaction surfaces of the interposed gas contact region may have any desired shape. Thus instead of being flat, as shown in FIGS. 1 to 5 , they may have curved portions, be fluted, include depressions or be otherwise modified to increase the surface area upon which the rapidly expanding pressurised gases 36 act.
After the pressure of the expanding gases has reduced, the breech block 14 and barrel 12 are returned to the positions shown in FIG. 1 by the energy stored in biasing means 20 and 16 , respectively. A mechanism for automatic ejection of the cartridge case 24 is indicated at 35 (FIG. 4 ). A mechanism for automatic loading of another cartridge in chamber 22 ready for firing is not shown in FIGS. 1 to 5 , but as is known may be operated by the backward and then forward motion of the breech block 14 , or alternatively the forward and then rearward motion of the barrel 12 , or a combination of both.
FIGS. 6A to D illustrate in principle a weapon where recoil is controlled by simultaneous “blow forward” of a barrel and “blowback” of a breech block without use of an interposed gas contact region. Thus the figures show a weapon 50 which comprises a frame 52 on which is reciprocally mounted a barrel 54 biased rearwardly by a compression spring 56 . The frame 52 also carries a breech block 58 which is biased forwardly by compression spring 60 .
On detonation of a cartridge 62 , the bullet 64 is propelled forwardly and its motion through the barrel 54 drives the barrel forwardly and this motion continues after the bullet 64 exits the barrel 54 (FIGS. 6B, C and D). Also upon firing, a rearwards force from the cartridge 62 is impacted on the breech block 58 and this drives the breech block rearwardly against the bias of spring 60 . Spring 56 is relatively weak such that a forwards force is generated by the moving mass of barrel 54 to counter the rearwards recoil. Some of this force is transferred to frame 52 via spring 56 such that, combined, a substantial forwards counter to the rearwards recoil is generated. Simultaneously the recoil force imposed on breech block 58 is absorbed by spring 60 . It is considered that the masses of barrel 54 and breech block 58 and the spring characteristics of springs 56 and 60 could be arranged such that recoil is effectively eliminated.
FIGS. 7A to F illustrate a weapon 80 having a frame 82 on which is mounted a barrel 84 and breech block 86 . A moveable mass 88 surrounds the barrel 84 . The barrel 84 is biased to its rest position relative to frame 82 by spring 90 , and mass 88 is biased against an abutment 92 on barrel 84 relative to frame 82 by a double spring arrangement 94 . Breech block 86 is biased forwardly relative to frame 82 by a spring 96 . An interposed gas contact region is defined by facing surfaces of the abutment 92 on barrel 84 and an end face of the mass 88 and is in gas communication with a chamber part of the barrel 84 via passages 98 .
The sequence of events for recoil control in the weapon 80 upon firing of a cartridge 100 will be evident from FIGS. 7A to F. Thus, on detonation, the barrel is initially driven forwardly against the bias of spring 90 by bullet 102 and virtually instantaneously gas forces into the gas contact region to drive mass 88 forwardly against double spring 94 , the initial portion of which is readily compressible (FIGS. 7 A and B). Spring 96 drives breech block 86 forwardly with the barrel 84 . Whilst mass 88 continues forwardly, barrel 84 is then driven rearwardly by spring 90 and gas pressure on abutment 92 to drive the breech block 86 rearwardly against spring 96 (FIGS. 7C, D and E). This extracts the cartridge case 100 from the chamber end of barrel 84 . Mass 88 continues forwardly, but is now moving against a stronger bias provided by the second portion of the double spring arrangement 94 until it reaches its forward most position (FIG. 7 F), at which point the breech block 86 also reaches substantially its rear most position. The mass 88 and breech block 86 are then reset to their initial positions by the energy which is stored in springs 94 and 96 , respectively.
The initial forward movement of barrel 84 , breech block 86 and mass 88 combined with the subsequent rearward movement of barrel 84 and breech block 86 against spring 96 simultaneously with continued forwards movement of mass 88 against double spring 94 allows for the recoil in the weapon 80 to be controlled.
An example weapon, namely a pistol 100 incorporating an embodiment of the invention, comprises a frame 102 (FIGS. 8 and 9) having a handle 104 within which a magazine 106 is received. Mounted on the frame 102 is a barrel 108 and a breech block in the form of a slide 110 . A breech face 112 of the slide (best seen in FIG. 9) closes a chamber 114 provided by a chamber unit 116 , and a forward portion 118 of the slide surrounds the barrel 108 . Forward portion 118 of the slide 110 includes a bushing 120 for supporting the forward end of barrel 108 for relative movement therebetween.
The slide 110 is rearwardly movable relative to frame 102 against the bias provided by a helical compression spring 122 which acts between a boss 124 which is pinned to the frame 102 by a pin 126 and a spring holding bracket arrangement 128 provided on the forward portion 118 of the slide beneath barrel 108 . A pin member 130 (which may be cylindrical) extends through bracket 124 for guiding and supporting the spring 122 as it compresses with rearwards movement of slide 110 . The frame 102 includes an extension 132 for covering the spring 122 .
The barrel 108 is forwardly movable relative to frame 102 against the bias provided by a helical compression spring 134 which acts between the boss 124 pinned to frame 102 and a depending lug 136 of the barrel 108 . The pin member 130 is associated with the lug 136 for supporting spring 134 . Pin member 130 can slide through boss 124 . A rib on the lowermost surface of lug 136 of barrel 108 slides within a groove in the frame 102 to guide the barrel.
Frame 102 carries a firing mechanism which includes a trigger 138 and hammer 140 adapted to be cocked by the slide 110 when it moves rearward from the position shown in full lines in FIG. 8 . Details of the firing mechanism are not shown but may be the same or similar to that in a Colt “Ace” pistol, upon which the present embodiment is modelled. When trigger 138 is pulled, the hammer 140 is released to strike the rear end of a firing pin 142 carried by the slide 110 .
The chamber unit 116 includes a cylindrical forward portion for telescopically engaging within a cylindrical recess in the rear end of barrel 108 to provide an interposed gas contact region 144 . The gas contact region is partly defined by facing reaction surfaces of the barrel and the chamber unit. The rear portion of chamber unit 116 includes a depending extension 146 (see FIG. 9) which includes a slot 148 . A pin 150 , which is fixed to the frame 102 , passes through the slot 148 whereby the slot and pin 150 in combination define the forward and rearward limits of movement of the chamber unit 116 . A V spring 152 is retained between the depending extension 146 of chamber unit 116 and a surface of frame 102 to bias the chamber unit 116 towards its forward most position. Extension 146 includes a rearward projection which has an inclined upper surface 154 (best shown in FIG. 9) for providing a ramp for guiding cartridges into the chamber 114 .
The slide 110 includes an extractor adapted for engaging and withdrawing cartridges from chamber 114 when the slide 110 moves rearward. When the cartridge shell is drawn back by the extractor it is engaged by an ejector and thrown out through ejection opening 156 in the slide 110 (see FIG. 9 ).
The magazine 106 holds cartridges 158 , the uppermost of which rests against a depending central rib 160 on the slide 110 . The magazine is provided with a known spring follower to press the cartridges upward successively as each topmost cartridge is withdrawn and fired by the pistol 100 .
FIG. 8 shows the pistol 100 loaded and cocked. Upon firing, the cartridge and chamber unit 116 recoil rearwardly (against the bias of V spring 152 ) and at virtually the same instant some of the high pressure expanding gases enter the gas contact region 144 and impinge on the reaction surfaces to blow the chamber unit 116 and barrel 108 apart. This drives the chamber unit 116 and slide 108 rearwardly against the bias of the spring 122 . The chamber unit 116 stops when the forward end of slot 148 contacts pin 150 , but slide 110 continues rearwardly for the recoil force to be further absorbed by spring 122 . Simultaneously force from the forward movement of the barrel 108 is transferred to frame 102 via spring 134 acting between lug 136 and boss 124 . This force counteracts the recoil, including that caused by extension 146 of chamber unit 116 striking pin 150 of frame 102 . The combined blowing back of the slide 110 and blowing forward of barrel 108 together with the action of springs 122 and 134 relative to frame 102 allows for the recoil of the pistol 100 to be substantially eliminated.
The slide 110 moves rearward to the position shown in FIG. 9 and thus recocks the firing mechanism. It is immediately returned forwardly by the energy stored in spring 122 , during which movement its central rib 160 engages the top most cartridge 158 in magazine 106 and pushes it forwards into chamber 114 of chamber unit 116 , by which time the chamber unit 116 has been reset by V spring 152 . The cartridge 158 is guided into chamber 114 by the inclined ramp surface 154 of chamber unit 116 . The slide 110 holds the chamber unit 116 forward in the position shown in FIG. 8 . At the same time the barrel 108 is returned rearwardly to its normal position shown in FIG. 8 by the energy stored in spring 134 . Recocking and reloading have thus been effected and the pistol 100 is ready to be fired again.
Although only a single detailed embodiment (FIGS. 8 and 9) has been described, the principle of the invention is not complex and is adaptable to other types of weapons without undue experimentation. Thus the invention is to be understood as applicable to weapons of much larger calibre, including mounted mobile or stationary artillery weapons. It is also considered that the invention is applicable to the types of weapons as disclosed in WO 94/20809 and WO 98/17962.
It is also to be understood that the invention is not restricted to applications where a projectile is fired via detonation of an explosive propellant, whether that propellant be encased, as in for example a cartridge, or otherwise presented for firing a projectile, as in for example caseless ammunition, or whether it be a solid, gaseous or liquid propellant. Thus, the invention is considered to be applicable to all types of weapons which fire a projectile and in which recoil occurs, notwithstanding the means or manner by which the high pressure is developed that is necessary to propel the projectile forwardly. It is considered that such means or manner may include for example electromagnetic (as in “rail guns”) or electrothermal systems, air propulsion systems of various types and others.
Finally, it is to be understood that various alterations, modifications and/or additions may be made to the present invention without departing from the ambit thereof as defined by the scope of the following claims.
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A recoil control mechanism for a weapon which fires a projectile which is characterized by the generation of a forward counterforce to the rearward recoil simultaneously with absorption of rearward recoil force upon initiation of propoulsion of the projectile. The forward counterforce is generated by propelling a first mass forwardly upon firing the projectile and substantially simultaneously propelling a second mass rewardly for absorbing some of the recoil force. In one mechanism ( 10 ), the first mass may be the weapon's barrel ( 12 ) and the second mass its breach block ( 14 ). Expaning gases ( 36 ) from detonation of propellant in cartridge ( 24 ) enter a reaction volume ( 28 ) between the barrel ( 12 ) and breech block ( 14 ). These gases drive barrel ( 12 ) forwardly against force transmission spring ( 16 ) to impose a forward counterforce on the weapon's frame ( 18 ). Substantially simultaneously recoil from detonation of cartridge ( 22 ) together with the gasses ( 36 ) in reaction volume ( 28 ) drive breech block ( 14 ) rearwardly against force absorbing spring ( 20 ).
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FIELD OF THE INVENTION
This invention is generally related to harvesting energy and more particularly to converting kinetic energy from a flowing fluid into electrical energy to power equipment.
BACKGROUND OF THE INVENTION
In order to recover natural resources from subterranean formations it is often necessary to perform tasks related to exploration, monitoring, maintenance and construction in remote locations that are either difficult or impractical for personnel to reach directly. For example, boreholes may be drilled tens of thousands of meters into the earth, and in the case of offshore drilling the borehole may be thousands of meters under water. One of the technical challenges to performing tasks in such remote locations is providing power to equipment. It is known to power downhole and undersea equipment via either stored energy or wireline connection to the surface. However, both of these techniques have disadvantages. For example, a wireline connection to the surface limits that distance at which the equipment can operate relative to the energy source, and may require a relatively significant portion of the limited volume of a borehole; and in many situations running a wireline is not even possible. Using stored energy avoids some of the disadvantages of a wireline connection to the surface, but relatively little energy can be stored in comparison to requirements because of size limitations. For example, the available volume in a borehole environment is relatively small for a battery having a relatively large storage capacity. Further, both wireline connection to the surface and stored energy techniques require the presence of operators, e.g., a surface vessel to either provide the wireline energy or recharge the energy storage means. Therefore, it would be beneficial to be able to generate electrical power in a remote location, e.g., in relatively close proximity to a well tool which consumes the electrical power without the need for physical connection with the surface or retrieval for recharge.
Various techniques are known for converting the kinetic energy associated with flowing fluid into electrical energy. U.S. Pat. No. 6,504,258 describes a downhole power generator which produces electrical power from vibrations in response to fluid flow. One limitation of this design is that the flow rate is greatly affected by the energy harvesting function. It is accordingly an object of the present invention to provide a method and an apparatus to harvest kinetic energy from fluid flow with minimal interference with fluid flow.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the invention, an apparatus for converting kinetic energy from fluid flow to electrical energy comprises a housing with at least two openings through which fluid is permitted to traverse; a vibrating sleeve operatively connected on the outside of the housing; the vibrating sleeve containing at least two sleeve openings; and the vibrating sleeve characterized by mechanical properties that permit the vibrating sleeve to oscillate and a device that converts sleeve oscillation to electrical energy.
In accordance with another embodiment of the invention, a method for converting kinetic energy to electrical energy, the method comprising the steps of flowing fluid in a first direction through the at least two openings of a tubular housing, vibrating a sleeve operatively connected on the housing in response to the flowing fluid through the at least two sleeve openings; and generating electrical energy in response to the vibrating sleeve moving in an oscillatory manner.
In accordance with another embodiment of the invention, an apparatus for converting kinetic energy to electrical energy comprises a housing having a first axial flow passage formed therethrough; a vortex shedding sleeve located on the end of the housing; the vortex shedding sleeve characterized by mechanical properties that permit the vortex shedding sleeve to oscillate; and a device that converts vortex shedding sleeve oscillations to electrical energy.
One advantage of the invention is that electrical energy can be produced in a remote environment. The energy harvesting device does not rely on a physical connection with a device at the surface for power. Further, because the source of kinetic energy is not dependent on a limited reservoir of fuel or battery power, the device can produce electrical energy continuously. A further advantage of the invention is that the fluid flow in the tubing remains nearly constant.
Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates an energy harvesting device located on the end of a production tubing.
FIG. 2 illustrates an embodiment of the energy harvesting device of FIG. 1 .
FIGS. 3A and 3B illustrates an alternative embodiment of the energy harvesting device.
FIG. 4 illustrates a cross-sectional view of the vibrating sleeve with two offset openings.
FIG. 5 illustrates orientation of the energy harvesting device of FIG. 3 with two aligned openings.
FIG. 6 illustrates orientation of the energy harvesting device of FIG. 3 with two openings on one side.
FIG. 7 illustrates orientation of the energy harvesting device of FIG. 3 with four openings, two per side.
FIG. 8 illustrates a cross-sectional view of the vibrating sleeve of FIG. 3 with four openings, two per side.
FIGS. 9A and 9B illustrates the energy harvesting of FIG. 1 with a series of alternating magnets.
FIG. 10 illustrates the embodiments of FIGS. 9A and 9B with cylindrical flexures.
FIG. 11 illustrates the embodiment of FIGS. 9A and 9B with a vibrating sleeve which moves relative to stationery coils.
DETAILED DESCRIPTION
The particulars described herein are by way of example for purposes of discussion of the illustrated embodiments of the present invention in order to provide what is believed to be a useful and readily understood description of the principles and conceptual aspects of the invention. No attempt is made to show structural aspects of the invention in more detail than is necessary for a fundamental understanding of the invention.
The invention may be implemented in various different embodiments of a device for converting external stimuli in the form of kinetic energy from the surrounding environment into electrical energy. The embodiments are described below in the context of the source of kinetic energy being vibrations caused by normal operations associated with creation and production of a petrochemical recovery well, fluid flow through a borehole, or both. However, the invention is not limited to petrochemical wells. The apparatus and method is described as being performed with a producing well in which fluid is produced from a formation into a tubular string and is then flowed through the tubular string to the earth's surface.
FIG. 1 illustrates a downhole energy harvester system ( 100 ) which embodies principles of the present invention. In the illustrated embodiment ( 101 ), a well includes a tubular string ( 104 ) (such as a production, injection, drill, test or coiled tubing string) that extends into a wellbore of the well ( 101 ). The tubular string may include a central passageway ( 103 ) that communicates a flow ( 102 ) from a subterranean formation zone ( 106 ) (or to a formation zone in the case of an injection well). The wellbore ( 101 ) includes perforations ( 110 ) which allow access to the subterranean formation zone ( 106 ) through the casing ( 107 ). The zone ( 106 ) may be defined (i.e., isolated from other zones) by one or more packers ( 105 ). Fluid flow ( 102 ) is a primary source of vibrational energy downhole, and this vibrational energy is captured by a vibrational energy harvesting mechanism ( 108 ) for purposes of converting the vibrational energy into downhole electrical power.
During oil recovery operations fluid flows through production tubing and, in many instances, this creates structural vibrations due to flow instabilities. These structural vibrations can be an important source of harvestable energy for downhole power. The very end of the production tubing is, in many cases, an aspirating cantilever type geometry. The packers as in FIG. 1 hold the tubing anchored to the casing, creating a cantilever that is free to vibrate. As fluid flows into the tubing, an instability is created, which drives the cantilever to vibrate at a certain frequency. Therefore, an optimal position for an energy harvester would be very close to the tip where the amplitude of vibrations is the greatest.
An energy harvester ( 108 ) is located at the end of the tubular string ( 104 ) in the present embodiment. The energy harvester ( 108 ) harvests kinetic energy from fluid flow (represented by arrows ( 102 )). During production of a well there is a constant outflow of oil upstream through the tubular string ( 104 ) and this fluid flow provides a large amount of kinetic energy. This kinetic energy can be harvested to provide electrical power downhole. The device ( 108 ) functions to convert the kinetic energy of a fluid flow 102 in the well 101 into electrical energy. In particular, the energy conversion is made from the hydraulic domain to the electrical domain by means of first converting fluid flow into vibrations, and then converting the vibrations into electrical energy. In the illustrated embodiment, fluid flows through a cylindrical (tubular) housing having an inlet and outlet. Kinetic energy associated with the fluid flow is converted to mechanical energy in the form of vibrations. Various techniques are known in the art for converting fluid flow into vibrations, and any of those techniques might be utilized depending on the desired characteristics for a particular purpose. The present invention is concerned with converting the vibrations to electrical energy. In particular, the invention concerns a vibrating device which keeps the flow rate nearly constant and prevents flow pulsations. These flow pulsations can be dangerous for any mechanical device located along the tubing. The energy harvester ( 108 ) is located at the end of the tubular string ( 104 ) and therefore is minimally interfering with the fluid flow in the tubing. The kinetic energy generated is not as a result of the opening and closing of any type of inlet for fluid flow.
A variety of methods may be used to produce electrical power from the vibration of the vibrating sleeve, including a coil and magnet, with relative displacement being produced between the coil and the magnet as the member vibrates. The energy harvesting device may include a piezoelectric material and a mass, with the mass bearing on the piezoelectric material and inducing strain as the member vibrates. It could also include a piezoelectric material as part of the vibrating sleeve so that strain is induced in the piezoelectric material as the member flexes when it vibrates. The electrical power may then be used to power one or more downhole power consuming-components, such as actuators, sensors, etc.
FIG. 2 shows an energy harvesting device ( 108 ) for converting kinetic energy associated with fluid flow into electrical energy for use in accordance with an embodiment of the present invention. The energy harvesting device ( 108 ) uses a spring ( 202 ) and a mass ( 201 ) mounted on the end of the tubular string ( 104 ). The mass ( 201 ) is attached to a vortex shedding device ( 203 ) extending into a flow passage which is positioned perpendicular to fluid flow ( 102 ). This vortex shedding device ( 203 ) provides a forcing that can be excited by turbulence in the flow and/or by vortexes shedding. This forcing will displace the mass ( 201 ) in an axial direction ( 205 ) which in turn compresses the spring ( 202 ) with the potential energy being stored in the spring ( 202 ). The energy is then harvested from the vibrating mass-spring system using certain mechanical to electrical generator systems. The frequency of oscillations of this energy harvester ( 108 ) can be tuned by varying the mass and/or spring constant. To enhance energy harvesting the frequency of oscillation may be selected to tune the energy harvesting device ( 108 ) to the source of vibrations.
FIGS. 3A and 3B illustrates a further embodiment of an energy harvesting device ( 108 ). The embodiment is mounted on the exterior of a tubular string ( 301 ) and consists of a vibrating sleeve member ( 304 ), a spring member ( 302 ) and a stopper member ( 303 ). The vibrating sleeve member ( 304 ) has two or more sleeve openings ( 305 ). The present embodiment has two sleeve openings ( 305 ) which are located at 180° from each other and are located at opposite ends of the vibrating sleeve member ( 304 ). The sleeve openings ( 305 ) are aligned with two or more openings through the tubular string ( 306 ) as depicted in FIG. 3B . The sleeve openings ( 305 ) are circular but other shapes would serve the same purpose and the present embodiment is not restricted to circular shapes. The vibrating sleeve member ( 304 ) is attached to a spring member ( 302 ) and a stopper ( 303 ). The stopper ( 303 ) serves to attach the vibrating sleeve member ( 304 ) and the spring member ( 302 ) to the tubular string ( 301 ) and also to support the spring member ( 302 ). The vibrating sleeve member ( 304 ) has flow passages formed through it. The vibrating sleeve member ( 304 ) and stopper ( 303 ) can be made from any metals/alloys for example steel or aluminum but are not limited to these materials. The material density can be changed or tuned to match a target weight in order to produce the desired system response, such as the amplitude and natural frequency of the motion. The energy harvesting device is anchored to the tubular string ( 301 ) in the following manner: the stopper ( 303 ) is anchored to the tubular string ( 301 ) and to a first end of the spring member ( 302 ). The second end of the spring member ( 302 ) is attached to the vibrating sleeve member ( 304 ) and this anchors the energy harvesting device in place.
Referring to FIG. 4 a cross-section of the embodiment of FIGS. 3A and 3B is depicted. As the fluid ( 401 ) flows from the external region ( 410 ) into the internal region ( 411 ) of the tubular string ( 301 ) it will cause the vibrating sleeve member ( 405 ) to vibrate in an axial direction ( 205 ). The vibrating sleeve member ( 405 ) is positioned so that at equilibrium 50% of each of the sleeve openings ( 408 ) and ( 409 ) are shielded. Fluid flow ( 401 ) enters the tubular string ( 301 ) through the sleeve openings ( 408 ) and ( 409 ). As fluid flows through the sleeve openings ( 408 ) and ( 409 ) the vibrating sleeve member ( 405 ) vibrates as the pressure exerted by the fluid moving from the annulus into the tubular string ( 301 ) is greater than the spring ( 404 ) reaction force. As the vibrating sleeve member ( 405 ) moves upward as depicted in FIG. 4 the opening marked 1 ( 408 ) in FIG. 4 is obstructed, therefore, reducing the flow rate through that opening. On the other hand the flow through the opening marked 2 ( 409 ) is increased, since more area is exposed, and the total flow rate through the tubing is nearly constant. As the sleeve keeps moving upward the force on the sleeve decreases below the spring reaction force and the sleeve will change direction. As the sleeve moves downward the process is repeated in the opposite direction. This instability allows for sustained axial oscillations of the sleeve. The total flow rate into the tubular string ( 301 ) remains nearly constant because as the opening marked 1 ( 408 ) closes the opening marked 2 ( 409 ) opens which ensure the same amount of area is always exposed thus keeping the flow of fluid through the tubular string ( 301 ) nearly constant. Aligning the sleeve openings ( 405 ) and ( 408 ) ensures that the flow rate in the tubular string ( 301 ) remains nearly constant. By choosing the right combination of sleeve weight and spring stiffness the oscillation frequency of the sleeve can be controlled while the oscillations amplitudes are set by the natural pressure difference between the environment downhole and upstream.
Referring to FIG. 5 the sleeve openings ( 501 ) and ( 502 ) are aligned. The arrangement of the sleeve openings in this embodiment is aimed at enhancing lateral vibrations. The lateral vibrations are generated because as the vibrating sleeve oscillates different amount of fluid flow enters into each sleeve opening causing the tubular string ( 301 ) itself to laterally vibrate. Energy can also be harvested from the lateral vibrations of the tubular string ( 301 ) by using the energy harvesting techniques disclosed in a previously filed application U.S. Ser. No. 12/366,119, filed Feb. 3, 2009, the contents of which are hereby incorporated by reference.
FIG. 6 and FIG. 7 depict different orientations of the sleeve openings. FIG. 6 depicts the vibrating sleeve with two sleeve openings on one side. This configuration will reduce lateral vibrations if desired. Alternatively FIG. 7 depicts the vibrating sleeve with two sleeve openings per side. The orientation of the sleeve openings in FIG. 7 would yield vibrations only in the axial direction as the geometry is symmetrical.
FIG. 8 depicts a cross-section of FIG. 7 where the vibrating sleeve has four sleeve openings, two per side. Vibrating sleeve member ( 804 ) has sleeve openings ( 806 ) and ( 807 ) on one side of the sleeve and sleeve openings ( 808 ) and ( 809 ) on the opposite side of the sleeve. The vibrating sleeve ( 804 ) is positioned so that at equilibrium 50% of each of the sleeve openings is shielded. As fluid flows through the sleeve openings it will cause axial oscillations of the sleeve. This total flow rate into the tubing remains nearly constant because as the openings marked ( 806 ) and ( 808 ) closes the opening marked ( 807 ) and ( 809 ) opens which ensure the same amount of area is always exposed thus keeping the flow of fluid through the tubular string ( 802 ) nearly unchanged.
FIGS. 9A and 9B illustrates the energy harvesting device with a series of alternating magnets. The vibrating sleeve member ( 905 ) is characterized by a plurality of stacked annular magnets ( 903 ), each of which is radially polarized. In particular, the radial polarization of adjacent magnets in the stack is alternated. The coils ( 902 ) are wound in partial wraps around the magnets, and disposed so as to enhance or even maximize the magnetic flux changes as the magnets move along an axis defined by the vibrating sleeve member ( 905 ). Cylindrical magnetically permeable backing plate ( 901 ) is disposed around the coils and the stacked cylindrical magnets, respectively. The specifics of the magnets and coil design have been previously disclosed in U.S. Ser. No. 12/366,119, filed Feb. 3, 2009, the contents of which is hereby incorporated by reference. A spring is selected to achieve a desired resonant frequency.
Representatively illustrated in FIG. 10 the spring is embodied as cylindrical flexures ( 1001 ). The vibrating sleeve member ( 1002 ) is attached on both sides to the cylindrical flexures ( 1001 ) and anchored to the tubular string. The vibrating sleeve member ( 1002 ) contains the plurality of stacked annular magnets ( 1003 ) as described in FIG. 9A and 9B . The flexures ( 1001 ) can perform the dual functionality of providing spring force and constraining movement in undesired directions e.g. up and down in the present embodiment. These flexures are compact structures constructed from a network of interconnected beams which are usually arranged in a zig-zag pattern. The flexures ( 1001 ) can be designed to have an appropriate axial spring constant to achieve a desired resonant behavior, while being appreciably more rigid along the lateral direction so as to allow the vibrating sleeve to essentially float around the tubing and eliminate the need for bearings. These flexures mitigate out of plane movement of the magnets.
FIG. 11 illustrates the energy harvesting device with a set of stationary coils attached to a cylindrical magnetically permeable backing plate ( 1101 ) which are placed around the vibrating sleeve member ( 1103 ) and are kept static by attaching the cylindrical magnetically permeable backing plate ( 1101 ) to the anchoring rings ( 1102 ) as shown in FIG. 11 . As the flow instability is excited the vibrating sleeve member ( 1103 ) will vibrate creating relative motion between the magnets on the sleeve and the coils which will induce an electric current.
It should be noted that the application of any of the various embodiments of the invention described above is not limited to the production phase of natural resource recovery operations. For example, a significant amount of fluid energy is available during fracturing operations, and a similar device may be used for distributed sensor networks or other applications requiring energy downhole, based on the energy harvesting principles described above. Another possible application is to use this Energy Harvester inside an oil/gas pipeline. Another application outside the oil industry could be placing these devices along currents in rivers, water pipelines, sewers, wind passages, and any other flow that can induce vibrations and therefore shaking the module that transforms kinetic energy into electric one.
While the invention is described through the above exemplary embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Moreover, while the preferred embodiments are described in connection with various illustrative structures, one skilled in the art will recognize that the system may be embodied using a variety of specific structures. Accordingly, the invention should not be viewed as limited except by the scope and spirit of the appended claims.
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Electrical energy is produced at a remote site by converting kinetic energy from fluid flow to electrical energy using a downhole harvesting apparatus. The downhole harvesting apparatus includes a vibrating sleeve member that vibrates in response to fluid flow through a tubular housing structure. The vibration of the sleeve is used to generate electrical power. The harvesting apparatus may include features to help maintain constant fluid flow in the tubular structure. The harvesting apparatus can be tuned to different vibration and flow regimes in order to enhance energy conversion efficiency.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a thin film transistor liquid crystal display (TFT-LCD) and, in particular, to a data driver thereof.
[0003] 2. Description of the Related Art
[0004] FIG. 1A , shows a thin film transistor liquid crystal display (TFT-LCD) with a resolution of 800 RGB×480 requiring five data driver ICs. Because there are 800×3 channels in a horizontal direction of the screen, 5 data driver ICs provide exactly 480-channel output to all channels. To reduce cost, the number of data driver ICs may be reduced to 3 from 5. Thus, the number of channels of each data driver IC should be 800 , which is not a multiple of 3. RGB, however, is regarded as an indivisible unit in data driver IC design, thus, 800 is not a feasible channel number and needs to be modified as 801 or 804 for use in data driver IC design. When symmetry is also taken into consideration, 840 are typically recommended.
[0005] When there are 804 channels in the data driver IC, existing timing controllers are not applicable. As shown in FIG. 1B , 12 channels in one of the data driver ICs are not used and thus are not applicable to bi-directional applications. In addition, the timing controllers must be modified. Additional first-in-first-out (FIFO) circuits are required to latch data and dump the data. FIG. 1C illustrates another case. In FIG. 1C , 6 channels on each end of the data driver IC are unused. Such a symmetrical layout is applicable to bi-directional applications. Existing timing controllers, however, cannot provide corresponding support.
BRIEF SUMMARY OF THE INVENTION
[0006] Data drivers and driving methods for TFT-LCDs are provided. In an exemplary embodiment of a data driver for a TFT-LCD N 1 channels of the data driver can be disabled. The data driver comprises a multiplexer and a shift register. The multiplexer receives a horizontal start pulse and at least one control signal. Output signals are transmitted from output terminals of the data driver according to the control signals. The shift register receives a clock signal and the output signals and generates a start pulse. The start pulse determines to provide first image data at a first channel or a (N 1 +1)th channel according to which output terminal the signal is output from.
[0007] An exemplary embodiment of a driving method for a thin film transistor liquid crystal display (TFT-LCD) comprises providing a plurality of control signals and determining whether to disable a predetermined number of output channels according to combinations of the control signals.
[0008] By use of the multiplexer and the shift register, a portion of channels of the data driver can be disabled via control signals such that flexibility in application of the data driver is improved.
[0009] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0011] FIG. 1A is a layout diagram of a conventional thin film transistor liquid crystal display (TFT-LCD);
[0012] FIGS. 1B and 1C are layout diagrams of a TFT-LCD according to an embodiment of the invention;
[0013] FIG. 2 is a schematic diagram of a channel disable select circuit of a data driver IC according to an embodiment of the invention;
[0014] FIG. 3 is a schematic diagram of a liquid crystal display (LCD) panel according to an embodiment of the invention;
[0015] FIG. 4 is a schematic diagram of a liquid crystal module (LCM) according to an embodiment of the invention; and
[0016] FIG. 5 shows a driving method of a thin film transistor liquid crystal display (TFT-LCD) according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
[0018] Flexibility in application of data driver ICs is improved in that compatibility with existing timing controllers is increased, additional circuits are added to the data driver ICs for selective disablement of some output channels thereof, thus rendering the total number of output channels of the data driver ICs equivalent to a horizontal resolution of a screen. A thin film transistor liquid crystal display (TFT-LCD) comprising data driver ICs with 804 channels are provided as an example, however, the scope of the invention is not limited thereto.
[0019] To selectively disable some output channels of data driver ICs, a designer can implement the instructions listed in the following table.
[0000]
TABLE I
ENOS
OS1
OS2
Function description
1
X
X
No output channel is disabled.
0
0
0
12 output channels on a left end of the data driver
IC are disabled.
0
0
1
12 output channels on a right end of the data
driver IC are disabled.
0
1
0
6 output channels on a left end of the data driver
IC are disabled.
0
1
1
6 output channels on a right end of the data driver
IC are disabled.
[0020] ENOS, OS 1 , and OS 2 are control signals of the circuit added by the designer. Some output channels are selectively disabled via combinations of the control signals. Layouts of a display panel and the data driver ICs are respectively shown in FIGS. 1B and 1C .
[0021] FIG. 2 is a schematic diagram of a channel disable select circuit of a data driver IC according to an embodiment of the invention. The channel disable select circuit comprises a multiplexer MUX, a first shift register SR 1 and a second shift register SR 2 . The multiplexer MUX receives a horizontal start signal STH and control signals OS 1 , OS 2 and ENOS. Output signals of the multiplexer MUX are determined according to combinations of the control signals OS 1 , OS 2 and ENOS. The horizontal start signal STH comes from a timing controller (not shown in FIG. 2 ). A user inputs the control signals via pins of the data driver IC. The first shift register SR 1 and the second shift register SR 2 have opposite directions. The shift registers receive the same output signals from the multiplexer MUX and clock signal CLK and generate a start pulse. The start pulse determines which channel to output the first image data according to which output terminal the signal is output from.
[0022] In FIG. 2 , the first shift register SR 1 and the second shift register SR 2 each comprise a plurality of D flip-flop (DFF). Each D flip-flop receives the clock signal CLK. A data input terminal D of the first D flip-flop is coupled to a first output terminal OUT 1 of the multiplexer MUX. A data input terminal D of each of the subsequent D flip-flop is coupled to a data output terminal Q of a preceding D flip-flop. The data output terminal Q of the sixth D flip-flop of the first shift register SR 1 is also coupled to a second output terminal OUT 2 of the multiplexer MUX. As a result, with a properly designed multiplexer, the data driver IC outputs the first image data at the first channel thereof when the control signal ENOS is 1. When the control signals ENOS, OS 1 and OS 2 are respectively 0, 1, and 0, six channels on the left end of the data driver IC are disabled and the data driver IC outputs the first image data at the seventh channel on the left end thereof. As shown in FIG. 2 , the data output terminal Q of the twelfth D flip-flop of the first shift register SR 1 is also coupled to a third output terminal OUT 3 of the multiplexer MUX. Thus, with a properly designed multiplexer, twelve channels on the left end of the data driver IC are disabled and the same outputs the first image data at the thirteenth channel on the left end thereof when the control signals ENOS, OS 1 and OS 2 are all 0. In the disclosure, the first shift register SR 1 is implemented with D flip-flops. The scope of the invention is, however, not limited thereto. RS flip-flops, T flip-flops, and JK flip-flops are also applicable to the first shift register SR 1 .
[0023] In FIG. 2 , I/O directions of the second shift register SR 2 are opposite to that of the first shift register SR 1 . The data output terminal Q of the sixth D flip-flop of the second shift register SR 2 is also coupled to a fourth output terminal OUT 4 of the multiplexer MUX. As a result, with a properly designed multiplexer, six channels of the right end of the data driver IC are disabled and the same outputs the first image data at the seventh channel on the right end thereof when the control signal ENOS, OS 1 and OS 2 are respectively 0, 1, and 1. As shown in FIG. 2 , the data output terminal Q of the twelfth D flip-flop of the second shift register SR 2 is also coupled to a first output terminal OUT 1 of the multiplexer MUX. Thus, with a properly designed multiplexer, twelve channels on the right end of the data driver IC are disabled and the same outputs the first image data at the thirteenth channel on the right end thereof when the control signals ENOS, OS 1 and OS 2 are respectively 0, 0, and 1. In the disclosure, the first shift register SR 2 is implemented with D flip-flops. However, scope of the invention is not limited thereto. RS flip-flops, T flip-flops, and JK flip-flops are also applicable to the second shift register SR 2 .
[0024] FIG. 3 is a schematic diagram of a liquid crystal display (LCD) panel 300 according to an embodiment of the invention. The LCD panel comprises a liquid crystal (LC) pixel array 310 , a gate driver 320 and a disclosed data driver 330 . The LC pixel array comprises a plurality of pixels arranged in array. Each pixel is driven by a pixel driving circuit. Each pixel driving circuit is coupled to the gate driver 320 and the data driver 330 .
[0025] FIG. 4 is a schematic diagram of a liquid crystal module (LCM) 400 according to an embodiment of the invention. The LCM comprises a liquid crystal display (LCD) panel 410 , a gate driver IC 420 , and a disclosed data driver IC 430 . The LC panel mainly comprises a LC pixel array comprising a plurality of pixels arranged in array. Each pixel is driven by a pixel driving circuit. Each pixel driving circuit is coupled to the gate driver IC 420 and the data driver IC 430 .
[0026] FIG. 5 shows a driving method of a thin film transistor liquid crystal display (TFT-LCD) according to an embodiment of the invention. The driving method comprises providing a plurality of control signals (step 510 ) and determining whether to disable a predetermined number of output channels of a data driver according to combinations of the control signals (step 520 ).
[0027] By use of the multiplexer and the shift register, a portion of channels of the data driver can be disabled via control signals such that flexibility in application of the data driver is improved.
[0028] While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A data driver for a TFT-LCD. N 1 channels of the data driver can be disabled. The data driver comprises a multiplexer and a shift register. The multiplexer receives a horizontal start pulse and at least one control signal. Output signals are transmitted from output terminals of the multiplexer according to the control signals. The shift register receives a clock signal and the output signals and generates a start pulse. The start pulse determines to provide a first image data at a first channel or a (N 1 +1)th channel according to which output terminal the signal is output from.
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BACKGROUND AND SUMMARY OF THE INVENTION
A hearing instrument for insertion into the user's ear canal may be manufactured by fabricating the hearing instrument shell using stereo lithography (SLA), one of the processes mentioned in U.S. Patent Application Publication No. 2002/0196954 A1, published Dec. 26, 2002 and titled, “Modeling and fabrication of three-dimensional irregular surfaces for hearing instruments,” incorporated here by reference. When using SLA, a part is constructed layer by layer. Since the raw material is a liquid bath, a means of supporting the initial layers is required to prevent the piece from floating away.
Typically, a support structure is created along with the part and then later discarded (e.g., during a finishing process such as tumbling). One such support structure comprises a plurality of thin columns, perhaps braced together. When the part is finished, it is lifted out of the structure and the bath, and the support structure is discarded.
Some hearing instrument shells have receiver holes with finely detailed features. Since the receiver hole is located on the tip of the shell, it is one of the first items formed during the SLA process. Further, as the support structures are created simultaneously with the shell, these structures may extend into openings on the bottom of the shell, such as the receiver hole. Once the part is finished, extensive machining may be required to remove the support from the receiver hole and restore the hole structure.
The entry of the support structure into the receiver hole can be prevented by shielding the receiver hole with a structure such as a dome having a thin shell. Once the part is completed, the dome can be removed without harming the part.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a hearing instrument in an ear canal and comprising a tip having a receiver hole and a vent hole;
FIGS. 2 and 3 are perspective views of the tip of the hearing instrument shell, illustrating the receiver hole and the vent hole;
FIG. 4 is a drawing of the tip of the hearing instrument shell as it is fabricated and the accompanying support structures;
FIG. 5 is a partial cross-sectional view of the tip of the hearing instrument shell, illustrating a protective dome covering the receiver hole;
FIG. 6 is a drawing of the shell tip, having a protective dome covering the receiver hole, as it is fabricated, with the accompanying support structures not shown; and
FIGS. 7 and 8 are drawings of the shell tip, having a protective dome, as it is fabricated and the accompanying support structures.
DESCRIPTION OF THE INVENTION
A hearing instrument 10 comprising a shell 20 and a faceplate 30 is shown in the user's ear canal 12 in FIG. 1 . The shell 20 has a shell tip 40 comprising apertures such as a receiver hole 42 and an optional vent hole 44 . The receiver hole 42 and the optional vent hole 44 are shown again in perspective views of the hearing instrument shell tip 40 in FIGS. 2 and 3 . Although the shell tip 40 is shown with a flat surface in FIGS. 2 and 3 . (and In the subsequent figures), it may be rounded or assume some other shape.
An apparatus 100 for fabricating the hearing instrument shell 20 using stereo lithography (SLA) is shown in schematic representation in FIG. 4 with a portion of the shell tip 40 . The figure also shows support structure elements 110 . Although these support structure elements 110 are illustrated as thin, rectangular columns in the figure, they may assume the shape determined by the particular SLA process employed.
Since the support structure elements 110 are designed to extend to a solid surface, they will enter openings in the underside of the device being fabricated. For example, in FIG. 4 , they extend into the receiver hole 42 and the vent hole 44 . After the part has been completed, the portions of the support structure elements 110 remaining in the receiver hole 42 and the vent hole 44 must be removed. Further, if the receiver hole 42 has a shape other than a simple round hole, the hole must be restored to the desired configuration. For example, the receiver hole may have a keyway slot that has been obscured or otherwise altered by a support structure element 110 . A machining operation may be required to restore that feature.
To prevent the intrusion of a support structure element 110 into the receiver hole 42 (or the vent hole 44 ), a protective structural shield may be built around or in front of the hole 42 , 44 . One such structure is a dome 120 with a thin shell, as shown in the cross-sectional view of the hearing instrument shell tip 40 in FIG. 5 and again in FIG. 6 . The dome 120 has a drain hole 122 that permits excess material, in liquid form, to drain from the dome 120 when the completed part is removed from the SLA apparatus 100 . Although the figures show a dome-shaped structure covering the receiver hole 42 , other shapes could be used as well.
The thickness of the dome 120 is selected to facilitate its removal from the hearing instrument shell 20 during the finishing phase. For example, where the hearing instrument shell 20 has a thickness of 0.6-1.0 mm, the dome 120 may have a thickness of 0.1-0.2 mm.
In FIG. 7 , the SLA apparatus 100 is again shown with a hearing instrument shell tip 40 having a dome 120 covering the receiver hole 42 . As illustrated, the dome 120 prevents the support structure elements 110 from entering the receiver hole 42 . In FIG. 8 , an additional dome 130 covers the optional vent hole 44 , similarly preventing the support structure elements 110 from entering the hole 44 .
After the hearing instrument shell 20 is completed, it will undergo a finishing process such as tumbling. During that process, the domes 120 , 130 and any support structure elements 110 that remain are removed.
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To prevent stereo lithography (SLA) support structures for parts fabricated in an SLA apparatus from interfering with features in the parts, a structural shield such as a dome may be place around the feature and then discarded at the conclusion of the SLA process.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a process for modifying the surface properties of a lignocellulosic material. In particular, the present invention concerns a process for producing fibre composites.
[0003] 2. Description of Related Art
[0004] A composite is a synergistic combination of two or more physically distinct materials. The properties of the composite material are superior to those of the individual constituents. Reinforced polymeric composites comprise three main features and elements: the reinforcement, the matrix resin and the interface between them. In conventional composites, these materials involved usually comprise a polymer and fibrous reinforcement consisting of mineral or siliceous materials, such as glass fibres or carbon fibres. These composites have good strength and resistance properties.
[0005] However, conventional, fibre reinforced composite products are not readily disposable. Although a biodegradable polymer may be used, the mineral or siliceous material fibre reinforcement makes the material non-biodegradable. There is therefore a need for biodegradable composite materials, in particular composite materials comprising a biodegradable fibrous component. Another important aim is to use renewable fibres and polymers.
[0006] There are some basic requirements placed on the various components of a composite. Thus, the matrix has to transfer loads between the reinforcement fibres, it has to protect fibres from aggressive environments, support the fibres in compression, and provide adequate toughness to minimize damage initiation and growth.
[0007] Lignocellulose-based materials have been used as fillers, but because of the poor adhesion they have not exhibited enough strength properties. U.S. Pat. No. 610,232 discloses a discontinuous lignocellulose fiber for use as a reinforcing filler for thermoplastic composite compositions. The fiber filler includes a significant percentage by weight of long, “hair-like” fibers. A moldable thermoplastic composite composition including the discontinuous lignocellulose fiber comprises about 20 to about 50 percent by weight of the fiber filler and about 50 to about 80 percent by weight thermoplastic. The discontinuous lignocellulose fiber filler yields thermoplastic composite compositions having improved physical properties over basic thermoplastic.
[0008] U.S. Pat. No. 6,368,528 discloses an improved method of making a molded composite article by combining a fibrous material with a binder to form a mixture, drying the mixture to a moisture content of about 6 wt. % to about 14 wt. % based on the weight of the fibrous material to form a mat, coating at least one surface of the mat with an aqueous solution comprising one or more additives selected from the group consisting of: a wetting agent, a mold release agent, a set retarder, and a binder. Thereafter, the mat is consolidated under heat and pressure to form the molded composite article.
[0009] Biodegradable plastics and composites from wood are disclosed in U.S. Pat. No. 6,013,774. Materials that completely degrade in the environment far more rapidly than pure synthetic plastics but possess the desirable properties of a thermoplastic: strength, impact resistance, stability to aqueous acid or base, and deformation at higher temperatures. There is provided a method for using the degradable plastic materials in preparing strong, moldable solids. There is further provided a method of making and applications for macromolecular, surface active agents that change the wetting behavior of lignin-containing materials. These surface active agents are used to provide a method of making and applications for synthetic polymers coupled to pieces of a vascular plant using macromolecular surface active agents.
[0010] As will appear from the above, wood-based fibres can be used in composites because they are biodegradable. However, the use of wood fibres in composites is not yet possible on a commercial scale, because there are problems related to the poor adhesion between the polymer and the fibre matrix. These are largely caused by the fact that the lignocellulosic matrix is basically hydrophilic and the synthetic or even natural polymer portion of the composite is hydrophobic.
SUMMARY OF THE INVENTION
[0011] It is an aim of the present invention to eliminate the problems of the prior art and to provide a novel way of producing biodegradable composites comprising a first component of a hydrophobic polymer material and a second, reinforcing component of cellulosic or lignocellulosic fibres derived from vegetable materials.
[0012] It is a particular aim of the present invention to produce fibres with improved adhesion properties with the polymer in composite materials.
[0013] The invention is based on the idea of producing composites of lignocellulosic or cellulosic fibres and hydrophobic polymers by activating the fibres of the matrix with an oxidizing agent capable of oxidizing phenolic groups, modifying the activated surface with a modifying agent, and then compounding the modified fibrous matrix with a natural or—in particular—synthetic polymer. The activation is carried out either enzymatically or chemically by mixing the fibres with an oxidizing agent. The activated fibres are then contacted with a bifunctional agent, such as a monomeric substance, in the following also called a “modifying agent”. This bifunctional agent has at least two functional groups or chemical residues, where the first functional portion provides for binding of the modifying compound to the lignocellulosic fibre material, in particular at the oxidized phenolic groups or corresponding chemical structures of the fibres, which have been oxidized during the activation step. The second chemical portion of the bifunctional agent forms a hydrophobic site on the surface of the material. Such a site is compatible with the hydrophobic material. Thus, once a modified site or “tag” has been formed onto the fibres of the matrix, the surface of the basically hydrophilic fibres is converted into a more hydrophobic form which is more readily compatible with natural and synthetic, hydrophobic polymers.
[0014] According to the invention, the tag formed on the fibre provides for good adhesion of the fibre component and the polymer component.
[0015] Thus, the present invention provides a process for modifying the surface properties of a lignocellulosic material, comprising the steps of
oxidizing the phenolic or groups having similar structure of the lignocellulosic fibre material to provide an oxidized fibre material, contacting the oxidized fibre material with a modifying agent containing at least one functional group to provide a lignocellulosic fibre material having a modified surface and contacting the fibre material with a polymer under conditions allowing for the forming of a composite.
[0019] In particular, the phenolic groups of similar groups are oxidized by reacting the lignocellulosic fibre material with a substance capable of catalyzing the oxidation of the groups by an oxidizing agent.
[0020] More specifically, the present invention is mainly characterized by what is stated in the characterizing part of claim 1 .
[0021] The present invention provides important advantages. One of the most important advantages is that the composite material produced by means of the present invention has improved strength properties and enhanced adhesion between the bifunctional fibre and the natural or synthetic polymer. Also other properties necessary for a composite strength, impact resistance, stability to aqueous acid or base, and deformation at higher temperatures are reached at a desirable level by using a fiber that is modified by means of the present invention.
[0022] Another advantage is that wood based fibres are biodegradable therefore making the final product where the fibre is used environmentally friendly.
[0023] A further advantage is that wood based fibres are readily available.
[0024] A further, clear advantage is that the price of wood based fibres is also lower than the reinforcement used in conventional reinforcements.
[0025] Further details and advantages of the invention will become apparent from the following detailed description comprising a number of working examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 depicts graphically the hydrophobicity of TMP pulp treated according to the invention FIG. 1 . Hydrophobicity is expressed in terms of contact angle measured after laccase catalysed bonding of isoeugenol (o) and after reference treatment (X)
[0027] FIG. 2 depicts graphically the hydrophobicity of TMP pulp treated according to the invention compared to a reference sample. Hydrophobicity is expressed as contact angle measured after laccase catalysed bonding of 3,4,5-trihydroxybenzoic acid dodecyl acid ester (o), after treatment with only 3,4,5-trihydroxybenzoic acid dodecyl acid ester (□) and after reference treatment without any enzyme or 3,4,5-trihydroxybenzoic acid dodecyl acid ester addition (X).
[0028] FIG. 3 depicts graphically the hydrophobicity of TMP pulp treated according to the invention. Hydrophobicity is expressed as contact angle measurement after laccase catalysed bonding of 3,4,5-trihydroxybenzoic acid dodecyl acid ester (dodecyl gallate) dispersion.
[0029] FIG. 4 depicts in a schematic fashion the effect of enzymatic bonding to kraft pulp on the strength of composite. The figure shows the ultimate tensile strength of injection molded composites containing untreated kraft pulp and polyhydroxybutyrate (PHB) (indicated as REF), kraft pulp containing isoeugenol bonded by enzyme catalysed method (Isoeugenol), and pure PHB without fibre addition (PHB).
DETAILED DESCRIPTION OF THE INVENTION
[0030] As mentioned above, the invention generally relates to a method of producing a fibre composition comprising bioprocessed wood fibres for composite materials. According to the present invention, a new composite product is provided, which comprises a fibre matrix and a hydrophobic agent in the interface between the fibres and the hydrophobic polymer in order to improve adhesion between the fibre and the polymer bound thereto and exhibits good strength properties.
[0031] The fibre matrix comprises fibres containing phenolic or similar structural groups, which are capable of being oxidized by suitable enzymes. Such fibres are typically “lignocellulosic” fibre materials, which include fibre made of annual or perennial plants or wooden raw material by, for example, mechanical or chemimechanical pulping. During industrial refining of wood by, e.g., refiner mechanical pulping (RMP), pressurized refiner mechanical pulping (PRMP), thermomechanical pulping (TMP), groundwood (GW) or pressurized groundwood (PGW) or chemithermomechanical pulping (CTMP), a woody raw material, derived from different wood species, is refined into fine fibres in processes which separate the individual fibres from each other. The fibres are typically split between the lamellas along the inter-lamellar lignin layer, leaving a fibre surface, which is at least partly covered with lignin or lignin-compounds having a phenolic basic structure. Such fibres are particularly useful as a matrix for the novel products.
[0032] Within the scope of the present invention, also chemical pulps are included if they have a oxidable groups or residual content of lignin sufficient to give at least a minimum amount of phenolic groups necessary for providing binding sites for the modifying agent. Generally, the concentration of lignin in the fibre matrix should be at least 0.1 wt-%, preferably at least about 1.0 wt-%.
[0033] In addition to paper and paperboard making pulps of the above kind, also other kinds of fibres of vegetable origin can be used, such as jute, flax and hemp.
[0034] In the first stage of the present process, the lignocellulosic fibre material is reacted with a substance capable of catalyzing the oxidation of phenolic or similar structural groups to provide an oxidized fibre material. The substance capable of catalyzing the oxidation is advantageously an enzyme. Typically, the enzymatic reaction is carried out by contacting the lignocellulosic fibre material with an oxidizing agent, which is capable—in the presence of the enzyme—of oxidizing the phenolic groups to provide an oxidized fibre material. Such oxidizing agents are selected from the group of oxygen and oxygen-containing gases, such as air, and hydrogen peroxide. These can be supplied by various means, such as efficient mixing, foaming, gas enriched with oxygen or oxygen supplied by enzymatic or chemical means or chemicals releasing oxygen or peroxides to the solution. Hydrogen peroxide can be added or produced in situ.
[0035] According to another embodiment, the lignocellulosic fibre material is reacted with a chemical oxidizing agent capable of catalyzing the oxidation of phenolic or similar structural groups to provide an oxidized fibre material in the first stage of the process. The chemical oxidizing agent may be a typical, free radical forming substance, an organic or inorganic oxidizing agent. Examples of such substances are hydrogen peroxide, Fenton reagent, organic peroxide, peroxo acids, persulphates, potassium permanganate, ozone and chloride dioxide. Examples of suitable salts are inorganic transition metal salts, specifically salts of sulphuric acid, nitric acid and hydrochloric acid. Ferric chloride is an example of suitable salts. Strong chemical oxidants such as alkali metal- and ammoniumpersulphates and organic and inorganic peroxides can be used as oxidising agents in the first stage of the present process. According to an embodiment of the invention, the chemical oxidants capable of oxidation of phenolic groups are selected from the group of compounds reacting by radical mechanism.
[0036] According to another embodiment, the lignocellulosic fibre material is reacted with a radical forming radiation capable of catalyzing the oxidation of phenolic or similar structural groups to provide an oxidized fibre material Radical forming radiation comprises gamma radiation, electron beam radiation or any high energy radiation capable of forming radicals in a lignocellulose or lignin containing material.
[0037] According to an embodiment of the invention, the oxidative enzymes capable of catalyzing oxidation of phenolic groups) are selected from, e.g. the group of phenoloxidases (E.C.1.10.3.2 benzenediol:oxygen oxidoreductase) and catalyzing the oxidation of o- and p-substituted phenolic hydroxyl and amino/amine groups in monomeric and polymeric aromatic compounds. The oxidative reaction leads to the formation of phenoxy radicals and. Another group of enzymes, comprise the peroxidases and other oxidases. “Peroxidases” are enzymes, which catalyze oxidative reaction using hydrogen peroxide as their electron aceptor, whereas “oxidases” are enzymes, which catalyze oxidative reactions using molecular oxygen as their electron acceptor.
[0038] In the method of the present invention, the enzyme used may be for example laccase, tyrosinase, peroxidase or other oxidases, in particular, the enzyme is selected the group of laccases (EC 1.10.3.2), catechol oxidases (EC 1.10.3.1), tyrosinases (EC 1.14.18.1), bilirubin oxidases (EC 1.3.3.5), horseradish peroxidase (EC 1.11.1.7), manganase peroxidase (EC1.11.1.13) and lignin peroxidase (EC 1.11.1.14).
[0039] The amount of the enzyme is selected depending on the activity of the individual enzyme and the desired effect on the fibre. Advantageously, the enzyme is employed in an amount of 0.0001 to 10 mg protein/g of dry matter.
[0040] Different dosages can be used, but advantageously about 1 to 100,000 nkat/g, preferably 10-500 nkat/g.
[0041] The activation treatment is carried out at a temperature in the range of 5 to 90° C., typically about 10 to 85° C. Normally, ambient temperature (room temperature) or a slightly elevated temperature (20-80° C.) is preferred. The pH is 2-12 and consistency 0.5-95%.
[0042] In the chemical activation method, fibres are treated with chemical oxidizing agents, such as ammonium-, sodium- or potassium persulphate. Different dosages can be used, typically about 5-95% as solids of fibre amount. The activation treatment is carried out at a temperature in the range of 5 to 90° C., typically about 10 to 85° C. Normally, ambient temperature (room temperature) or a slightly elevated temperature (20-80° C.) is preferred.
[0043] In the second step of the process, a modifying agent is bonded to the oxidized phenolic groups of the matrix to provide binding surfaces for the hydrophobic component of the composite, viz. the thermoplastic or thermosetting polymer. Such a modifying agent typically exhibits at least two functional sites, a first functional site, which is capable of contacting and binding with the oxidized phenolic group or to its vicinity, and a second hydrophobic site or a hydrocarbon chain or a site for linking the hydrophobic agent, which is compatible with a hydrophobic polymer. The term “bifunctional” is used to designate any compound having at least two functional groups or chemical structures capable of achieving the above aims. The functionalities of the first group include reactive groups, such as hydroxyl (including phenolic hydroxy groups), carboxy, anhydride, aldehyde, ketone, amino, amine, amide, imine, imidine and derivatives and salts thereof, to mention some examples. The second group provides for hydrophobicity or a site for linking the hydrofobing agent, and it typically comprises an aliphatic, saturated or unsaturated, linear or branched hydrocarbon chain having at least 1 carbon atom, preferably 2 to 24 carbon atoms As an example, the various derivatives of ferulate can be mentioned, namely eugenol and isoeugenol and their alkyl derivatives, such as methyleugenol and methyl-isoeugenol. Another example is constituted by the alkyl derivatives of gallate (esters of 3,4,5-trihydroxybenzoic acid), such as propyl gallate, octanyl gallate and dodecyl gallate. All of these comprise at least one functional group, which bonds to the oxidized lignocellulosic matrix, and a hydrocarbon tail, which is saturated or unsaturated. Typically, the hydrocarbon tail contains a minimum of two, preferably at least three carbon atoms, and extends to up to 30 carbon atoms, in particular 24 carbon atoms. Such chains can be the residues of fatty acids bonded to the core of the modifying agent. As mentioned above, the hydrophobic tail can be utilized for the preparation of composites comprising a hydrophobic polymer, which is reinforced with fibres of plant origin.
[0044] The first and second functional and hydrophobic sites (functional groups/hydrocarbon chains) can be attached to a residue, which can be a linear or branched aliphatic, cycloaliphatic, heteroaliphatic, aromatic or heteroaromatic. According to one preferred embodiment, aromatic compounds having 1 to 3 aromatic ring(s) are used. Thus, in the above examples, the residue, to which the first and second groups are attached, comprises an aromatic residue. Oftentimes, the first and the second sites are located at para-positions with respect to each other, in case of aromatic compounds having a single aromatic nucleus.
[0045] The modifying agent can comprise a plurality of first functional groups and of second hydrophobic structures. In the gallate compounds there are three phenolic hydroxyl groups, one or several of which may take part in the bonding of the compound to the oxidized phenolic structure of the fibre matrix.
[0046] According to an embodiment of the invention, the modifying agent is activated with an oxidizing agent. The oxidizing agent may be same or different as the oxidizing agent used for the activation of the fibre material.
[0047] The modifying agent can be added as such or in the form of a dispersion. The dispersion may be prepared immediately prior to the reaction or well in advance.
[0048] It is essential that modifying agent is bonded chemically or by chemi- or physisorption to the fibre matrix to such an extent that at least an essential part of it cannot be removed. One criterion, which can be applied to test this feature, is washing in aqueous medium, because often the fibrous matrix will be processed in aqueous environment, and it is important that it retains the new and valuable properties even after such processing. Thus, preferably, at least 10 mole-%, in particular at least 20 mole-%, and preferably at least 30 mole-%, of the modifying agent remains attached to the matrix after washing or leaching in an aqueous medium.
[0049] Depending on the modifying agent or its precursor, the pH of the medium can be neutral or weakly alkaline or acidic (pH typically about 2 to 12). It is preferred to avoid strongly alkaline or acidic conditions because they can cause hydrolyzation of the fibrous matrix. Normal pressure (ambient pressure) is also preferred, although it is possible to carry out the process under reduced or elevated pressure in pressure resistant equipment. Generally, the consistency of the fibrous material is about 0.5-95% by weight during the contacting stage.
[0050] According to one embodiment, the first and second stages of the process may be carried out in sequence. According to another embodiment, the first and second stages are carried out simultaneously.
[0051] In the third stage of the process, the fibre material having a modified, hydrophobic surface is contacted with a polymer under conditions allowing for intimate contacting between the modified fibre and the polymer to form a composite. For this, specific dispersion techniques may be used. The contacting can take place in a mould or in a conventional press under heat (e.g. at a temperature close to or even above the melting point of the polymer component) and pressure (typically 1 to 20 bar).
[0052] Conventional composites include a thermoset resin matrix or a matrix comprising a thermoplastic polymer. Examples of thermoset include epoxy or polyester polymers. Thermoset resins are inherently brittle, and are formed by a chemical reaction and as such cannot be remelted or reformed once set. By contrast, thermoplastics, such as polyethylene, including HD-polyethylene, LD-polyethylene, MD-polyethylene and blends thereof, polypropylene, polyurethanes, TP-elastomers, polyesters, including PET, POM, and polystyrene, are tough and can be remelted. Also biopolymers, such as polylactide, polyhydroxybuturate or polyvalerate of their mixtures can be used find use in composites.
[0053] The above reaction and contacting steps can be carried out sequentially or simultaneously.
[0054] The composite products can be used in several areas. They are used in consumer and food products, and different industries such as the automotive industry. The product may be processed by methods know in the field of polymer technology, e.g. by moulding, including injection moulding. Polymers can be also used in multilayer packaging materials as structural or barrier materials, which are produced by layering technique.
EXAMPLES
Example 1
[0000] Preparation of Dispersions
[0055] Dispersions useful in the present invention can be prepared as disclosed in
[0000] FI Patent No. 105566 and the corresponding U.S. Pat. No. 6,780,903;
[0000] FI Patent No. 113874 and the corresponding published International Patent Application No. WO 04/029097; and
[0000] FI Patent No. 108038 and the corresponding U.S. Pat. No. 6,656,984, the contents of which are herewith incorporated by reference.
[0056] Experimentally, dispersions I to VI were prepared in the following manner:
[0000] I. Preparation of DoGa Dispersion (I)
[0057] 2.0 g gallic acid dodecyl alcohol ester (DoGa) was dissolved in 100 ml of 1:1 acetone-water mixture. After that 0.2 g POLYSALZ S (BASF Ag) dispersant was added. Then the solution was diluted with 150 m of water. During the dilution process the substrate formed a white colloidal precipitate. The mixture was then heated to 90-100° C. During the heating period acetone evaporated and the precipitate turned to a homogeneous dispersion. Finally 0.1 g lecithin was added and the dispersion was left to cool down. The formed dispersion was stabile.
[0000] II. Preparation of DoGa Dispersion (II)
[0058] 2.0 g DoGa was dissolved in 36 ml acetone and 0.5 g of gyseroltriacetate (triacetin) was added. After that 100 ml water containing 0.2 g Tween 81 was added. The mixture was heated to 90° C. and mixed. During the heating period the mixture turned to pale dispersion and the acetone evaporated. The formed dispersion is stabile in the temperature range of 45-90° C.
[0000] III. Preparation of Poly(L-Lactic Acid):DoGa Dispersion
[0059] 45.0 g poly(L-lactic acid) prepared by the method described in WO 96/01863 and U.S. Pat. No. 6,087,456, 5.0 g Doga, 6.0 g 40-88 Mowiol (Clariant GmbH), 35.0 g water and 35 g glycerol triacetate (triacetin) were combined and mixed 1-2 h at 90-100° C. in a glass reactor. During the heating period the reaction mixture turned to a white paste-like viscous dispersion. After heating period the paste was diluted with water first at 70-90° C. and then temperature bellow 30° C. to the water concentration of 50%.
[0000] IV. Preparation of poly(3-hydroxybutyrate-co-valerate) Dispersion
[0060] 50.0 g of poly(3-hydroxybutyrate-co-valerate)polymer, BIOPOL PHBV12 (Monsanto Europe S.A) 40 g triacetin, 12 g 40-88 Mowiol (Clariant GmbH) and 35 g of water were mixed in glass reactor.
[0061] The reaction mixture was heated and mixed 2-6 h at 100° C. During the heating period the reaction mixture turned on pale highly viscous paste After that the paste was diluted with water first at 70-90° C. and finally at the temperature bellow 30° C. to the water content of 50% of the dispersion.
[0000] V. Preparation of BIOPOL PHB Dispersion
[0062] 100. g of poly(3-hydroxybutyrate-co-valerate)polymer, BIOPOL PHBV12 (Monsanto Europe S.A) 80 g 1:1 mol mixture of triethylcitrate: n-octenyl-succinic-acid anhydride (OSA), 20 g 8-88 Mowiol (Clariant GmbH) and 50 g of water were mixed in glass reactor. The reaction mixture was heated and mixed 4 h at 100° C. During the heating period the reaction mixture turned on pale highly viscous paste. After that the paste was diluted with water first at 70-90° C. and finally at the temperature bellow 30° C. to the water content of 50% of the dispersion. The formed viscous dispersion is stable in storage and can be easily mixed with aqueous TMP pulps.
[0063] Examples 2 to 6 illustrate the forming of a hydrophobic surface on a lignocellulosic matrix, and Example 7 discloses a specific embodiment of a fiber/polymer composite.
Example 2
[0000] Chemical Bonding of DoGa Dispersion to TMP.
[0064] 2.0 g 3,4,5-trihydroxy benzoic acid dodecyl alcohol ester was dissolved in 100 ml 1:1 vol/vol acetone:water mixture. After that 0.2 g Polysalz(S) (BASF)(polyacrylic acid) dispersion agent was dissolved in the mixture. After that 200 ml water containing 0.1 g lecitin was added. The mixture was heated to 60-80° C. and mixed. Acetone was evaporated at elevated temperature. During the heating period the reaction mixture turned on whitish dispersion. 50 g of TMP was mixed with water and the pulp consistency was adjusted to 5% at 20° C. 60° C. DoGa dispersion was mixed with pulp. Thereafter 1.5 g ammoniumpersulfate (APS) dissolved in water was added and reaction continued 60 min. After that the pulp was filtered twice and washed with 400 ml water. The hydrophobicity of the handsheets prepared from the pulp as analysed by contact angle measurement was increased significantly by APS oxidative bonding of 3,4,5-trihydroxy benzoic acid dodecyl alcohol ester dispersion to TMP compared with the reference pulp (oxidation of pulp with APS).
Example 3
[0000] Chemical Bonding of Poly(Lactic Acid):DoGa Dispersion to TMP
[0065] 50 g of TMP pulp was diluted with water to 5% consistency. 10 g of poly(lactic acid):3,4,5-trihydroxy benzoic acid dodecyl alcohol ester dispersion prepared as described above was mixed with the pulp. Immediately after that 0.5 g of ammonium persulfate dissolved in water was added. Reaction was continued for 60 min. After that, the pulp was diluted with water in 2000 ml volume, filtered twice an washed with 0.4 ml water. The hydrophobicity of the handsheets prepared from the pulp analysed by contact angle measurement was increased significantly by APS oxidative bonding of poly(lactic acid):3,4,5-trihydroxy benzoic acid dodecyl alcohol ester: dispersion to TMP compared with the reference treated pulp (oxidation of pulp with APS).
Example 4
[0000] Enzymatic Bonding of Isoeugenol to TMP Matrix
[0066] A 100 g portion of spruce TMP was suspended in water. The pH of the suspension was adjusted to pH 4.5 by addition of acid. The suspension was stirred at 40° C. Laccase dosage was 1000 nkat/g of pulp dry matter and the final pulp consistency was 4%. After 30 minutes laccase reaction, 0.12 mmol isoeugenol/g of pulp dry matter was added to the pulp suspension. After 2 h total reaction time, the pulp suspension was filtered and the pulp was washed thoroughly with water. For comparison purposes, a reference treatment was carried out using the same procedure as described above but without addition of laccase or isoeugenol. The hydrophobicity of the handsheets prepared from pulp analysed by contact angle measurement was increased by laccase catalysed bonding of isoeugenol as compared with the reference treated pulp ( FIG. 1 ).
Example 5
[0000] Enzymatic Bonding of Dodecyl Gallate to TMP
[0067] A 100 g portion of spruce TMP was suspended in water. The pH of the suspension was adjusted to pH 4.5 by addition of acid. The suspension was stirred at 40° C. Laccase dosage was 1000 nkat/g of pulp dry matter and the final pulp consistency was 4%. After 30 minutes laccase reaction, 0.12 mmol 3,4,5-trihydroxybenzoic acid dodecyl acid ester/g of pulp dry matter was added to the pulp suspension. After 2 h total reaction time the pulp suspension was filtered and the pulp was washed thoroughly with water. For comparison purposes, a reference treatment was carried out using the same procedure as described above but without addition of laccase and 3,4,5-trihydroxybenzoic acid dodecyl acid ester or only laccase. The hydrophobicity of the handsheet prepared from pulp analysed by contact angle measurement was increased by laccase catalysed bonding of 3,4,5-trihydroxybenzoic acid dodecyl acid ester to TMP as compared with the reference treated pulps ( FIG. 2 ).
Example 6
[0000] Enzymatic Bonding of Dodecyl Gallate Dispersion to TMP Matrix
[0068] A 100 g portion of spruce TMP was suspended in water. The pH of the suspension was adjusted to pH 4.5 by addition of acid. The suspension was stirred at 40° C. Laccase dosage was 1000 nkat/g of pulp dry matter and the final pulp consistency was 4%. After 30 minutes laccase reaction, 0.12 mmol 3,4,5-trihydroxybenzoic acid dodecyl acid ester dispersion/g of pulp dry matter was added to the pulp suspension. After 2 h total reaction time the pulp suspension was filtered and the pulp was washed thoroughly with water. The hydrophobicity of the handsheet prepared from pulp analysed by contact angle measurement was high after laccase catalysed bonding of 3,4,5-trihydroxybenzoic acid dodecyl acid ester dispersion to TMP ( FIG. 3 ).
Example 7
[0000] Compatibility of Hydrophobiced Fibres with Polymers
[0069] Softwood kraft pulp was hydrophobised as explained in Example 4 using isoeugenol as a bonded component. The hydrophobic fibre material was thereafter compounded with polyhydroxybutyrate (PHB) used as a matrix and injection molded to test specimens. Reference test specimens with untreated fibres were also injection molded. From the results in FIG. 4 it can be seen that composite strength is increased by addition of hydrophobised kraft pulp as compared with composite with reference kraft pulp and pure PHB composite. Thus, it can be stated that specific enzyme catalysed bonding of hydrophobic compound, here isoeugenol, to fibre material increases the compatibility of fibre material with organic polymer such as PHB. Similar results can be obtained when using inorganic polymer as a matrix with fibre material hydrophobised with enzyme catalysed method.
[0070] The above results demonstrate that it is possible to increase the compatibility of the lignocellulosic material with polymers in production of composite materials by increasing the hydrophobicity of lignocellulosic material (in this case wood fibre pulp) significantly by bonding a hydrophobic agent onto the fibre material. Similar results were obtained with peroxidases.
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The present invention concerns a process for producing fibre composites. In particular, the invention provides a novel way of producing biodegradable composites comprising a hydrophobic polymer material and a reinforcing component of fibres derived from plant materials. Composite material produced by means of the present invention has improved strength properties and enhanced adhesion between the bifunctional fibre and the natural or synthetic polymer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of pending International patent application PCT/EP2006/007807 filed on Aug. 7, 2006 which designates the United States and claims priority from Italian patent application UD2005A000132 filed on Aug. 10, 2005, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention is applied to particular bottle openers, called automatic bottle openers, of the type already known and it consists of an innovation, an improvement on the said openers that in general are able to open wine bottles.
[0003] In particular the invention is useful when the bottles, rather than being closed with the normal cork closures, are closed with another type of closure called synthetic closures.
[0004] These closures are made from plastic material, silicone etc. and are usually more viscid and more slippery than cork.
[0005] In the type of bottle openers that are to be considered and where the invention has an application, the worm-screw (screw), during the extraction stage of the closure from the bottle neck in an anti-clockwise rotation motion, does not dispose of any stop other than that represented by the friction that the closure offers on the bottle neck.
[0006] If this friction is not sufficient, the worm-screw, once it has penetrated the closure in the bottle neck and then been pushed upwards in order to carry out the extraction, can be unthreaded with an anti-clockwise rotary movement and the opening does not take place.
[0007] The aim of the invention is to obviate this disadvantage.
BACKGROUND OF THE INVENTION
[0008] Automatic bottle openers are know that are applied to a wall or to a table or are also directly placed on the neck of the bottle and are held there tight during the opening operation. Allen. U.S. Pat. No. 4,253,351.
[0009] In this type of bottle opener, the worm-screw does not penetrate the closure due to the pushing effect and the rotary movement produced by the operator's hand but rather because it is pushed to penetrate with only a downward axial movement and the rotation is imposed as it is constrained, during this movement, to cross a nut or nut screw, that forces it to rotate.
[0010] With this type of bottle opener, it is possible to distinguish two families; in the first, as that described by Allen U.S. Pat. No. 4,253,351, it is the worm-screw itself that crosses the nut to assume the rotary movement; in the second family, the one that we shall be considering, the worm-screw has the sole function of penetrating the closure in order to extract it and the rotary movement is assumed by means of a complementary helicoidal screw integral with the worm, positioned on the same axis.
[0011] In the bottle openers where the worm crosses the nut (Allen), to complete the opening operation and release the worm from the closure, two complete movements are necessary from the top downwards and vice-versa.
[0012] Instead, in the type of bottle openers that are to be considered and described and where the invention will find an application, the worm makes a single movement, first downwards to penetrate the closure, then upwards, with a single operation to extract said closure and proceeding in the same movement to release it after from the closure.
[0013] This second method allows a faster operation that is safer, less complex, with less breakages and improved simplicity of construction, however it presents the disadvantage, as already mentioned and until now unresolved, that if in the extraction stage the closure does not offer sufficient friction on the worm, the worm is unthreaded from the closure that remains perforated in the bottle.
[0014] Said friction is necessary with respect to the worm, in the prolongation of its upward axis, it is fixed to a movable support by means of an idle system, a bearing, two flanges etc. that do not offer any type of stop to the rotation of the worm.
[0015] The need for the worm-screw to be free to rotate in both directions derives from the fact that first, when it is pushed into the closure it must rotate clockwise to penetrate it and then once the closure has been extracted from the neck of the bottle it must still be free to rotate in the opposite direction, namely anti-clockwise, to be able to release itself from the closure itself.
[0016] As long as it concerns cork closures, the extraction operation is generally successful. However, in the last few years, new types of closures have appeared on the market, namely synthetic closures: (Silicone plastic material etc.). These closures offer the advantage of being odourless and not having unpleasant flavours, they generally cost less and their use is increasingly widespread.
[0017] In general, these closures are viscid, slippery and impose less friction on the worm-screw than that normally imposed by cork, therefore during the opening operations, the worm penetrates the closure but when the movement is inversed and pushed upwards in order to achieve extraction, the worm, not disposing of any other way of stopping in rotation can be unthreaded with the anti-clockwise rotary movement and the closure remains perforated but in the neck of the bottle and therefore opening does not take place.
SUMMARY OF THE INVENTION
[0018] The aim of this invention is to avoid this disadvantage and for this reason, during the single extraction stage, a mechanical system is made to take over automatically that substitutes the lack of friction and keeps the worm blocked in rotation so as to as allow the extraction and then in the process of the same upward movement, still to leave it free in the anti-clockwise rotation, so that the worm can release itself from the closure. This also allows all types of closures to be extracted and without almost greater cost or greater effort.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a side view of a bottle opener in accordance with the invention.
[0020] FIG. 2 is a partially cross-sectional, front elevational view of the bottle opener of FIG. 1 .
[0021] FIG. 3 is a partially cross-sectional, side view of the bottle opener of FIG. 2 without the lever.
[0022] FIG. 4 is a cross-sectional top view of the bottle opener of FIG. 3 along line A-A.
[0023] FIG. 5 is an exposed side view of the top of the bottle opener of FIG. 3 .
[0024] FIG. 6 is a cross-sectional top view of the bottle opener of FIG. 3 along line B-B.
[0025] FIG. 7 is a cross-sectional top view of the bottle opener of FIG. 3 along line C-C.
[0026] FIG. 8 is a cross-sectional top view of the bottle opener of FIG. 3 along line D-D.
[0027] FIG. 9 is a partially cross-sectional, side view of the bottle opener of FIG. 3 when in the first working stage.
[0028] FIG. 10 is an exposed side view of the top of the bottle opener of FIG. 5 when one of the pins strikes the head of one of the ribs.
[0029] FIG. 11 is a partially cross-sectional, side view of the bottle opener of FIG. 3 when the small block has achieved the lower dead center.
[0030] FIG. 12 is a cross-sectional top view of the bottle opener of FIG. 3 along line A-A during the penetration stage of the worm in the closure.
[0031] FIG. 13 is a partially cross-sectional, side view of the bottle opener of FIG. 3 during the extraction of the closure from the neck of the bottle.
[0032] FIG. 14 is a cross-sectional top view of the bottle opener of FIG. 3 along line A-A when the upper movement of the closure does not offer sufficient friction on the worm.
[0033] FIG. 15 is a partially cross-sectional, side view of the bottle opener of FIG. 3 when the nut screw has stricken the stops.
DETAILED DESCRIPTION OF THE INVENTION
[0034] This description that is intended as illustrative and not limitative will be provided with a series of drawings that give an improved understanding of the invention.
[0035] In the field of bottle openers that we will be considering, the assembly that has the worm-screw to carry out the opening and release of the closure only executes one movement from the top downwards and only one subsequent inverse movement.
[0036] In this process, we can distinguish four different work stages.
[0037] Starting from the rest position, the sequences will have the following order.
[0038] First stage=Approach of the worm to the closure
[0039] Second stage=Penetration in the closure
[0040] Third stage=Extraction of the closure from the neck of the bottle
[0041] Fourth stage=It is the stage in which the worm is released from the closure.
[0042] FIG. 1 shows a general view of one of these bottle openers, called automatic, in which the worm 16 assumes the rotary movement since a helicoidal screw 15 integral to it and placed on the same axis is forced to cross a nut screw 17 that in the downward and upward movements will force said worm to rotate.
[0043] As set out in FIG. 1 , the bottle opener is in the resting position and is seen from the side.
[0044] The number 1 indicates the external tubular casing, with 2 a support base on a table to which will it be locked by means of a clamp 2 a.
[0045] The numbers 11 and 3 indicate a lever that in the lower part 3 extends in a U-shape to encompass the casing.
[0046] Said lever is connected to the support base 2 by means of a pin 4 .
[0047] From the two prolongations of the U-shaped lever 3 originate two arms 5 connected to said lever by two pins 7 a - 7 b and on the opposite side, said arms connect to a small cylindrical block 6 placed in the casing 1 by means of two pins 7 c - 7 d.
[0048] At the base, the casing 1 comprises a receptacle 9 where the neck of the bottle 28 will be placed in abutment and immediately above, comprising an empty sector 10 , face downwards to allow the closure to exit once extracted from the neck of the bottle.
[0049] The casing 1 also comprises, laterally on both sides, two openings 8 that will allow the two pins 7 c - 7 d and therefore the small cylindrical block 6 to make the downward and upward movement during the work stages.
[0050] FIG. 2 is a section seen from the front of the same bottle opener in FIG. 1 made to rotate clockwise at 45[deg.]. In this Figure it is to be noted how the two arms 5 that originate from the lever 3 are connected with the small cylindrical block 6 by means of the two pins 7 c - 7 d . These two pins are locked on the said small block 6 with a screw system.
[0051] The small cylindrical block 6 is longitudinally perforated in the centre along its entire its length and on the upper part said perforation extends to make a seat with a bearing 12 that is locked here and that will have a thrust bearing function.
[0052] Said small block 6 , is free in the casing to scroll from above to below and vice-versa, but cannot rotate.
[0053] A pin 13 passes in said central perforation of the small block 6 , said pin is free to rotate in the small block and in the upper part it is fixed to the central ring of the bearing 12 . Said pin 13 continues upwards with an appendix 14 with a smaller diameter.
[0054] On the pin 13 , proceeding downwards and under the small block 6 , a helicoidal screw 15 is obtained for a section of 7-9 cm. and at the base of said screw the worm-screw 16 is connected integrally.
[0055] The screw of said worm 16 will have the same pitch as the helicoidal screw 15 .
[0056] The helicoidal screw 15 crosses a small cylindrical block 17 , said small block has a nut screw function. Said nut screw 17 can scroll axially in the casing but cannot rotate and is blocked in the upward movement by a series of stops 18 a - 18 b secured on the casing itself 1 .
[0057] Still on the casing 1 , towards the bottom and at the height where the point of the worm reaches 16 in the resting position, a flange 19 is secured, perforated in the centre in order to allow the passage of the worm 16 and the helicoidal screw 15 .
[0058] From said flange 19 , a series of relieves or ribs 20 that will be better seen in another drawing, extend upwards in contact and fixed on the inside wall of the casing 1 .
[0059] After having described a large part of the details, attention is now drawn to the pin 14 . It is on this pin that the novelty regarding the invention is found. On said pin 14 , a small cylindrical block 21 is inserted held over by a stop 22 .
[0060] Said small block 21 is perforated in the centre and can rotate on the pin 14 .
[0061] The small block 21 includes in the lower part a free wheel with HF.23 type rollers.
[0062] Said free wheel is fixed on the small block 21 and is suitable for working on the pin 14 ; this is directed so that the pin 14 , the pin 13 , the helicoidal screw 15 and therefore eventually also the worm-screw 16 can freely rotate in the clockwise direction even if the small block 21 and free wheel 23 included, do not rotate.
[0063] However, in the anti-clockwise rotary motion, the pin 14 and eventually also the worm 16 , cannot rotate if the free wheel 23 and the small block 21 do not also rotate with them.
[0064] Said small block 21 , includes on its exterior, a series of projections 24 .
[0065] The particulars will be seen in more detail in the following Figures.
[0066] FIG. 3 is something of a repetition of FIG. 2 but as seen from the side and namely made to rotate with respect to this in the anti-clockwise direction at 45[deg.].
[0067] Due to a question of space, the drawing of levers 11 - 3 - 5 is not repeated as the movement and the working of the invention can equally be understood.
[0068] Moreover, it is not that these levers are always necessary as the downward and upward movement essential to obtaining opening can also be obtained by the force of a small electric motor that, for example, in the movement downward can make the screw-worm rotate in order to make it penetrate the closure.
[0069] FIG. 3 highlights the two relieves or ribs 20 a - 20 b that originate from the flange 19 and extend over a well defined section upward and in the case described here, until penetrating a few millimetres into the base of the small block 6 in two lateral grooves 26 on said small block made over its entire length.
[0070] FIG. 4 shows in plan view the section A-A of the small block 21 . This small block, on its upper part, above the free wheel 23 , presents three equidistant grooves, hollowed as a trench, FIG. 5 - 0 -in each one of these grooves a spring 25 is positioned which, on one side towards the centre of the small block 21 , is fixed on this and on the other part towards the exterior a small pin 24 is positioned that projects to the exterior.
[0071] The small pin 24 can be a screw that for a small section is screwed on the spring. 25 .
[0072] FIG. 5 , is a front elevation of the small block 21 , made to rotate 45[deg.] anticlockwise with respect to FIG. 3 . The trench groove 0 on the upper part is highlighted. These grooves will act as a counter shoulder to the small pins 24 when they strike the ribs 20 .
[0073] FIG. 6 , is a plan view of the section B-B. This section is practically the lower part of the small cylindrical block 6 .
[0074] It is noted how this small block 6 past the central hole, comprises for the entirety of its length, various lateral grooves. Of these, two 26 a - 26 b will serve to allow the passage of the two ribs 20 a - 20 b the other four 26 will serve to allow the small block 6 , in the movement downwards, to go past the stops 18 placed in a fixed way further below on the casing 1 .
[0075] FIG. 7 , is a plan view of the section C-C that corresponds to the upper part of the nut screw 17 .
[0076] The four stops 18 are highlighted that originating in a secured way from the casing 1 , project for a few millimetre from the interior of the casing in order to block the upward movement of the nut screw 17 , moreover the two grooves 27 are highlighted that are obtained laterally on the same nut screw so that the latter can scroll longitudinally along the two ribs 20 a - 20 b but not rotate.
[0077] FIG. 8 , shows in plan view the section D-D that corresponds to the upper part of the flange 19 .
[0078] The flange 19 is highlighted from where the two ribs 20 extend upwards.
[0079] The flange 19 is perforated in the centre and the point of the worm 16 is highlighted.
[0080] This flange 19 , is secured in a fixed way to the casing 1 as are also the relieves or ribs 20 .
[0081] After having described the various components that form the bottle opener, the four stages and the movements for understanding working will now be described.
[0082] In the first working stage, FIG. 9 , from the rest position seen in the previous FIG. 1 , by lowering the lever 11 the movement of the arms 5 is also obtained and therefore also the movement downwards of the small cylindrical block 6 and therefore also of the whole assembly that is connected to this small block 6 by means of the bearing 12 .
[0083] Therefore the movement downwards of the entire apparatus will take place and the point of the worm 16 will approach the top of the neck of the bottle 28 and the closure 29 , placed under the base 9 of the bottle opener.
[0084] Also the nut screw 17 , not encountering obstacles, will move downwards together with the helicoidal screw 15 until striking the upper part of the flange 19 .
[0085] This first stage, defined as transfer, is idle and there is no rotation.
[0086] Together with the entire assembly, the small block 21 will also be lowered, placed higher up on the pin 14 and the small pins 24 , when the nut screw 17 is in abutment on the flange 19 , will be positioned near the highest point of the ribs 20 .
[0087] FIG. 10 shows what could occur if one of the small pins 24 in the process of the movement downwards, should strike the head of one of the ribs 20 .
[0088] In this case, the spring 25 to which the small pin is connected, will allow said pin to take a position so as not to obstruct the assembly in the process of the movement downwards, which could occur if the small pin 24 were fixed on the small block 21 .
[0089] The case represented with FIG. 10 , is extreme and normally does not occur because even if the small pin 24 struck the head, at the top of the rib 20 , said pin, aided by the flexibility of the spring and by the fact that the small block 21 can rotate, will position itself immediately at one side or the other of the ribs 20 .
[0090] It is to be noted that the small pin 24 can assume that position only in the movement from above downwards while in the opposite movement, namely upwards, it will remain blocked between the trench groove 0 and it will behave as if it were fixed on the small block 21 .
[0091] The reason for which the projections 24 of the small block 21 are connected with it by means of a flexible system 25 can now be understood.
[0092] Here, the first stage is completed.
[0093] Proceeding in the downward movement, the second stage will begin FIG. 11 that consists in the penetration of the worm 16 in the closure 29 .
[0094] In this second stage, since the nut screw 17 has struck the upper part of the flange 19 and is blocked here in the movement downwards and is still blocked in the rotary motion by the ribs 20 , the helicoidal screw 15 in order to be able to proceed in the movement will be forced to rotate clockwise and thus the worm 16 that is pushed downwards and rotating will penetrate the closure 29 .
[0095] This rotation is possible because the entire movable assembly that starts from the pin 13 , is fixed on the central ring of the bearing 12 that has a thrust bearing function and allows therefore the entire assembly connected with it to rotate freely both in the anti-clockwise and clockwise direction.
[0096] FIG. 11 shows the position that the various components come to assume when the small block 6 in the downward movement has achieved the lower dead centre.
[0097] Now we will examine what occurred and how the small block 21 behaved.
[0098] When the helicoidal screw 15 , pushed downwards started to rotate, the pin 13 and the pin 14 also followed that movement.
[0099] The small block 21 , positioned on pin 14 where the free wheel 23 operates, by means of inertia, will begin a rotary movement together with the pin 14 and this will continue until one of the small pins 24 strikes one of the ribs 20 .
[0100] At this point, the small block 21 , will be obstructed in the rotary motion and will proceed downwards without rotating. This fact will not prevent, however, the rotation of the pin 14 since, in that clockwise rotation direction, thanks to the free wheel, it is free to rotate even if the small block 21 and said free wheel 23 do not rotate.
[0101] Proceeding in the movement, it is understood therefore that the small pin 24 a in contact with the rib 20 a FIG. 12 will follow the movement of the assembly downwards, sliding and touching the wall of the rib 20 a until it reaches the lower dead centre.
[0102] FIG. 12 shows in plan view, the position that the small pins 24 a - 24 b - 24 c will have taken with respect to the ribs 20 a - 20 b during the penetration stage of the worm in the closure.
[0103] The small pin 24 a will be in contact with the rib 20 a while the other two small pins 24 b , 24 c will be free in the space between the casing 1 , the small block 21 and at a certain distance from the rib 20 b.
[0104] Here the second stage is completed, the one that we call penetration.
[0105] The following third stage FIG. 13 will be that in which the extraction of the closure from the neck of the bottle takes place and it is in this stage that the invention finds its application.
[0106] In order for the operation to be carried out, it is necessary to invert the force on the small block 6 to push the assembly upwards. We repeat that in this stage, it is essential that the worm only has upward axial movement and is not rotated.
[0107] Pushing upwards, the entire system will move away from the top of the neck of the bottle and if the closure 29 offers sufficient grip and friction on the worm 16 the opening will take place.
[0108] In this case, the friction offered by the closure being sufficient to keep the worm blocked, there is no anti-clockwise rotation of said closure and eventually, also the pin 14 and the small block 21 that includes the free wheel 23 , will move upwards with only the axial movement and with the small block 21 the small pin 24 will also follow the movement, maintaining the position, with respect to the ribs 20 , assumed during the previous penetration stage.
[0109] In this case therefore the invention that is presented here does not intervene and the opening will be carried out according to the traditional system.
[0110] Instead the behaviour of the worm will be different and as a result of the axis that supports it, until reaching the pin 14 where the small block 21 is positioned with the respective free wheel, if the closure does not offer sufficient grip and friction on the worm.
[0111] In this case, as the closure 29 is tightly held in the neck 28 and offers a certain resistance to extraction and considering the fact that it does not offer sufficient friction, the worm, free in rotary motion when the upwards movement begins, rather than operate the extraction will prefer to attempt to unthread itself from this closure by starting an anti-clockwise rotary movement.
[0112] This fact will also cause the rotation of the pin 14 and also the small block 21 that now, due to the effect of the free wheel 23 is integral with said small block. This start of rotation will last until one of the small pins 24 strikes against one of the ribs 20 .
[0113] FIG. 14 shows in plan view, the position that the small pins 24 are to assume when in the movement upwards the closure does not offer sufficient friction on the worm. In this case, the small pin 24 a will be moved away from the rib 20 a until the small pin 24 b strikes against the rib 20 b.
[0114] The way in which the small pins 24 are arranged with respect to the ribs 20 will determine the width of the rotation angle that the small block 21 can carry out before one of the small pins 24 goes against one of the ribs 20 and in conclusion before the invention takes effect.
[0115] This rotation angle, with the closure blocked between the neck of the bottle and the worm in this, must be as small as possible in order not to lose the opening effect.
[0116] In an attempt to reduce the space between the small pins and the ribs, these have been arranged according to the drawing in FIGS. 12 and 14 .
[0117] At this point, proceeding in the upward movement, the small pin 24 b , will follow that axial movement, sliding while supported and rubbing along the wall of the rib 20 b thus preventing the rotation to the small block 21 and therefore also to the axis that starts from the pin 14 to the worm 16 and namely until the extraction of the closure is not possible.
[0118] The lower the friction offered by the closure 29 on the worm 16 , the greater will be the rubbing force of the pin 24 b on the rib 20 b.
[0119] In this case, the small pin 24 b is practically placed to replace and compensate the low friction offered by the closure.
[0120] In this third stage, the nut screw 17 , already when the upward movement begins, not encountering any obstacles, and being included in the helicoidal screw 15 that does not rotate, must follow the upward movement until it goes against the stops 18 .
[0121] The fact that the pin 24 does not allow the rotation of the pin 14 , together with the fact that the nut screw 17 moves upwards following the axial movement of the helicoidal screw 15 , will be the motive for which the entire axis, including the worm that is now found within the closure, moves upwards without rotating.
[0122] When the nut screw 17 is in abutment on the stops 18 , the worm 16 will have passed upwards, making a sufficient space to extract the closure and the opening will take place.
[0123] The fourth stage will begin in which the worm is released from the closure.
[0124] FIG. 15 , shows the position that the various components have come to assume when the nut screw 17 , in its upward movement, has struck the stops 18 .
[0125] The closure 29 extracted from the neck of the bottle 28 is seen placed towards the lower part of the flange 19 and with the worm 16 inside.
[0126] The most important aspect now is that it is fundamentally important in the end to obtain the result that the invention intended to achieve as well as that of observing the position the small pins 24 have taken in this moment. They have now overcome the highest part of ribs 20 and are in a position in which, in the process of the upward movement, not encountering obstacles in the casing, are free to rotate together with the small block 21 , the pin 14 and eventually therefore also with the worm 16 .
[0127] At this point, continuing in movement, the nut screw 17 being blocked both in the rotary motion (the ribs 20 ), as well as in axial movement (the stops 18 ), the helicoidal screw 15 , in order to be able to proceed upwards, is forced into anti-clockwise rotation and in that direction will make the entire axis rotate including the worm 16 .
[0128] The closure 29 , included in the worm 16 will be in abutment at the base of the flange 19 and here will remain blocked without the possibility of rotating, as a result, the upward movement and the contemporary anti-clockwise rotation of the worm 16 , will make the worm release itself from the closure 29 for the lower part of the flange 19 to disappear further.
[0129] The closure released in this way can exit the bottle opener across the perforation 10 of the casing 1 .
[0130] The upward movement can occur until the top dead centre has been reached that coincides with the rest stage ( FIG. 1 ).
[0131] At this point the opening has taken place, the closure has been expelled by the bottle opener and the assembly is ready to start a new operation.
[0132] The importance and the function of the ribs 20 that together with the free wheel 21 with the small pins 24 , allow the realization of the invention is now understandable.
[0133] It is important to establish the point that the ribs 20 can reach in their upward extension. This point will must always be below that reached by the small pins 24 at the moment in which the nut screw 17 is in abutment against the stops 18 because this is the moment in which the rotary motion begins.
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This invention is an improvement to be applied to certain known bottle openers, called automatic bottle openers, in which, in order for the extraction to take place it is essential that the closure offers sufficient friction on the worm. Otherwise, once the worm has penetrated the closure, at the point of extraction, it can unthread itself from the closure by means of an anti-clockwise rotary movement and the perforated closure remains inside the neck of the bottle. The invention solves the disadvantage and is characterised in that; if the friction of the closure on the worm is not sufficient, a mechanical system takes over automatically that stops the worm only in anti-clockwise rotary motion during the single extraction stage to then, in the process of the same upward movement, allow the restoration to anti-clockwise rotation so that that the worm can be released from the closure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a detonator for the electrical ignition of detonating materials, in particular explosives.
2. Discussion of the Prior Art
A detonator for the direct electrical ignition or detonation of secondary explosives has already become known from German Pat. No. 16 46 337. This detonator relates to a gap-pole member, the gap of which is bridged by a thin and at least semi-conductive layer. In order to achieve a high ignition quality for the secondary explosive, the grain size distribution of the explosive is so selected that at least the portion of the secondary explosive which lies against the semi-conductive layer possesses specific surfaces in the range of between 300 and 10,000 cm 2 /g.
The disadvantage of this known arrangement, on the one hand, lies in the quite complicated construction of the gap-pole member which has a gap width for the pole member of between 20 and a few 100μ, which sets demands for finely-precisioned mechanical components for the manufacturing devices and, resultingly, renders the detonator more expensive. On the other hand, the mounting and contacting of the semi-conductive layer represents an additional expensive and complex manufacturing procedure. Furthermore, the dependable functioning of this known prior art detonator requires an accurate knowledge of the grain size distribution of the employed secondary explosive, the desired fine granularity and, in effect, specific surface must be achieved through grinding of the commercially available secondary explosive.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to produce in a simple manner a detonator without an initiating or triggering explosive of the above-mentioned type, without necessitating the extremely expensive and complex manufacturing steps of the above-mentioned German patent.
In order to achieve the foregoing object of the invention, the detonator inventively incorporates at least one piezo element which is at least partially encompassed by secondary explosive, which can be subjected to a steeply rising voltage impulse and thereby extraordinarily rapidly expanded whereby the adjacent contacting secondary explosive can be resultingly triggered through the generated shock wave.
In this invention there is utilized the property of explosives which can be triggered by a percussion or impact pressure. Thus, for example, tetryl can be triggered by an impact pressure of from about 10 kbar.
In this instance, it is a novel principle that for the generation of a shock wave in the secondary explosive which leads to the triggering of the explosive, that there is utilized the piezo-electric effect. With a disc constituted of a predetermined piezo ceramic and at a compression of about 1 μm, a voltage of 2 kV can be taken off at the oppositely located surfaces. Conversely, at the application of an oppositely poled voltage of 2 kV there occurs an expansion of about 1 μm. This expansion propagates extremely rapidly at a correspondingly steep voltage rise so as to trigger a shock wave in the medium encompassing the ceramic, which forms due to the mass moment of inertia of the explosive and which accelerates during the expansion time interval.
In accordance with military standards, all primary explosives (initiating explosives) must be securable, in effect, must be pivotable out of the line of detonation or, respectively, separable through the use of discs from the main charge of the secondary explosive. For secondary explosives this is not prescribed in an obligatory manner. The limit of sensitivity can be found with tetryl. The utilization of tetryl or, respectively, of other secondary explosives of the same or lower sensitivity hereby leads to a significant simplification in the construction of detonators since the otherwise necessary complicated mechanical safety arrangements become superfluous. It is also advantageous that in the present invention there can be employed commercially available secondary explosives without the need for additional grinding.
In a preferred embodiment of the invention there are utilized two or more piezo elements which are connected electrically in parallel and mechanically in series. Herewith, at a predetermined maximum voltage, there can be increased the overall attainable expansion amplitude of the piezo elements.
Further modifications of the invention contemplate that the detonating capsule can be constructed in a packed down or unpacked manner which, pursuant to the type of application, represents a further advantage.
A preferred embodiment of the invention further contemplates that a metal powder and/or other additives are admixed with the secondary explosive so as to increase the density of the secondary explosive. Through this measure the formation of a shock wave is rendered easier. The same goal is served by a heavy-metal insert, preferably one of lead, which is encompassed by secondary explosive and is arranged to extend in parallel opposite the piezo element whereby the cross-sectional surface of the heavy-metal insert is smaller than the cross-sectional surface of a recess formed in the detonator.
It is also advantageous in the present invention that the cross-sectional surface of the piezo element is constructed in conformance with the inner cross-sectional surface of the recess in the detonator so that the shock wave will expand as a planar surface through the secondary explosive.
In a further preferred embodiment of the invention the piezo element is formed as a tubularly-shaped member having electrodes coaxially arranged on the outer circumference and inner circumference thereof, and which is internally and/or externally encompassed by secondary explosive. This exemplary embodiment, above all, can be advantageously employed in rotationally-symmetrical members. For rapidly rotating projectiles the steeply rising voltage impulse is hereby to be selected at such a magnitude so as to compensate for the piezo voltage which is generated by the centrifugal acceleration.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be had to exemplary embodiments of the invention taken in conjunction with the accompanying drawings; in which:
FIG. 1 illustrates a cross-sectional view through a detonator in a packed arrangement and having a heavy-metal insert positioned opposite a piezo element;
FIG. 2 illustrates an embodiment with two piezo elements which are connected electrically in parallel and mechanically in series;
FIG. 3 illustrates a sectional view through a detonator with a tubularly-shaped piezo element, which is reinforced along its external circumference; and
FIG. 4 illustrates an electronic circuit for the ignition of the detonator.
DETAILED DESCRIPTION
Referring now in detail to the drawings, FIG. 1 illustrates a detonator 1 consisting of a cup-shaped container 2, preferably constituted of steel, which includes a recess 3 whose transverse surface 4 is larger or equal in size to the contact surfaces 6 of a plate-shaped piezo-element 5 which is arranged on the transverse surface 4 of the recess 3. Arranged on both sides of the plate-shaped piezo element 5 in a usual manner are laminarly constructed and insulated electrodes 7 which, by means of electrode leads (not shown), supply the necessary energy to the piezo element 5 for ignition. Secondary explosive 8 is directly pressed, for example, against one side of the piezo element 5 which is provided with the electrodes 7 and, thereby, the receptacle 2 is filled. For the purpose of tamping, the recess 3 is closed off through the intermediary of a packing or cover disc 9 and an equalizing plate 10 both of which, for example, are constituted of metal. The cover disc 9 is threaded together with the cup-shaped container 2, for example, by means of a screw thread 11 which is correspondingly present also on the upper exterior rim 12 of the circular cup-shaped container 2. The cover disc 9 hereby presses with its planar inside against the similarly planar circularly-shaped adjusting or equalizing plate 10 which is fitted into the recess 3 and, in turn, is positioned on the secondary explosive 8. In order to enhance the explosive effect, there can, inventively, be provided a heavy-element insert 13 as a thrust member, preferably constituted of lead, and arranged opposite piezo element 5 wherein the heavy-metal insert 13 is on all sides thereof encompassed by the secondary explosive 8. In a circular container 2 this heavy-metal insert 13 can be constructed as a circular cylindrical disc whose transverse surface 14 is smaller than the transverse surface 4 of the recess 3, and which is arranged coaxially within the recess 3. Within the context of this invention there can also be employed other containers 2 which are not rotationally-symmetrical and whose recess 3 and heavy-metal inserts 13 do not possess circular cross-sections. Inventively, it is also conceivable that the secondary explosive 8 is positioned directly on the bottom of the container and that the piezo element 5 is arranged between the secondary explosive 8 and the equalizing plate 10.
In a preferred embodiment of the invention as illustrated in FIG. 2, there are utilized two piezo elements 5 which are superimposed on each other and separated through a thin lamilarly constructed center electrode 7' provided with an electrode lead 16', wherein the outer electrodes 7 can be connected with each other through electrode leads 16. Since lengthy electrode leads 16 and 16' are subjected to correspondingly high inductivities, due to necessary steeply rising voltage impulses necessary for ignition, there are preferably used short electrode leads 16 and 16'. The utilization of an unpacked detonator 1 may also be of advantage. In this instance, the cover disc 9 and the equalizing plate 10 can be arranged so as to be removable.
Pursuant to a further inventive exemplary embodiment there can be employed a tubularly-shaped piezo element 15 within the container 2 having now arranged coaxially on the inner and outer circumferences thereof annularly-shaped electrodes 17, as well as secondary explosive 8 interiorly thereof. The electrodes 17 are provided with supply leads in a manner not illustrated in detail herein. At the application of a steeply rising voltage impulse to the two electrodes 17, there is generated a radially inwardly propagating shock wave in the secondary explosive 8.
In modifications of this exemplary embodiment it is also possible to contemplate embodiments in which the secondary explosive 8 is arranged within as well as exteriorly of the piezo element 5. Furthermore, there can also be inventively utilized two or more concentric, oppositely movable tubularly-shaped piezo elements 15 which compress the intermediately arranged explosive.
This modification of the invention can also be applied to the plate-like piezo elements 5 of FIGS. 1 and 2, wherein the secondary explosive 8 is arranged intermediate the oppositely moving piezo elements 5.
The generation of the voltage impulses leading to detonation or ignition can be inventively effectuated through an electronic circuit as shown in FIG. 4 and which is described hereinbelow. A piezo generator 20 generates, in an already known manner, electrical energy which upon reaching a sufficiently high voltage of, for example, 2 kV over a spark discharge gap 21 is charged over to the capacitance of the piezo elements 5 or 15, and thereby detonates the secondary explosive 8. Hereby, the piezo generator 20, the spark discharge gap 21 and the piezo elements 5 or 15 are connected electrically in series. In a preferred embodiment, a safety switch 22 is connected in parallel with the piezo generator 20, the switch being short-circuited, for instance, up to the firing of the projectile. Furthermore, it is advantageous to connect a relatively high-ohmic resistor 23 in parallel with the piezo element 5 or 15 so as to reduce the charges which are produced comparatively slowly at the piezo elements 5 or 15 through, for example, ionization.
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A detonator for the electrical ignition or detonation of detonating materials, such as explosives. The detonator incorporates at least one piezo element which is at least partially encompassed by a secondary explosive. The piezo element is subjected to a steeply rising voltage impulse and thereby rapidly expanded so as to generate a shock wave which will detonate the secondary explosive.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for deinking printed waste paper using a peroxidase in the presence of a peroxide as the deinking agent. In accordance with the preferred embodiment of the invention, the enzyme is soybean peroxidase.
2. Description of the Prior Art
The recycling and use of waste paper has been dramatically influenced in recent years by public presence and by existing and pending government legislation. With the utilization of waste paper expected to continually increase in the future, the recycling of waste paper is believed to be one of the main issues facing the paper industry in the next decade and beyond.
Waste paper is most often used in the production of lower quality commodity grades such as linerboard, newsprint, etc. Recent advances in recycling technology, particularly, with respect to the deinking of printed waste papers allows the recycled pulp to be used in the production of higher grades of paper such as bond paper, etc. In the past, most papers were printed using primarily water or oil-based inks which are satisfactorily removed by conventional deinking methods which includes forming an aqueous pulp and contacting the pulp with a surfactant. The ink is separated from the pulp fiber and the ink is then subsequently removed by washing or floatation procedures. For example, the use of a substituted oxyethylene glycol nonionic surfactant along with a low molecular weight polyelectrolyte for deinking secondary fiber is described in U.S. Pat. No. 4,599,190 to Maloney. Betscher, U.S. Pat. No. 5,094,716 describes an improvement in the process for deinking groundwood newsprint wherein a combination of certain anionic surfactants in conjunction with a defoamer and a naphthalene-formaldehyde condensate is employed. Oil-based inks are generally saponified or dispersed under alkaline conditions and are thus broken up releasing the ink which can then be easily removed by any satisfactory means. There is, however, an increased use of electrostatic inks employed in printed matter such as xerography, etc. and these inks are much more difficult to remove than the common water or oil-based inks. As a result, waste paper produced from electrostatic ink-printed paper has a higher dirt count making for a lower grade product.
The removal of electrostatic inks and toners from xerographically printed waste paper has been described for example in U.S. Pat. No. 4,561,733 to Wood, U.S. Pat. No. 4,276,118 to Quick; U.S. Pat. No. 4,820,379 and U.S. Pat. No. 5,102,500 both to Darlington. While such attempts have been successful in removing most of the electrostatic inks or toners, generally some large agglomerates remain in the processed fiber giving it an undesirable appearance, particularly, when used in high quality paper.
Enzymes have been used in the treatment of paper pulps and for purifying the waste water effluents from paper mill operations. According to a 1991 article, "Enzyme Technology for Fiber Treatment" by T. W. Jefferies of the Institute for Microbial and Biochemistry Technology, USDA Forest products, Madison, Wis., lipases are presently being applied to pitch removal and deinking in lignocellulose bioprocesses. Japanese Pat. Nos. JP 2160984 and JP 2080684 describe the use of the enzyme, lipase, in the hydrolysis of soya-based inks. This enzyme, however, has no apparent effect on mineral-based inks. Another enzyme, cellulase, has been described in Japanese patent No. JP 2080683 where cellulase in combination with a surfactant may improve certain deinking processes. It is anticipated that such deinking would be advantageous in processes where fibers other than cellulosic fibers are used since it is known that cellulase is likely to damage cellulose fibers. European patent application No. EP 447672 describes deinking waste paper using a lignolytic enzyme. According to the European application, oxidation potential of the enzyme is critical to the deinking process.
SUMMARY OF THE INVENTION
The present invention provides a method for deinking printed waste paper which not only overcomes the problems previously associated with deinking procedures, but it also has the advantage of being extremely attractive economically.
In accordance with a preferred embodiment of the invention, an aqueous slurry of the printed waste paper pulp fiber is contacted with soybean peroxidase and a peroxide whereby the fibrous pulp is deinked. The deinked fibrous pulp is separated from the aqueous medium and recovered for reuse. The recycled fiber is useful in the production of high quality fine papers such as bond paper, etc.
DETAILED DESCRIPTION OF THE INVENTION
As described herein, it has been discovered that newsprint such as newspapers, magazines, etc. can be reclaimed as secondary fiber for use in the production of high quality fine paper for printing and writing by treating an aqueous slurry of pulped newsprint with a peroxidase enzyme and a peroxide such as hydrogen peroxide. Preferably the original newsprint contains up to about 5% moisture.
Any of a variety of peroxidases can be used in the present invention. Soybean peroxidase is preferred because tests have shown that it is more reactive and that it is more chemically and thermally resistant than other peroxidases. Furthermore, soybean peroxidase (SBP) exhibits a higher redox potential than some other enzymes such as horseradish peroxidase (HRP) as shown in Table 1:
TABLE 1______________________________________Redox Potential of Soybean Peroxidase (SBP) vs. HorseradishPeroxidase (HRP)Substrate (λmax) E1/2 (V) SBP* HRP*______________________________________pentamethoxybenzene (300 nm) 1.07 8.76 2.501,2,3,5-tetramethoxybenzene 1.09 3.02 0.30(295 nm)1,2,4-trimethoxybenzene 1.12 9.23 1.64(450 nm)hexamethoxybenzene (425 nm) 1.24 0.22 01,4-dimethoxybenzene (315 nm) 1.34 0.072** 0______________________________________ *all values in Δ Abs/(mg enzymemin). **curve of ΔAbs/time slopes upward as reaction proceeds.
Although soybean peroxide is preferred, the invention is also open to the use of peroxidases such as peroxidases from other legumes, horseradish peroxidase, rice peroxidase and peroxidases from malvaceous plants such as cotton.
The aqueous slurry of the printed waste paper pulp fibers may be treated with the peroxidase in the form of a plant extract or, in the case of soybean peroxidase, the soybean seed hulls may be employed directly. In the deinking process, the peroxidase may be extracted from the hulls or, because the soybean seed hulls are composed of cellulosic fibers similar to the cellulosic fibers of paper, it may not be necessary to separate the hulls from the papers. Not only is the method simplified by using the soybean seed hulls as the source of soybean peroxidase but the seed hull fibers may become a useful part of the reclaimed paper to significantly improve the yield of secondary fiber.
The amount of peroxidase is not particularly critical provided that adequate enzyme is employed to sufficiently deink the fibers. The amount of enzyme used will depend upon its activity and its stability under the conditions of the deinking operation. While the enzyme is not consumed in the reaction, it gradually loses activity. Typically, the amount of soybean peroxidase used will be in the range of about 0.01 to 20 units of soybean peroxidase per gram of dry pulp in the slurry. A "unit" of soybean peroxidase as used in this application means the amount of peroxidase which produces a change of 12 absorbance units measured at 1 cm pathlength in one minute at 420 nm when added to a solution containing 100 mM potassium phosphate, 44 mM pyrogallol and 8 mM hydrogen peroxide, and having a pH of 6 (Sigma Chemical Co., Peroxidase Bulletin).
The peroxides useful in this invention are those commonly used in conjunction with peroxidase enzymes. Hydrogen peroxide is generally preferred, but any of the water soluble peroxides such as methyl peroxide, ethyl peroxide, etc. may also be useful.
The peroxide may be reacted neat or in a solution. The preferred peroxide, hydrogen peroxide, is typically dissolved in water in which the concentration of hydrogen peroxide may range from about 0.1 mM to 1M, and preferably from about 2 mM to 5 mM. The solution of hydrogen peroxide is generally added dropwise to the pulp slurry containing the soybean peroxidase over a period of time which will vary with deinking conditions such as temperature and mixing speed. An excess of peroxide can inhibit the deinking reaction. Accordingly, it is desirable to control the rate of addition of the peroxide to maximize the efficiency of the deinking process without inhibiting the reaction. In accordance with one embodiment of the invention, the peroxide is initially reacted at a rate of approximately twice the average reaction rate and thereafter the rate of addition of the peroxide is adjusted downwardly to compensate for the decrease in the rate of reaction. Typically, the rate of addition of the peroxide is controlled such that the peroxide concentrate does not exceed about 23 millimolar and more preferably does not exceed 2 to 5 millimolar.
The fibrous pulp slurry may be treated with the soybean peroxidase at a temperature up to about 90° C. or higher. The treatment is preferably conducted at a temperature in the range of about 25° to 90° C.
While it is in the scope of this invention to conduct the treatment of printed waste paper pulp with the soybean peroxidase and peroxide at a pH of about 1 to 13, it is preferred that the treatment be conducted at a pH of about 4 to 9. The pH is adjusted by the addition of acid or base.
In order to facilitate the deinking of the fibers, it may be desirable to employ a co-solvent in the reaction medium. The co-solvent is typically an organic solvent and, preferably, a water miscible or water immiscible organic solvent. Co-solvents which are useful in this invention include but are not limited to water immiscible solvents such as hexane, trichloromethane, methyl ethyl ketone, ethyl acetate, and butanol; and water miscible solvents such as ethanol, methanol, isopropanol, dioxane, tetrahydrofuran, dimethyl formamide, methyl formate, acetone, n-propanol, t-butyl alcohol. The amount and type of co-solvent employed will depend on various factors such as the nature of the coating on the paper and the type and/or amount of ink to be removed from the fibers. It is expected that the ratio of the amount of co-solvent to the amount of water by volume will be in the range of about 1:10 to 10:1. However, to minimize solvent recovery preferably the ratio will not exceed 1:2 and still more preferably it will not exceed 1:4.
While not desiring to be bound by any particular theory, it is believed that the deinking of the fibrous pulp in accordance with this invention involves an oxidation reaction in which the peroxidase in combination with the peroxide enzymatically oxidizes at least a portion of the ink to a colorless form with or without removal of the ink. It is further believed that oxidation may occur in ink carriers rather than the pigment so that mineral pigments containing oxidizable carriers or binders may be susceptible to the present invention.
Physical removal of ink, whether it be colored or noncolored, may be achieved by the action of one or more additional conventional deinking agents. These additives loosen the ink from the fiber so that it can easily be removed and separated from the fiber. Additives which are useful in the present invention include agents which are known to be effective in such reactions and include, e.g., detergents such as nonionic surfactants, ethoxylated linear alcohols, ethoxylated alkyl phenols, or other chemicals such as caustic to swell the fibers and chelators such as phosphates to remove metals.
Other agents which are commonly used in deinking operations such as surfactants, bleaches, brighteners, softeners, defoamers, dispressants, chelating agents and the like may also be useful in this invention for their conventional purpose.
Removal of the inks from the slurry is otherwise achieved in a conventional manner. Ink can be separated from the fibers once the bond between fiber and ink is broken. In a washing procedure, the ink particles are finely dispersed using dispersants and surfactants and the fibers are filtered or sedimented out of solution. In a flotation procedure, ink particles are agglomerated and carried to the surface adhered to air bubbles of a foam. The foam containing the ink is then skimmed off leaving the fiber free of ink.
It is, of course, to be understood that the method of the present invention may be practiced batchwise or continuously. The invention is further illustrated, but not limited by the following examples.
EXAMPLE I
Ground untoasted soybean seed hulls obtained from Central Soya, Marion, Ohio, were stirred in tap water at a ratio of 50 pounds of hulls per 100 gallons of water. The mixture was stirred in a Cowles mixer at 1000 rpm for 15 minutes. The mixture was filtered on a 0.002" screen (Sweco 34TBC), allowed to settle for 1 day, and then concentrated twenty-fold by ultrafiltration on a 30,000 molecular weight cut off polysulfone membrane. The concentrate was used as the source of soybean peroxidase in the following examples.
EXAMPLE II
A newspaper (Mar. 15, 1992 edition of the Columbus Dispatch) was cut into 2 inch squares and homogenized in tap water at a ratio of 190 grams of paper in 4 liters of water using a Waring blender. 307 grams of pulp/water mixture was mixed with 36 ml isopropanol, 485 ml tap water, and 55 ml of the soybean seed hull extract obtained in Example I. The pulp/isopropanol/soybean seed hull extract was poured into a jacketed round bottom flask and stirred at 300 rpm at 60° C. 5 ml of a 15% H 2 O 2 solution and added to the pulp/extract solution at 60° C. and 300 rmp over 5 minutes. At the end of the reaction, the mixture was filtered on a Whatman #4 filter paper by vacuum filtration and the damp pulp was separated from the filter.
EXAMPLE III
Example II was repeated except that prior to reaction the soybean extract was placed in a 250 ml Erlenmeyer flask and heated on a steam bath for 20 minutes to destroy enzymatic activity. Otherwise, the reaction was the same as Example II.
EXAMPLE IV
Example II was repeated using fresh extract, but without hydrogen peroxide.
The results of Examples II-IV are shown in Table 2.
TABLE 2______________________________________ENZYMATIC DEINKING OF NEWSPRINTExample Observed Color % Black______________________________________II Light Tan +1/2III (Boiled Enzyme) Gray-black +2IV (No Peroxide) Gray-black +2______________________________________ .sup.1 --Visual % Black Scale (0-10)
A direct assay of peroxidase in the aqueous fraction of each reaction using 1,4-dimethoxybenzene as a substrate indicates that heating reduces the oxidation potential of the peroxidase as shown in Table 2.
TABLE 3______________________________________PEROXIDASE ACTIVITY OF DEINKING REACTIONS.sup.2Fraction Ex. II Ex. III Ex. IV______________________________________Zero time 1.22 0.94 ND.sup.35 ml H.sub.2 O.sub.2 /5 min. 0.16 0.23 ND.sup.3Filtrate After 0.06 0.22 2.43Reaction______________________________________ .sup.2 --Units/ml .sup.3 --ND means not done
Table 3 indicates that heating at 60° C. did not destroy peroxidase and that high levels of activity were present in each reaction, but that more vigorous heating, by placing the peroxidase directly in a 100° C. stream of steam, completely destroyed peroxidase activity.
In conclusion, both an active enzyme and hydrogen peroxide are required to deink newsprint using soybean seed hull extract. The mechanism may include perhydrolysis by a lipase and peroxide or oxidative bleaching by soybean lipoxygenase or other peroxidase.
It will be obvious to those skilled in the art that various changes can be made without departing from the scope of the invention and the invention is not to be considered limited to what is described in the specification.
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A method of deinking printed waste paper for recycle which comprises converting a printed waste paper to a fibrous pulp in an aqueous medium to form a fibrous pulp slurry; contacting the slurry with a soybean peroxidase and a peroxide to deink the pulp; separating the deinked pulp from the aqueous medium; and recovering the deinked pulp.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to wrinkle resistant fabrics.
2. Description of the Prior Art
The use of acetals for crosslinking cellulosic materials to produce improved wrinkle recovery has been reported. Walker (U.S. Pat. No. 2,548,455) reported the crosslinking of paper, starch, regenerated cellulose, and cotton with 2,5-dimethoxytetrahydrofuran. However, his process was not very practical since it required curing for 15 min. at 140° C. Although Walker used 2,5-dimethoxytetrahydrofuran, he in effect obtained crosslinking with the dialdehyde, succinaldehyde, which is the hydrolysis product formed in the reaction with the cellulose.
Frick and Harper [Frick, J. G., Jr., and R. J. Harper, Jr., J. Applied Polymer Sci. 29, 1433-1447 (1984) and Frick, J. G., Jr., J. Applied Polymer Sci. 30, 3467-3477 (1985)] found that acetals derived from dialdehydes crosslinked cotton to produce improved wrinkle recovery but they also reported that acetals of monoaldehydes were not reactive to produce wrinkle resistance.
SUMMARY OF THE INVENTION
Novel improved wrinkle resistant cellulosic fabric characterized by a glyceraldehyde crosslink of the following structure: ##STR1## with a cellulose matrix and process for production is disclosed.
The main object of the invention is to provide a process for treating cellulosic materials with dialkoxy acetals of glyceraldehyde in the presence of special combination acid catalysts, thereby crosslinking the cellulose at a very rapid rate to produce a material with an improved wrinkle recovery.
A second object of the invention is to provide a process for treating cotton fabric with glyceraldehyde diethyl acetal or glyceraldehyde dimethyl acetal in the presence of an acid catalyst and an hydroxy acid activator, thereby producing a fabric with improved wrinkle recovery.
A third object of the invention is to provide a conventional pad-dry-cure process for treating cotton fabric with said diacetals in the presence of said catalysts to provide wrinkle resistant fabrics for use in permanent press textiles, said textiles having the advantage of no release of toxic formaldehyde.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Acetals of glyceraldehyde are found to react with cellulosic materials, which in theory crosslink the hydroxyl groups of the cellulose to give desirable wrinkle resistant properties. Acetals suitable for this invention include acetals of glyceraldehyde such as dimethyl, diethyl, diisopropyl, and di(tert-butyl) although the preferred aldehyde is dl-glyceraldehyde, which is a mixture of the d- and l-isomers. The preferred acetal is dl-glyceraldehyde dimethyl acetal.
The following general equation represents how the reaction of celulose with acetals of glyceraldehyde proceeds: ##STR2##
Whereas this invention is primarily concerned with a process for treating cotton fabrics, other cellulosic materials may be used. These include regenerated cellulose, paper, starch, and the cotton in cotton/polyester blends. When the cellulosic material is cotton fabric or a cotton/polyester blend, an improvement in wrinkle recovery and dimensional stability of the fabric is obtained. Such improvement in wrinkle recovery is an indication of cellulose crosslinking. Fibers from fabrics treated with acetals of the preferred embodiment are insoluble in cupriethylenediamine dihydroxide, which is also an indication of crosslinking. Since these crosslinks form an ether linkage with the cellulose they are resistant to hydrolytic conditions encountered in laundering. In the crosslinking reaction the hydroxyl groups of the cellulose react with the alkoxy groups of the acetals and the corresponding alcohol is eliminated in the process.
The acetals used are glyceraldehyde diethyl acetal, hereinafter referred to as GDEA, and glyceraldehyde dimethyl acetal, hereinafter referred to as GDMA. The GDEA and GDMA used in this invention are prepared by the aqueous potassium permanganate oxidation of the appropriate acrolein acetal as described in Organic Synthesis Volume II, pp. 307-308 (1943), the procedure of which is herein incorporated by reference.
Suitable acid catalysts would include metal salts such as aluminum sulfate, aluminum chlorohydroxide, magnesium chloride, zinc nitrate, and certain organic acids such as p-toluene sulfonic acid. The preferred catalyst is aluminum sulfate. A catalyst activator may also be used in combination with any of those mentioned. Activators can be chosen from the group consisting of organic hydroxy acids. The preferred hydroxy acids would be citric acid and tartaric acid or a combination thereof. Although acid catalysts may be used alone it is preferable to use a combination of catalyst and hydroxy acid activator.
Solutions used in treating cellulosic materials are prepared by dissolving acetal and catalyst in water. Concentration of acetal may vary over a range of from about 5% to 20%, and the combined catalyst activator concentration is from about 0.4% to 2.0% on a weight basis, depending on the particular catalyst system selected. In preparing solutions it is advantageous, though not necessary, to use a buffer to help prevent excessive strength loss of fabric due to acid catalyst. An exemplary buffer is a basic aluminum acetate borate of the formula, Al(OH) 2 OAc.1/3H 3 BO 3 . It is also advantageous, although not necessary, to add a surface active agent and a softening agent to the solution in order to improve wetting of cellulosic material as well as increase strength and abrasion resistance of material. The pH of the solutions can range from about 2.3 to 6.5 depending on catalyst selected.
Before treating cellulosic material it is important to determine if the material contains any residual alkalinity since this would neutralize a portion of the catalyst and render the catalyst less effective during treatment. If the material is found to be alkaline, it should be soured prior the impregnation step. Souring is conveniently achieved by passing the material through dilute acetic acid and drying. The cellulosic material is impregnated with acetal solution and any excess solution removed, preferably by padding. The material may then be cured without a drying step, or it may be dried prior to curing. It is preferable to dry prior to curing at temperatures ranging from about 70° C. to 90° C. for from about 3 to 5 minutes. After drying, the material is cured at from about 115° C. to 170° C. for from about 10 seconds to 5 minutes, the shortest time at the highest temperature.
The fabric samples treated according to this invention are bleached and scoured 80×80 cotton printcloth, and are tested for conditioned wrinkle recovery angles by the standard method of the American Society for Testing Materials, Philadelphia, Pa., 1964 Book of ASTM Standards, designation D1295-60T, the procedure of which is herein incorporated by reference. After curing, fabric samples were thoroughly rinsed in hot running tap water and oven dried before testing.
The following examples illustrate but are not intended to limit the scope of the invention. All of the fabric samples are soured with 1% acetic acid prior to treatment unless stated otherwise. All of the percentages in the examples are by weight. Wrinkle recovery angles are designated by WRA and the sum of the warp and fill directions (W+F).
EXAMPLE 1
A water solution was prepared containing 10% glyceraldehyde diethyl acetal (GDEA), 0.4% aluminum sulfate of the formula, Al 2 (SO 4 ) 3 .16H 2 O and 0.4 L(+)-tartaric acid. Samples of cotton printcloth were padded with the solution to a wet pick-up of 70-80% using a laboratory padder. The samples were then dried for 5 minutes in a forced draft oven at 85° C., and cured similarly for 1 minute at 150° C. The fabric was then rinsed in water, oven dried and air equilibrated. It had a weight gain of 3.0% and a wrinkle recovery angle (WRA) of 253° C. (W+F). A similar sample cured for 0.5 minutes at 160° C. had a WRA of 248° C. An untreated control sample had a WRA of 190°.
EXAMPLE 2
A water solution of GDEA was prepared in the same manner as in Example 1 except that it contained 1% of a reactive silicone fabric softener containing silanol end groups. Five cotton printcloth samples were padded with the solution and cured at the following time and temperatures as indicated in Table I. Weight gain (or % add-on) and WRA (warp & fill) are also shown.
______________________________________Cure Add-on WRA(W + F)°C./min. (%) (degrees)______________________________________125/2 4.3 226140/0.5 5.4 232115/2 3.2 222115/3 4.3 231Untreated Control 190______________________________________
The untreated control fabric had a WRA of 190°. All of the samples of Table I show improved results.
EXAMPLE 3
A water solution was prepared containing 10% GDEA, 0.76% Al 2 (SO 4 ) 3 .16H 2 O, 0.77% tartaric acid, 0.28% Al(OH) 2 OAc.1/3H 3 BO 3 as a buffer, 1% silanol softener, and 0.1% of an alkylaryl polyether alcohol [in this case a nonionic wetting agent, Triton X-100 (Rohm and Haas)]. Cotton printcloth samples were treated as in Example 1 and cured as indicated in Table II. Percent weight gain (add-on) and WRA are also shown.
TABLE II______________________________________Cure Add-on WRA(W + F)°C./min. (%) (degrees)______________________________________115/3 3.5 220115/5 3.5 222150/1 3.8 244160/0.5 4.2 247160/1 4.4 254170/0.25 3.3 251170/0.17 4.2 273Untreated Control 190______________________________________
Samples shown in Table II were dried for 5 minutes at 85° C. When a fabric sample was dried for 2 minutes at 115° C. and cured for 1 minute at 150° C. a WRA of 245° was obtained. All of the treated sample show improvement over the control.
EXAMPLE 4
A water solution was prepared containing 10% GDEA, 0.57% Al 2 (SO 4 ) 3 , 2.1% L-(+)-tartaric acid, 0.35% Al(OH) 2 OAc.1/3H 3 BO 3 , and 1% polyethylene softener instead of the silanol softener used in previous examples. Samples of cotton fabric were padded with the solution, dried 2 minutes at 115° C. and cured as indicated in Table III. Data on % add-on and WRA are also given.
TABLE III______________________________________Cure Add-on WRA(W + F)°C./min. (%) (degrees)______________________________________150/0.5 2.2 231160/0.25 1.9 224160/0.5 2.4 248Untreated Control 190______________________________________
EXAMPLE 5
A water solution was prepared containing 10% GDEA, 0.77% Al 2 (SO 4 ) 3 , 0.76% (L-(+)-tartaric acid, 0.28% Al(OH) 2 OAc.1/3H 3 BO 3 , and 1% silanol softener. Cotton printcloth samples were padded with the solution, dried 2 minutes at 115° C. and cured as indicated in Table IV. Data on % add-on and WRA are also given. Improvement in all samples over untreated control.
TABLE IV______________________________________Cure Add-on WRA(W + F)°C./min. (%) (degrees)______________________________________150/1 2.8 245160/0.5 2.9 236170/0.25 3.3 251Untreated Control 190______________________________________
EXAMPLE 6
A water solution was prepared containing 10% GDEA, 0.77% Al 2 (SO 4 ) 3 . 16H 2 O, 0.37% L-(+)-tartaric acid, 0.35% citric acid, and 0.28% Al(OH) 2 OAc. 1/3H 3 BO 3 . No softener was used in this formulation. This formulation differs from the preceding examples in that the catalyst activator is a combination of tartaric and citric acids. The samples were dried for 2 minutes at 115° C. Data on treated cotton printcloth samples are shown in Table V clearly indicating improvement over untreated control.
TABLE V______________________________________Cure Add-on WRA(W + F)°C./min. (%) (degrees)______________________________________140/2 2.5 236150/1 2.5 226160/0.5 2.1 225Untreated control 190______________________________________
EXAMPLE 7
In this example and the following ones dl-glyceraldehyde dimethyl acetal (GDMA) was used instead of glyceraldehyde diethyl acetal. A water solution was prepared containing 10% GDMA, 0.77% Al 2 (SO 4 ) 3 .16H 2 O, 0.76% L-(+)-tartaric acid, 0.28% Al(OH) 2 OAc.1/3H 3 BO 3 , 1% silanol softener, and 0.1% Triton X-100 wetting agent. Cotton printcloth samples were padded with the solution to a wet pick-up of about 90%, dried for 5 minutes at 85° C. and cured as indicated in Table VI clearly indicating improved values over untreated control. Data on % add-on and WRA are also given.
TABLE VI______________________________________Cure Add-on WRA(W + F)°C./min. (%) (degrees)______________________________________140/2 2.9 265150/1 3.7 271160/0.5 3.8 270170/0.17 2.7 241Untreated control 190______________________________________
The WRA of the untreated control fabric was 190°. From the WRA values obtained with GDMA it is evident that GDMA is more reactive than GDEA, and therefore preferred. WRA values of 270° are within the range of those required for durable press finishes.
EXAMPLE 8
Example 7 was repeated except that the fabric was not soured with 1% acetic acid prior to treatment. The results are shown in Table VII.
TABLE VII______________________________________Cure Add-on WRA(W + F)°C./min. (%) (degrees)______________________________________140/2 3.2 247150/1 3.3 260160/0.5 3.3 248Untreated control 190______________________________________
From the WRA values it is obvious that better results were obtained when the fabric was given an acid sour prior to treatment.
EXAMPLE 9
A water solution was prepared containing 10% GDMA, 1% Al 2 (OH) 5 Cl.2H 2 O, 1% citric acid, and 1% polyethylene softener. A sample of cotton fabric composed of 50% cotton and 50% polyester was padded with the solution to a wet pick-up of about 65%. The fabric samples were dried for 5 minutes at 85° C. and cured as indicated in Table VIII.
TABLE VIII______________________________________Cure Add-on WRA(W + F)°C./min (%) (degrees) Fabric Color______________________________________200/0.17 2.5 299 slightly yellow190/0.17 2.6 288 white190/0.25 2.9 296 slightly yellow______________________________________
The WRA of an untreated sample of cotton/polyester (50/50 blend) was 257°. From the table it can be seen that there was a significant improvement in WRA at high temperatures for very short periods of time. A curing temperature of 190° C. for about 10 seconds is preferred since a higher temperature or a longer cure time yellowed the fabric slightly.
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Acetals of glyceraldehyde, when applied to cotton fabric by conventional pad-dry-cure procedures using special combined acid catalysts, were found to crosslink the cellulose hydroxyl groups at a very rapid rate (e.g., 10 seconds at 170° C.), thereby imparting improved wrinkle recovery. In particular, the aldehydes studied were the diethyl and dimethyl acetals of glyceraldehyde. The best results were obtained with glyceraldehyde dimethyl acetal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to an improved process wherein aniline is synthesized from phenol over ammonia.
2. Description of the Prior Art
Aniline is an important organic chemical. Many highly useful products can be produced from it. Aniline is the simplest of the primary aromatic amines. Aniline and other aromatic amines can be prepared by several prior art methods, one, for example, is the reduction of nitro compounds obtained by direct nitration of the benzene ring. Important derivatives of aniline include toluidines, xylidenes, n-alkyl, n-aryl and n-acyl derivatives.
Aniline was first produced in 1826 by dry distillation of indigo. Traditionally, it has been prepared by nitrating benzene, then reducing the nitrobenzene with iron and hydrochloric acid such as in the reduction of nitrobenzene with iron filings or borings and 30 percent hydrochloric acid; catalytic reaction of chlorobenzene with aqueous ammonia in the vapor phase and the reduction of nitrobenzene with hydrogen. Also a catalytic (Al 2 O 3 ) process is known wherein the organic amines are obtained by ammoniation of phenolic-type compounds; U.S. Pat. No. 3,860,650. Additionally, phenol can also be subjected to gas phase ammonolysis with the Halcon-Scientific Design process. This process employs high temperatures and high pressures and is catalyzed by catalysts such as alumina-silica and mixtures of manganese-boron oxides and alumina-titania or are combined with additional co-catalysts such as cerium, vanadium or tungsten. Although selectivity in such processes is as high as 90 percent, highly undesirable by-products such as diphenylamine and carbazole are produced. U.S. Pat. No. 3,272,865 is drawn to a method of obtaining high yields of aromatic amines from hydroxybenzenes by catalytic exchange of the hydroxyl group for the amino group in the presence of ammonia. It is also of interest in that it uses silica-alumina, titanium-alumina, zirconia-alumina catalysts plus phosphoric acid and tungsten oxide apparently as co-catalysts.
SUMMARY OF THE INVENTION
In accordance with the present invention, phenol and phenolic-type compounds may be converted to aniline by passing ammonia or suitable amines over ZSM-5 type zeolite catalysts. The process is highlighted by good selectivity to aniline with only minor amounts of undesirable by-products.
DESCRIPTION OF PREFERRED EMBODIMENTS
The phenols in accordance with the present invention may be aminated with ammonia or other suitable amino-type compounds. In this process, by-products such as diphenylamine and carbazole are suppressed or eliminated through use of ZSM-5-type zeolites, by virtue of their shape selectivity. Phenol or any other suitable phenolic compound may be used in accordance with the present invention to produce aniline or substituted anilines such as 2,4,6-tribromoaniline, iodaniline, n-methylaniline or p-toluidine. Ammonia or other suitable amine may be used to convert the phenol to aniline and N-substituted anilines. Suitable amines include primary alkyl amines as methylene, ethylamine, etc., and also such alkyl amines as tertiary-butyl amine.
Process parameters may vary from about 400° to about 1200° F., from about 1-250 atmospheres and from about 0.5 to about 50 LHSV. The phenolic-type compounds and ammonia or a suitable amine may be reacted directly over the ZSM-5 type catalyst, or a suitable solvent such as benzene may be used.
The zeolite catalysts utilized herein are members of a novel class of zeolites exhibiting some unusual properties. The zeolites induce profound transformations of aliphatic hydrocarbons to aromatic hydrocarbons in commercially desirable yields and are generally highly effective in conversion reactions involving aromatic hydrocarbons. Although they have unusually low alumina contents, i.e. high silica to alumina ratios, they are very active even when the silica to alumina ratio exceeds 30. The activity is surprising since catalytic activity is generally attributed to framework aluminum atoms and cations associated with these aluminum atoms. These zeolites retain their crystallinity for long periods in spite of the presence of steam at high temperatures which induces irreversible collapse of the framework for other zeolites, e.g., of the X and A type. Furthermore, carbonaceous deposits, when formed, may be removed by burning at higher than usual temperatures to restore activity. In many environments the zeolites of this class exhibit very low coke forming capability, conducive to very long times on stream between burning regenerations.
An important characteristic of the crystal structure of this class of zeolites is that it provides constrained access to, and egress from the intracrystalline free space by virtue of having a pore dimension greater than about 5 Angstroms and pore windows of about a size such as would be provided by 10-membered rings of oxygen atoms. It is to be understood, of course, that these rings are those formed by the regular disposition of the tetra-hedra making up the anionic framework of the crystalline aluminosilicate, the oxygen atoms themselves being bonded to the silicon or aluminum atoms at the centers of the tetrahedra. Briefly, the preferred type zeolites useful in this invention possess, in combination: a silica to alumina mole ratio of at least about 12; and a structure providing constrained access to the crystalline free space.
The silica to alumina ratio referred to may be determined by conventional analysis. This ratio is meant to represent, as closely as possible, the ratio in the rigid anionic framework of the zeolite crystal and to exclude aluminum in the binder or in cationic or other form within the channels. Although zeolites with a silica to alumina ratio of at least 12 are useful, it is preferred to use zeolites having higher ratios of at least about 30. Such zeolites, after activation, acquire an intracrystalline sorption capacity for normal hexane which is greater than that for water, i.e. they exhibit "hydrophobic" properties. It is believed that this hydrophobic character is advantageous in the present invention.
The type zeolites useful in this invention freely sorb normal hexane and have a pore dimension greater than about 5 Angstroms. In addition, the structure must provide constrained access to larger molecules. It is sometimes possible to judge from a known crystal structure whether such constrained access exists. For example, if the only pore windows in a crystal are formed by 8-membered rings of oxygen atoms, then access by molecules of larger cross-section than normal hexane is excluded and the zeolite is not of the desired type. Windows of 10-membered rings are preferred, although, in some instances, excessive puckering or pore blockage may render the zeolites ineffective.
Rather than attempt to judge from crystal structure whether or not a zeolite possesses the necessary constrained access, a simple determination of the "constraint index" may be made by passing continuously a mixture of an equal weight of normal hexane and 3-methylpentane over a small sample, approximately 1 gram or less, of catalyst at atmospheric pressure according to the following procedure. A sample of the zeolite, in the form of pellets or extrudate, is crushed to a particle size about that of coarse sand and mounted in a glass tube. Prior to testing, the zeolite is treated with a stream of air at 1000° F. for at least 15 minutes. The zeolite is then flushed with helium and the temperature adjusted between 550° F. and 950° F. to give an overall conversion between 10 percent and 60 percent. The mixture of hydrocarbons is passed at 1 liquid hourly space velocity (i.e., 1 volume of liquid hydrocarbon per volume of zeolite per hour) over the zeolite with a helium dilution to give a helium to total hydrocarbon mole ratio of 4:1. After 20 minutes on stream, a sample of the effluent is taken and analyzed, most conveniently by gas chromatography, to determine the fraction remaining unchanged for each of the two hydrocarbons.
The "constraint index" is calculated as follows: ##EQU1##
The constraint index approximates the ratio of the cracking rate constants for the two hydrocarbons. Zeolites suitable for the present invention are those having a constraint index in the approximate range of 1 to 12. Constraint Index (CI) values for some typical zeolites are:
______________________________________CAS C.I.______________________________________ZSM-5 8.3ZSM-11 8.7ZSM-12 2ZSM-38 3ZSM-35 4.5TMA Offretite 3.7Beta 0.6ZSM-4 0.5H--Zeolon 0.4REY 0.4Amorphous Silica-Alumina 0.6Erionite 38______________________________________
It is to be realized that the above constraint index values typically characterize the specified zeolites bu that such are the cumulative result of several variables used in determination and calculation thereof. Thus, for a given zeolite depending on the temperature employed within the aforenoted range of 550° F. to 950° F., with accompanying conversion between 10 percent and 60 percent, the constraint index may vary within the indicated approximate range of 1 to 12. Likewise, other variables such as the crystal size of the zeolite, the presence of possible occluded contaminants and binders intimately combined with the zeolite may affect the constraint index. It will accordingly be understood by those skilled in the art that the constraint index, as utilized herein, while affording a highly useful means for characterizing the zeolites of interest is approximate, taking into consideration the manner of its determination, with probability, in some instances, of compounding variable extremes. However, in all instances, at a temperature within the above-specified range of 550° F. to 950° F., the constraint index will have a value for any given zeolite of interest herein within the approximate range of 1 to 12.
The class of zeolites defined herein is exemplified by ZSM-5, ZSM-11, ZSM-12, ZSM-35, ZSM-38 and other similar materials. U.S. Pat. No. 3,702,886 describing and claiming ZSM-5 is incorporated herein by reference.
ZSM-11 is more particularly described in U.S. Pat. No. 3,709,979, the entire contents of which are incorporated herein by reference.
ZSM-12 is more particularly described in U.S. Pat. No. 3,832,449, the entire contents of which are incorporated herein by reference.
ZSM-38 is more particularly described in U.S. Pat. No. 4,046,859, which is incorporated herein by reference. This zeolite is, in one aspect, identified in the patent in terms of mole ratios of oxides and in the anhydrous state, as follows:
(0.3-2.5)R.sub.2 O:(0-0.8)M.sub.2 O:Al.sub.2 O.sub.3 :>8SiO.sub.2
wherein R is an organic nitrogen-containing cation derived from a 2-(hydroxyalkyl) trialkylammonium compound and M is an alkali metal cation, and is characterized by a specified X-ray pwder diffraction pattern.
In a preferred synthesized form, the zeolite has a formula, in terms of mole ratios of oxides and in the anhydrous state, as follows:
(0.4-2.5)R.sub.2 O:(0-0.6)M.sub.2 O:Al.sub.2 O.sub.3 :>xSiO.sub.2
wherein R is an organic nitrogen-containing cation derived from a 2-hydroxyalkyl) trialkylammonium compound, wherein alkyl is methyl, ethyl or a combination thereof, M is an alkali metal, especially sodium, and x is from greater than 8 to about 50.
The synthetic ZSM-38 zeolite possess a definite distinguishing crystalline structure whose X-ray diffraction pattern shows substantially the significant lines set forth in Table I. It is observed that this X-ray diffraction pattern (significant lines) is similar to that of natural ferrierite with a notable exception being that natural ferrierite patterns exhibit a significant line at 11.33 A.
TABLE I______________________________________d (A) I/Io______________________________________ 9.8 ± 0.20 Strong 9.1 ± 0.19 Medium 8.0 ± 0.16 Weak 7.1 ± 0.14 Medium 6.7 ± 0.14 Medium 6.0 ± 0.12 Weak4.37 ± 0.09 Weak4.23 ± 0.09 Weak4.01 ± 0.08 Very Strong3.81 ± 0.08 Very Strong3.69 ± 0.07 Medium3.57 ± 0.07 Very Strong3.51 ± 0.07 Very Strong3.51 ± 0.07 Very Strong3.34 ± 0.07 Medium3.17 ± 0.06 Strong3.08 ± 0.06 Medium3.00 ± 0.06 Weak2.92 ± 0.06 Medium2.73 ± 0.06 Weak2.66 ± 0.05 Weak2.60 ± 0.05 Weak2.49 ± 0.05 Weak______________________________________
A further characteristic of ZSM-38 is its sorptive capacity providing said zeolite to have increased capacity for 2-methylpentane (with respect to n-hexane sorption by the ratio of n-hexane/2-methylpentane) when compared with a hydrogen form of natural ferrierite resulting from calcination of an ammonium exchanged form. The characteristic sorption ratio n-hexane/2-methylpentane for ZSM-38 (after calcination at 600° C.) is less than 10, whereas that ratio for the natural ferrierite is substantially greater than 10, for example, as high as 34 or higher.
Zeolite ZSM-38 can be suitably prepared by preparing a solution containing sources of an alkali metal oxide, preferably sodium oxide, an organic nitrogen-containing oxide, an oxide of aluminum, an oxide of silicon and water and having a composition, in terms of mole ratios of oxides, falling within the following ranges:
______________________________________R.sup.+ Broad Preferred______________________________________R.sup.+ M.sup.+ 0.2-1.0 0.3-0.9OH.sup.- /SiO.sub.2 0.05-0.5 0.07-0.49H.sub.2 O/OH.sup.- 41-500 100-250SiO.sub.2 /Al.sub.2 O.sub.3 8.8-200 12-60______________________________________
wherein R is an organic nitrogen-containing cation derived from a 2-(hydroxyalkyl) trialkylammonium compound and M is an alkali metal ion, and maintaining the mixture until crystals of the zeolite are formed. (The quantity of OH - is calculated only from the inorganic sources of alkali without any organic base contribution). Thereafter, the crystals are separated from the liquid and recovered. Typical reaction conditions consist of heating the foregoing reaction mixture to a temperature of from about 90° C. to about 400° C. for a period of time of from about 6 hours to about 100 days. A more preferred temperature range is from about 150° C. to about 400° C. with the amount of time at a temperature in such range being from about 6 hours to about 80 days.
The digestion of the gel particles is carried out until crystals form. The solid product is separated from the reaction medium, as by cooling the whole to room temperature, filtering and water washing. The crystalline product is thereafter dried, e.g. at 230° F. for from about 8 to 24 hours.
ZSM-35 is more particularly described in U.S. Pat. No. 4,016,245, all of which is incorporated herein by reference. This zeolite is, in one aspect, identified in the patent in terms of mole ratios of oxides and in the anhydrous state, as follows:
(0.3-2.5)R.sub.2 O:(0-0.8)M.sub.2 0:Al.sub.2 O.sub.3 :>8SiO.sub.2
wherein R is an organic nitrogen-containing cation derived from ethylenediamine or pyrrolidine and M is an alkali metal cation, and is characterized by a specified X-ray powder diffraction pattern.
In a preferred synthesized form the zeolite has a formula, in terms of mole ratios of oxides and in the anhydrous state, as follows:
(0.4-2.5)R.sub.2 O:(0-0.6)M.sub.2 O:Al.sub.2 O.sub.3 :xSiO.sub.2
wherein R is an organic nitrogen-containing cation derived from ethylenediamine or pyrrolidine, M is an alkali metal, especially sodium, and x is from greater than 8 to about 50.
The synthetic ZSM-35 zeolite possess a definite distinguishing crystalline structure whose X-ray diffraction pattern shows substantially the significant lines set forth in Table II. It is observed that this X-ray diffraction pattern (with respect to significant lines) is similar to that of natural ferrierite with a notable exception being that natural ferrierite patterns exhibit a significant line at 11.33 A. Close examination of some individual samples of ZSM-5 may show a very weak line at 11.3-11.5 A. This very weak line, however, is determined not to be a significant line for ZSM-35.
TABLE II______________________________________d (A) I/Io______________________________________9.6 ± 0.2 Very Strong ± Very Very Strong7.10 ± 0.15 Medium6.98 ± 0.14 Medium6.64 ± 0.14 Medium5.78 ± 0.12 Weak5.68 ± 0.12 Weak4.97 ± 0.10 Weak4.58 ± 0.09 Weak4.58 ± 0.09 Weak3.99 ± 0.08 Strong3.94 ± 0.08 Medium Strong3.85 ± 0.08 Medium3.78 ± 0.08 Strong3.74 ± 0.08 Weak3.66 ± 0.07 Medium3.54 ± 0.07 Very Strong3.48 ± 0.07 Very Strong3.39 ± 0.07 Weak3.32 ± 0.07 Weak Medium3.14 ± 0.06 Weak Medium2.90 ± 0.06 Weak2.85 ± 0.06 Weak2.71 ± 0.05 Weak2.65 ± 0.05 Weak2.62 ± 0.05 Weak2.58 ± 0.05 Weak2.54 ± 0.05 Weak2.48 ± 0.05 Weak______________________________________
A further characteristic of ZSM-35 is its sorptive capacity proving said zeolite to have increased capacity for 2-methylpentane (with respect to n-hexane sorption by the ratio n-hexane/2-methylpentane) when compared with a hydrogen form of natural ferrierite resulting from calcination of an ammonium exchanged form. The characteristic sorption ratio n-hexane/2-methylpentane for ZSM-35 (after calcination at 600° C.) is less than 10, whereas that ratio for the natural ferrierite is substantially greater than 10, for example, as high as 34 or higher.
Zeolite ZSM-35 can be suitably prepared by preparing a solution containing sources of an alkali metal oxide, preferably sodium oxide, an organic nitrogen-containing oxide, an oxide of aluminum, an oxide of silicon and water and having a composition, in terms of mole ratios of oxides, falling within the following ranges:
______________________________________R.sup.+ Broad Preferred______________________________________R.sup.++ M.sup.+ 0.2-1.0 0.3-0.9OH.sup.- /SiO.sub.2 0.05-0.5 0.07-0.49H.sub.2 O/OH.sup.- 41-500 100-250SiO.sub.2 /Al.sub.2 O.sub.3 8.8-200 12-60______________________________________
wherein R is an organic nitrogen-containing cation derived from pyrrolidine or ethylenediamine and M is an alkali metal ion, and maintaining the mixture until crystals of the zeolite are formed. (The quantity of OH - is calculated only from the inorganic sources of alkali without any organic base contribution). Thereafter, the crystals are separated from the liquid and recovered. Typical reaction conditions consist of heating the foregoing reaction mixture to a temperature of from about 90° C. to about 400° C. for a period of time of from about 6 hours to about 100 days. A more preferred temperature range is from about 150° C. to about 400° C. with the amount of time at a temperature in such range being from about 6 hours to about 80 days.
The digestion of the gel particles is carried out until crystals form. The solid product is separated from the reaction medium, as by cooling the whole to room temperature, filtering and water washing. The crystalline product is dried, e.g., at 230° F., for from about 8 to 24 hours.
The specific zeolites described, when prepared in the presence of organic cations, are catalytically inactive, possibly because the intracrystalline free space is occupied by organic cations from the forming solution. They may be activated by heating in an inert atmosphere at 1000° F. for one hour, for example, followed by base exchange with ammonium salts followed by calcination at 1000° F. in air. The presence of organic cations in the forming solution may not be absolutely essential to the formation of this type zeolite; however, the presence of these cations does appear to favor the formation of this special type of zeolite. More generally, it is desirable to activate this type catalyst by base exchange with ammonium salts followed by calcination in air at about 1000° F. for from about 15 minutes to about 24 hours.
Natural zeolites may sometimes by converted to this type zeolite catalyst by various activation procedures and other treatments such as base exchange, steaming, alumina extraction and calcination, in combinations. Natural minerals which may be so treated include ferrierite, brewsterite, stilbite, dachiardite, epistilbite, heulandite, and clinoptilolite. The preferred crystalline aluminosilicates are ZSM-5, ZSM-11, ZSM-12, ZSM-38 and ZSM-35, with ZSM-5 particularly preferred.
In a preferred aspect of this invention, the zeolites hereof are selected as those having a crystal framework density, in the dry hydrogen form, of not substantially below about 1.6 grams per cubic centimeter. It has been found that zeolites which satisfy all three of these criteria are most desired because they tend to maximize the production of gasoline boiling range hydrocarbon products. Therefore, the preferred zeolites of this invention are those having a constraint index as defined above of about 1 to about 12, a silica to alumina ratio of at least about 12 and a dried crystal density of not less than about 1.6 grams per cubic centimeter. The dry density for known structures may be calculated from the number of silicon plus aluminum atoms per 1000 cubic Angstroms, as given, e.g., on Page 19 of the article on Zeolite Structure by W. M. Meier. This paper, the entire contents of which are incorporated herein by reference, is included in "Proceedings of the Conference on Molecular Sieves, London, April 1967", published by the Society of Chemical Industry, London, 1968. When the crystal structure is unknown, the crystal framework density may be determined by classical pyknometer techniques. For example, it may be determined by immersing the dry hydrogen form of the zeolite in an organic solvent which is not sorbed by the crystal. It is possible that the unusual sustained activity and stability of this class of zeolites is associated with its high crystal anionic framework density of not less than about 1.6 grams per cubic centimeter. This high density, of course, must be associated with a relatively small amount of free space within the crystal, which might be expected to result in more stable structures. This free space, however, is important as the locus of catalytic activity.
Crystal framework densities of some typical zeolites are:
______________________________________ Void FrameworkZeolite Volume Density______________________________________Ferrierite .28 cc/cc 1.76 g/ccMordenite .28 1.7ZSM-5, -11 .29 1.79Dachiardite .32 1.72L .32 1.61Clinoptilolite .34 1.71Laumontite .34 1.77ZSM-4 (Omega) .38 1.65Heulandite .39 1.69P .41 1.57Offretite .40 1.55Levynite .40 1.55Erionite .35 1.51Gmelinite .44 1.46Chabazite .47 1.45A .5 1.3Y .48 1.27______________________________________
When synthesized in the alkali metal from, the zeolite is conveniently converted to the hydrogen form, generally by intermediate formation of the ammonium form as a result of ammonium ion exchange and calcination of the ammonium form to yield the hydrogen form. In addition to the hydrogen form, other forms of the zeolite wherein the original alkali metal has been reduced to less than about 1.5 percent by weight may be replaced by ion exchange with other suitable ions of Groups IB to VIII of the Periodic Table, including, by way of example, nickel, copper, zinc, palladium, calcium or rare earth metals.
In practicing the desired conversion process, it may be desirable to incorporate the above described crystalline aluminosilicate zeolite in another material resistant to the temperature and other conditions employed in the process. Such matrix materials include synthetic or naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Naturally occurring clays which can be composited with the zeolite include those of the montmorillonite and kaolin families, which families include the sub-bentonites and the kaolins commonly known as Dixie, McNamee-Georgia and Florida clays or others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification.
In addition to the foregoing materials, the zeolites employed herein may be composited with a porous matrix material, such as alumina, silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-berylia, silica-titania as well as ternary compositions, such as silica-alumina-thoria, silica-alumina-zirconia, silica-alumina-magnesia and silica-magnesia-zirconia. The matrix may be in the form of a cogel. The relative proportions of zeolite component and inorganic oxide gel matrix may vary widely with the zeolite content ranging from between about 1 to about 99 percent by weight and more usually in the range of about 5 to about 80 percent weight of the composite. Indications are that the catalyst will show very slow aging in this configuration.
The following examples are meant in no way to limit the invention.
EXAMPLE 1
Phenol (94 g) and NH 3 (34 g) were reacted over HZSM-5 at 950° F., 5.3 atm., and 1 LHSV. The conversion of phenol was 70 percent. The products consisted of aniline with only slight traces of diphenylamine, less than 3 percent of other products and no detectable carbazole.
It is clear from these data that the process of the present invention produces an essentially pure product and that unwanted by-products are suppressed or substantially eliminated.
EXAMPLE II
A charge stock comprising 75 percent phenol in benzene was fed (4 cc/hr.) along with liquid NH 3 (7.5 cc/hr.) over 6 cc of the zeolite H-mordenite at 950° F. and 400 psig. The conversion of phenol was 96 percent in the first half hour, but dropped to 75 percent after 11/2 hours. Product selectivities are compared with results from HZSM-5 under similar reaction conditions in the following table:
______________________________________ HZSM-5 H--Mordenite______________________________________Time on stream, hr. 8 0.5 1.5Conversion, wt. percent 92.4 96.0 74.9Selectivity, wt. percentAniline 99.6 95.8 99.2Diphenylamine 0.2 0.6 0.2Carbazole 0.1 0.5 0.3Tars, etc. 0.1 3.1 0.3 100.0 100.0 100.0______________________________________
It is clear from the data of this example that HZSM-5 is much more stable toward aging than H-mordenite, and that at high conversions HZSM-5 shows superior selectivity.
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A process for converting phenolic compounds to aniline by passing them over ammonia in the presence of ZSM-5 type zeolites under conversion conditions whereby high conversion, high selectivity and improved rates of production are achieved.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to excavation machines. Specifically, the present invention relates to a mounting arrangement for cutting teeth for use with trencher chains.
BACKGROUND OF THE INVENTION
[0002] Trenchers are conventionally used to dig lengths of trenches for laying underground pipe and cable. Most trenchers include a tractor unit equipped with an elongated boom. The boom is typically movable between a raised, generally horizontal position, and a lowered, substantially vertical position. The boom typically includes a cutting chain that is entrained about the boom. The chain generally includes exterior teeth or cutters for engaging the soil. Trenchers also commonly include a conveyer assembly for transporting the soil this is excavated by the chain.
[0003] There are various types of cutting teeth or attachments that are commonly bolted to a trencher digging chain. Exemplary cutters are disclosed in U.S. Pat. No. 3,022,588 to Brown and U.S. Pat. No 6,154,987 to Rumer et al. Looking at the mounting arrangements disclosed in these two references: the '588 reference discloses a cup cutter having a leading edge and a cupped portion for scooping loose material from a trench. The cup cutters are mounted on headed projections that extend from the side plates of the chain wherein the cutters have keyhole shaped openings that engage with the projections for securing the cutters to the chain. This design does not require the projections to be removed from the chain to repair the cutters. However, this design does not hold the cutters securely, the components are relatively delicate, and relatively expensive to manufacture. The '987 reference discloses cutting teeth that are designed for cutting very compacted soils, gravel or rock and are mounted onto the digger chain by a more robust standard nut and bolt combination.
[0004] Cutters, such as the cutters disclosed in the '588 and '987 patents, work effectively in a variety of digging conditions. The cup cutters disclosed in the '588 patent work well in relatively soft soils while the cutters disclosed in the '987 patent are intended for conditions wherein very abrasive materials are being trenched, including solid rock and loose rock conditions. In the harder digging conditions the cutters are subjected to higher loads and need to be mounted in a robust fashion. In those same conditions the cutters wear quickly and as a result the digging chain assembly needs frequent maintenance. The more robust mounting arrangement, as disclosed in the '987 patent, subjects the mounting bolts to potential wear. This wear on the mounting hardware typically results in difficulties engaging a tool with the mounting hardware and as a result the chain assembly becomes difficult, time consuming and expensive to repair. Cutters used in the more demanding applications are typically mounted as shown in the '987 patent and operators are confronted with the difficulty of properly maintaining them due to the wear of the mounting hardware.
[0005] In these more demanding conditions the loads on the components of the chain assemblies increase and the structural integrity of those components becomes more critical. As a result the specific shapes and the material selected for the components becomes critical. During development and testing of this invention many different combinations of both shapes and materials were tested. A satisfactory combination has been identified, as set forth in the description that follows.
SUMMARY OF THE INVENTION
[0006] One aspect of the present invention relates to a cutting tooth for a trencher chain. A cutting tooth includes a base portion aligned along a first plane. The base portion includes means for allowing the cutting tooth to be connected to the trencher chain. The cutting tooth further includes a pocket that cooperates with the mounting means, the pocket being located opposite from the first plane.
[0007] Another aspect of the present invention relates to a trenching or digging chain assembly for use with a trencher. The chain assembly includes a plurality of sidebars aligned along a longitudinal centerline. The trencher chain also includes a plurality of rollers substantially permanently interconnecting the sidebars. The rollers are aligned along a lateral dimension that is transverse with respect to the longitudinal centerline. The chain further includes a plurality side mounting plates, these side mounting plates being substantially permanently interconnected with the rollers and sidebars. The chain further includes a plurality of cutting teeth that are fixedly mounted to the side mounting plates such that they can be removed for service. The cutting teeth include a physical feature that provides the mounting hardware with protection from wear that results from contact with the soils being excavated, yet does not interfere with installation tools required to secure the mounting hardware.
[0008] A variety of advantages of the invention will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practicing the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate several aspects of the invention and together with the description, serve to explain the principles of the invention. A brief description of the drawings is as follows:
[0010] [0010]FIG. 1 shows a side view of a trencher;
[0011] [0011]FIG. 2 shows a schematic diagram of the components of the trencher of FIG. 1;
[0012] [0012]FIG. 3 shows a perspective view of a prior art trencher chain assembly;
[0013] [0013]FIG. 4 shows a cross-section of the prior art chain assembly taken along line 4 - 4 of FIG. 3 with a cutting tooth mounted in a first position;
[0014] [0014]FIG. 5 shows a cross-section of the prior art chain assembly taken along line 5 - 5 of FIG. 3 with a cutting tooth mounted in a second position;
[0015] [0015]FIG. 6 shows a cross-section of the prior art chain assembly taken along line 6 - 6 of FIG. 3 with a cutting tooth mounted in a second position;
[0016] [0016]FIG. 7 shows a perspective view of trencher chain assembly using the principles of the present invention;
[0017] [0017]FIG. 8 shows a cross-section of a chain assembly taken along line 8 - 8 of FIG. 7 with a cutting tooth mounted in a first position;
[0018] [0018]FIG. 9 shows a cross-section of a chain assembly taken along line 9 - 9 of FIG. 7 with a cutting tooth mounted in a second position;
[0019] [0019]FIG. 10 shows a cross-section of a chain assembly taken along line 10 - 10 of FIG. 7 with a cutting tooth mounted in a third position;
[0020] [0020]FIG. 11 shows a perspective view of a cutting tooth with the principles of the invention;
[0021] [0021]FIG. 12 shows a perspective view of an alternative embodiment of a trencher chain assembly with the principles of the invention;
[0022] [0022]FIG. 13 shows a side elevational view of an alternate embodiment of the cutting tooth; and
[0023] [0023]FIG. 14 shows a side elevational view of an alternate embodiment of the cutting tooth
[0024] [0024]FIG. 15 shows a perspective view of an alternate embodiment of the trencher chain assembly with cup cutters installed
[0025] [0025]FIG. 16 shows a perspective view of a detailed drawing of the cup cutter with the principles of the invention;
[0026] [0026]FIG. 17. shows a perspective view of a detailed drawing of an alternate cutter with the principles of the invention.
DETAILED DESCRIPTION
[0027] Reference will now be made in detail to the prior art and to exemplary aspects of the present invention that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Prior Art
[0028] [0028]FIGS. 1 and 2 show an exemplary trencher 15 . The trencher 15 includes an engine 17 coupled to a right track drive 18 and a left track drive 20 , which together form a tractor portion 22 of the trencher 15 . A boom 24 is pivotally coupled to the tractor portion 22 . A digger chain 26 is mounted on the boom 24 . The chain 26 is driven around the boom 24 by a chain drive mechanism 23 powered by the engine 17 . The boom 24 is pivotally movable between a substantially horizontal transport configuration 25 , and a substantially vertical trenching configuration 27 .
[0029] When maneuvering the trencher 15 around the work site, the boom 24 is maintained in the transport configuration 25 such that the chain 26 generally remains above the ground. To excavate a trench, the boom 24 is lowered toward the trenching configuration 27 and the chain 26 is driven around the boom 24 . When the chain 26 contacts the ground, cutting teeth of the chain 26 penetrate the ground and begin to excavate a trench. Once the boom 24 reaches the trenching configuration 27 , the tracks 18 and 20 are engaged causing the tractor 22 to creep forward. The chain 26 digs the trench and removes loose geologic material from the trench as the tractor 22 creeps forward.
[0030] The trencher 15 is being disclosed exclusively for the purpose of illustrating an exemplary environment in which the various aspects of the present invention can be applied. It will be appreciated that the variety of trenchers are known in the art, and that the various aspects of the present invention can be applied or used in association with any type of trenching device.
[0031] FIGS. 3 - 6 Illustrate a digging chain assembly 70 constructed in accordance with the prior art. The chain assembly 70 includes a base chain sub assembly that includes a plurality of rollers 74 , side bars 72 , side mounting plates 76 , and rivets 78 . The majority of these components are semi-permanently interconnected: the rivets 78 are typically upset or swaged such that the outer diameter of the portion extending through or beyond the side mounting plates 76 is bigger than the hole in the side mounting plates 76 . In this manner the rivets 78 are effectively connected to the side mounting plates 76 . Each chain assembly typically includes one connector link that includes one side bar 76 , 2 rivets that are semi-permanently connected to the side bar including cross holes for pass-through retainers or grooves for a snap ring or snap connector. This connector link is removable from the assembly and is used to form a continuous chain assembly that is wrapped around the desired sprockets. It is installed into the holes through the sidebars, and through the rollers on each end of the chain, and then a side mounting plate 76 is installed on the rivets and pass through retainers or a snap connector installed onto the rivets, after the chain sub assembly is properly installed onto the sprockets.
[0032] This base chain sub assembly is repairable, but is not typically to be repaired in the field. Due to the mounting arrangement of the rivets 78 they do not substantially extend beyond the plane of the outside surface of the side mounting plates 76 and are typically not subjected to wear as the other components, as will now be explained. For the purpose of this invention this sub assembly, with the exception of the connector link, is considered to be permanently assembled.
[0033] The chain assembly as seen in FIG. 3 also includes tube spacers 82 , mounting bolts 80 , nuts 96 , washers 94 and cutting teeth 84 , 86 , 88 , 90 , and 92 . FIG. 3 shows a section of the chain assembly 70 with the components assembled and the teeth arranged in one of many possible patterns. The pattern includes both externally mounted cutting teeth 88 and 90 as shown in FIGS. 5 and 6 and internally mounted cutting teeth 86 as seen in FIG. 4. Long tube spacers 82 L are used for the externally mounted cutting teeth and short spacer tubes 82 S are used with internally mounted cutting teeth. The teeth, which can be designed with many different shapes and characteristics, can be arranged in a wide variety of patterns to provide unique cutting characteristics as required by the type of soil being trenched, or the width of the desired trench. The cutting teeth include a base portion with a first flat mounting surface 98 and a second flat mounting surface 100 opposite the first, and a hole through which the mounting bolts 80 can pass. The head of the mounting bolt 80 cooperates with the second mounting surface 100 of the cutting tooth. In these figures there is shown an optional washer 94 mounted between the head of the mounting bolt 80 and the second mounting surface 100 of the base portion of the cutting tooth. As shown in FIG. 4 the shape of the cutting tooth is typically curved away from the first mounting surface 98 . The type of cutting tooth or pattern in which they are installed on the base chain assembly, is not a part of this invention, the invention being applicable in all the possible configurations as will be understood by one skilled in this technology.
[0034] [0034]FIGS. 4, 5, and 6 illustrate the prior art assembly and the interaction of various cross-sections of the chain assembly. Plane 1 , on both the left and right sides is defined by the outer most surface of the side mounting plates 76 . Anything that is located between Planes 1 L and 1 R will be substantially protected from excessive wear by the side mounting plates 76 .
[0035] Plane 2 , on both the left and right sides, is defined by the second mounting surface 100 of the base portion of the externally mounted cutting teeth 88 , or 90 . In this manner the second mounting surface 100 of the cutting teeth serves as a wear surface when the cutting teeth are externally mounted. It is found, in actual use, that anything that is located between Planes 2 L and 2 R will be substantially protected from excessive wear by these surfaces of the cutting teeth. For instance nut 96 in FIG. 5 or FIG. 6 will be substantially protected and they typically do not experience excessive wear.
[0036] Plane 3 , on both the left and right sides, is defined by the plane passing through the outer-most surface of the head of bolt 80 . The head of bolt 80 is the only material in that plane. The result is that the head of bolt 80 in that position experiences excessive wear. When the bolt head wears significantly it becomes impossible to get a wrench to properly engage with the bolt head, and it becomes impossible to disassemble the chain assembly with standard, non-destructive tools.
Best Modes
[0037] FIGS. 7 - 10 illustrate a digging chain assembly 70 constructed in accordance with the current invention. The chain assembly 70 includes a base chain sub assembly that is considered to be permanently assembled as described previously as related to the prior art shown in FIGS. 1 - 6 . The remaining components of the chain assembly are also similar to those described in the prior art FIGS. 1 - 6 with the following exceptions.
[0038] The cutting teeth have been modified to include a void 102 that is formed by removal of a portion of the second mounting surface 100 . This void 102 is designed such that it is defined by a fastener engaging surface 104 of the base portion of the cutting tooth that is between the second mounting surface 100 and the first mounting surface 98 . It is also defined by a surface of variable shape, a side 106 , also part of the base portion of the cutting tooth. This shape is designed to minimize the amount of material removed from the base portion of the cutting tooth, and the resultant stress level seen in the tooth upon loading in actual use.
[0039] As a result of the addition of this void 102 , the head of the mounting bolts 80 is substantially located between Plane 2 L and Plane 2 R, as described in relation to prior art FIGS. 4 - 6 . These results in the heads of bolts 80 being protected from excessive wear by the second mounting surface 100 of the base portion of the cutting teeth.
[0040] [0040]FIG. 7 illustrates the complete assembly. Due to the loading conditions on the cutting teeth, the selection of fasteners as well as the shape of the void are important details. The FIG. 7 and FIG. 11 illustrate a preferred embodiment of the invention wherein the fastener is a standard hex-headed bolt 80 and hex nut 96 . The void 102 is a counterbore wherein the diameter of the counterbore is sufficient to allow a standard socket that fits on the head of the bolt 80 or the cooperating hex nut 96 to be inserted for full engagement.
[0041] The choice of a standard hex-headed bolt 80 is made to assure availability of a wide selection of bolt lengths and materials. As can be seen by comparing FIG. 8 with FIG. 9 the bolt 80 needs to be of different lengths to accommodate externally mounted or internally mounted cutting teeth. In addition it is possible to mount a cutting tooth on both sides of the base chain. This is not illustrated, but it is clear that this arrangement would require a slightly longer bolt.
[0042] The selection of the counterbore 102 of tooth 188 as illustrated in FIG. 11 is made to minimize manufacturing cost, to maximize strength, and maximize flexibility. This type of configuration, including a hole 101 and a counterbore or void 102 , can typically be manufactured in one process with a specialized drilling tool, minimizing cost. This design can also be used in either single internal or external mounts as illustrated in FIGS. 8 - 10 . It can also be used in a double external mount not illustrated, wherein the head of the bolt 80 will be within the void 102 on one side and the cooperating nut 96 will be within the void 102 on the opposite side.
[0043] [0043]FIG. 12 illustrates an alternate embodiment of the assembly wherein the bolt 80 has been changed from a standard hex headed bolt to a countersunk head bolt 80 with the mating void 102 in the cutting tooth base being correspondingly changed to a countersink. This figure also illustrates dual mounts, an assembly designed with cutting teeth specifically designed as dual mount teeth with alternating counterbored voids for engagement with a nut 96 and countersunk voids 102 for engagement with the countersunk head of the bolt 80 . The cutting teeth used for single external mount applications will have exclusively countersunk voids 102 for engagement with the countersunk head of the bolt 80 .
[0044] [0044]FIGS. 13 and 14 Illustrate alternate embodiments wherein the voids in teeth 288 and 388 are a closed slot 202 and an open slot 302 . The slot 202 surrounds hole 201 . Both of these embodiments can be designed such that the width of the slot 202 , 302 is equal to the width across flats of the bolt head selected. This results in the slot 202 , 302 acting to hold the bolt from rotating, and installation requires simple insertion of the bolt into the slot 202 , 302 with subsequent tightening of the nut 96 against the side mounting plate on the opposite side. This type of configuration is typically more difficult and more costly to manufacture than the embodiment of FIGS. 7 - 11 .
[0045] [0045]FIG. 15 illustrates a digging chain assembly 70 constructed in accordance with the present invention with cup cutters 170 . FIG. 16 Illustrates a cup cutter constructed in accordance with the present invention. FIG. 17 illustrates another type of cutter 180 , known as a rotary cutter, constructed in accordance with the present invention.
[0046] The nut 96 and bolt 80 is the preferred type of fastener for the present invention but other fasteners may be substituted for these nut and bolt fasteners.
[0047] With regard to the foregoing description, it is to be understood that changes may be made in detail, especially in matters of the construction materials employed and the size, shape and arrangement of the parts with departing from the scope of the present invention. It is intended that the specification and the depicted aspects be considered exemplary only, with a true scope and spirit of the invention being indicated by the broad meaning of the following claims.
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The present disclosure relates to a mounting arrangement for a cutting tooth for a trencher chain. The tooth includes a base portion aligned along a first plane. The base portion includes structure for allowing the cutting tooth to be connected to the trencher chain. The tooth also includes a distal portion that is generally obliquely aligned with respect to the first plane. A curved transition is located between the distal portion and the base portion. The curved transition curves away from the first plane and at least partially forms a cupped portion that is effective in the trenching operation. The base portion also includes a recess into which the mounting hardware can fit, to protect the mounting hardware from wear.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to compositions that are able to provide an abrasion-resistant, dye-tintable coating on a thermoplastic or thermoset polymeric substrate, such as an ophthalmic lens.
2. Background of the Art
It is known that transparent plastic materials such as polycarbonate ophthalmic lenses or screen face plates are subject to becoming dull and hazy due to scratching and abrasion during use.
Attempts have been made to overcome this problem. The technical solutions proposed in the past, which involved applying a UV-curable coating, generally used an organic or aqueous solvent-borne composition which was usually substrate-dependent. That is, the coating compositions were formulated for one specific ophthalmic lens material such as CR-39 (an allyl diglycol carbonate) or thermoplastics such as polycarbonate. The few compositions found in the literature that were solvent-free or substantially organic solvent-free were substrate-dependent. They also usually contained a partially hydrolyzed or fully hydrolyzed silane used both for adhesion and for abrasion resistance.
Moreover, coatings for ophthalmic lenses should also be capable of being tinted by incorporating a dye therein. However, abrasion and scratch resistance, on the one hand, and tintability, on the other hand, are often regarded as hardly parallel properties. Among the solutions proposed to reconcile these properties, U.S. Pat. No. 5,614,321 suggests a curable coating composition comprising colloidal silica, together with a (meth)acrylate compound capable of reacting with said silica, a monomer (preferably an alkoxysilane) bearing (meth)acryloxy groups, a free radical initiator and an organic tintability additive.
US 2002/0193479 teaches a composition comprising both a hydrolyzed and a non-hydrolyzed epoxy-functional alkoxy silane, together with a curing agent and an acrylic monomer preferably bearing not more than two acrylic functions.
Similarly U.S. Pat. No. 6,100,313 (Treadway) discloses a composition comprising an epoxy-functional alkoxysilane, a glycidyl ether, a cationic photoinitiator, an acrylic monomer and a free-radical photoinitiator. It is purported to be solvent-free, but an analysis of the carrier materials and solvents in photoinitiators added indicate a significantly high level or organic solvents.
U.S. Pat. No. 8,033,663 (Valeri) discloses a curable coating composition includes: a) at least one monomer chosen from polyol poly(meth)acrylate monomers having from 3 to 6 (meth)acrylate functions, b) at least one monomer chosen from polyol polyglycidyl ethers having at least three epoxy functions, c) at least one difunctional monomer, d) at least one free-radical photoinitiator, and e) at least one cationic photo-initiator, wherein the molar ratio of acrylate equivalents to epoxy equivalents in the composition ranges from 3:1 to 4:1, and wherein the composition is free of silica and of monomers bearing a silane function. The patent discloses a method for coating a substrate, such as an ophthalmic lens, with this composition, and the coating substrate thus obtained. It is asserted that the coating composition is more stable than the alkoxysilane compositions. However, acryolyl curable compositions are also moisture-sensitive and can produce less abrasive compositions if moisture is introduced into the reaction mixture, even from the air.
It is difficult to find rapidly curing compositions that are relatively stable in a pot during coating operations, provide good abrasion resistance, and then remain dye-tintable, e.g., exhibiting less than 15% transmission to white light after immersion for 15-20 minutes at 90-100° C. in an approximately 5% by weight aqueous solution of a black azo dye such as azo dye Sudan black:
or an anthroquinone dye such as Alizarin blue-black (further identified as CAS Number 1324-21-6 Molecular Formula C 26 H 16 N 2 O 9 S 2 Na 2 , Molecular Weight 610.5, Color Index 63615, EC Number 215-366-9).
BFI Black, manufactured by Brainpower, Inc. of Miami, Fla. has become a standard black tint dye in the ophthalmic industry and would be preferably used for the tint test.
To perform a tinted coating, the surface of the substrate coated with the cured resin matrix of the invention is contacted by a suitable colored dye, in many instances, any commercially viable method of applying the dye may be utilized. The leading manufacturer of suitable dyes is Brainpower, Inc. (BPI) and the usual procedure in tinting follows BPI instructions. In a typical tinting operation the surface of a substrate coated with a cured coating of the present invention is immersed in a heated aqueous dye bath (typically between 90-100° C., usually between 92-98° C.) containing a suitable colored dye, e.g., BPI Sun Black, a molecular catalytic dye sold by BPI of Miami, Fla. The dye solution may be prepared by diluting one part of BPI dye concentration to ten parts water, and then heating the resulting solution to a temperature in the range of about 190° to 212° F. while constantly stirring the solution. The coated surface of the substrate is preferably cleaned by wiping with a compatible solvent prior to immersion in the dye bath at about 90-100° C. for a period of time sufficient to absorb or transmit the desired amount of dye (typically 15-20 minutes), then washed with tap water to remove the excess dye and blown dry with nitrogen. The intensity of the tint can be adjusted by varying the concentration of any organic tintability additive in the coating composition, the thickness of the coating, the time of immersion, or the thickness of the coating. The degree of tint obtained can be determined by using a calorimeter, such as a Gardner XL-835 colorimeter, which measures the percent of light transmittance.
Tintability Test
The percent light transmittance of the samples was determined using a Gardner Haze Meter Model 835 colorimeter with a wavelength range of 600 nanometers. Lexan® (polycarbonate from General Electric Company, Schenectady, N.Y. or any commercial CR-39 polycarbonate), was used as a reference sample and substrate. The percent light transmittance of the uncoated polycarbonate is about 86.9%. The coating compositions were applied to the polycarbonate or other substrate and the percent light transmittance was determined as a direct reading from the meter. For tinted samples, the coated sample was immersed in the dye bath rinsed in cold tap water and blown dry with nitrogen. The formulations of the comparative examples were coated on panels, cured and the coated panels immersed in a 9% tint bath (BPI Black) maintained at 90-100° C. for 15 minutes. The process may also be used with some photochromic dyes including spiro-naphthoxazines, naphthopyrans, anthraquinones, phthalocyanines, spiro-oxazines, chromenes, pyrans, fulgicides and mixtures thereof. Reversacol™ photochromic dyes are available from James Robinson Ltd. (UK) and several of these dyes are listed in the examples below. Permanent dyes can be any permanent dye. Preferred permanent dyes are those that are soluble in the curable material. Permanent dyes include BPI dyes from Brain Power, Inc. (USA) such as BPI Gray and BPI Black. Sigma Aldrich offers a line of permanent dyes such as Solvent Blue, Solvent Black, Solvent Yellow, Solvent Red and Solvent Orange dyes. Preferred dyes include Solvent Black 3, Solvent Black 5, Solvent Black 7, Solvent Blue 43, Solvent Blue 35, Solvent Blue 59, Solvent Blue 14, Solvent Blue 37, Solvent Green 3 and Solvent Red 24. A particularly preferred dye is Solvent Blue 35.
When adding the dye to the curable material (to mask the slight yellow color that some polymers exhibit), a purple or blue dye may be added to the curable material in amounts to mask the yellowness but also in amounts that do not turn the polymer a noticeable blue. A neutral color is desired. In the case of dyes (such as black tinting dyes or Solvent Blue 35 dye) a suitable amount of dye in the curable material is from about 0.0007 wt % to about 0.0020 wt % and preferably from about 0.0010 wt % to about 0.0015 wt % of the total coating. A particularly preferred amount of dye in the curable material is about 0.0008-0.0015%, such as 0.0012 wt %. When adding the dye for tinting for use as sunglasses then the dyes are also added in amounts that aesthetically or cosmetically desirable. Typical classes of dyes include:
Chemical class
C.I. Constitution numbers
Monoazo
1000-19999
Azine
50000-50999
Disazo
20000-29999
Oxazine
51000-51999
Triazo
30000-34999
Thiazine
52000-52999
Polyazo
35000-36999
Sulphur
53000-54999
It is believed that within these classes, Disazo, and Triazo dyes are preferred. Other dyes that have been considered are those typically used as dye classes for fibers.
Dye class
Fiber type
Fixation degree,
% Loss in effluent
Acid
Polyamide
80-95
5-20
Basic
Acrylic
95-100
0-5
Direct
Cellulose
0-95
5-30
Disperse
Polyester
90-100
0-10
Metal complex
Wool
0-98
2-10
Reactive
Cellulose
50-90
10-50
Sulphur
Cellulose
60-90
10-40
Dye-stuff
Cellulose
80-95
5-20
SUMMARY OF THE INVENTION
A coating photoreactive composition comprising a hydrolyzed epoxysilane and other active ingredients is able to provide an organic dye-tintable abrasion resistant coating without the use of traditional dye-tinting enhancing agents such as (e.g., open-chain) polymerizable ethers or polymerizable diethers. The compositions exhibit consistently higher abrasion resistance without significant impact on tintability.
A hydrolyzed epoxy-silane composition, silica (or equivalent inorganic oxide particles), dialkyl acrylate, tetrahydrofuryl acrylate, a combination of cationic and anionic initiators, urethane acrylate, a low level or optional silicone acrylate, hindered alkyl-bis-phenol stabilizer or a hindered amine stabilizer.
DETAILED DESCRIPTION OF THE INVENTION
The compositions of the present technology accomplish the task of providing good tintability after curing and abrasion resistance with compositions that comprise:
A hydrolyzed epoxy-silane composition, silica (or equivalent inorganic oxide particles), dialkyl acrylate, tetrahydrofuryl acrylate, a combination of cationic and anionic initiators, urethane acrylate, a low level or optional silicone acrylate, a stabilizer for reducing photodegradation of the cured composition (e.g., hindered alkyl-bis-phenol stabilizer).
A coating composition for application to polymeric surfaces to provide cured organic dye-tintable abrasion resistant coatings, the composition may include, for example, in weight percent portions:
at least 30% of silane group hydrolyzed epoxy-silane
25-85%
inorganic oxide particles
6-20%
dialkyl (C-3 to C-5 alkyl) acrylate
10-30%
tetrahydrofuryl acrylate
5-16%
cationic photoinitator
1.0-5%
anionic initiators
2.5-9%
urethane acrylate
3-15%
silicone acrylate
0-5%
hindered alkyl-bis-phenol stabilizer
0.5-5%.
or hindered amine stabilizer
The compositions generally comprise ingredients that may include, by total weight of the coating composition:
Percent by Weight
GENESIS COMPONENT
(excluding solvents)
hydrolyzed epoxy-silane composition
25-85%
(30-80% hydrolyzed)
inorganic oxide particles (e.g., silica, titania, etc.)
6-20%
dialkyl (C-3 to C-5 alkyl) acrylate
10-30%
tetrahydrofuryl acrylate
5-16%
cationic photoinitator
1.0-5%
anionic photoinitiator or thermal initiators
2.5-9%
urethane acrylate
3-15%
a low level or optional silicone acrylate
0-5%
hindered alkyl-bis-phenol stabilizer
0.5-5%
or hindered amine stabilizer
Many epoxy-functional alkoxysilanes are suitable, but not limited to, compounds such as hydrolysis precursors, including (where a- is alpha, b- is beta, g- is gamma, and d- is delta) γ-glycidoxymethyl-trimethoxysilane, glycidoxymethyltriethoxysilane, glycidoxymethyl-tripropoxysilane, glycidoxymethyl-tributoxysilane, b-glycidoxyethyltrimethoxysilane, b-glycidoxyethyltriethoxysilane, b-glycidoxyethyl-tripropoxysilane, b-glycidoxyethyl-tributoxysilane, b-glycidoxyethyltrimethoxysilane, a-glycidoxyethyl-triethoxysilane, a-glycidoxyethyl-tripropoxysilane, a-glycidoxyethyltributoxysilane, g-glycidoxypropyl-trimethoxysilane, g-glycidoxypropyl-triethoxysilane, g-glycidoxypropyl-tripropoxysilane, g-glycidoxypropyltributoxysilane, b-glycidoxypropyl-trimethoxysilane, b-glycidoxypropyl-triethoxysilane, b-glycidoxypropyl-tripropoxysilane, b-glycidoxypropyltributoxysilane, a-glycidoxypropyl-trimethoxysilane, a-glycidoxypropyl-triethoxysilane, a-glycidoxypropyl-tripropoxysilane, a-glycidoxypropyltributoxysilane, g-glycidoxybutyl-trimethoxysilane, d-glycidoxybutyl-triethoxysilane, d-glycidoxybutyl-tripropoxysilane, d-glycidoxybutyl-tributoxysilane, d-glycidoxybutyl-trimethoxysilane, g-glycidoxybutyl-triethoxysilane, g-glycidoxybutyl-tripropoxysilane, g-propoxybutyl-tributoxysilane, d-glycidoxybutyl-trimethoxysilane, d-glycidoxybutyl-triethoxysilane, d-glycidoxybutyl-tripropoxysilane, a-glycidoxybutyl-trimethoxysilane, a-glycidoxybutyl-triethoxysilane, a-glycidoxybutyl-tripropoxysilane, a-glycidoxybutyl-tributoxysilane, (3,4-epoxycyclohexyl)-methyl-trimethoxysilane, (3,4-epoxycyclohexyl)methyl-triethoxysilane, (3,4-epoxycyclohexyl)methyl-tripropoxysilane, (3,4-epoxycyclohexyl)-methyl-tributoxysilane, (3,4-epoxycyclohexyl)ethyl-triethoxysilane, (3,4-epoxycyclohexyl)ethyl-triethoxysilane, (3,4-epoxycyclohexyl)ethyl-tripropoxysilane, (3,4-epoxycyclohexyl)-ethyl-tributoxysilane, (3,4-epoxycyclohexyl)propyl-trimethoxysilane, (3,4-epoxycyclohexyl)propyl-triethoxysilane, (3,4-epoxycyclohexyl)propyl-tripropoxysilane, (3,4-epoxycyclohexyl)propyl-tributoxysilane, (3,4-epoxycyclohexyl)butyl-trimethoxysilane, (3,4-epoxycyclohexy)butyl-triethoxysilane, (3,4-epoxycyclohexyl)-butyl-tripropoxysilane, and (3,4-epoxycyclohexyl)butyl-tributoxysilane. The attachment of these groups without a-, b-, d- or g- indicated may be any one of those positions.
The composition is most conveniently formed by first hydrolyzing the epoxy-silane, such as γ-glycidoxy-propyl-trimethoxysilane with water and then extracting the resultant alcohol (e.g., methanol, ethanol, etc.) derived from the removed alkoxy group. This is a well understood process in the chemical arts. (e.g., see U.S. Pat. Nos. 3,961,977; 4,167,537; 4,241,116; 4,196,014; 6,100,313 (Treadway); U.S. Pat. No. 6,821,657 (Takahashi); and U.S. Pat. No. 7,732,006 (de Rojas)). The compositions of the present technology may be formulated and used commercially with less than 15% by total weight of non-reactive (in the epoxy, silane or acrylic reactions) solvents such as propylene carbonate or ethylene carbonate, tetrahydrofuran, polyethylene glycol, alcohols and the like. It is preferred that such organic solvents, which may be present and carried into the formulations with the initiators, which are often provided in solution form with solvents, are present as less than 10% by weight of the total coating composition. It is more preferred that such organic solvents are present as less than 5% of the total weight, less than 4% of the total weight of the coating composition, or at a weight level provided only by amounts of solvent carried by initiator compositions (which although used in relatively small absolute amounts, often contain as much as 50% by weight of solvent as carrier).
Useful cationic initiators for the purposes of this invention include the aromatic onium salts, including salts of Group Va elements, such as phosphonium salts, e.g., triphenyl phenacylphosphonium hexafluorophosphate, salts of Group VIa elements, such as sulfonium salts, e.g., triphenylsulfonium tetrafluoroborate, triphenylsulfonium hexafluorophosphate and triphenylsulfonium hexafluoroantimonate, and salts of Group VIIa elements, such as iodonium salts, e.g., diphenyliodonium chloride. The aromatic onium salts and their use as cationic initiators in the polymerization of epoxy compounds are described in detail in U.S. Pat. No. 4,058,401, “Photocurable Compositions Containing Group VIA Aromatic Onium Salts,” by J. V. Crivello issued Nov. 15, 1977; U.S. Pat. No. 4,069,055, “Photocurable Epoxy Compositions Containing Group VA Onium Salts,” by J. V. Crivello issued Jan. 17, 1978; U.S. Pat. No. 4,101,513, “Catalyst For Condensation Of Hydrolyzable Silanes And Storage Stable Compositions Thereof,” by F. J. Fox et al. issued Jul. 18, 1978; and U.S. Pat. No. 4,161,478, “Photoinitiators,” by J. V. Crivello issued Jul. 17, 1979, the disclosures of which are incorporated herein by reference. Other cationic initiators can also be used in addition to those referred to above; for example, the phenyldiazonium hexafluorophosphates containing alkoxy or benzyloxy radicals as substituents on the phenyl radical as described in U.S. Pat. No. 4,000,115, “Photopolymerization Of Epoxides,” by Sanford S. Jacobs issued Dec. 28, 1976, the disclosure of which is incorporated herein by reference. Preferred cationic initiators for use in the compositions of this invention are the salts of Group VIa elements and especially the sulfonium salts. Particular cationic catalysts include diphenyliodonium salts of tetrafluoroborate, hexafluorophosphate, hexafluoroarsenate, and hexafluoroantimonate; and triphenylsulfonium salts of tetrafluoroborate, hexafluorophosphate, hexafluoroarsenate, and hexafluoroantimonate.
Although photoactivated free-radical initiators are preferred, thermally activated free radical initiators may also be used. Useful photoinitiators for this purpose are the haloalkylated aromatic ketones, chloromethylbenzophenones, certain benzoin ethers, certain acetophenone derivatives such as diethoxyacetophenone and 2-hydroxy-2-methyl-1-phenylpropan-1-one. A preferred class of free-radical photoinitiators is the benzil ketals, which produce rapid cures. A preferred photoinitiator is α,α-dimethoxy-α-phenyl acetophenone (Iragacure™ 651, Ciba-Geigy, disclosed in U.S. Pat. Nos. 3,715,293 and 3,801,329). The most preferred photoinitiator, in accordance with this invention, is 2-hydroxy-2-methyl-1-phenylpropane-1-one (Darocure™ 1173, Ciba-Geigy Corporation). Specific examples of photoinitiators include ethyl benzoin ether, isopropyl benzoin ether, dimethoxyphenyl acetophenone, diethoxy acetophenone, and benzophenone. The coatings of the present invention combine one or more organofunctional trialkoxysilane monomers, deionized or distilled water to effect hydrolysis with or without the aid of an acid or base catalyst. The hydrolysis of the trialkoxysilane monomer is the first step in preparing coatings of the present invention. This is optionally but preferably done in an open vessel over a period of 4 to 24 hours, depending on the rate of hydrolysis of the specific siloxane, how much water is added and if a catalyst is used. By hydrolyzing in an open vessel, a substantial volume of alcohol is evaporated rendering the hydrolyzed solution essentially free of any volatile constituents. Optionally, a nitrogen sparge or a partial vacuum or both may be used to facilitate the removal of the alcohol that is liberated as a result of hydrolysis. An organic acid or a mineral acid or a combination of one or more of each may be used to catalyze the hydrolysis. Alternatively, an organic base or a mineral base or a combination of one or more of each may be used to catalyze the hydrolysis. The hydrolyzed solution is then stored at room temperature or below in a closed container until needed or immediately used to prepare the coating solution. Stability is a critical factor in developing this and similar coatings. A coating with a 3:1 molar ratio of water to trialkoxysilane tends to increase in viscosity as the alkoxy groups hydrolyze to form silanols, which then condense with the evolution of water resulting in polymerization thereby causing the viscosity to increase until it is too high for proper coating application characteristics. Customers, such as some optical laboratories, with high rates of coating consumption typically consume the fresh coating within one week such that the viscosity increase is not critical but many smaller optical laboratories do not rapidly consume coating and may need up to six months to consume a bottle of coating solution during which time absorption of water from the air, evaporative losses of alcohol, and exposure to ultraviolet light from overhead fluorescent lights, or some combination of these may contribute to a substantial increase in viscosity over weeks and months unless the coating is well formulated to prevent this increase in viscosity under such conditions. Through hundreds of tests, it has been determined that by reducing the molar ratio of water to trialkoxysilane to limit the extent of hydrolysis, the coating solution is much more stable. Coatings of the present invention with a water to trialkoxysilane molar ratio of 1.5:1 increased less than 5 cps in viscosity, typically 1 to 3 cps, after aging for several weeks at room temperature. Whereas a 1.5:1 molar ratio of water to trialkoxysilane will tend to be more stable than a similar coating having a 3:1 molar ration of water to trialkoxysilane, the latter will have better mar resistance than the former.
The hydrolysis is often measured in terms of the number of silane groups reacted together to prepolymerize portions of the epoxysilane compounds. It is desired that at least 25 number percent of all hydroxyl groups on the silane, preferably at least 30-35 number percent of silane group, more preferably at least 50 number percent of the silane groups, up to any percentage that would allow the final composition to be coated and completely cured.
The hydrolyzed epoxy-silane composition used was formed as (˜50% hydrolyzed glycidoxypropyltrimethoxy silane) as 80% by weight of a reaction mixture of deionized water as 20% by weight of the reaction mixture. Detailed methods of forming these hydrolyzed alkoxysilane and epoxysilane materials are well known in the art and further described herein.
This combination is used to form a hydrolyzed silane solution referred to as GLYMO. After initial hydrolysis is allowed to proceed to a desired degree the alcohol (e.g., methanol, ethanol, etc.) byproduct (50% of the solution) is extracted to leave the hydrolyzed silane.
In the preferred composition of the present technology, to the hydrolyzed silane is added a composition consisting of proportionally identified weight amounts of:
1)
Silica
12-18
(17~26% by weight)
2)
Sartomer ® 213 dibutyl acrylate
20-30
(~27-40% by weight)
3)
Sartomer ® 285 tetrahydrofuryl
8-12
(~11-17% by weight)
acrylate
4)
CPI 6076 solvent based (50%)
5-10
(7~15% by weight)
Initiator
5)
IRGACURE ® 754 Initiator
1.5-3.5
2-5% by weight)
6)
CN980 urethane acrylate
5-10
(7~15% by weight)
7)
EB1360 silicone acrylate
0.2-0.6
(~0.06-0.9% by weight)
8)
Lowinox ™ 44b25 hindered
0.2-3.6
(~0.06-5% by weight)
alkyl-bis-phenol stabilizer
Comparative Examples
Bayer
Taber
Tint
Abrasion
Abrasion
Adhesion
Company and
Viscosity
after
Test
1 to 10 on CR-
Product Name
Centipoise
Heating
(higher better)
39
ULTRA
27-34 cps
1.701
15-16% haze*
6
Optics UVNV
ULTRA
18-24 cps
3.01
1.01
8.1
AST 1
ULTRA
24-30 cps
1.85
2.5
8.2
UV87
Arrotek INTL
28-32 cps
1.56
1.85
7.2
H Coating
Coburn
35-40 cps
1.82
2.1
8.1
UVMAX
Coburn
28-32 cps
1.97
2.3
8.2
UVAR
Genesis
25-30 cps
2.38
2.39
8.5
1T
Genesis
27-32 cps
2.46
2.78
8.7
2NT
*This haze level was so high due to abrasion that measurement of Taber Abrasion results were not warranted.
The Genesis coatings of the present technology also exhibited a scholastic value of abrasion resistance adhesion of 9.0, which was equal to or higher than every other coating.
NOTES; 1) ALL TESTING WAS DONE IN HOUSE; 2) ALL TESTING WAS DONE WITH A COATING THICKNESS OF 4.5 MICRONS; 3) ALL TESTING WAS DONE WITH SURFACED CR-39 LENSES (SURFACED POLYCARBONATE LENSES SURFACED WITH TRIVEX AND HIGH INDEX LENSES; 4) ALL TINTING WAS DONE WITH BPI BLACK AT 205° F.; 5) ALL COATINGS WERE APPLIED IN HOUSE USING THE EZCOAT® UV SYSTEM; 6) ALL POST CURING WAS DONE IN A CONVECTION OVEN AT 85° C.
It is to be further noted that this unique combination of ingredients provides a highly abrasion resistant final coating that is easily tintable to commercially required levels without the need for specific components (referred to in the art as tint enhancers or tintability agents) that reduce the abrasion resistance of the final composition. Specifically, the compositions and methods of the present technology do not require and may be made in the substantial absence (less than 2% by total weight of the composition, less than 1% by total weight of the composition, less than 0.5% by total weight of the composition) and in the complete absence 0% or less than a measurable 0.01% by total weight of the composition of any one of or combination of glycidyl ethers, allyl ethers and vinyl ethers. These results for abrasion resistance are clearly evidenced by the data in the above table. In every single testing procedure but one (the ULTRA AST 1 composition with Bayer Abrasion after Heating) the Genesis compositions of the present technology (all within the scope of compositions described under the above tabulation showing the range of Genesis Components consistently displayed improved abrasion resistance. Even where the single test against a single composition showed less abrasion resistance, both Genesis compositions consistently showed significantly improved abrasion resistance under other standard testing procedures. This is a remarkable result in view of the fact that these compositions based on epoxysilanes have been known and marketed for over thirty years, and the compositions of the present invention exceed the prior art results so consistently and significantly, yet retain tintability, without sacrifice of abrasion resistance,
One main category of light stabilizers consists of what are known as hindered amine light stabilizers (abbreviated as HALS). They are derivatives of 2,2,6,6-tetramethyl piperidine and are extremely efficient stabilizers against light-induced degradation of most polymers.
HALS do not absorb UV radiation, but act to inhibit degradation of the polymer. They slow down the photochemically initiated degradation reactions, to some extent in a similar way to antioxidants. A hindered amine stabilizer such as, for example, 2,2,6,6,-tetramethylpiperidine, can be added to the UHMWPE powder along with the tocopherol phosphite, prior to consolidation and under moisture controlled conditions to prevent premature hydrolysis. The hindered amine stabilizer and other components can be dissolved in a suitable dry state and then into an organic solvent (preferably only in carrier amounts of less than 5% total weight of the composition) to promote uniform distribution. The solvent can then be removed prior to or after blending of the composition with final additional components to obtain a substantially uniform distribution of the individual ingredients. The blended solution is then bottled in a moisture free environment. The bottling can be conducted in a low oxygen and low moisture environment to prevent premature oxidation of materials and to prevent premature hydrolysis of the reactive ingredients. The composition is then coated and crosslinked by ionizing radiation such as gamma, ultraviolet or electron beam radiation, which can also be performed using low moisture conditions. After crosslinking, the coated article can be subjected to humid conditions or water to promote at least some further hydrolysis. See also U.S. Pat. Nos. 8,399,535 and 4,405,579. All references cited herein are incorporated by reference in their entirety.
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A coating photoreactive composition comprising a hydrolyzed epoxy-silane and other active ingredients is able to provide an organic dye-tintable abrasion resistant coating without the use of traditional dye-tinting enhancing agents such as polymerizable ethers or polymerizable diethers. The compositions exhibit consistently higher abrasion resistance without significant impact on tintability.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to solar systems employing reflectors for reflecting the radiant energy onto one or more collectors. More particularly, this invention relates to an improvement in a solar system having a plurality of reflectors and collectors in which the nonfunctional expense of towers and the like is reduced without sacrificing precision and efficiency.
2. Background of the Invention
The prior art has seen the development of a wide variety of systems for producing useful work. As some of the systems, such as nuclear fission, suffer from bad publicity, there is increasing emphasis on the use of solar energy and the like. The systems for using this solar energy are referred to as solar systems. These systems have taken a wide variety of forms ranging from the photovoltaic cells that convert the radiant energy directly into electrical current, such as used in space probes, space vehicles and the like; to the more mundane systems converting the energy to heat for heating of fluid for use in generation of power. Regardless of which system is employed, it is generally conceded to be beneficial to employ a concentrating principle in which the sun's radiant energy from a much larger area than the collector per se, is directed, or focused, onto the collector that uses the radiant energy.
In typical installations heretofore, the collector was mounted on an expensive tower or the like that was non-functional and was a major item of expense. The reflectors were spaced thereabout for directing the radiant energy onto the collector on top of the tower. Heretofore it has been axiomatic that the tower in excess of 100 feet or more has been required, where three or more rows of the reflectors were employed about the tower for directing the radiant energy onto the collector.
As described in our co-pending patent application "SOLAR SYSTEM HAVING IMPROVED HELIOSTAT AND SENSOR MOUNTINGS," U.S. Ser. No. 953,469, filed Oct. 23, 1978, the descriptive matter of which is incorporated herein by reference for details that are omitted herefrom; there was disclosed the prior major expense of having to have the reflectors mounted on one post and the sensors mounted on another post, both of the posts being deeply embedded into the earth's surface such that they were firmly anchored and resisted receiving minor surface movements that were independent of each other. In that patent application there was disclosed the improved co-mounted reflector and sensor on a single post to eliminate that nonfunctional and inefficient expense.
Thus it can be seen that the prior art has not been totally satisfactory in providing a solar system that did not require inefficient and nonfunctional major expenses, such as the tower for the collector or the double support structures for the respective heliostat and sensors. Also, the prior art did not provide a totally satisfactory solar system in which the respective ground level mounted heliostats and collectors in their respective predetermined arrays, could be serially connected together to incrementally and cumulatively heat a circulated fluid such that the heat was ultimately available at potential levels feasible to produce power or the like with conventional methods and apparatus.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a solar system that is more economical than the prior art systems by eliminating the nonfunctional and inefficient major expense items without sacrificing efficiency.
It is a specific object of this invention to provide a solar system in which there is employed a plurality of collectors and their respective heliostats for maximizing the use of radiant energy from a large surface area in a combination system employing sensors for maximizing the reflected energy and a serially connected arrangement wherein a circulated fluid is heated above the temperature required to generate steam or the like such that the heat is at a potential readily employable in a steam generating system to produce steam for generating power.
These and other objects will become apparent from the descriptive matter hereinafter, particularly when taken in conjunction with the appended drawings.
In accordance with one embodiment of this invention, there is provided an improvement in a solar system, or combination, located on the surface the earth and exposed to the sun and including at least one receiver collector for receiving and using the radiant energy from the sun and at least one reflector means for reflecting radiant energy from the sun onto the collector. The term "collector" is employed herein as synonymous with the term "receiver" as employed in solar central receiver technology. The improvement comprises having the collector a towerless collector that is disposed at substantially the same level as the reflector means and having the reflector means at least one towerless heliostat that is disposed at substantially the same level as the collector onto which it reflects the radiant energy; the heliostat being movable to maximize its reflected energy onto the collector. Preferably, there are a plurality of collectors each having their own plurality of heliostats arranged in an array of two rows. Still more preferably, the respective heliostats and sensors are co-mounted on a single support structure to further minimize the nonfunctional costs, just as the towerless construction eliminates the nonfunctional cost of the tower for the collectors.
In accordance with another embodiment of this invention, there is provided a solar system, or combination, for using solar energy comprising a power generating means that includes a steam powered prime mover; steam generating means and accessories for generating the steam for powering the prime mover; fluid storage means for storing a heated fluid and the heat exchanged return fluid, respective fluid circulating means for circulating the fluid through the collectors to be heated and through the steam generating means for transferring the heat to generate steam; a plurality of solar collectors for collecting the radiant energy and using it to heat the fluid; the solar collectors being connected together in a series such that the temperature of the fluid is raised progressively higher as it passes through respective collectors until a desired temperature greater than the boiling point of water at the pressure in the steam generating means is reached; the collectors being towerless collectors that are disposed at substantially the same levels as their respective heliostats; and the plurality of heliostats for each of the collectors, the heliostats being movable to maximize the radiant energy reflected onto its collector; the heliostats being towerless and disposed at substantially the same level as their respective collectors. In this embodiment, the same preferable features of the two row arrangement of the heliostats and the co-mounting of each sensor and heliostat on a single pole are employed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial side elevational view, partly schematic, showing the prior art arrangement of collectors, reflectors and sensors and their respective supporting structures.
FIG. 2 is a side elevational view of an improved mounting of the heliostat and sensor in accordance with one aspect of this invention.
FIG. 2a is a side elevational view showing greater details of a drive mechanism.
FIG. 3 is a front elevational view of the improved mounting of FIG. 2.
FIG. 4 is partial perspective view of the improved mounting of FIG. 2 in operating position.
FIG. 5 is a partial side elevational view, partly schematic, showing the present arrangement of collectors reflectors and sensors in accordance with the improvement of this invention.
FIG. 6 is a partial plan view, partly schematic, showing the arrangement of collectors, reflectors, sensors, storage tank and accessories of a portion of one embodiment of this invention.
FIG. 7 is a schematic drawing showing the combination, or solar system, in accordance with the embodiment of FIG. 6.
DESCRIPTION OF PREFERRED EMBODIMENTS
In one embodiment of this invention it is immaterial whether the collector be of photovoltaic cells for converting the radiant energy directly to electricity or converting the radiant energy to heat, as for heating the fluid that will be used ultimately in the generation of power. The latter application is easily understood and this invention will be described in this context.
Referring to FIG. 1, the solar system 11 includes a collector 13 for receiving and using the radiant energy from the sun, shown by the ray 15. The solar system 11 also includes at least one reflector means 17 for reflecting the sun's radiant energy, shown by ray 19, onto the collector 13. Ordinarily, in the prior art, the collector 13 was supported on a tower 21 to facilitate receiving the radiant energy from a plurality of the reflector means 17 spaced about the collector 13. For example, where a plurality of three or more rows of the respective reflectors were employed, the tower 21 was at least 100 feet high, or higher, usually about 200 feet high.
In the prior art, the collector 13 could have been a steam generator for heating water to produce steam; or photovoltaic cells to produce electricity; or the like. Where the water was converted to steam, it was used in passing through turbines for generating electricity by rotating generators. Alternatively, as in one embodiment of this invention, the collector 13 may absorb the radiant energy, convert it to heat for heating an oil or other high boiling liquid that will be passed in heat exchange relationship with the water to generate the steam in a steam generator. How the collector 13 uses the radiant energy is relatively immaterial in one aspect of this invention.
The tower 21 had to be structurally adequate to hold the collector 13 against the ambient winds and the like. Thus, the tower 21 was inordinately expensive because of its height and structural requirements. Moreover, this expense was nonfunctional and inefficient from the standpoint of the cost of the whole system. The cost of the collector depended to a large measure on the temperatures that were generated in the collector. For example, temperatures as high as 1500° F. (degrees Fahrenheit) (860° C.) were generated in some designs; and required expensive high temperature metals to hold the pressure and temperatures. Thus, it can be seen that these prior art systems were expensive and much of the expense was unwarranted and nonfunctional.
It is ordinarily desirable, when the temperature is to be in excess of a few hundred degrees Fahrenheit, to try to maximize the radiant energy absorbed by the collector. In such instances, respective sensors 25 are disposed intermediate the reflector means 17 and the target collector 13. The sensors 25 detect and control the alignment of the reflected beam. The sensors may comprise any of those commercially available. It has been found advantageous in this invention to employ dual tube sensors having photovoltaic cells arranged in matched pairs at the base of an elongate tube. The open end of the tube faces directly into the reflector means 17. As long as there is uniform lighting on the cell surfaces, the cells are matched and no error signal is generated. Once the sun moves such that there is non uniform lighting or shadowing of one or more of the cells, an error signal is generated, causing the reflector means to be positioned at a new angle, aligned with the reflector-collector vector to effect best focusing of the sun's rays onto the collector 13. As will be appreciated, it is critical that the sensor 25 always be correctly and carefully aligned with the center of the reflector means 17 and the target 13.
Consequently, in the prior art, the sensor 25 was firmly mounted in the surface 27, as was the reflector means 17. Expressed otherwise, the support structures 29, 31 and foundations 33, 35 were both firmly anchored sufficiently deep that both the sensor 25 and the reflector means 17 received the same movements and there were no spurious surface movements received by either one alone. Ordinarily, each supporting structure 29 and 31 comprised relatively large steel posts designed to resist movement by ambient winds and the like. Respective foundations 33 and 35 were formed of concrete and penetrated into the subsurface layers of the earth deeply enough to resist spurious movement of the surface layers, as from expansion of clays or the like when wet by rain.
It is believed helpful to build the descriptive matter in this invention from the simple elements, such as the heliostat and sensors, to the subsystem for which they are arrayed to reflect the radiant energy onto the respective collectors and then into the total combination including both a charging loop for heating the liquid to be circulated and a discharging loop for using the heat stored in the liquid to generate steam to run a power generating facility.
Referring to FIGS. 2-4, there is illustrated, in accordance with an embodiment of this invention, the reflector means 17 in the form of heliostat 37 with both it and the sensor 25 being carried by the dual purpose supporting structure, or post, 39. The post 39 is, in turn, carried by the foundation 41. Ordinarily, a plurality of heliostats are employed for reflecting the radiant energy onto a given respective collector 13. The respective heliostats may have any suitable dimension and form. For example, the heliostat may comprise an arcuate reflector means, such as a mirror, to convert the substantially parallel rays from the sun into focused rays that converge on the collector 13. As illustrated, each heliostat is about 24 feet (9.7 meters) tall and about 20 feet (6.1 meters) wide on each single post structure. Focusing is obtained by aligning a plurality of relatively small; for example, four feet by four feet (1.2 meters by 1.2 meters) flat facets into a Fresnel approximation of a spherical concentrator. Each facet has a reflecting surface of a mirrored glass plate for utmost reflectivity. The mirroring may be of conventional design, such as aluminum or silver. Second surface silvering has proved to be the most durable and best reflective material found. The making of the individual flat facets involves only state of the art technology and need not be detailed herein.
As can be seen in FIG. 4, the illustrated facets 43 are arranged in rows and columns on the heliostate and are supported by structural elements 45 in a unitary array of 26 facets. The heliostat 37 has a central reflector 47. The heliostat 37 has a slot 49 below the central reflector 47 so as to be pivoted through a limited arc without hitting the post 39 or with connected elements such as the co-mounted sensor. The heliostat 37 is light in weight. Accordingly, the structural elements are preferably formed of a light weight metal such as aluminum, magnesium, or the like, although steel is frequently employed because of its high strength. The facets 43 are affixed to the structure element by any suitable means, as by bonding or the like. Preferably, the reflecting area is maintained at or near the maximum.
As illustrated, the heliostat 37 is movable pivotally about a horizontal axis through the central reflector 47 to accomodate, primarily, the daily path of the sun. If desired, the heliostat 37 also may be radially movable about a vertical axis passing through the central reflector 47. The radial movement is through a limited arc to accomodate the 231/2 degrees variance between the sun's path during the different seasons.
The means for moving the heliostat to maximize the radiation towards the collector 13, includes a motor 51 and a worm gear drive 53, serving as an elevation drive means for pivoting the heliostat about its horizontal axis through the central reflector 47. The worm gear acts on the circular pinion 55 in attaining and holding a desired angle. The worm gear also serves as a braking means so as to resist movement of the heliostat once a given angle is obtained.
To rotate the heliostat through a limited arc about the vertical axis through the central reflector 47, a suitable motor, gear reducer and rack 57, FIG. 2a, is employed, engaging a circular pinion 59 for effecting the rotation. The respective motors, worm gear drives, gear reducers, are all well known and are conventionally available so need not be described in detail herein.
With respect to the foregoing, it is sufficient to note that the slot 49 enables the heliostat to be pivoted or rotated through its limited arc without striking the sensor 25 or its cantilever mounting member 61.
Specifically, the sensor 25 is a dual tube sensor such as described hereinbefore employing two sets of photovoltaic cells each with the cells matched to balance each other when each are receiving the same intensity of light. In the event that there is a moving of the sun without corresponding movement of the heliostat, one of the cells suffers a loss of intensity. Consequently, an error signal is generated that causes the motor to pivot the heliostat 37 to reestablish proper alignment of the reflected beam and achieve a uniform of distribution of light over the photovoltaic cells. The respective cell of a matched pair indicates the nature of the correction to be made; for example, greater tilting of the heliostat. The use and connection of the sensor, controls, motor drives is conventional and need not be delineated in detail herein. The conductors from the sensor 25 are usually run interiorly of the cantilever mounting member 61.
The sensor 25 is carried by the cantilever mounting member 61; which in turn, is affixed, as by welding, to the post 39. The cantilever mounting member 61 is structurally adequate to retain the sensor 25 in place against ambient winds or the like. When the conductors are run interiorly of the member 61, it is tubular with a passageway through its interior. Otherwise, member 61 can be of any desired shape. Preferably, both the cantilever mounting member 61 and the sensor 25 resist destructive effects of weather such as, the destructive effects of sun, rain, ice or the like. This cantilever mounting member 61 may be affixed by any suitable means to the post 39 as long as it is structurally adequate to move in unison with the post 39 and heliostat 37, responsive to outside forces such as wind or the like. It is readily apparent that, as closely mounted as the sensors are to the heliostat, small movements are reflected as large movements of the reflected rays by the time the radiant energy is at the distance of the collector 13.
The heliostat sensor assembly will survive earthquake environment experienced in the continental United States. Reattainment of performance following earth movement is achieved with minor aiming adjustments. The mirrors are readily maintained because of the flat unstressed shape of the glass.
In accordance with this invention, the respective heliostats 37 are mounted in rows angled to reflect toward their respective collector 13, as can be seen in FIGS. 5 and 6.
In the illustrated embodiment, the respective heliostats are towerless reflectors that are mounted at substantially the same level as the respective collectors 13. The respective collectors 13 are also towerless collectors that are mounted at substantially the same elevation as the respective heliostats. While the respective heliostats and collectors may be mounted on the top of the surface and may follow the contour of the surface, the respective elevations will not differ by a distance of greater than plus or minus 25 feet from the horizontal axis of the center of the respective collector 13 and heliostat 37. This is in contrast to the prior art where the tower structures required for the collectors was in excess of 100 feet. As can be seen in FIGS. 5 and 6, the respective heliostat 37 are arranged in two rows with respect to their respective collectors 13. The front row of the heliostats are closest to the collector 13. The second row of heliostats are farther away from the collector 13 and the individual heliostats are offset so as to reflect between the front row heliostats and onto the reflector 13. This arrangement is illustrated by the respective lines 63 and 65 from the respective front row and rear row heliostats, FIG. 6.
Almost any number of heliostats can be employed. As will be apparent from the consideration of FIGS. 2-4, the heliostats require room for pivoting about their respective axes. Consequently there is required to be a space between the adjacent front row heliostats. The back row heliostats fill in this space such that the sunlight from a large area is reflected onto the respective collector 13 without shadowing by the individual heliostats. While any number of rows of heliostats can be employed, it has been found most advantageous to employ two rows as delineated. As can be seen, there may be employed as many as twelve heliostats in the front row and seven to nine heliostats in the second row to optimize the reflected radiant energy for a given area exposed to the sunlight. Use of greater number of rows of heliostats require that the collector be elevated on a tower structure such as in the prior art, if there is not to be a loss of efficiency.
Each of the respective collectors 13 may comprise a cavity receiver or a simple planar receiver for receiving the reflected energy and converting it to heat for heating a fluid being flowed through a conduit passing through the collector. As illustrated, the respective collectors are substantially planer receivers about 20 feet by 20 feet (6.1 meters by 6.1 meters) heat exchangers with oil being flowed through the conduit to absorb the heat energy from the radiant energy. The collectors are designed to work at temperatures of from 190° F. (87.8° C.) to about 590° F. (293.3° C.). The collectors may be in any desired array. Preferably, the collectors are in line with rear row of heliostats, as illustrated by the collectors 13b-d, FIG. 6. This facilitates placing a central heliostat 37e to reflect between the front row heliostats. If desired, of course, the collectors may be offset from the last row of heliostats; for example, similar to the others illustrated in FIG. 6.
The fluid that is circulated as the working fluid and heat storage medium may be any of the high temperature heat transfer fluids. As illustrated, it is a high temperature heat transfer oil known as Rubilene S315, available from Atlantic Richfield Co. Because of the low pressure, the oil may be heated in a low pressure heat exchanger, rather than high pressure tubing that lowers the thermal efficiency. In this way, collector thermal efficiency at about 500° F. (260° C.) is above 80% (percent). The efficiency is energy into the fluid divided by energy reflected to the receiver, or collector, expressed as percentage.
As can be seen in FIGS. 6 and 7, each of the collectors 13 are serially connected in a fluid circulation conduit, as by conduits 67 intermediate the respective collectors. Connected into the fluid circuit is pump 69, FIG. 7, that takes its suction by line 71 from the bottom of the thermocline tank 73 serving as the fluid storage means. The fluid circuit is also connected by line 75 with the top of the thermocline tank 73 for circulating the heated fluid to the top of the thermocline. For example, the pump 69 may take suction of oil that is only about 195° to 200° F. and put it into the first collector 13a, FIG. 7. As the oil is circulated through each of the collectors 13, it is elevated in temperature by the appropriate increment; for example, about 31 degrees Fahrenheit. Consequently, the oil is able to be returned to the fluid storage means, on the top of the thermocline at a temperature of about 500° F. Suitable temperature sensors T and temperature control valves TCV allow bypassing of the fluid to the lower temperature fluid if desired.
The heat in the heated fluid is employed in a heat exchanger in the steam generator means 79 for generating power to power a prime mover 81 turning a power generator 83. Specifically, the heated fluid is circulated by a pump 85 that is connected at its suction side via line 87 with the top of the thermocline 73. The heat exchanged fluid is returned via line 89 from the steam generator means 79 to the thermocline 73. A hot temperature detector 91 and a cold temperature detector 93 are connected with a temperature differential discharging loop controller 95. The temperature differential loop controller 95 is, in turn, connected with the control valve 97 to control the rate of flow through the heat exchanger 99 interiorly of the steam generator means 79.
Water is fed to the steam generator by a feed water pump 101 that is connected with a source of water. As illustrated, the source of water is from makeup water pump 103 and the condensor 108. Of course, suitable surge tanks can be employed for receiving the water from the condensor 105 and the makeup pump 103.
The water level is maintained at the desired predetermined level in the steam generator means 79 by the water level controller W L 107, that is operationally connected with the feed water regulator valve 109. The feed water regulator valve 109 is interposed in the conduit 111 connecting the pump 101 with the steam generator means 79 for controlling flow of water responsive to control signals from the controller 107. The steam generator means 79 is connected at its discharge by a conduit 113 with the steam turbine serving as the prime mover 81. The steam turbine 81 discharged by a conduit 115 to the condenser 105. A safety valve 117 is connected to relieve steam to the condenser 105 in the event the pressure becomes too high. A steam bypass valve 119 is also provided for bypassing steam. A steam control valve 121 is interposed in the conduit 113 for controlling the rate of steam flow to the turbine 81. The control valve 121 operates responsively, as indicated by the control line 123, to the load control 125 monitoring the load output from generator 83.
Cooling water is circulated by pump 127 in a fluid circuit including the heat exchanger 129 in the condenser 105 and through the cooling tower 131.
In operation, the respective elements are interconnected as illustrated in the drawings and described hereinbefore. Specifically, the collectors installed on their respective foundations and the respected heliostats are mounted on their respective posts 39 with their respective slots disposed about and encompassing their posts. The respective means for moving the heliostats are interconnected with the suitable gears and pinions meshing, and with the sensors 25 and the cantilevered mounting members 61 then emplaced so as to detect the rays aimed at the collector 13. Thereafter, suitable controls are connected and activated to pivot the heliostat 37 to the desired angle for the sun at any given point. Calibration of the sensors 25 is made.
The oil circulation pump 69 pumps the oil, as the fluid to be heated, through the respective collectors 13 and into the hot portion of the fluid storage means 73. When sufficiently high temperature is obtained, the pump 85 is started to circulate the hot fluid through the steam generator 79. When steam is developed at the desired pressure, it is vented through the steam turbine 81 to power the generator 83. The load controller 125 then controls the steam control valve 121. Boiler makeup water is provided from suitable treated boiler water, as by the pump 103 supplying to the suction side of the fresh water makeup pump 101, either directly or through a surge tank (not shown). Water is made up as needed responsive to the water level controller 107 through the regulator valve 109 to keep the desired water level. The heat exchanged oil is returned through the line 89 to the cool side of the thermocline 73. The cool oil is passed to the suction side of the pump 69 to complete a cycle.
The following information is given on a typical installation. The oil sent to the first collector 13a, may have a temperature of about 195° F. Each subsequent collector 13 then heats it about 31° F. As a consequence of this, in combination with the cooling of about 1° F. experienced in going between the respective serially connected collectors 13, the oil is heated successively to temperatures as follows:
220° F.--from the first one
256° F.--from the second
286° F.--from the third
316° F.--from the fourth
346° F.--from the fifth
376° F.--from the sixth
406° F.--from the seventh
436° F.--from the eighth
466° F.--from the ninth
496° F.--from the tenth
526° F.--from the eleventh
556° F.--from the twelfth
The lines for circulating the fluid may be six inch lines for achieving the results delineated to the tables hereinafter. Of course, larger or smaller lines can be employed as appropriate to the size of the installation.
Table I shows the respective elements of the power system and the major perimeters.
TABLE I__________________________________________________________________________CATEGORY PARAMETER VALUE__________________________________________________________________________RATED POWER-SOLAR 1 MWeRATED POWER-STORAGE 1 MWe (24 hours)NO. COLLECTOR MODULES 12NO. HELIOSTATS PER MODULE 19NO. HELIOSTATS TOTAL 228OPTICAL CONFIGURATION FLAT FACET FRESNELHELIOSTATMIRROR AREA PER HELIOSTAT 416 Ft.sup.2 (38.6m.sup.2)TOTAL MIRROR AREA 94,848 Ft..sup.2 (8811m.sup.2)LAND USE 990 × 1200 ft (1.188 × 106 Ft.sup.2) 110,408 m.sup.2 27.3 ACRESRECEIVER TYPE NORTH FACING-VERTICAL FLAT PLATENO. RECEIVERS 12MAXIMUM RECEIVERUNIT - INPUT 0.893 MWtMAXIMUM HEAT TO RECEIVERS 10.714 MWtRECEIVER UNIT AREA 400 Ft.sup.2 (37.1m.sup.2)TOTAL RECEIVER AREA 4800 FT.sup.2 (446m.sup.2)RECEIVER TEMP. RANGE 190-560F. (87.8- 293° C.)STORAGE TYPE SENSIBLE HEAT USING HIGH TEMPERATURE OIL (ARCO RUBILENE S 315)NO. TANKS 1 (THERMOCLINE HOT AND COLD ZONE SEPARATION)TANK DIMENSIONS 30 ft. (9.14m) DIAMETER 46.2 Ft. (14.08m) HEIGHT 32,640 Ft.sup.3 (924m.sup.3) VOLUME 244,180 GALLONS (924,309 liters)HOT ZONE TEMP 550° F. (287.8° C.)COLD ZONE TEMP 200° F. (93.3° C.)STEAM GENERATOR TYPE SHELL AND TUBE HEAT EXCHANGERSTEAM OUTPUT CONDITIONS 500° F. (260° C.) SATURATED 680 PSIA (4695 kPa) 120° F. (48.9° C.) CONDENSATESTEAM FLOW 14,275 Pounds/Hr. (6475 kg/Hr)GROSS TURBINE GENERATORHEAT RATE 14.314 Btu/Kw - Hr. (15102 kJ/Kw - Hr)__________________________________________________________________________ MWt Megawatt, thermal MWe Megawatts, electrical? ft foot? m Meter? kPa kilo Pascal? kg kilogram? hr hour? Btu British Thermal Unit? Kw kilowatt?
Such a typical solar process steam plant may have the relative cost, efficiencies, and the like as shown in Table II:
TABLE II______________________________________One Module 19 HeliostatsPower Capacity 6.52 × 10.sup.9 Btu/yearArea 2.75 acresOutput 1190 lbs*/hr steam at 500° F.Efficiency Approximately 60% at 500° F.Material Proven long-life second surface mirror glassEnergy Cost Now $8/mm* Btu-Projected $2.67/mm BtuCost per sq. ft. Now $22 - Projected $10System Life 20 + years______________________________________ *lbs pounds *mm million
The collectors are designed to take 90 mile per hour winds. Both the heliostats and collectors are designed to resist adverse effects of weather conditions such as rain, hail, or sandstorms.
From the foregoing, it can be seen that this invention achieves the objects delineated hereinbefore in providing economical, basic sub-combinations and combinations in solar systems in which major nonfunctional expenses for towers and the like are eliminated.
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This specification discloses an improvement in a solar system having one or more collectors for receiving and using radiant energy from the sun and at least one and preferably a plurality of respective reflector means for reflecting the radiant energy onto the collectors. The improvement is characterized by having towerless collectors and towerless reflectors that are disposed at ground level or substantially the same level, to eliminate the major expense of a collector tower, which is inefficient and nonfunctional in a solar system.
Also disclosed is a complete system, or combination, for generating power employing solar energy and the improvement delineated above; as well as structural details of preferred arrangements and equipment.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method for fracturing a subterranean formation. More specifically, the invention is directed to a method and apparatus for placing multiple fractures in a horizontal or vertical openhole well.
2. Description of the Prior Art
In the recovery of oil and gas from subterranean formations it is common practice to fracture the hydrocarbon-bearing formation, providing flow channels for oil and gas. These flow channels facilitate movement of the hydrocarbons to the wellbore so they may be produced from the well. Without fracturing, many wells would cease to be economically viable.
In such fracturing operations, a fracturing fluid is hydraulically injected down a wellbore which penetrates the subterranean formation. The fluid is forced down the interior of the wellbore casing, through perforations, and into the formation strata by pressure. The formation strata or rock is forced to split or crack open, and a proppant is carried by the fluid into the crack and then deposited. The resulting fracture, with proppant in place to hold the crack open, provides improved flow of recoverable fluid, i.e., oil, gas, or water, into the wellbore.
Fracturing horizontal wells can significantly enhance well productivity, but the cost of multiple fracture completion according to the current industry practice is often unacceptably high. Therefore, operators often choose to complete wells, particularly horizontal wells, as open hole and in some cases, use slotted or preperforated liner or wire wrap screen to maintain hole integrity or provide solids exclusion.
One method currently used for multiple fracture completion is placing the fractures in stages (i.e., one fracture at a time at a wellbore location). Fracturing in stages has the advantage of precise fracture locations and design control, but is relatively expensive. A particular zone or interval is isolated using methods common in the industry, such as using retrievable or drillable bridge plugs with packers, sand or gravel, and a fluid. Well completion consists of setting a bridge plug below each target interval, perforating the target interval, pumping the fracture treatment, and cleaning out any sand remaining in the well bore to prepare for the same process for the next interval. This process repeats until all the target intervals are fractured. The bridge plugs then have to be retrieved or drilled out and well bore cleaned out to proceed with installation of production tubing. In some applications, sand plugs are set in the well bore for fracture isolation in lieu of bridge plugs. This method requires multiple trips into the well during the fracture completion and hence, long rig time and high well completion cost. Special tools have been developed to allow performing multiple tasks, such as setting plug, perforating, fracturing or cleaning, in one pipe trip to reduce rig cost, but at least one trip is required for each interval to be fractured and overall cost is still relatively high.
Another method that is commonly used to create multiple fractures in a single pumping stage is the use of diversion techniques, particularly the limited entry technique. The method of limited entry, such as that described in U.S. Pat. No. 4,867,241 (Strubhar) relies on high perforation entry friction to regulate fluid distribution into multiple perforated intervals. Some or all of the intervals are perforated with a limited number of holes, which causes an increase in pressure at the entrance of the perforations when the fracture treatment is pumped at high flow rate. The high entrance pressure forces fluid to enter multiple intervals, instead of entering only a single interval. Single stage treatment with diversion is less costly but uniform proppant placement is more difficult to achieve in multiple fractures and typically results in decreased well productivity. This is because the earth stress is seldom uniform even within a single rock formation. This causes fractures to be initiated in the lower stress intervals first. Once these fractures are initiated, they become the preferable flow path for the fracturing fluid being injected, leaving other perforated intervals unfractured. Even elevated treating pressure from the limited entry will not entirely mitigate this problem. Furthermore, as proppant enters the perforations, it erodes and enlarges the perforations, which causes the entry friction to decrease rapidly. As a result, the flow distribution among the multiple intervals is drastically altered when the proppant reaches the perforations. This causes a majority of the proppant to be placed only in a few dominant intervals, leaving other intervals unstimulated.
A method for producing multiple fractures from a single operation is described in U.S. Pat. No. 5,161,618 (Jones et al.). A plurality of packers are used to isolate the various intervals to be fractured, then a tool having a plurality of alternate paths or conduits and associated openings is used to supply fracturing fluid to different levels in the isolated interval or section. Each alternate path provided in the apparatus is associated with a specific set of holes or openings in the tool for providing fracturing fluid into the wellbore. Slurry is pumped through the conduits and fills the lower end of the tool prior to flowing into the wellbore, where it creates hydraulic pressure to fracture a first break-down zone. Slurry will continue to flow into this first zone until a bridge is formed or some other impediment to flow is created. At that point, the slurry will flow out of a second set of openings in the tool, which are positioned further up the wellbore to fracture a second break-down zone. However, providing slurry into a new fracture without first providing a clean fluid pad will typically cause the fracture to immediately screen out, thereby prohibiting further treatment of the fracture. Therefore, it would be advantageous to provide an apparatus that allows fracturing fluids to be provided to specific zones or intervals without the need for an alternate path for each zone and wherein the fluid delivered to each zone could be specifically controlled (i.e., providing a pad fluid prior to proppant slurry).
Yet another method for placing multiple fractures in horizontal wells is described in U.S. Pat. No. 6,070,666 (Montgomery). A tool having a packer and tubing for transporting a fracturing fluid and slump-inhibiting materials is used to produce multiple fractures in a horizontal wellbore. The tool is passed into the wellbore and positioned such that the packer may be inflated above a proposed fracture site, to effectively isolate the fracture zone (one end being sealed by the packer and the other end being the outer end of the horizontal well.) Fracturing fluid is then injected via the tubing to produce a fracture in the formation. Once the first fracture is formed, the tool must be withdrawn up the wellbore, where it is again put in place by inflating the packer and the fracturing process is repeated. This process may be used to produce any number of fractures; however, the tool must be moved for each new fracture site. It would be advantageous to provide a tool that could provide multiple fractures in a formation without requiring movement of the tool in the wellbore after each individual fracture was created.
SUMMARY OF THE INVENTION
The present invention is a method and apparatus for producing multiple fractures in a vertical or horizontal well. The tool or apparatus is typically incorporated in, or forms a part of, a completion or work string which is passed into the wellbore. Multiple burst disk assemblies are spaced along the string and serve as fluid entry and fracture initiation points when the fracture treatment is started. Burst disks contained in each assembly are preset at different bursting pressures, with the lowest bursting pressure typically at the toe or distal end of the string. Bursting pressures may increase towards the heel. This allows the disks to burst sequentially, thereby allowing the corresponding intervals to be treated from toe to heel. An advantage of the present invention over the prior art is that a single fluid conduit (i.e., the work or completion string for instance) may provide treatment fluid to a plurality of zones or intervals.
The overall treatment process is continuous, allowing treatment of multiple intervals without the need to stop treatment or to move the tool. The treatment typically includes pumping multiple fluid stages, each corresponding to a specific burst disk assembly. Initially, where the interval to be treated is the first or lowest interval, it may be necessary to form a plug at the end of the liner or string to prevent fluid loss and allow pressure build up in the liner.
As the fluid is pumped, pressure inside the liner or string builds until it exceeds the bursting pressure of the disk corresponding to the interval being treated. Once the disk bursts, the treatment fluid may exit the apparatus and interact with the formation. In the context of a fracturing operation, the fracturing fluid will increase pressure on the formation rock, causing it to fracture. Typically, the fracturing fluid will contain proppant which is pumped into the fracture to maintain permeability once the treatment is completed. Once a sufficient quantity of proppant is pumped into the fracture, it may be necessary to block further flow into the interval.
At the end of each fracture stage, the interval being treated should be blocked off, so the pressure in the liner or string will increase, leading to rupture of the burst disk in the subsequent interval. This may be accomplished using any suitable mechanism, but typically includes either using ball sealers or by forming a proppant plug (i.e., intentionally screening out and packing the treated interval.) If ball sealers are used, they should be dropped near the end of the last proppant stage for each interval. Any excess slurry behind the ball sealers should have a volume less than the wellbore volume between consecutive intervals to ensure that when the next disk ruptures and the corresponding interval starts to take fluid, the fluid entering the new interval is flush or pad fluid instead of proppant laden slurry, which could cause the new fracture to immediately screen out.
Intentional screen out of the fracture may also be used to block off the interval being treated. Typically, this involves decreasing the rate at which slurry is pumped downhole to allow fluid to leakoff into the formation, thereby dehydrating the slurry. This leads to packing of the annulus and blocking of the ruptured disk, effectively preventing further fluid from entering the treated interval.
Once the treated interval has been blocked off, pressure in the apparatus will begin to rise until it exceeds the bursting pressure of the next disk, thereby effectively restarting the cycle. The newly opened interval may then be treated as previously described. In this way, multiple zones or intervals may be treated or fractured in a single, continuous treatment simply by providing a plurality of burst disk assemblies in the tool and repeating the procedure of treating and diverting for each fracture or interval.
To ensure each treatment stage is stimulating the interval adjacent to the corresponding burst disk, a zone isolation method should be employed to block fluid flow in the annulus formed by completion string and openhole to contain the fluid in the interval being treated. The present invention describes an annulus gel plug, mechanical cup packers, and annulus sand plug as three methods to accomplish zone isolation. However, the same may be accomplished using any suitable method known in the industry. The annulus gel plug uses a gel with sufficient strength to resist the fluid flow in the openhole annulus. The gel can have relatively low viscosity to allow it to be placed in the annulus, after which the gel will set or harden over time, thus requiring a relatively large pressure difference in order to cause it to move in the annulus. When a burst disk is ruptured and fluid enters the annulus, the high treating pressure is limited to an area close to the burst disk due to the resistance of the gel, preventing the fracturing fluid entering a different interval. Mechanical cup packers provide direct hydraulic seal against the borehole wall and block the annulus flow. Annulus sand plug formation requires that multiple sand plug tools installed between adjacent burst disk assemblies. The sand plug tool is capable of dehydrating the sand slurry as it flows past the tool and forming a sand plug in the annulus to provide pressure isolation.
The apparatus is thus capable of effectively and efficiently creating multiple fractures or treating multiple zones in a single, continuous treatment operation without requiring movement of apparatus during treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a tool string for providing multiple fractures in a formation.
FIG. 2 is a lateral, cut-away view of the burst disk assembly.
FIG. 3 is a longitudinal, cut-away view of the burst disk assembly.
FIG. 4 shows the insert of the burst disk assembly.
FIG. 5 shows the burst disk assembly and cup packers.
FIG. 6 is a lateral, cut-away view of the sand plug tool.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , the present invention includes an apparatus 10 for producing multiple fractures 26 in a horizontal or vertical well 18 . The apparatus may include a plurality of burst disk assemblies 20 arranged in a spaced configuration along the length of a completion or work string, production liner 28 or other suitable conduit. Generally, the burst disk assemblies 20 are spaced such that they correspond to a specific interval to be fractured or treated. The apparatus is preferably made up at the surface and then passed into the wellbore until it reaches the desired depth. Once the apparatus is in position, the liner hanger 14 is set at or near the end of the casing 12 . A treatment tubing 11 with a packer 16 can be run and set above, or stabbed into, the liner to form a conduit for the fracture treatment. In one embodiment, the apparatus 10 may include a mechanism for providing interval or zone isolation. FIG. 1 shows a plurality of sand plug tools 22 for forming sand plugs 24 interspersed between the burst disk assemblies 20 to provide interval isolation.
As shown in FIGS. 2 and 3 , the burst disk assembly 20 is preferably incorporated into a relatively shortened tool section 48 having suitable couplings on each end thereof to allow the tool section to be attached or positioned within a standard completion string or other pipe or liner segments. In a preferred embodiment, the couplings are threaded sections 34 , 36 . The burst disk assembly comprises a hole 44 formed in the tool wall 50 , the tool wall having an internal surface 54 and an external surface 52 . A perforated disk 40 having a plurality of holes or orifices 38 and a diameter slightly less than the diameter of the hole 44 is positioned within the hole and attached such that the disk 40 is flush with the internal surface 54 of the tool section 48 thereby maintaining the smooth interior surface of the tool section. The disk may be attached using any suitable method, but is preferably fusion welded. The perforated disk may be formed of any suitable material and may have any suitable number of holes or orifices 38 formed therein. These orifices are preferably of sufficient size and number to allow adequate flow of fluid from the interior bore 32 of the apparatus into the formation. Preferably, the perforated disk is formed of stainless steel. When using proppant laden slurry, the orifice surfaces may be eroded sufficiently to prevent proper sealing of the orifices after treatment particularly if ball sealers are used. Where the treatment fluid being used may cause such erosion, hardened inserts may be mounted or positioned in the orifices to decrease erosion. Preferably, the inserts are formed from tungsten carbide. As shown in FIGS. 2 and 3 , the inserts 46 may be countersunk in the perforated disk, and need not extend completely through the disk, as the primary purpose of the inserts is to prevent enlargement of the orifices which would prevent sealing of the orifice with ball sealers, for instance, after the interval has been treated or fractured.
A burst disk 30 is placed between or sandwiched by the perforated disk 40 and a holder or retainer ring 42 . The burst disk 30 is preferably a domed metal membrane designed to fail in tension when the differential pressure exceeds the designed bursting pressure. The burst disk may be of any suitable material, but is preferably stainless steel. The bursting pressure of the disk may be varied, for instance, by increasing the thickness of the membrane or changing the material from which the membrane is formed. Once in place between the perforated disk and the retainer ring, the retainer ring may then be attached to the tool section in any suitable manner, but preferably by fusion welding, thereby affixing the burst disk inside the hole 44 . The retainer ring 42 should have a sufficient diameter 56 so that is does not obstruct the orifices in the perforated disk.
In operation, the apparatus 10 is passed into the wellbore 18 until it reaches a suitable position, such that the burst disk assemblies 20 are positioned to correspond to the specific intervals or zones to be fractured or treated. Preferably, the apparatus will be at least partially supported by a liner hanger 14 or similar device, once the apparatus has been properly positioned. In a preferable arrangement, and as shown in FIG. 5 , the burst disk assemblies may be positioned between corresponding cups 60 , which are used for interval isolation. Alternatively, the cups may be replaced by a more sophisticated sand plug tool, such as that shown in FIG. 6 , which allows formation of sand plugs in openhole annulus to increase the reliability of zone isolation. It should be understood that neither the cups nor sand plug tools are required, but may be included as a preferable isolation mechanism. Once the apparatus is in place, the treatment process may begin.
Prior to fracturing or treating an interval or zone, the interval must be isolated from intervals already treated, as well as intervals yet to be treated. This prevents reopening of treated intervals or premature fracturing of untreated intervals. There are many methods known in the art for interval isolation. Any suitable method may be used in accordance with the present invention. One preferred method for interval isolation is the use of cup packers, as shown in FIG. 5 . For each target fracture interval, a pair of cup packers 60 are installed above and below the burst disk assembly 20 and thus isolate the open hole section 80 between the cups 60 from the rest of the borehole 82 . The cups provide an interference fit against the wall of the wellbore 84 , thereby preventing fluid flow around the cups. Therefore, in a preferred embodiment, the diameter of the cups is slightly larger than that of the wellbore. It may also be desirable to use centralizers 62 to aid in reducing cup wear as the apparatus is run downhole. The centralizers maintain the tool in a centralized position within the wellbore, thereby preventing uneven or undue wear of the cups through excessive contact with the wellbore.
Yet another preferred method for isolating an interval is the use of an annulus gel packer (AGP). The AGP is a non-solids containing polymer chemical system for zonal isolation. Gel is placed in the entire openhole/liner annulus thereby providing sufficient strength to withstand the fracturing pressures and maintain isolation of each interval. However, the gel is not so strong or thick as to inhibit actual fracturing of the formation during treatment. Preferably, gel is passed down the string and into the annulus prior to beginning treatment, thereby allowing the gel to thicken or set sufficiently prior to the start of treatment operations.
Depending on the nature of the formation and the wellbore, it may be necessary to initially form a plug at the end of the liner. This may be accomplished using any suitable method, but typically involves pumping a mechanical plug to land at the liner shoe. Once the plug is formed, the pressure inside the apparatus will rise quickly and the first disk (i.e., the disk with the lowest burst pressure) will burst. The treatment fluid may then enter the openhole annulus causing the formation to fracture. The bursting pressure in subsequent disks should be set well above the expected breakdown and fracturing pressure of the previous intervals, so they will not inadvertently rupture during the preceding fracture treatments. For instance, assuming the interval or zone of interest has a fracture gradient of 0.8 psi/ft., the reservoir pressure gradient is 0.43 psi/ft. and zone TVD is 10,000 ft., the expected differential pressure on the disks during fracturing should be approximately 3700 psi. If the annulus is not completely isolated, the differential pressure could be less. In this example, the disks should have bursting pressures higher than 3700 psi. Preferably, the bursting pressure would be approximately 5000 to 6000 psi.
Treatment of the first zone or interval is preferably carried out according to a designed proppant schedule, thereby ensuring adequate fracturing and propping of the formation interval without bursting or rupturing additional disks. At the end or completion of the interval treatment, the orifices must be blocked off to allow pressure to increase within the apparatus, thereby causing rupture of subsequent burst disks. Any suitable method may be used to block off the orifices; however, in a preferred embodiment, ball sealers are used. In order to seat the ball sealers on the orifices of the perforated disk, the size of the ball sealers should be larger than the size of the orifice. An excess of ball sealers may be dropped in order to ensure that all of the orifices are blocked prior to beginning treatment of subsequent intervals. Ball sealers useful in the present invention include, but are not limited to, conventional rubber coated ball sealers or self-dissolving “bioballs.”
Yet another preferred method of blocking off the orifices after a zone has been treated is through the formation of a proppant plug. Proppant plug formation is known in the industry and any suitable method may be employed in conjunction with the present invention. Typically, proppant plug formation involves pumping proppant laden slurry at a reduced rate to allow the slurry to dehydrate through fluid loss to the formation. Here, proppant builds up in and around the perforated disk, effectively blocking further fluid flow there through.
Yet another preferred method for isolating an interval is the use of a sand plug tool, such as that shown in FIG. 6 . The sand plug tool 100 allows the formation of sand plugs 102 by dehydrating a sand-laden slurry when the slurry is pumped through the tool 102 . Multiple tools may be installed as components of the completion string between consecutive burst disks as shown in FIG. 1 . Each tool includes an inner mandrel 104 and an outer mandrel 106 . At least a pair of cups 108 are mounted on the outer mandrel 106 . Preferably, the cups are oriented such that they face away from each other. Attached to the outer mandrel 106 and positioned on both sides of the cups 108 are sand screens 110 upon which the sand plug 102 will be formed when sand slurry flows through the screen 110 and tool annulus 112 , and exits the other side of the cups. Centralizers 114 may be incorporated into the tool 102 in order to maintain the tool in a centralized position in the wellbore. The inner mandrel 104 is connected with the completion string on both ends via threaded connections. As shown in FIG. 6 , sand slurry is pumped down through the completion string or inside of the inner mandrel 116 , exits the burst disk down stream of the sand plug tool 100 , and back up the annulus between the wellbore and the completion string, finally encountering or contacting the sand screen 110 .
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A method and apparatus is provided for created multiple fractures in a subterranean formation with a single, continuous treatment operation. A plurality of burst disk assemblies are included, each having an independent burst pressure and corresponding to a specific interval to be treated, whereby the assemblies are arranged on a work or completion string such that the assembly with the lowest burst pressure is positioned at the toe, or lowest position, and subsequent assemblies have increasing burst pressures toward the heel of the string. As fluid is pumped down the string, pressure builds up to exceed the burst pressure of the first disk, allowing treatment fluid to contact the formation. Once a first interval treated or fractured, it may be isolated thereby allowing pressure to again build up in the string and burst subseqent disks.
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FIELD OF THE INVENTION
The present invention relates generally to language recognition. More particularly, the present invention relates to an improved language recognition system utilizing a probabilistic lexical associations model.
BACKGROUND OF THE INVENTION
Speech recognition is a process by which an unknown speech utterance ("input signal") is identified. Speech recognition typically involves a signal processing stage in which a plurality of word string hypotheses, i.e., possible word sequences, are proposed for the input signal. The task is then to recognize or identify the "best" word string from a set of hypotheses, i.e., proposed word strings consistent with the input signal. Speech recognition systems utilize a language model for such a purpose.
Typical speech recognition systems may employ a quantitative language model. Quantitative models associate a "cost" with each hypothesis, selecting the lowest cost hypothesis as the recognized word string.
One example of a quantitative model is a probabilistic language model. Probabilistic models assign probabilities to word strings and choose the string that has the highest probability of representing a given input signal. The probability calculation can be performed using a variety of methods. One such method, referred to as the N-gram model, specifies the probability of a word that is part of a string conditional on the previous N-1 words in the string. See, for example, Jelinek et al., "Principles of Lexical Language Modeling for Speech Recognition," Adv. Speech Signal Processing, pp. 651-699 (1992). This article, and all other articles mentioned in this specification, are incorporated herein by reference. The N-gram model is lexically sensitive in that the parameters of the model are associated with particular lexical items, i.e., words. This sensitivity allows the model to capture local distributional patterns that are idiosyncratic to particular words.
A second method, referred to as stochastic context-free grammar, uses a tree-like data structure wherein words within an input signal appear as fringe nodes of a tree. Probabilities are assigned as the sum of probabilities of all tree derivations for which words in the candidate string appear as fringe nodes. See, for example, Jelinek et al., "Computation of the Probability of Initial Substring Generation by Stochastic Context-Free Grammers," Computational Linguistics, v. 17(3), pp. 315-324 (1991). In context-free grammars, structural properties are modeled, i.e., the probability that a phrase of a particular category, e.g., noun or verb phrases, can be decomposed into subphrases of specified categories.
Both of the aforementioned methods for assessing probability suffer from disadvantages. The N-gram model, while lexically sensitive, suffers as a result of its failure to capture meaningful long range associations between words. When grammar is ignored, useful information that can only be derived from grammatical relationships between words is lost. While a stochastic context-free grammar is sensitive to such grammatical relationships, it fails to capture associations between lexical items that reflect semantic information that makes one string much more likely than another. A language model that fails to consider both semantic and structural information inevitably suffers from a loss in accuracy.
The prior art probability models are typically compiled into one large state machine. The aforementioned drawback of the lexically-sensitive probability models are due, in part, to this structure. The machines usually implemented for speech recognition are typically limited to moving left to right through the word string hypotheses, processing word strings in a word-by-word manner. As a result, the long-range associations between words are lost.
Compiling stochastic context-free grammars, or, more properly, approximations of such grammars, into one large state machine does not limit the ability of those models to capture long-range associations. As previously discussed, such associations are captured due to the nature of the model. There is another drawback, however, related to the use of a single large state machine that affects both types of probability models. When compiling the model into one large state machine, the complete lexicon or vocabulary of the language model must be contained therein. In the typical case of a software implementation, such state machines become too large for computers with limited RAM memory.
Thus, there is a need for a language model that possesses both lexical and structural sensitivity, and when implemented in software, is compact enough to be installed on computers having limited RAM memory.
SUMMARY OF THE INVENTION
Methods and apparatus for an improved language model and language recognition systems are disclosed. According to the present invention, a plurality of "small" finite state machines drive the language model. Each of such machines have the ability to recognize a pair of sequences, one scanned leftwards, the other scanned rightwards. Each finite state machine, referred to herein as a lexical head machine, corresponds to a word in the vocabulary of the language model. Only the lexical head machines corresponding to the words contained in the word string hypotheses are activated according to the present methods.
The activated lexical head machines build or derive phrases from the words contained in the word string hypotheses, by a series of left or right transitions. A plurality of such phrases are created by the lexical head machines for the various words as they form associations with other words in the word string hypotheses. The lexical head machines incrementally compute a "cost" for the derived phrases. The cost relates to the probability that the derived phrase matches the input language signal. The lowest cost phrase is selected as the phrase that corresponds to the input language signal.
As noted above, the present method utilizes a limited set of "small" lexical head machines corresponding to the words in the word string hypotheses rather than one "large" state machine incorporating the entire vocabulary. As such, the present methods and apparatus can be implemented using significantly less RAM memory than prior art language recognition systems.
The finite state machines of the present invention that recognize a pair of sequences are distinct from so-called "two-way" finite state machines that can move either left or right but recognize only a single sequence. Such two-way machines are known in the art and have the same recognition power as finite state machines that can move only left to right. See, for example, Hopcroft et al., Introduction to Automata Theory Languages, and Computation, (Addison Wesley, 1979).
Notwithstanding such two-way state machines, the state machines typically used in the prior art for speech recognition are usually limited to processing word strings by moving from left to right, whereas the lexical head machines utilized in the present invention simultaneously scan the input to the left and right of particular words in the middle of the string. This results in more accurate predictions of adjoining words since processing can start with a less common word, which limits the possibilities for the adjoining word. Consider the following example sentence: "I want the transistor." A state machine constrained to processing from left to right will have to select the word following "the", i.e., "I want the ?". Presumably, a large number of words in the particular vocabulary being used can suitably follow the word "the" in the example sentence. The lexical head machines of the present invention that process in either direction are free to start with the word "transistor" and select the preceding word. There are far fewer choices for words that can suitably precede the word "transistor" than follow the word "the."
By virtue of using a plurality of small lexical head machines, the present methods and apparatus are both lexically and structurally sensitive. Lexical associations are captured because every head machine transition involves costs tied to particular lexical items, i.e., word associations. The structural associations implicit in the hierarchical organization of a sentence is captured as a result of the cascade of lexical head machines.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the invention will become more apparent from the following detailed description of specific embodiments thereof when read in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a method according to the present invention for implementing a speech recognition system;
FIG. 2 is an illustration of a word lattice;
FIG. 3 is diagram showing state transitions for an exemplary lexical head machine according to the present invention;
FIG. 4 is an embodiment of a method according to the present invention for generating a plurality of phrase records for selecting the best choice of a plurality of word string hypotheses;
FIG. 5 shows an exemplary subphrase derivation produced by the present methods and apparatus for a sample word string; and
FIG. 6 shows the lexical head machines and the transitions required to generate the subphrase derivation of FIG. 5.
DETAILED DESCRIPTION
The present invention relates to language modelling methods for use in a variety of language recognition applications. The role of the language model in language recognition involves identifying the "best" word string from a set of word string hypotheses developed by other parts of the language recognition system. The present invention will be described in the context of speech recognition. It should be understood, however, that the present methods are applicable to all modalities of language recognition, including, without limitation, handwriting recognition and optical character recognition. It should also be appreciated that the present methods may be implemented as software or hardware.
FIG. 1 is an illustration of a speech recognition method according to the present invention. Reduced to its basics, such a method may include speech signal processing SSP, language analysis LA and application processing AP.
The method begins with speech signal processing SSP wherein a speech signal is accepted and a set of word string hypotheses consistent with such speech signal are generated. In a speech recognition system, the word string hypotheses are generated by what is referred to as an "acoustic model". Such models are well known to those skilled in the art.
In more detail, speech signal processing SSP includes converting an analog speech signal to a digitized speech signal in operation block 10 and searching with a recognition network and generating word string hypotheses in operation block 15. As utilized in the present language recognition methods, such signal processing generates the word string hypotheses as a sequencing of words, whether processing a speech signal or whether such processing pertains to other modalities of language recogition. Such word sequencing can include, without limitation, an explicit set of candidate word strings, or, preferably, a word lattice data structure. The word lattice is a well known construct for storing a collection of possible strings allowing substrings to be shared. The techniques referenced in operation blocks 10 and 16 are well known in the art.
Language analysis LA accepts the word string hypotheses and, using a language model according to the present teachings, selects therefrom the best word string. The methods and apparatus of the present invention pertain, in particular, to this aspect of the language recognition process. The present language model can then be implemented in an language recognition system, such as the speech recognition system presently being described.
In more detail, the word string hypotheses are received from speech signal processing SSP in operation block 20. The language model is applied to generate and rank a list of possible word strings or phrases corresponding to the input speech signal in operation block 22. In operation block 24, the best word string is selected and, as indicated in operation block 26, the best word string is sent to application processing AP. Application processing thus accepts the best string and then processes that string as appropriate, e.g., translation, transcription or the like. Having described where the methods and apparatus for the present language model fit in a language recognition process or system according to the present invention, the present language model and methods for its implementation will now be described in detail.
As previously described, language analysis LA receives a set of word string hypotheses. Preferably, such word strings are in the form of a word lattice, i.e., a directed acyclic graph. An exemplary word lattice is illustrated in FIG. 2. The word lattice has a set of initial nodes I, represented in FIG. 2 by i0 and a set of final nodes J, represented in FIG. 2 by j1 and j2. The hypotheses represented by the word lattice correspond to possible paths from the set of initial nodes I to the set of final nodes J.
The word lattice is also characterized by a plurality of "lattice arcs" or "word arcs" that are labeled with a word, w, between two positions that represent time points for speech. The arcs are also labeled with a cost, c 0 , that reflects how well the word matches that portion of the input signal. For example, in FIG. 2, the word arcs are labeled w0, c0 through w8, c8. The lattice and costs are generated during speech signal processing SSP using techniques well known in the art. The word arc cost is accumulated by the present method and thus contributes to the cost of a phrase thereby playing a role in determining the best phrase.
The set of arcs in the input word lattice can thus be represented by a set of records of the form <w, i, j, c 0 > in which i and j are indices for the lattice nodes. For a lattice produced from a speech signal, the usual interpretation of such an arc record is that word w matches the input speech signal from time position i to time position j with cost c 0 .
Presented with a word lattice, the lexical head machines for the words present in the lattice are activated. Each lexical head machine consists of a finite set of states, Q, and a costed action table, T. Entries in the action table can be either starting actions, left transitions, right transitions or stopping actions. The notation C(A,m) represents the total cost of a sequence of actions, A=a 1 . . . a k undertaken by lexical head machine m in which a 1 is a start action and a k is a stop action. C(A,m) is thus the sum of the costs for actions in the sequence A.
FIG. 3 is a diagram showing state transitions for an exemplary lexical head machine according to the present invention. Nodes q1-q6 represent various states of the lexical head machine. Arcs between the nodes show state transitions, wherein the head machine is consuming a phrase, indicated by w "n", e.g., w2, etc. The state transitions can be characterized as left or right actions, indicated by the direction of the arrow adjacent to the phrase. For example, the exemplary lexical head machine moves from state 1 to state 2 by consuming phrase w2 in a left transition. The machine keeps track of two position pointers in the string. A left transition moves the left pointer leftwardly and a right transition moves the right pointer rightwardly. The arrow heads at q1 and q2 indicate that there is a finite start action cost at these states. In other words, these are probable starting points for the phrase. The other states have infinite start action costs and thus are improbable starting points for the phrase. The concentric circles at q3 and q6 indicate that there is a finite stop action cost at these states.
The lexical head machine for a word, w, builds or derives a phrase, i.e., an ordering of the words in the lattice, by a series of left or right transitions. In each transition, the phrase is extended by "consuming" an adjacent phrase, which in turn was formed as a "subphrase derivation" by another lexical head machine for a word w'. Such a move corresponds to forming an association between w, "the head," and w', "the dependent". Thus a plurality of such phrases are created by the lexical head machines for the various words as they form associations with other words in the word lattice. An Example of a subphrase derivation, lexical head machines and the actual transitions for those machines, as generated according to the present invention to recognize a sample sentence, are presented later in this specification.
The method proceeds by adding such phrases, in different states of completion, to a phrase lattice. This lattice, distinguished from the word lattice, is a set of phrase records, each corresponding to a particular state of running a lexical head machine for some word. A phrase record has the following fields: <w,s,i,j,q,m,c>. In the record, w is the head of a phrase, possibly incomplete, which spans the positions i to j in its current stage of completion. The phrase is constructed according to lexical head machine m, the current state of m being q. Further, s is the output word list constructed to that point and c is the current score associated with the phrase hypothesis. The current score is the sum of the costs applied to that point in the formation of the phrase.
The cost for a phrase is computed by the lexical head machines. Each move of the head machine adds to the cost of the phrase by an amount that depends on the state of the machine and the identities of the two words w and w'. The phrase or word string selected by the method is the one having the lowest cost that spans the complete word lattice, i.e., from the start of the input speech signal to the end of that signal.
The cost for deriving a phrase spanning the entire lattice involves the costs of machine actions leading to the derivation, together with additional costs for associating machines with words and for associations between each head word and its dependent words. The additional cost parameters include association parameters that specify the cost for a word w i being the head of word w j : C(h(w i , w j )), and lexical parameters that supply the cost for word w running machine m : C(m,w). Each pairing between a word and a machine, together with the corresponding lexical parameter, appears as an entry in a lexicon or dictionary. It should be understood that there may be more than one entry, i.e., machine, per word in the lexicon. The reason for this is that a given word may be used in more than one way, such as, for example, as a noun or a verb.
The cost C(D 0 , w 0 ) of a subphrase derivation, D 0 , with a head word w 0 , is the sum of the lexical cost for choosing a machine m 0 , the cost of machine actions A 0 taken by m 0 in the derivation, the association parameters for associating w 0 with its dependent words w 1 . . . w m , and the costs of derivations of the subphrases headed by these dependents computed recursively:
C(D.sub.0, w.sub.0)=C(m.sub.0, w.sub.0)+C(A.sub.0, m.sub.0)+σ.sub.1≦m≧n C(h(w.sub.0,w.sub.m))+C(D.sub.m, w.sub.m)
Various cost functions may be used for computing the cost of a phrase. Usually, the cost function is based on probabilities, wherein less probable or less likely word associations lead to higher costs. In this manner, the cost reflects long range associations between words in a string. Cost functions will be described in more detail later in this specification.
The method by which the lexical head machines analyze the word lattice is described in more detail below. In a preferred embodiment, as phrases are extended, a running cost of such phrases is calculated, so that phrases may be pruned as it becomes evident that they will not be part of the lowest cost phrase. A hash table is preferably used for this purpose. The entries in the hash table include a hash key, <w,i,j,q,m>, and a hash value that is a pointer to the phrase record. The hash table maintains a pointer to the lowest cost phrase record found between i and j headed by w in state q of machine m. The information making up the hash key is referred to as a "full state" and c is referred to as the "full state cost."
The method for analyzing the word lattice preferably has a "bottom-up" control structure similar to that for context free parsing algorithms such as CKY as described by Younger and uses data structures similar to those in so called "chart parsing" as described by Early. See, Younger, D., "Recognition and Parsing of Context-Free Languages in Time n 3 ," Information and Control, Vol. 10, pp. 189-208, 1967; Early, J., "An Efficient Context-Free Parsing Algorithm," Comm. Of the ACM, Vol. 14, pp. 453-460, 1970. The present method is driven by the lexical head machines for the words in the word lattice.
FIG. 4 depicts an embodiment of a method according to the present invention by which the plurality of lexical head machines are used to generate a plurality of phrase records from which a best phrase record, i.e., best word string, is selected. Thus, FIG. 4 illustrates a method according to the present invention for accomplishing step 22 of FIG. 1. As indicated in operation block 100, the word lattice generated by the speech signal processor SSP is received. The method begins with an initialization step, which is accomplished by the operation blocks 105 through 120, collectively identified by the reference numeral 130. Initialization takes place by adding to a queue a set of phrase records <w, w!, i, j, m, q 0 , c > developed from the word lattice. Such a phrase record is added for each item <w, i, j, c 0 > in the word lattice and each entry (m, w) in the lexicon. Thus, in operation block 105, a lexical head machine corresponding to one of the words in the word lattice is activated. More specifically, a lexical head machine corresponding to a word, w, from the word lattice is retrieved from a lexicon stored in a memory device. The lexicon entry corresponding to the word w includes a machine, m, and a cost, c 1 =C(m,w). The machine m includes a start action having a cost, c 2 =C(start, q 0 , m). The cost, c, of each phrase record is the sum of lexical cost c 1 , the machine start cost c 2 and the word arc cost c 0 assigned by the speech recognizer 10. All lexical head machines for each word arc in the word lattice are activated through the loops sets up by decision blocks 115 and 105.
The remaining operation/decision blocks 140-195 form a loop that consumes items from the queue and creates new phrase records. Decision block 140 queries whether the queue is empty. If the queue is empty, all low cost phrase records that can be developed from the input word lattice have been extended as fully as possible. The phrase lattice, i.e., collection of phrase records, developed by the present methods is then post-processed to select the best word string as indicated in operation block 200. Such post-processing is described later in this specification. If the queue is not empty, processing continues at operation block 145, wherein a phrase record is removed from the queue. In a preferred embodiment of the present method, the cost c of the phrase record is compared with the lowest cost phrase, i.e., the full state cost, in the hash table in block 150. If the cost c of the phrase record under consideration ("the current phrase") is not less the full state cost, the current phrase is discarded or "pruned". Processing then returns to block 140 to determine if another phrase record is available. If the current phrase record has a lower cost than the lowest cost phrase in the hash table, it is added to the phrase lattice in operation block 155. While block 150 is not required as a step in the present method, it improves efficiency because it avoids creating phrase records that will be discarded later.
If, after adding the phrase record to the phrase lattice in operation block 155, the phrase record is adjacent to another phrase, then a combination action may take place. Thus, decision block 160 queries whether or not there are more phrases to combine with. If not, processing loops back to decision block 140. If there are more phrases, a combination operation performed by the operation blocks collectively identified by the reference numeral 180 results in a new record for an extended phrase. The old records still remain in the lattice. Two types of combination are possible, left combination and right combination. In a left combination, the machine for the phrase record to the right undergoes a left action as described below. If the lattice contains a first phrase record <w 1 , s 1 , i, k, m 1 , q 1 , c 1 > to the left of a second phrase record <w 2 , s 2 , k, j, m 2 , q 2 , C 2 >, m 2 includes a left action with a cost, c 3 =C(left, q' 2 , q 2 , m 2 ), and m 1 includes a stop action with a cost, c 4 =C(stop, q 1 , m 1 ), then the combination performed in operation block 165 yields the following extended phrase: <w 2 , s' 2 , i, j, m 2 , - , - >, where s' 2 =concatenate (s 1 , s 2 ). Right combination is the mirror image of left combination. A new state is set in operation block 170, according to the machine transition. In the example above, the new state is q' 2 , so that the extended phrase becomes: <w 2 , s' 2 , i, j, m 2 , q' 2 , - >. The cost of the new phrase is determined in operation block 175. The new cost is the sum of machine transition cost, word association cost, consuming phrase cost, consumed phrase cost and consumed machine stop cost. For the above example, the new cost, c' 2 , is thus given by c' 2 =c 1 +c 2 +c 3 +c 4 +C(h(w 2 , w 1 )). The extended phrase record then becomes: <w 2 , s' 2 , i, j, m 2 , q' 2 , c' 2 >.
For each new phrase record resulting from the combination operation 180, the cost of the record is compared, in block 185, with the full state cost in the hash table. If the cost of the new phrase record is higher than the full state cost, then processing returns to operation block 160 without adding the new phrase record to the queue so that it is effectively discarded. If the cost of the new phrase record is less than the full state value, then the hash table entry is updated with the new record pointer in step 190 and the old full state record is removed from the phrase lattice. The new low cost phrase record is then added to the queue in step 195 and processing continues at block 160.
After the queue has been emptied, processing continues at operation block 200, wherein the following steps are performed to select the word string having the lowest cost. First, a list of all lattice records <w, s, j, q, m, c> from an inital node iε I to a final node j ε J is compiled. For each record in the list, add the cost for machine m stopping in state q, i.e., C(stop, q, m). Then, select the string s from the record with the lowest total cost. If there are several such spanning phrases with the minimal cost, then one is preferably chosen at random.
Regarding cost parameters, the present methods do not require any specific interpretation of the various cost parameters for machine actions and lexical and association costs other than the general requirement that lower costs correspond to more desirable strings. There are methods known to those skilled in the art for providing specific cost functions applicable to the present methods. Preferably, the cost function is negated log-likelihood. A method for deriving log-likelihood costs for the methods of the present invention is described below. The machine actions, lexical choices and association choices are taken to be events in a generative model, specifically a probabilistic model for generating word strings. A set of input speech utterance signals are transcribed from collected data for the particular speech recognition application. The method illustrated in FIG. 4 for generating phrase records is run over the word lattices produced by speech signal processing, keeping a count of machine actions, lexical machine choices and word association choices leading to the transcribed strings for each speech utterance signal. Next, probabilities are estimated from these counts using standard statistical methods. For each estimated probability P(e) for an event e, set the cost for e to be -log (P(e)).
It should be appreciated that other methods for estimating probabilities known to those skilled in the art can be used such as expectation-maximization. Further, cost functions other than log-likelihood can be used, such as, without limitation, the likelihood ratio. The likelihood ratio is the ratio of the number of times in training that a particular machine action or choice leads to the incorrect string and the number of times that it leads to selecting the transcribed string.
EXAMPLE
FIG. 5 shows an exemplary subphrase derivation produced by the present methods and apparatus for the string "Please show me the cheapest flights from Boston to Newark". Example lexical head machines associated with the words in this sentence are shown in FIG. 6. The actual transitions required to recognize the string are shown in FIG. 6 as solid lines. A few of the many other possible transitions not taken in this particular derivation are shown as dashed lines. The notation "→" indicates a right transition and the notation "←" indicates a left transition. The words under which the machines would appear in the lexicon are shown next to the start states, i.e., q1, q4, q7, etc.
The transitions taken by the lexical head machines in recognizing the string "Please shown me the cheapest flights from Boston to Newark" that are shown in FIG. 6 are described below. Start actions for all the words in the string are taken: "please" at q9, "show" at q1, "me" at q8, "the" at q7, "cheapest" at q16, "from" at q10, "Boston" at q14, "to" at q12 and "Newark" at q15. The words for the following machines take stop actions since no transitions are possible for them: "please", "me", "the", "cheapest", "Boston" and "Newark". The machine for the word "from" takes a right transition from q10 to q11 consuming the machine for the word "Boston", and stops, forming a completed phrase "from Boston". The machine for the word "to" takes a right transition from q12 to q13 consuming the machine for the word "Newark", and stops, forming a completed phrase "to Boston". This completes the lowest level of the subphrase derivation shown in FIG. 5.
The machine for the word "flights" takes a left transition from q4 to q5 consuming the machine for the word "cheapest", a right transition from q5 back to q5 consuming the phrase "from Boston", another right transition from q5 back to q5 consuming the phrase "to Newark", a left transition form q5 to q6 consuming the machine for the word "the", and stops. This completes the recognition of the phrase "the cheapest flights from Boston to Newark" corresponding to the two lower levels of the subphrase derivation shown in FIG. 5.
The machine for the word "show" takes a left transition from q1 back to q1 consuming the machine for the word "please", a right transition from q1 to q2 consuming the machine for the word "me", a right transition from q2 to q3 consuming the phrase headed by "flights", i.e., "the cheapest flights from Boston to Newark", and stops. This completes the entire derivation shown in FIG. 5, and the recognition of "Please shown me the cheapest flights form Boston to Newark."
It should be understood that the embodiments described herein are illustrative of the principles of this invention and that various modifications may occur to, and be implemented by, those skilled in the art without departing from the scope and spirit of this invention. For example, while the embodiments described herein relate to speech recognition, the present methods can be utilized in other types of language recognition systems.
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Methods and apparatus for a language model and language recognition systems are disclosed. The method utilizes a plurality of probabilistic finite state machines having the ability to recognize a pair of sequences, one sequence scanned leftwards, the other scanned rightwards. Each word in the lexicon of the language model is associated with one or more such machines which model the semantic relations between the word and other words. Machine transitions create phrases from a set of word string hypotheses, and incrementally calculate costs related to the probability that such phrases represent the language to be recognized. The cascading lexical head machines utilized in the methods and apparatus capture the structural associations implicit in the hierachical organization of a sentence, resulting in a language model and language recognition systems that combine the lexical sensitivity of N-gram models with the structural properties of dependency grammar.
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TECHNICAL FIELD
[0001] The present invention relates to an improved data processing system and, in particular, to a method and apparatus for optimizing performance in a data processing system. Still more particularly, the present invention provides a method and apparatus for profiling multithreaded or multitasking processes to improve performance.
BACKGROUND INFORMATION
[0002] In analyzing and enhancing performance of a data processing system and the applications executing within, it is helpful to know which software modules are using system resources. Effective management and enhancement of data processing systems require knowing how and when various system resources are being used. Performance tools are used to monitor and examine resource consumption as various software applications are executing. For example, a performance tool may identify modules that execute most frequently, allocate the largest amount of memory, or perform the most I/O requests.
[0003] In analyzing and enhancing performance of a data processing system, a developer may focus on where time is being spent by the processor in executing software code. Such efforts are commonly known in the computer processing arts as locating “hot spots.” Ideally, one would like to isolate such hot spots at the instruction level in order to focus attention on areas that might benefit most from improvements to the code.
[0004] For example, isolating such hot spots to the instruction level permits compiler writers to find significant areas of less than optimal code generation, at which they may focus their efforts to improve code generation efficiency. Another potential use of instruction level detail is to provide guidance to the designer of future systems. Such designers employ profiling tools to find threads, modules, functions, codepaths, characteristic code sequences, or single instructions that require optimization for a given hardware environment.
[0005] Multitasking can describe a processor or set of processors that operate on one process or subprocess before another is completed. The term “process” is sometimes used interchangeably with “task,” “thread,” and other such terms. A multitasking system splits time between processes depending on factors such as input/output (I/O) activity, interrupts, or the expiration of a fixed time interval. Threading can be a form of multitasking.
[0006] Threading can improve single-application performance by constantly feeding instructions to a single processor. For example, a single-threaded web server would be trapped in a wait state every time it fetched data from a disk. However, a multithreaded web server can handle new requests with one thread while another thread waits on the data from the disk. Multiple threads running on a processor can be analyzed to determine how much time a processor spends on each thread. Such a multithreaded arrangement improves performance by allowing the processor to operate continuously rather than wait for a slow process, such as I/O, to complete.
[0007] Process scheduling is the method by which the operating system determines which thread to run on the processor. Threads are sometimes assigned a class depending on the thread's priority. Threads running in a lower-priority class often only receive the processor time left over by higher-priority classes. Schedulers may allocate processor time to threads based on class and may interrupt a thread before the thread is complete. Schedulers may determine the order in which a thread should run and how much processor time each thread is allocated while running.
[0008] Sample-based profiling can describe a technique of periodically interrupting the operation of process execution at regular intervals. At each interruption, samples are taken to inform a developer which function was executing just before the interruption. After the interruption, normal processing is restarted. The interrupting and restarting of the process is looped for a predetermined length of time, for a predetermined number of events of interest, or upon an event such as user input.
[0009] At each time interval, the processor collects a sample that is then used to determine the function the processor is running. By sampling for many time intervals, a profiler can determine statistically on which functions a processor is spending its time. A profiler can then generate a report summarizing the sampled data.
[0010] An example profiler stops an application and samples the program counter of the currently executing thread. The profiler repeatedly stops the processor over many clock cycles to obtain a statistically meaningful quantity of data. The program counter values may be resolved against a load map and symbol table information for determining the function on which the processor is executing. The profiler increments a counter for the area of the particular area of code that is executing. Some profilers process information on the fly and create data structures representing an ongoing history of the runtime environment. Other profilers add data to a buffer or file for processing after sampling.
[0011] If profiling was carried out for 100 interrupts, a profile might indicate that the processor was running code from function A during 50 interrupts, the processor was running code from function B during 25 interrupts, and the processor was running code from function C during 25 interrupts. Such data would indicate to the developer that processor time was split among functions A, B, and C on a percentage basis of 50%, 25%, and 25%, respectively. If functions A, B, and C all were written to have equal distribution, the example profile would tend to indicate that functions B and C are not receiving enough processor time and function A is processor-bound, requiring too much processor time.
[0012] A sample-based profiler may obtain information from the stack of an interrupted thread. A “stack” is a region of reserved memory in which a program or programs store status data, such as procedure and function call addresses, passed parameters, and local variables. A “stack frame” is a portion of a thread's stack that represents local storage (arguments, return addresses, return values, and local variables) for a single function invocation. Every active thread of execution has a portion of system memory allocated for its stack space. A thread's stack could consist of sequences of stack frames. The set of frames on a thread's stack could represent the state of execution of that thread at any time. Many operating systems provide software timer interrupts useful to profilers. These timer interrupts can be employed to sample information from a call stack.
[0013] In a multitasking system, threads can be queued before the threads are executed. One technique for queuing threads is to maintain a single. centralized queue that may be referred to generically as a “run queue.” If a processor becomes available, the next available thread is assigned from the run queue to the processor.
[0014] In some multi-processor systems, queuing threads may be accomplished by maintaining separate queues for each processor. Thus, when a thread is created, it could be assigned to a processor in a round robin fashion. With such a technique, some processors may become overloaded while other processors are relatively idle. Furthermore, some low priority threads may become starved, i.e. not provided with enough processing time, because higher priority threads are added to the run queue of the processor for which the low priority threads are waiting.
[0015] Previous sample-based profiling systems collected data relating to a specific process the processor was executing during each scheduled interruption of a process. Such profilers provided no data or limited data on a process that was runnable but not running when the interruption occurred. Runnable but not running means that the only resource the process is waiting on is the CPU itself. Such previous profiling systems are limited in the ability to determine whether a process is starved of processor time. Thus, there is a need for an apparatus and method for profiling processes are runnable but not running in a multithreaded environment.
SUMMARY OF THE INVENTION
[0016] An embodiment of the present invention is a computer program in a computer readable medium for profiling a multithreaded system. The computer program has first instructions for interrupting the operation of an application running in a multithreaded system. Second instructions identify, for a desired process, if this process is runnable but not running. Third instructions increment a counter for the process, signifying that it was runnable but not running, or signifying a function of the process was running. In an embodiment, the computer program loops for a predetermined amount of time or until otherwise interrupted. An embodiment includes instructions for generating a report summarizing function counts to allow developers the ability to see function characteristics including which functions may be starved of processor time.
[0017] Another embodiment is a method for profiling a multithreaded process after identifying a process to be profiled. Instructions are executed on a processor in a multithreaded manner and the executing of instructions is interrupted. A determination is made of whether the process is runnable but not running and a counter is incremented for the process if the process is runnable but not running.
[0018] Another embodiment is a data processing system for processing a multithreaded application. A profiler system waits a predetermined period of time, interrupts the processing of the multithreaded application, identifies a thread that is runnable but not running, and increments a counter for the thread that is runnable but not running. The multithreaded application is restarted and a report is generated summarizing the value of the counter.
[0019] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention can be used to profile process starvation for processes operating in a multithreaded environment. For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0021] FIG. 1 illustrates a representative hardware environment for practicing the present invention.
[0022] FIG. 2 is a flow chart illustrating steps in a profiler.
[0023] FIG. 3 is an illustration of an example report generated by a profiler.
[0024] FIG. 4 is a flow chart illustrating steps performed by an embodiment of the present invention.
[0025] FIG. 5 is an illustration of an example report generated by an embodiment of the present invention.
[0026] FIG. 6 is a flow chart illustrating an embodiment's steps for determining whether a task is runnable but not running.
DETAILED DESCRIPTION
[0027] In the following description, numerous specific details are shown in flow diagrams to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known circuits, software, and hardware functions have been summarized as flow chart elements in order not to obscure the present invention in unnecessary detail. For the most part, details concerning software encoding and the like have been omitted inasmuch as such details are not necessary to obtain a complete understanding of the present invention and are within the skills of persons of ordinary skill in the relevant art.
[0028] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0029] FIG. 1 illustrates a representative hardware environment for practicing the present invention. An exemplary hardware configuration of data processing system 113 is shown having central processing unit (CPU) 110 , such as a conventional microprocessor, and a number of other units interconnected via system bus 112 . Data processing system 113 could include random access memory (RAM) 114 , read only memory (ROM) 116 , and input/output (I/O) adapter 118 for connecting peripheral devices such as disk units 120 and tape drives 140 to bus 112 . Data processing system 113 could include user interface adapter 120 for connecting keyboard 124 , mouse 126 , and/or other user interface devices such as a touch screen device (not shown) to bus 112 . Further, processing system 113 could include communications adapter 134 for connecting data processing system 113 to a data processing network, and display adapter 136 for connecting bus 112 to display device 138 . CPU 110 may include other circuitry not shown herein, which will include circuitry commonly found within a microprocessor, e.g., execution unit, bus interface unit, arithmetic logic unit, etc. CPU 110 may also reside on a single integrated circuit. Communications adapter 134 could be any network adapter such as an Ethernet adapter. Disk unit 120 could be any computable readable medium and could be used for storing a computer program embodiment in conjunction with the present invention.
[0030] FIG. 2 illustrates profiling steps taken by a profiler. First, an application is started in step 202 for executing on CPU 110 . In step 204 , the developer identifies to the operating system (OS) a specific process, for example process “ABC,” in need of profiling. Process ABC may include function_A, function_B, and function_C, for example. In step 206 , the developer starts the profiler and then in step 214 the profiler interrupts the application after a predetermined period or after the occurrence of some event. In step 216 , the profiler then determines whether process ABC was running at the time processing on CPU 110 was stopped. If process ABC was running function_A, for example, then in step 208 the profiler collects samples for function_A. If process ABC was not running when CPU 110 was interrupted, then a determination is made in step 218 whether the time for sampling has expired. If the time for sampling has not expired, then in step 220 , the profiler waits for a proper amount of time for the next interrupt and then loops through steps 214 , 216 , and 208 until a determination is made in step 218 that the time for sampling has expired. When the time for sampling has expired, step 210 stops sampling and step 212 generates a report.
[0031] FIG. 3 is an illustration of a report 300 that might be generated in step 212 of FIG. 2 . The report 300 could inform a software developer how much processor time was spent on function_A, function_B, and function_C. The report 300 generated by the profiler might indicate on line 302 that function_A had 50 hits, on line 304 that function_B had 25 hits, and on line 306 that function_C had 25 hits. A hit would be indicated by the value of the counter for that function. If the software developer expected each function to share the processor equally, the report 300 might cause the software developer concern because the processor appears to have executed function_A 50% of the time and remainder of time was split equally between function_B and function_C. The software developer would likely investigate further to determine why function_A was receiving twice as much processor time as each of function_B and function_C. Profiling as described in this paragraph is useful, but such profiling may be deficient for determining information on functions, threads, or processes that were not running when the CPU 110 was stopped. Further, in the above scenario the software developer might mistakenly attempt optimization of function_A to achieve a better balance when the problem was with a parameter other than function_A. With such profilers, no sample is taken if process ABC is runnable but not running, which means that the process is ready to run, is not running, and is waiting for the processor rather than waiting for I/O, lock, or the like. To aid in software development, a method and apparatus are needed for profiling processes that are runnable but not running.
[0032] FIG. 4 illustrates profiling steps taken by an embodiment of the present invention: First, in step 402 an application is started on CPU 110 by profiler 400 . In step 404 , the developer identifies a specific process in need of profiling to the operating system. For example, the developer could instruct that process ABC is in need of profiling. Process ABC includes function_A, function _B, and function_C. The developer in step 406 starts the profiler and then in step 414 the profiler interrupts the application after a predetermined period or after the occurrence of some event. In step 416 , the profiler determines whether process ABC is running and in step 408 the profiler collects samples for process ABC if the process is running. If process ABC is not running, the profiler in step 424 determines whether process ABC is runnable but not running. If process ABC is runnable but not running, the profiler in step 422 collects a sample and then cycles to step 418 for possible further profiling. If process ABC is waiting on I/O or is otherwise not runnable, the profiler cycles back to step 418 for further profiling without collecting a sample in step 422 . In step 408 , samples are collected if process ABC is running and in step 422 samples are collected if process ABC is runnable but not running. In step 420 , the profiler 400 waits for the proper period for the next interrupt and then loops, as appropriate, through steps 414 , 416 , 408 , 424 , and 422 until a determination is made in step 418 that the time for sampling has expired. When the time for sampling is over, sampling is stopped in step 410 and a report is generated in step 412 .
[0033] FIG. 5 shows an example of a report 500 illustrating data generated by sampling as shown in FIG. 4 . Data on line 502 represents that function_A from process ABC was running during 5% of the 1000 samples. Data on line 504 represents that function_B from process ABC was running during 2.5% of the samples. Likewise, data on line 506 represents that function_C was running during 2.5% of the samples. In an embodiment, data on line 508 represents that during 90% of samples taken, process ABC was runnable but not running. By collecting information on such processes that are runnable but not ruining, a developer can better determine how to optimize a process, application, or system. This method and apparatus of the present invention potentially prevents a developer from diving into an area for performance optimization where such optimization may not be needed. Using the technique described in FIG. 2 , a developer might conclude that optimizing function_A, as shown in FIG. 3 will yield the most improvement. However, with the data from FIG. 5 , if CPU starvation is observed, the prudent approach may be to solve the starvation problem before attempting to optimize function_A.
[0034] FIG. 6 is a flow chart illustrating a methodology 600 for an embodiment profiler determining whether a process is runnable but not running. Methodology 600 could be incorporated into step 424 from FIG. 4 . If the identified process in step 416 is not running at the time of interruption in step 414 , the profiler reads the run queue in step 602 . If a process is not queued for the CPU in step 604 , in step 418 the profiler determines whether the time for sampling has expired. If the process is queued for the CPU in step 604 , the profiler in step 606 determines whether the process is waiting only for the CPU or whether the process is waiting for I/O, lock, or some other event. If the process is queued for the CPU and waiting only for the CPU, a sample is collected and the process counter is incremented in step 422 . In an alternate embodiment, the run queue can be read again in step 602 as necessary to look for any other process flagged for profiling. After determining whether a process is runnable but not running and sampling accordingly, the profiler returns to step 418 for determining whether the time for sampling has ended.
[0035] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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A profiler of a multithreaded process that determines whether a process is runnable but not running by determining whether a process is both waiting for the processor and also not waiting for other events such as I/O. Counters are maintained for each such process that is runnable but not running. Reports are generated summarizing data relating to any process that may be starved due to lack of processor time. Information obtained by the method and apparatus assists developers in optimizing resources in multithreaded environments.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/251,348, filed Oct. 14, 2008, now issued as U.S. Pat. No. _,___,___, and incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present invention relates to systems and methods for network communications. More particularly, the present invention relates to a timing interface module with daughter timing reference modules.
[0003] The increasing use and expansion of digital voice, TV and Internet services continue to apply pressure for increased bandwidth. In fact, even more bandwidth-intensive services are on the horizon. This increased demand means service providers need to add capacity to their networks as quickly as possible. Previously, that process required the integration of additional hardware or even the complete replacement of existing networks because a service provider's network typically only allows so much data traffic to travel through at any given time.
[0004] However, advancements in optical transport systems fully integrate additional bandwidth capability in easily expandable modules. Moreover, such advancements are allowing providers to increase the bandwidth available on their existing networks without extensive network redesign or reconfiguration. For example, rather than installing additional stand-alone hardware, an optical transport system may be used to integrate pure optical switching via wavelength selective switches, reconfigurable optical add-drop multiplexing, Ethernet switching, next-generation SONET/SDH add-drop multiplexers and dense wavelength division multiplexing (DWDM) into a single platform. Thus, traffic may be added or dropped into a DWDM network to easily increase bandwidth to offer HDTV, video-on-demand and high-speed Internet access.
[0005] A SONET multiplexer enables carriers to cost-effectively combine signals of multiple optical carrier levels onto one wavelength for transport. Further, SONET network equipment transports and/or multiplexes traffic that has originated from a variety of different clock sources. Thus, SONET requires timing sources to provide synchronization. External timing connections provide the timing signals to ensure synchronous accuracy of the network. In contrast, other types of networks do not require timing, e.g., Ethernet, ATM, SAN, etc. For example, legacy DWDM and other data systems do not have external timing connections.
[0006] It can be seen then that there is a need for a method and apparatus for providing external timing to systems for combining synchronous and data signals while complying with all relevant industry standards.
SUMMARY
[0007] Exemplary embodiments address these and other issues by providing a timing interface module with daughter timing reference modules. Timing modules are provided in a rack platform to eliminate routing problems and which is compliant with all relevant industry standards.
[0008] According to one embodiment, a timing reference module includes a face plate having a first and second substantially rectangular opening, the face plate further comprising mounting slots for receiving mounting hardware therein and a first and second timing module, the first and second timing module disposed within the first and second substantially rectangular openings, wherein the first and second timing modules provides timing terminations of timing reference signals for network elements of a synchronized optical network.
[0009] These and other features and advantages will be apparent from a reading of the following detailed description and a review of the associated drawings. It is to be understood that both foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a rack mounted optical transport system according to an embodiment;
[0011] FIG. 2 illustrates a multiplexer in a SONET network according to an embodiment;
[0012] FIG. 3 shows a system using an external timing source; and
[0013] FIG. 4 illustrates a timing interface module according to an embodiment.
DETAILED DESCRIPTION
[0014] In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration exemplary embodiments. It is to be understood that embodiments are applicable to a timing interface module with daughter timing reference modules.
[0015] FIG. 1 illustrates a rack mounted optical transport system 100 according to an embodiment. In FIG. 1 , a plurality of components 112 , 114 , 116 are mounted in a rack 110 . According to an exemplary embodiment, components 112 , 114 , 116 of the optical transport system 100 may include an optical transmission module, optical repeater module, optical reception module, etc. The optical transport system 100 conducts the processing, such as amplification, repeating, termination, add-drop, etc., with respect to optical signals. Moreover, a large number of optical cables (optical fibers) are brought into each optical transmission station that then carries out the processing, such as amplification, repeating, etc. A portion of the processed optical signal may be provided to an optical cable, while the remaining optical signal may be, for example, converted to an electric signal for transmission as a packet signal.
[0016] The amplification, repeating and other processing are conducted in the optical transport system 100 . A plurality of shelves 120 may be configured as one unit on one rack to provide for an increase in mounting density of these shelves. The entire equipment in which a desired device works (or operates) in a rack may be referred to as a rack mount apparatus.
[0017] In FIG. 1 , a front view of the optical transport system 100 is shown. Slots 130 are formed in a front surface side of shelf rack 120 so that each of the slots 130 allows the insertion of a plug-in unit, printed board unit or package. Connectors 140 may be provided on the front or at the back of the rack. Components 116 may provide lighted indicators 150 on the front to provide an indication of a state for the components 114 or to a signal status.
[0018] Although the size of a rack is determined according to the industry standard, for non-standard shelving the size of the shelf 120 may be designed to match the size of the rack to achieve the high-density mounting in one rack. The optical transport system 100 may also include an internal fan unit 160 with a cooling fan, for example, at the base of the optical transport system 100 .
[0019] As mentioned above, advancements in transponder modules have led to fully integrated bandwidth capability in easily expandable modules. Moreover, such advancements are allowing providers to increase the bandwidth available on their existing networks without extensive network redesign or reconfiguration. With reference to FIG. 1 , an optical transponder module may be simply plugged into a slot for coupling to a network's existing switches of the optical transport system 100 to provide a dramatic increase in capacity.
[0020] A SONET multiplexer may be installed in the rack mount system to enable a carrier to cost-effectively combine signals of multiple optical carrier levels onto one wavelength for transport. A timing interface module as described below may be mounted in the shelf 120 to provide timing signals to enable the signals from different clock sources to be synchronized.
[0021] FIG. 2 illustrates a multiplexer in a SONET network 200 according to an embodiment. In FIG. 2 , three datastreams 210 , 212 , 214 are shown as inputs to a SONET multiplexor 216 . SONET allows datastreams of different formats to be combined onto a single high-speed fiber optic synchronous datastream 220 . However, combining datastreams of different formats requires the connection of external timing source to synchronize the datastreams. Moreover, the timing source must be compliant with all relevant industry standards.
[0022] FIG. 3 shows a system using an external timing source 300 . In FIG. 3 , a primary reference source (PRS) 310 provides signals to a synchronization supply unit (SSU) 320 . The synchronization supply unit 320 provides primary 322 and secondary 324 timing signals to equipment, such as an add/drop multiplexer 330 and telecommunications switch 340 . For example, the add/drop multiplexer 330 may be used to combine datastreams 332 of different formats as described above with reference to FIG. 2 . The switch 340 may be coupled to a communications network 350 , such as a cellular network.
[0023] FIG. 4 illustrates a timing interface module 400 according to an embodiment. In FIG. 4 , the timing interface module 400 is configured for mounting in a rack system, such as the rack mount system 100 illustrated in FIG. 1 . The timing interface module 400 includes daughter timing reference modules 462 , 464 . The timing interface module 400 is designed as a circuit pack-like device that is slotted in the shelves of the rack mount system 100 shown in FIG. 1 .
[0024] The timing interface module 400 may be permanently mounted in the rack mount system 100 of FIG. 1 , for example, with four screws through mounting slots 410 - 416 in the faceplate 418 . The timing interface module 400 provides timing terminations for any synchronous components that might be mounted in the rack. The timing interface module 400 may also include wire wrap pins 420 to physically tie down the synchronization signals. The wire-wrap pins are recessed and the cover provides strain relief for the timing cables that are terminated there. External cabling (other than the cables to the SSU) is not are not required. The two slots may be configured with redundant modules 462 , 464 to provide copies of both the primary and secondary timing reference signals to the backplane 430 . Accordingly, the timing interface module 400 provides a solution that will not require any external cabling to make connections between T 1 timing reference termination points and distribution to the backplane of the rack mount system.
[0025] The timing interface module 400 according to an embodiment replaces the need for a previously required Timing Interface Bracket (TIB) and application of power for the timing interface module 400 is made simpler. In addition, the timing interface module 400 according to an embodiment eliminates the need for any special cables previously required to interconnect the TIB and timing reference modules (TRMs). The timing interface module 400 may therefore be installed so that an optical transport system may behave like a SONET NE with respect to timing connections, i.e., as if external timing were an option from the beginning The dimensions of the timing interface module 400 may be configured to occupy two or more adjacent slots in a shelf of the rack mount system. Captive screws utilizing existing threaded holes in the chassis of the rack and threaded through the mounting slots 410 - 416 make the timing interface module 400 a semi-permanent extension of the shelf.
[0026] Sub-modules 462 , 464 are the redundant Timing Reference Modules (TRM) that, as indicated above, provide copies of both the primary and secondary timing reference signals to the backplane 430 . In addition, the sub-modules 462 , 464 are easily removable using, for example, thumb-latches 470 - 476 . An insulated metal cover 480 may be provided to protect wire-wrap pins 420 and provide mechanical strain relief for timing cables. Recessed wire-wrap pin fields 420 are provided for primary and secondary BITS clock connections.
[0027] Accordingly, the timing interface module 400 enables data and SONET services to be multiplexed onto a single wavelength. The combining of different services and data signals of different formats allows service providers to provide additional wavelength services. Additional advantages could be realized through cost savings for transport of IOF or other “internal” traffic.
[0028] The circuit pack-like device provided by the timing interface module 400 serves the same purpose as the backplane timing terminations found on all existing SONET network elements. Wire wrap pins physically tie down the synchronization signals. Thus, the timing interface module 400 eliminates the need for external cabling to make connections between the primary timing reference termination point and distribution to the backplane of the shelf.
[0029] The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A timing interface module installs within a rack to increase bandwidth. The timing interface module receives a reference timing signal and outputs the reference timing signal to an optical multiplexer. The optical multiplexer also receives multiple data streams of different formats, and the optical multiplexer synchronizes the multiple data streams to the reference timing signal.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of producing inner parts of a tripod joint. The inner parts include radial arms followed by a tubular shaft.
It is common practice to produce inner parts of tripod joints by forging or forming the parts with an annular member with inner teeth and subsequent, integrally producing radial arms to receive tripod rollers. An externally toothed tubular shaft is inserted into the inner teeth and axially secured by securing means to the annular member. Furthermore, it is known to form inner parts with an annular member and integral radial arms and to connect the annular member, via an end face, to a tubular shaft by welding. Friction welding is a particularly suitable process for this type of connection. At its end facing away from the tubular shaft, the annular member may be closed by a bottom part. Both above types of forming are described in EP 0 115 232 B1, published Aug. 8, 1984. Machining of the inner parts of both the above described joint designs is relatively complicated since they include three joint arms with deviating axes.
The first mentioned method has a weak point in the region where the arms are connected to the internally toothed annular member. This weak point is due to the joint size and its relatively small wall thickness. In addition, it is relatively expensive to produce the teeth on the tubular shaft and in the annular member.
When selecting material for the inner joint part of the second above mentioned method, a compromise must be made between the wear resistance of the arms and the mechanical load bearing capacity of the inner part, e.g. fracture strength, of the annular member.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method which enables the inner part of a tripod joint, with a subsequent tubular shaft, to be produced cost-effectively and with an improved quality.
The objective is achieved by deforming, in a non-chip forming way, one end of the tubular shaft. This deforming increases the wall thickness and, in the thickened region, the radial arms are connected to the tubular shaft end. By thickening the material, it is possible to achieve a much greater strength in the region of the arm base as compared to the teeth insertion solution. By integrating the tubular shaft and the annular member of the inner joint part, this eliminates the connection in the region of the tubular shaft. Also, individual arms may be produced of a higher quality material and are easier to machine.
To thicken the tubular shaft end, known round hammering, upsetting or forging process techniques may be used. These processes will not be described in greater detail. The selected process enables separate heat treatment of the tubular shaft on the one hand and, prior to the connecting operation, of the arms on the other hand. Thus, the tubular shaft may be optimized with respect to its mechanical load bearing capacity and the arms optimized with respect to the wear resistance of their surfaces. In preparation for connection, the thickened region of the tubular shaft end may be provided with three faces which extend tangentially relative to the tubular shaft member, preferably, and optionally in combination with three radial countersunk regions or bores.
According to a first possibility, the arms may abut the faces and may be secured by friction welding. Also, it may be advantageous to provide the arms with axial extensions or shoulder faces. The shoulder faces are inserted into the countersunk regions or bores and connect in the region by friction welding. In the case of friction welding, heat treatment of the surfaces may be restricted to the region of the external arm parts, whereas a tougher arm extension of the above shape establishes the connection with the thickened region of the tubular shaft end.
According to further embodiments it is possible to produce the arms as described above and solder them into countersunk regions and/or bores. Also, the arms and bores may be threaded around the corresponding threads and threaded together.
From the following detailed description taken in conjunction with the accompanying drawings and subjoined claims, other objects and advantages of the present invention will become apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are illustrated in the drawings wherein:
FIG. 1 is a longitudinal cross sectional view of a tubular shaft end with a thickened portion in accordance with the invention.
FIG. 2 is an exploded partial cross sectional view of a tubular shaft end prepared for inserting an arm, as well as an individual arm.
FIG. 3 is a cross sectional view of a tubular shaft end according to FIG. 2, with the arm in the inserted condition.
FIG. 4 is a longitudinal cross sectional view through a tubular shaft end similar to that shown in FIG. 3.
FIG. 5 is an exploded partial cross sectional view of a second embodiment of a tubular shaft end and an individual arm.
FIG. 6 is a cross sectional view of a tubular shaft end according to FIG. 5, with the arm in the inserted condition.
FIG. 7 is a longitudinal cross sectional view of a tubular shaft end according to FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a tubular shaft end 1 with an internally conical region 2 for wall thickening purposes, a conical region 3 for diameter reducing purposes and an external part-spherical thickened region 4 at its outer end is located between the regions 2, 3. A short cylindrical portion 5 is located between the regions 3, 4. Also, longer cylindrical portion 6, with a smaller diameter is located between the regions 3, 4. The inner bore 7 of the tube continues with a reduced diameter as far as and into the thickened region 4.
FIG. 2 shows a partially machined thickened region 4' with the inner bore 7, three flattened regions 8, which reduce the originally round cross section, and three radial bores 9 starting from said flattened regions and arranged perpendicularly thereon. The flattened regions 8 and bores 9 are formed at angles of 120° with respect to one another. FIG. 2 also shows a joint arm 10 with a cylindrical portion. The joint arm 10 includes an enlarged collar region 11 and an adjoining insertion region 12. The parts illustrated are suitable for being connected by friction welding, soldering or gluing.
FIG. 3 illustrates three arms 10 inserted into the thickened region 4' of a completed outer joint part 13. The collar regions 11 abut and, at the same time, rest on the said flattened regions 8. In the regions marked by intersecting lines, the arms 10, by friction welding, are connected to one another in their insertion regions and to the thickened region 4' in the region of the collar regions 11. Instead of these welded regions it is also possible to provide soldered or glued regions produced by corresponding processes.
FIG. 4 shows the tubular shaft end and the same details as illustrated in FIG. 1, with radial arms 14 inserted into the thickened region 4'. The arms 14 deviate from the arms 10 shown in FIGS. 2 and 3 in that they do not include collar regions and do not contact one another in the region of insertion. The contour of the inserted arm 14 is not shown in greater detail inside the thickened region 4'.
FIG. 5 illustrates a cross-section through the thickened region 4". The thickened region 4" includes the inner aperture 7 and three circumferentially distributed countersunk regions 15. Radial threaded bores 16 start from the countersunk regions 15 and extend as far as the inner aperture 7. An arm 18 including a collar region 19 is fit into the countersunk region and a threaded journal 20, shown in the form of a detail, is threaded into the bore 16.
FIG. 6 shows a cross-section of a completed inner joint part 17. The joint part 17 includes three of joint arms 18 threaded into the thickened region 4" until the collar region 9 abuts the countersink 15.
FIG. 7 illustrates a tubular shaft end, with the details already described in FIG. 1, and with arms 18 according to FIGS. 5 and 6 threaded into its thickened region 4,,
While the above detailed description describes the preferred embodiment of the present invention, the invention is susceptible to modification, variation, and alteration without deviating from the scope and fair meaning of the subjoined claims.
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A method of producing inner parts of a tripod joint followed by a tubular shaft has one end of the tubular shaft deformed in a non-chip-forming way. The deforming increases the wall thickness. Radial arms are connected to the thickened region of the tubular shaft end, preferably by friction welding.
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BACKGROUND OF THE INVENTION
The field of the present invention relates to techniques for screening differences in gene expression between various cell types or between different stages of cell development.
In higher organisms, every cell expresses about 10-20% of the 100,000 possible different genes. Gene expression is involved in all life processes, such as development, aging and disease states. Thus, the analysis of which genes are expressed at any given time, and the identification of the expressed mRNAs, is of prime interest in molecular biology.
One such method for screening differences in gene expression is known as Differential Display. This method is described in Pardee et al., U.S. Pat. No. 5,262,311, hereby incorporated by reference. Differential Display involves amplifying partial cDNA sequences from subsets of mRNAs by reverse transcription and the polymerase chain reaction (PCR), then displaying these sequences on a sequencing gel.
In the Differential Display method, the primers which hybridize to the 3' end of the mRNA [the 3' primers] are selected to take advantage of the polyadenylate [polyA] tail present on most eukaryotic mRNAs to anchor the primers at the 3' end of the mRNA. Each 3' primer hybridizes to a portion of the polyA tail and additionally to 2 bases which are immediately 5' of the polyA tail. The 2 nucleotides of the 3' primer which are not complementary to the polyA tail are of the sequence VN, where V is deoxyadenylate ("dA"), deoxyguanylate ("dG"), or deoxycytidylate ("dC"), and N, the 3' terminal nucleotide, is dA, dG, dC, or deoxythymidylate ("dT"). By probability, each 3' primer Will recognize one-twelfth of the total mRNA population, since there are twelve different combinations of the two 3' bases, eliminating T as the base which hybridizes immediately 5' of the polyA tail. Such primers are used to reverse transcribe specific subpopulations of mRNAs.
A second set of primers, the 5' primers, is designed to randomly select a subset of the cDNAs generated using the 3' oligonucleotide primers. The 5' primers are of arbitrary base sequence. The cDNA sequences defined by these two primer sets are then amplified by PCR. The amplified products can then be displayed on a sequencing gel, and visualized by autoradiography. Using this method, comparisons can be made of the genes expressed by different cell types, or by cells in various stages of development or disease.
Differential Display uses short 9 to 14 base primers that require low temperature annealing throughout PCR amplification. Such low temperature annealing conditions result in a decline in the reproducibility of the method. As noted by the creators of Differential Display (Liang et al., Nucl. Acids Res. 21:3269-3275), "[a] troublesome aspect of the method is that the noise level of false positives, though a few percent, can be very appreciable relative to the truly different bands between cells."
SUMMARY OF THE INVENTION
Applicant provides an improved method of Differential Display, named Enhanced Differential Display (EDD). EDD is designed as a technique for screening differences in gene expression between various cell types or between different stages of cell development. The technique is highly reproducible, leading to precise typing of the expressed genes in any given cell. EDD analysis permits the identification of novel genes involved in differentiation, aging, and disease, and enables direct comparisons of different cell types and disease states.
EDD uses the polymerase chain reaction (PCR) to amplify cDNA produced from a selected set of expressed mRNA sequences from particular cell types. The EDD method is similar to Differential Display, which also uses reverse transcriptase and PCR to identify differentially expressed genes. However, unlike Differential Display, which uses short 9 to 14 bases primers, EDD uses longer primers.
We have surprisingly found that by using longer primers, and/or an alteration in the annealing temperatures, the number of false positives can be significantly reduced. By "longer primers" it is meant that the primers are of at least 21 nucleotides in length, and can be up to 50 nucleotides in length. Most preferably, the oligonucleotide primers are between 22 and 30 nucleotides in length.
Thus, in a first aspect, the invention features an improved method for detecting differences in gene expression which comprises, first, contacting nucleic acid which comprises an mRNA sequence with a first oligonucleotide primer, wherein said first oligonucleotide primer has a hybridizing sequence sufficiently complementary to a region of said mRNA to hybridize therewith. Next, the first oligonucleotide primer is extended in an extension reaction using the mRNA as a template to give a first DNA primer extension product complementary to the mRNA. The first DNA primer extension product is then contacted with a second oligonucleotide primer, wherein the second oligonucleotide primer has a hybridizing sequence sufficiently complementary to the first DNA primer extension product to hybridize therewith. The second oligonucleotide primer is then extended in an extension reaction using the first DNA primer extension product as a template to give a second DNA primer extension product complementary to the first DNA primer extension product, and the first and second DNA primer extension products are amplified. The improvements of this method comprise one or more of the following: providing first and second oligonucleotide primers with a length of at least 21 oligonucleotides; the use of a two-step PCR amplification; and, not adding additional 3' oligonucleotide primers to the PCR amplification reaction mixture.
In a preferred embodiment, the PCR amplification is carried out in two steps. The first one to four cycles of PCR are carried out under non-stringent conditions. By "non-stringent" conditions it is meant that low annealing temperatures are used. Preferably, the annealing temperature used for the non-stringent conditions cycles is between 35° C. and 45° C. Most preferably, the annealing temperature used for the non-stringent conditions cycles is about 41° C. The next 16 to 20 cycles of amplification are carried out in stringent conditions. By "stringent" conditions it is meant that higher annealing temperatures are used. Preferably, the annealing temperature used for the stringent conditions cycles is between 55° C. and 70° C. Most preferably, the annealing temperature used for the stringent conditions cycles is about 60° C.-65° C. The buffer conditions used for both the stringent and non-stringent cycles are the same. An example of the annealing conditions used for both the stringent and nonstringent cycles is: 1 μl cDNA (3'primer carried over from cDNA), 2 μl 10x PCR buffer, 1.5 μl 0.1 mM dNTP, 1.25 μl 20 μM 5'primer, 1 μl 1 to 5 dilution of alpha- 32 P dATP, 0.5 μl Taq polymerase, and 12.75 μl dH 2 O.
"Cycle" refers to the process which results in the production of a copy of a target nucleic acid. A cycle includes a denaturing step, an annealing step, and an extending step. An example of the non-stringent PCR cycles is: denature the DNA at 94° C., for 45 sec.; anneal the primers at 41° C., for 1 min.; extend the primers at 72° C., for 1 min. An example of the stringent PCR cycles is: denature the DNA at 94° C., for 45 sec.; anneal the primers at 60° C., for 1 min.; extend the primers at 72° C., for 1 min.
In another preferred embodiment, a portion of the 3' oligonucleotide primer hybridizes to the polyA tail of the mRNA sequence. Preferably, the 3' oligonucleotide primer has at least one nucleotide which can hybridize to an mRNA sequence which is immediately 5' to the polyA tail. More preferably, the 3' oligonucleotide is at least 21 nucleotides in length, and contains two nucleotides which can hybridize to a mRNA sequence which is immediately 5' to the polyA tail, and the remaining portion of the 3' oligonucleotide can hybridize to the polyA tail. Most preferably, the 3' oligonucleotide is at least 21 nucleotides in length, and contains two nucleotides which can hybridize to a mRNA sequence which is immediately 5' to the polyA tail, and the middle 10-15 bases of the 3' oligonucleotide can hybridize to the polyA tail, while the 5' end of the 3' oligonucleotide contains a restriction site.
In another embodiment, 3' oligonucleotide primers which do not hybridize to the polyA tail of mRNA can be used. In this embodiment, mRNA having a polyA tail is first isolated from total cellular RNA. A random set of 10-15 primers is used to hybridize to different regions of the mRNA.
In another preferred embodiment, no additional 3' oligonucleotide primers are added to the PCR amplification reaction mixture. The amplification proceeds using only the 3' oligonucleotide primers which remain in the cDNA reaction mixture. The use of lower amounts of 3' oligonucleotide primers results in lowered production of non-specific sequences.
EDD was designed to eliminate false positives as well as to increase the efficiency of obtaining authentic differentially expressed genes. Long primers and the two-stage PCR amplification appear to eliminate totally the problem of false positives and the subsequent labor-intensive work to verify true positives. Moreover, PCR amplification is highly efficient with EDD. In addition, when a preferred embodiment of the method is used, the amplified gene fragments are easily subcloned into bacterial vectors owing to the restriction sites designed into the 5' end of the primers.
Freedom from false positives is especially important when comparing many tissues simultaneously, such as is done when screening for senescent-specific genes. FIG. 4 shows an example of EDD performed on RNA from 11 different cell samples at different stages of senescence and immortalization. Since the chances of false positives increase with the number of samples being compared, a comparison such as this would not be very informative using standard Differential Display. By contrast, we have identified many authentic differentially expressed genes using EDD on these 11 samples.
With the increased accuracy and reproducibility of EDD, catalogues of expressed genes can be prepared from different cell types during aging, development, and disease. These catalogues can then be used to identify rapidly most of the genes involved in the processes. Therefore, EDD represents a significant advance in our technical capability to identify novel genes likely to be functionally important in aging, development, and disease states.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawings will first be briefly described.
Drawings
FIG. 1 depicts the basic method of EDD.
FIG. 2 depicts typical primer sets used in the basic EDD method.
FIG. 3 depicts PCR products from differentially expressed genes which are displayed simultaneously on a DNA sequencing gel and visualized by autoradiography.
FIG. 4 depicts an example of EDD performed on RNA from 11 cell samples at different stages of senescence and immortalization.
The method of the present invention is generally described above. Below are non-limiting examples depicting this method.
The EDD method can be used as follows to screen differences in gene expression. First, cDNA is prepared from total cellular RNA using twelve different 22-base oligonucleotide primers (3' oligos, see FIG. 2) that are targeted to the poly A tail of pol II mRNA transcripts. The last two bases of each primer varies so as to anchor the primer to the 3' end of different sets of mRNAs. A second set of ten 22-base oligo primers (the 5' oligos, see FIG. 2) is designed to randomly select a subset of cDNAs from each of the twelve 3' primers. PCR amplification of a subset of cDNAs is carried out in a two step process using particular 5' and 3' primers. The first 2-4 cycles are carried out with annealing temperature of 41° C. which allows degenerate priming with the 3'-terminal 5 to 7 bases of each primer. The next 18 to 20 cycles of amplification are carried out with a 60° C. annealing temperature to give specific annealing of all 22 bases in each primer.
The PCR products can be labeled by including alpha- 32 P dATP in the reaction mixture. The 32 P-labeled PCR products from many cell types are then displayed simultaneously on a DNA sequencing gel and visualized by autoradiography (FIG. 3-4). Each lane contains hundreds of expressed genes specific to the particular 5' and 3' primers used and can be directly compared to the cDNA samples in adjacent lanes that were amplified with the same oligo primer set using RNA from different cell types. When differences in band intensity are observed in adjacent lanes, the up- or down-regulated gene fragments can be cut out of the gel and amplified by PCR. The amplified gene products can then be directly sequenced or rapidly subcloned into a plasmid vector for DNA sequencing. The DNA sequence can be used to search GENBANK to determine whether the gene is a known or novel gene. The full-length cDNA copy of novel genes can be isolated by screening a lambda gt11 library with labeled probes made to the EDD gene fragment.
In a further aspect, the invention comprises a kit for performing the above method. Such a kit may be prepared from readily available materials and reagents.
The following examples demonstrate the mechanism and utility of the present invention. They are not limiting and should not be considered as such.
Example 1: Synthesis of the cDNA
The cDNA copies of RNA are produced using the following procedure.
Annealing reaction:
Mix: 1 μg total RNA
2.5 μl 20 μM 3'primer (dT 12 mer)
dH 2 O to 13 μl
Heat for 10 min. at 75° C. cool on ice for 7 min.
Elongation reaction:
The following reagents are added to the above mix:
5 μl 5x first strand synthesis buffer
1 μl RNAsin (Promega, or Pharmacia)
2.5 μl 0.1M DTT
2.5 μl 1 mM dNTP
1 μl Reverse Transcriptase (M-MLV, BRL)
Incubate for 70 min. at 37° C.
Heat to inactivate enzyme for 10 min. at 95° C.
The reaction mixture can be stored at -20° C. for later use.
Example 2: PCR amplification of cDNA
The cDNA copies produced in example 1 are amplified as follows.
Mix: 1 μl 1 cDNA (3'primer carried over from cDNA)
2 μl 10x PCR buffer
1.5 μl 0.1 mM dNTP
1.25 μl 20 μM 5'primer
1 μl 1 to 5 dilution of alpha- 32 P dATP
0.5 μl Taq polymerase
12.75 μl dH 2 O
Run PCR for 4 cycles at 94° C., 45 sec.
41° C., 1 min.
72° C., 1 min.
and 18 cycles at 94° C., 45 sec.
60° C., 1 min.
72° C., 1 min.
Example 3: Sequencing gel analysis
The PCR amplified cDNA produced in example 2 can be analyzed on a sequencing gel as follows.
3 μl PCR product from example 2 is mixed with 2 μl running dye (Formamide dye). The samples are heated for 3 min. at 80°-90° C. and loaded on a 6% sequencing gel (1xTBE) and the gel is run at 2000 V (or the current <50 mA). The gels are run until the second dye reaches the bottom. This can be varied depending on the size range of the mRNA which is being compared. The gel is then dried down, and the gel and the film are taped together. Holes are carefully punched at three corners of the gel, and the film is exposed overnight.
Example 4: Recovery of the differentially displayed bands
The dried gel and the autoradiograph are lined up, and a needle is used to mark the differential bands to be cut. The bands are then cut out using a razor blade. It is important to rinse the razor blade between each band to avoid cross contamination. The gel slide is transferred into a 1.5 ml microfuge tube, and 1 ml TE is added. Next, the TE, the strips of the Saran wrap, and the Whatman paper are taken off. 40 μl of the elution buffer (TE+100 mM NaCI) is added to the gel slice, and it is heated for 10 min. at 95° C., and incubate at room temperature overnight.
Example 5: Reamplification of recovered bands
The bands recovered in example 4 can be amplified as follows.
Mix: 2-5 μl of overnight gel slice mix
5 μl 10x PCR buffer
2.5 μl 1 mM dNTP
3 μl 20M 5'primer
3 μl 20 μM 3'primer
1 μl Taq polymerase
dH 2 O to 50 μl
Run PCR for 24 to 30 cycles at 94° C., 45 sec.
60° C., 1 min.
72° C., 1 min.
When cycles are completed, extend for 5 more min. at 72° C.
At this point the PCR products can either be subcloned into a vector or purified from LMP agarose gel and sequenced from the 5' primer by a PCR sequencing kit (Stratagene).
Example 6: Use of EDD to identify genes that are specifically expressed in young or senescent cells
An initial catalog was made for RNA isolated form young and senescent cells, using 144 primer combinations, made up from 12 different 3'-T rich primers and 12 arbitrary 5' primers. The analysis of the information generated by this process showed that:
1) EDD is reproducible. Samples were analyzed with the same primer set several times within the span of several months, generating the same interpretable results.
2) Great care should be taken with all reagents. cDNA, primers and nucleotides should be aliqouted at the time of preparation, stored at -20° C. and not be thawed more than a few times.
3) The 3' primer plays a major role in determining the quality of the EDD. In the conditions used, most 3' T rich primers gave consistently good results, independent of the 5' primer that was used.
The primers ending in T12-CT and T12-AT gave poor results.
The primers ending in T12-AA, T12-AC and T12-AG gave results of mixed quality.
The primers ending in T12-CC, T12-CG, T12-GT, T12-GG T12-GA, T12-CA and T12-GC gave excellent results.
It was also shown that the pen-ultimate base in the 3' primer does contribute to its specificity, and that different display patterns are obtained if different primers are used that only differ in the pen-ultimate base.
4) In summary, out of the possible 144 combinations, 85 were deemed interpretable. On average, it is possible to identify 50 bands per lane. Therefore, the first catalog was an investigation of about 4250 gene-tags.
5) From the information obtained so far by searching GenBank, most of the known RNA sequences found to be differentially expressed by EDD have already been identified as young or senescent expressed RNAs by conventional assays published by others. Moreover, Northern blots have confirmed the EDD analysis of differential expression in the case of the novel genes tested.
6) With the conditions that were used (42° C. annealing), the specificity of annealing by the 5' primer is determined by 7 out of the last 8 bases at the 3'primer end (22 sequences analyzed). Using 7 out of 8 bases as the determinant of specificity and all 3' primers, the following probability for detecting a desired gene sequence in a 300 base pair stretch is found:
use of 10 different 5' primers: 69%
use of 15 different 5' primers: 83%
use of 20 different 5' primers: 90%
Thus, a nearly complete catalog of all expressed genes can be prepared using a large enough set of primer combinations.
7) The genes or gene-tags identified in the above screen can be investigated for their use as markers of senescence. It also anticipated that these genes can be used for the development of novel therapeutics. For instance, young genes might be growth factors, extra-cellular matrix proteins or receptors. The re-administering (in whatever form) of these kinds of gene products could themselves prove to be treatments for agerelated diseases. Senescent specific genes could, for instance, be receptors, (anti-)growth factors or extra-cellular matrix proteins. Inhibition of expression of such genes is a possible therapeutic for age-related diseases.
8) The discovered markers (gene-tags) can also be used for the identification of novel compounds that alter or modulate the pattern of senescent gene expression.
Other embodiments are within the following claims.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 30(2) INFORMATION FOR SEQ ID NO: 1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 6(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: The letter "N"stands for dA, dG, dC ordeoxythymidylate ("dT")(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 1:TTTTNN6(2) INFORMATION FOR SEQ ID NO: 2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 14(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: The letter "N"stands for dA, dG, dC ordeoxythymidylate ("dT")(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 2:AAAAAAAAAAAANN14(2) INFORMATION FOR SEQ ID NO: 3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 12(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: The letter "N"stands for dA, dG, dC ordeoxythymidylate ("dT")(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 3:TTTTNNGGTACT12(2) INFORMATION FOR SEQ ID NO: 4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 12(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: The letter "N"stands for dA, dG, dC ordeoxythymidylate ("dT")(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 4:AAAANNCCATGA12(2) INFORMATION FOR SEQ ID NO: 5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 12(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: The letter "N"stands for dA, dG, dC ordeoxythymidylate ("dT")(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 5:TTTTNNGGTACT12(2) INFORMATION FOR SEQ ID NO: 6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 12(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: The letter "N"stands for dA, dG, dC ordeoxythymidylate ("dT")(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 6:AAAANNCCATGA12(2) INFORMATION FOR SEQ ID NO: 7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 7:CGGGAAGCTTATCGACTCCAAG22(2) INFORMATION FOR SEQ ID NO: 8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 8:CGGGAAGCTTTAGCTAGCATGG22(2) INFORMATION FOR SEQ ID NO: 9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 9:CGGGAAGCTTGCTAAGACTAGC22(2) INFORMATION FOR SEQ ID NO: 10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 10:CGGGAAGCTTTGCAGTGTGTGA22(2) INFORMATION FOR SEQ ID NO: 11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 11:CGGGAAGCTTGTGACCATTGCA22(2) INFORMATION FOR SEQ ID NO: 12:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 12:CGGGAAGCTTGTCTGCTAGGTA22(2) INFORMATION FOR SEQ ID NO: 13:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 13:CGGGAAGCTTGCATGGTAGTCT22(2) INFORMATION FOR SEQ ID NO: 14:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 14:CGGGAAGCTTGTGTTGCACCAT22(2) INFORMATION FOR SEQ ID NO: 15:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 15:CGGGAAGCTTAGACGCTAGTGT22(2) INFORMATION FOR SEQ ID NO: 16:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 16:CGGGAAGCTTTAGCTAGCAGAC22(2) INFORMATION FOR SEQ ID NO: 17:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 17:CGGGAAGCTTCATGATGCTACC22(2) INFORMATION FOR SEQ ID NO: 18:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 18:CGGGAAGCTTACTCCATGACTC22(2) INFORMATION FOR SEQ ID NO: 19:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 19:GCGCAAGCTTTTTTTTTTTTCT22(2) INFORMATION FOR SEQ ID NO: 20:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 20:GCGCAAGCTTTTTTTTTTTTCC22(2) INFORMATION FOR SEQ ID NO: 21:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 21:GCGCAAGCTTTTTTTTTTTTCG22(2) INFORMATION FOR SEQ ID NO: 22:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 22:GCGCAAGCTTTTTTTTTTTTGT22(2) INFORMATION FOR SEQ ID NO: 23:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 23:GCGCAAGCTTTTTTTTTTTTGG22(2) INFORMATION FOR SEQ ID NO: 24:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 24:GCGCAAGCTTTTTTTTTTTTGA22(2) INFORMATION FOR SEQ ID NO: 25:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 25:GCGCAAGCTTTTTTTTTTTTAT22(2) INFORMATION FOR SEQ ID NO: 26:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 26:GCGCAAGCTTTTTTTTTTTTAC22(2) INFORMATION FOR SEQ ID NO: 27:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 27:GCGCAAGCTTTTTTTTTTTTAG22(2) INFORMATION FOR SEQ ID NO: 28:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 28:GCGCAAGCTTTTTTTTTTTTAA22(2) INFORMATION FOR SEQ ID NO: 29:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 29:GCGCAAGCTTTTTTTTTTTTCA22(2) INFORMATION FOR SEQ ID NO: 30:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 30:GCGCAAGCTTTTTTTTTTTTGC22__________________________________________________________________________
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An improved method for detecting and isolating differentially expressed mRNAs which comprises using first oligonucleotide primers for reverse transcription of mRNAs and both the first oligonucleotide primers and second oligonucleotide primers for amplification of the resultant cDNAs. The improvement of this method comprises providing first and second oligonucleotide primers with a length of at least 21 oligonucleotides. The method further comprises using a two-step PCR amplification, wherein non-stringent conditions are used for the first 1 to 4 cycles, and stringent conditions are used for the next 16 to 22 cycles. This highly reproducible method will permit the preparation of comprehensive catalogs of gene expression for any given cell type.
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FIELD OF THE INVENTION
[0001] The invention relates generally to improvements in vehicular energy generating systems and more particularly to mechanical means and preferably hydraulic pumps inside its tires for recovering wasted tire flexure energy and putting that recovered energy to useful work.
DESCRIPTION OF THE PRIOR ART
[0002] The prior art has numerous methods for recovering lost tire flexure energy. Most are highly complex, requiring many parts and thus expensive to produce.
[0003] U.S. Pat. No. 1,574,095 to Jokisch for an electric generator powered by the vibrations of a vehicle's body and wheels. Ratchet movements resulting from the vibrations actuating linkages drive the generator.
[0004] U.S. Pat. No. 4,061,200 to Thompson uses spring-loaded bellows in the tire to operate a pump to drive a fluid motor.
[0005] U.S. Pat. No. 3,699,367 to Thomas uses tire flexure to operate plungers which rotate a cog that turns a generator drive shaft.
[0006] U.S. Pat. No. 3,760,351 to Thomas uses a different type of plunger/actuator to turn a generator as a result of tire flexure.
[0007] U.S. Pat. No. 5,767,663 to Lu uses a means for more or less straightforwardly inducing current flow in a wire as a result of wheel movement.
[0008] The prior art is not confined to the rim of the vehicle wheels. Thus, changing tires and otherwise working upon the wheel is made priorly difficult.
[0009] Contrary to the prior art, the instant invention can provide both fluid and electrical power generation in one vehicle both during acceleration and regenerative braking. It is a run-flat type tire that adds safety to the vehicle
[0010] operation. Both features protect the power generation components of the instant wheel assembly, especially if the tire should fail.
BRIEF DESCRIPTION OF THE DRAWING
[0011] [0011]FIG. 1 is a plan view of the invention using ratchets and levers.
[0012] [0012]FIG. 2 is a cutaway view of the invention showing the power generating means.
[0013] [0013]FIG. 3 is a cutaway of the invention of FIG. 2 without a fluid motor.
[0014] [0014]FIG. 4 is a cutaway of the invention showing fluid flow paths and a lever and bellows system.
[0015] [0015]FIG. 5 is a cutaway of the invention showing the fluid flow paths of FIG. 4 with internal hydraulic motors and a plunger system.
[0016] [0016]FIG. 6 is a cutaway of the invention showing a close-up of a plunger system.
[0017] [0017]FIG. 6A is an elevation showing the invention used on steel wheels that travel on steel rails.
[0018] [0018]FIG. 7 is a cutaway of the wheel hydraulic bellows system.
[0019] [0019]FIG. 8 is a plan view of the wheel internal fluid motor external ratchet gears, ring gear and invention driveshaft gear.
[0020] [0020]FIG. 9 is partial cutaway of a direct electromagnetic linear generator with the driveshaft dynamo.
[0021] [0021]FIG. 10 is a cross section view of the driveshaft dynamo of FIG. 9.
[0022] [0022]FIG. 11 is a detail of the drive gearing for a fluid motor version of the instant invention.
[0023] [0023]FIG. 12 is a cross section view of the gearing of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Turning to FIG. 1, we see a weight-powered wheel 10 . The force of gravity pulling on the mass of a vehicle such as an automobile causes tire with its interior donut 32 to deflect 12 when the wheel 10 turns the rubber of the tire 11 against the ground. This deflection 12 is well known and is normally used to absorb some shock forces so to produce a smoother ride for the passengers of the vehicle using the wheel 10 .
[0025] A plurality of levers 14 are supported by the rim 16 of power-producing wheel 20 located within the pneumatic interior 18 of wheel 10 .
[0026] Rim 16 has a plurality of ratchet gears 22 that articulate with a common ring gear 24 . Gear 24 is shown located at the periphery of the internal diameter of the rim 16 and tire bead. Gear 24 drives axle 26 , which is connected to weight-powered gearbox 30 (FIG. 2). Gearbox 30 may then be used to help turn the vehicle driveshaft either via electric motor 50 (FIG. 9) and driveshaft dynamo or hydraulic motor 50 (FIG. 11).
[0027] Axle 26 (FIG. 2) is a hydraulic motor located at each wheel as against the one or more hydraulic motors located at the driveshaft and differential. Element 26 in FIG. 2 is a pair of hydraulic conduits. These allow the invention gearbox to be replaced by a hydraulic motor (Master Hydraulic Motor) 50 at the differential that receives fluid from all four wheel motors 46 . An hydraulic bypass line 32 in or at motor 50 would redistribute fluid to an hydraulic air compressor or electric generator when excess power is to be stored (not shown). While cruising, most of the fluid from the wheel motors would bypass the Master Hydraulic Motor 50 to the power storage motor. When the brake is applied, the Master Hydraulic Motor 50 is switched to a hydraulic pump driven by the kinetic energy in the vehicle driveshaft to recover regenerative braking energy to the energy storage system (either compressed air or electricity).
[0028] The air compressor charges an air receiver that is then used to drive a well known air motor (not shown).
[0029] Air motors are known art and have successfully self-powered at least one prior art vehicle called the e.Volution car, put out by Zero Pollution Motors of France.
[0030] Alternatively, the air receiver may simply boost the hydraulic drive line pressure.
[0031] Lever 14 when activated by the tire deflection 12 turns ratchet gears 22 which then turns ring gear 24 separately from the spin of tire 11 . It is the spin of gear 24 , separate from that of wheel 10 , that turns axle 26 .
[0032] Turning to FIG. 2, tire 11 interior space 18 contains an interior non-deflatable donut 32 that pushes on interior ratchet gear lever roller 34 when it itself is pushed inwardly by tire deflection 12 . Thus the energy of deflection 12 is transferred to roller 34 , which then turns ratchet gears 36 located on the inner wheel rim 38 . Gears 36 then turn ring gear 40 , which powers the axle gear 42 , which turns axle 26 .
[0033] Exterior hydraulic wheel motor 46 is shown attached to vehicle axle housing 48 to provide hydraulic fluid pumping power from its wheel to the hydraulic generator 50 or the Master Hydraulic Motor 50 to provide power assist and/or power assisted braking; or to the hydraulic air compressor or electric generator to provide power storage. The assist is then used to increase vehicle gas mileage, decrease electric motor power needs and otherwise help in moving and/or braking the vehicle.
[0034] [0034]FIG. 3 shows motor 46 gone while line 32 feeds strut 52 . The hydraulic fluid pressure in strut 52 is used to automatically modulate or adjust the gear ratio so that the power harvested from axle 26 can be matched to a specific percentage of vehicle weight. The heavier the vehicle, the more power it produces when it closes the donuts:
[0035] In FIG. 4, a plurality of hydraulic donuts, bellows or pistons 60 are placed upon rim 16 . A different configuration of pistons 60 is shown in FIGS. 5 and 6.
[0036] The configurations of FIGS. 4 - 6 are activated by interior donut 32 as the tire 11 itself and donut 32 deflect at 12 . Donut 32 is attached all around the tire interior. It does not matter whether these configurations are applicable to road wheels or train wheels. The instant invention has the ability to add power to all moving vehicles.
[0037] Internal hydraulic motors 70 are driven by common hydraulic output duct 72 which is fed by one-way valve 74 . Ball valves 74 are shown, but any suitable valve 74 may be used. Springs 76 (shown in FIG. 6), in conjunction with the return fluid pressure, push pistons 60 back into waiting position after they pass through deflection 12 .
[0038] [0038]FIG. 7 shows a solid tire donut 32 . The donut 32 may otherwise be made inflatable (FIGS. 2, 3) if so desired. Doing so would endanger the invention's run-flat abilities. Donut 32 may also have a hard or spongy texture depending upon power production vs. passenger comfort requirements. The donut 32 may otherwise be made hollow (FIGS. 2, 3).
[0039] Here donut 32 pushes on bladder compression bar 90 at the deflection 12 . Bar 90 compresses interior bladder 92 . Interior donut 92 then squeezes fluid through one-way valve 94 . Once fluid passes through valve 94 , it activates interior hydraulic motor 96 having vanes 98 . The fluid then passes out one-way valve 100 into fluid return duct 102 .
[0040] The center axle in FIG. 7 is the vehicle's axle 48 .
[0041] All fluid power can be transmitted to gearbox 30 either by axle 26 or via typical direct hydraulic tubing (not shown) instead. The same option occurs for powering the hydraulic motor 50 .
[0042] [0042]FIG. 8 shows interior hydraulic system cover plate 110 having ring gear 40 operated by interior hydraulic motor gears 114 and the gear 118 for the exterior hydraulic motor axle 119 or the invention's gearbox axle 26 .
[0043] [0043]FIG. 9 shows linear induction driveshaft dynamo 120 . Axle 121 serves as the rotor having windings or permanent magnets 122 while stator windings 123 surround them. Through suitable and well-known means, electric energy is produced and can then be fed into the stator winding 123 of driveshaft dynamo 120 surrounding the vehicle driveshaft 121 . The windings on the vehicle driveshaft 121 serve to directly propel the vehicle as the rotor energizing stator 123 induces a magnetic torque on driveshaft 121 rotor windings or permanent magnets. Thus the induced torque provides vehicle propulsive power.
[0044] [0044]FIG. 10 shows the system of FIG. 9 (in cross section) cutaway. Driveshaft 121 is in the center with its own windings or permanent magnets 122 . Thus, the induced torque provides propulsive power.
[0045] Driveshaft 121 has rubber mounts 130 for the driveshaft mount 131 . Shaft 121 is in the center with its own windings 122 . Stator windings 123 surround them. Protective casing 136 is enclosing the works.
[0046] Hydraulic motor 50 may here be alternator 50 having alternator drive shaft 51 (which is the same as driveshaft 26 and 119 ). Differential casing 155 shows the location relative to the vehicle.
[0047] Universal joint 157 may remain exactly the same as the usual vehicle design in the dynamo driven electrical 120 power systems or may be modified to accept gear 180 that is driven by the hydraulic motor 50 in the hydraulic drive system. Gear 180 may instead be incorporated into a modified differential drive shaft as shown in FIG. 11. The hydraulic air compressor could be located on the driveshaft 121 in an arrangement similar to the dynamo 120 (FIG. 12) where it could function as a second hydraulic power assist motor in addition to its functions as a power storage pump driven by either the wheel hydraulic fluid that bypasses the Master Hydraulic Motor 50 , by compressed air from storage or by the driveshaft itself in a regenerative braking energy recovery role. Direct fluid intake and output via ports(s) and tube(s) 161 to and from Master Hydraulic Motor 50 as shown. Tube 161 is in phantom as it can be either an alternative to the electric feed or it can also be an adjunct for delivering even more power overall.
[0048] Finally, FIG. 11 shows Master Hydraulic Motor 50 output shaft 51 running bevel gears 180 which drive the vehicle via the differential 155 or the universal joint 157 . This depends upon the exact placement of Master Hydraulic Motor 50 upon driveshaft 121 . FIG. 12 is a view of the bevel gears 180 or the driveshaft installed hydraulic air compressor.
[0049] It should be noted that the wheel levers and pumps 46 , 50 and 60 when loaded with more weight produce more hydraulic power. Also the faster the vehicle travels, the more power it produces. The hydraulic modulation of strut 52 is based on loaded vehicle weight. As such, depending upon vehicle weight and speed, the instant invention may in fact generate more power then the vehicle needs. This is not available in the prior art. The extra power may be used to charge batteries, spin a superflywheel or even be traded by magnetic induction with the ground or rails, catenary or whatever is useful and put back into the electric power infrastructure. Induction coils on the vehicle will interact via magnetic lines of force in a well-known manner with other coils or super magnets in the ground, etc so to transfer the extra electrical power. Here is a time when the vehicle can operate without fueling stops. Using magnetic induction and actively transferring electrical power to the vehicle from the ground or rails placed upon the ground, the vehicle can be powered directly without refueling stops.
[0050] IN OPERATION, mechanical linkages or fluid pressure (pneumatic, hydraulic or any suitable system made after the manner of the instant invention) via pumps 60 in various configurations, is made to run either an alternator, a fluid motor 50 or an excess fluid pressure receiver for boosting either drive line pressure or directly driving the vehicle driveshaft itself.
[0051] Onboard electric generation is directly accomplished via the instant driveshaft dynamo. Fluid pressure operated generator can also produce electricity onboard the vehicle.
[0052] Both fluid pressure and dynamo output can be directed to top off energy storage devices such as batteries and/or superflywheel, or the like.
[0053] Pneumatic power storage is the safest of all storage options and has the capability of propelling vehicles all by itself.
[0054] Thus, an environmentally friendly and useful vehicle powering system for both long and short runs is capable of being produced and could be designed to retrofit existing railroad ICE-type vehicles with minimal disturbance of prevailing vehicle designs and components.
[0055] It should be understood, of course, that the foregoing relates to preferred embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A wheeled vehicle has mechanical and preferably hydraulic pumps inside its tires. The weight of the vehicle pumps up a reservoir as the tires roll. The pressure in the reservoir is used to directly or indirectly propel the vehicle.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a control apparatus for an AC generator of a motor vehicle. More particularly, the invention is concerned with a control apparatus for an AC generator of a motor vehicle which is adapted to control switching or changing-over of the output of the AC generator of a motor vehicle from a battery for charging thereof to a high-voltage load such as a catalyst heating system, a defreezing system or the like which is designed to be driven with a high voltage for a short period.
2. Description of Related Art
In order to operate during a relatively short period a catalyst heating system for purifying an exhaust gas of an internal combustion engine immediately in succession to the start thereof or a defreezing system for removing within a short time the ice layers adhering to window panes of the motor vehicle in the coldest season, it is required to operate the system of concern with a high voltage falling within a range of 30 to 50 volts because the system constitutes a high-voltage load. However, it is impossible to supply such a high voltage to the system from an onboard battery of the motor vehicle. Under the circumstances, the output power of an AC generator for the motor vehicle is directly supplied to the system.
As a control apparatus for an AC generator of a motor vehicle known heretofore, there may be mentioned an apparatus disclosed in Japanese Unexamined Patent Application Publication No. 31212/1988 (JP-A-63-31212). FIG. 5 is a circuit diagram showing a structure of the control apparatus disclosed in the publication mentioned above. Referring to FIG. 5, an AC generator 1 driven by an internal combustion engine (not shown) is comprised of an armature coil 101 and a field coil 102. The electric power generated by the AC generator 1 undergoes a full-wave rectification by a rectifier circuit 2, as a result of which a DC voltage is generated across a terminal 201 of positive polarity (hereinafter referred to as the plus terminal) and a terminal 202 of negative polarity (hereinafter referred to as the minus terminal) which is connected to the ground potential.
A voltage regulator 3 serves for controlling an exciting current fed to the field coil 102 of the AC generator 1 in dependence on whether the output of the rectifier circuit 2 is to be changed over to a battery 4 or to an onboard high-voltage electric load 5 such as the exhaust gas heating system, defreezing system or the like of the motor vehicle to thereby regulate the AC output voltage of the AC generator 1 to a preset corresponding value.
A key switch 6 is closed upon starting of the engine. As a result of this, an initial exciting current is supplied to the field coil 102 of the AC generator from the battery 4 by way of an excitation line L3 led out from an output change-over controller 7 while a power supply source voltage is supplied to the voltage regulator 3 from the battery 4.
The voltage regulator 3 is constituted by a series circuit of voltage divider resistors 301 and 302 for dividing a plus terminal voltage of the battery 4 applied via a voltage detection line L1 led out from the output change-over controller 7 or the output voltage of the rectifier circuit 2, a Zener diode 303 having a cathode connected to a junction P1 between the voltage divider resistors 301 and 302 and a series connection of a base resistor 306 and a transistor 304 connected between the pulse terminal of the battery 4 via the excitation line L3 and the ground potential, wherein the anode of the Zener diode 303 is connected to a base of the transistor 304 so that the transistor 304 is turned on or off in response to the turn-on (conducting state) or turn-off (nonconducting state) of the Zener diode 303.
Further connected between the ground potential and the plus terminal of the battery 4 via the excitation line L3 is a series circuit of a surge absorbing diode 307 and an output transistor 305, wherein a base of the output transistor 305 is connected to a junction between a base resistor 306 and a corrector of the transistor 304 so that the output transistor 305 is turned on or off under the control of the transistor 304.
The field coil 102 is connected in parallel to a surge absorbing diode 307 via wiring conductors. Thus, the exciting current supplied to the field coil 102 from the battery 4 can flow through the field coil 102 and then to the ground by way of the output transistor 305.
The output change-over controller 7 is composed of an output change-over switch 71, an excitation switch 72 and a voltage detection change-over switch 73, wherein the contact change-over operation of the output change-over switch 71 is controlled by an excitation coil CL1. A common terminal C1 of the output change-over switch 71 is connected to the plus terminal 201 of the rectifier circuit 2, while a contact A1 of the output change-over switch 71 is connected to the onboard high-voltage electric load 5 with a contact B1 of the switch 71 being connected to the plus terminal of the battery 4. On the other hand, the excitation switch 72 includes a timer contact T which is opened about one second when an excitation coil CL2 is energized by way of the output change-over switch 71. The excitation switch 72 has one end connected to the plus terminal of the battery 4 via the key switch 6 and the other end connected to a positive or plus pole of the field coil 102 via the excitation line L3.
The voltage detection change-over switch 73 has a common terminal C2 which is connected to one end of the voltage divider resistor 301 via the voltage detection line L1, while a contact A2 of the switch 73 is connected to the common terminal C1 of the output change-over controller 7 by way of a high-voltage detecting resistor 731 with a contact B2 of the switch 73 being connected to the plus terminal of the battery 4. Thus, when the common terminal C2 of the voltage detection change-over switch 73 is closed to the contact A2, the high-voltage detecting resistor 731 is electrically inserted in series to the voltage divider resistors 301 and 302, resulting in that the output voltage of the rectifier circuit 2 is applied across the voltage divider resistors 301 and 302. On the other hand, when the common terminal C2 of the voltage detection change-over switch 73 is closed to the contact B2, the plus terminal voltage of the battery 4 is applied across the voltage divider resistors 301 and 302.
Next, operation of the known control apparatus shown in FIG. 5 will be described. In the battery charge operation mode for charging the battery 4, the common terminals C1 and C2 of the output change-over switch 71 and the voltage detection change-over switch 73 are closed to the contacts B1 and B2, respectively, whereby the plus terminal of the battery 4 is connected to the plus terminal 201 of the rectifier circuit 2 and the voltage divider resistor 301.
When the key switch 6 is closed upon starting of the engine of the motor vehicle, the excitation switch 72 is automatically closed. As a result of this, an exciting current flows to the field coil 102 of the AC generator 1 from the battery 4 by way of the key switch 6 and the excitation switch 72.
When the engine operation is started, the field coil 102 rotates relative to the armature coil 101, whereby an AC voltage is induced in the armature coil 101. The induced AC voltage is rectified by the rectifier circuit 2 and thus a DC voltage makes appearance between the plus terminal 201 and the minus terminal 202 of the rectifier circuit 2, as a result of which the battery 4 is charged by way of the output change-over switch 71.
There may arise such situation that the battery 4 is overcharged when the AC generator 1 continues to generate the output power after starting of the engine. To cope with such situation, the plus terminal voltage of the battery 4 is applied across the series circuit of the voltage divider resistors 301 and 302 by way of the voltage detection change-over switch 73. When the applied terminal voltage of the battery 4 increases beyond, for example, 14 volts, the divided voltage making appearance at the junction P1 between the voltage divider resistors 301 and 302 rises up to a voltage level which enables the Zener diode 303 to conduct. Thus, the Zener diode 303 assumes the conducting state.
Consequently, the transistor 304 is turned on to thereby lower the base potential of the output transistor 305 to the ground potential level, rendering the output transistor 305 to the non-conducting or off-state. Thus, the exciting current supplied to the field coil 102 from the battery 4 via the output transistor 305 is interrupted, which results in that the potential at the plus terminal 201 of the rectifier circuit 2 is lowered. In this manner, the terminal voltage of the battery 4 is so controlled as to assume a predetermined constant value without being overcharged.
By contrast, when the terminal voltage of the battery 4 becomes lower due to power supply to a load of the motor vehicle, the voltage appearing at the junction between the voltage divider resistors 301 and 302 becomes lower than a voltage for maintaining the Zener diode in the conducting state. Thus, the Zener diode 303 becomes nonconducting with the transistor 304 being turned off. In the mean while, a base current flows to the base of the output transistor 305 by way of the base resistor 306, whereby the output transistor 305 is turned on. As a result of this, the exciting current flows to the field coil 102 from the battery 4 via the output transistor 305 to thereby set the AC generator 1 to the power generation mode. The operation described above is repeated every time the terminal voltage of the battery 4 lowers, for regulating the terminal voltage of the battery 4 so that it assumes a predetermined level constantly.
Next, description will turn to a high-voltage load operation mode of the AC generator for actuating a catalyst heating system, a defrosting system or the like which is represented by the high-voltage load 5. Upon supplying the output of the rectifier circuit 2 to the onboard high-voltage electric load 5 by switching the output change-over switch 71 to the contact A1, the excitation switch 72 is turned off about one second under energization of the excitation coil CL2, whereby the exciting current flowing to the field coil 102 is attenuated. Thus, the output change-over switch 71 can be protected against damage or injury due to spark or similar unwanted phenomena which may take place in conjunction with the operation of the output change-over switch 71.
During a period in which the excitation switch 72 is in the off-state, the output change-over switch 71 is closed to the contact A1, whereby the plus terminal 201 of the rectifier circuit 2 is connected to the onboard high-voltage electric load 5. Furthermore, because the voltage detection change-over switch 73 is closed to the contact A2, the high-voltage detecting resistor 731 is electrically connected in series to the voltage divider resistor 301, which means that the high-voltage detecting resistor 731 and the voltage divider resistors 301 and 302 are connected in series between the plus terminal 201 of the rectifier circuit 2 and the ground potential.
After completion of the change-over operations of the output change-over switch 71 and the voltage detection change-over switch 73, the excitation switch 72 is restored to the closed state. At this juncture, it should be mentioned that the sequential control of the output change-over switch 71 and the voltage detection change-over switch 73 is automatically carried out by a control circuit (not shown) which is incorporated in the output change-over controller 7. Upon closing of the excitation switch 72, the exciting current flows to the field coil 102 of the AC generator 1 from the battery 4. Thus, the voltage of the electric power generated by the AC generator 1 increases as the engine rotation speed increases, causing the DC potential at the plus terminal 201 of the rectifier circuit 2 to increase correspondingly. Thus, the electric power generated by the AC generator 1 is supplied to the onboard high-voltage electric load 5 by way of the output change-over switch 71.
The output voltage of the rectifier circuit 2 is detected by the high-voltage detecting resistor 731 and the voltage divider resistors 301 and 302. In that case, when the value of the output voltage of the rectifier circuit 2 increases beyond, for example, 50 volts, the voltage appearing at the junction P1 between the voltage divider resistors 301 and 302 reaches the turn-on threshold value of the Zener diode 303 to thereby set it to the conducting state (on-state).
As a consequence, the transistor 304 is turned on to lower the potential applied to the base of the output transistor 305 to the ground potential, whereby the output transistor 305 is turned off. Thus, the exciting current supplied to the field coil 102 from the battery 4 via the output transistor 305 is interrupted. Due to the interruption of the exciting current, the potential at the plus terminal 201 of the rectifier circuit 2 is prevented from increasing beyond 50 volts and remains at a constant voltage level.
It is however noted that when the potential at the plus terminal 201 lowers below a predetermined value during the period in which the voltage is supplied to the onboard high-voltage electric load 5, the voltage appearing at the junction P1 between the voltage divider resistors 301 and 302 lowers to such a level that the Zener diode 303 and hence the transistor 304 become nonconductive. Consequently, a base current flows to the base of the output transistor 305 via the base resistor 306 to turn on the output transistor 305. Thus, the DC current can again flow to the field coil 102 from the battery 4 by way of the output transistor 305, whereupon the power generating operation of the AC generator 1 is started again.
By repeating the operation described above every time the potential of the plus terminal 201 of the rectifier circuit 2 becomes low, the high voltage of the power supplied to the onboard high-voltage electric load 5 is so controlled as to remain to be constant. As is apparent from the foregoing description, in the high-voltage load operation mode such as described above, the battery 4 can not be charged by the output power of the AC generator 1 but continues to supply the exciting current to the field coil 102. Thus, the battery 4 may ultimately assume the discharged state.
For preventing the battery 4 from the overdischarge such as mentioned above, the high-voltage load operation is limited to a short duration (on the order of several minutes). Further, when the terminal voltage of the battery 4 becomes lower than a predetermined value, the high-voltage load operation is stopped in order to resume the ordinary battery charge operation. These operations are effected under the control of a control circuit (not shown) which is incorporated in the output change-over controller 7.
However, the conventional output control apparatus for the AC generator of the motor vehicle of the structure described above suffers from problems mentioned below.
1) Because of the necessity of changing over the terminal voltage of the battery in the normal battery charge operation mode with the rectified output power in the high-voltage load operation mode, it is required to provide a voltage detection change-over switch, which means that the number of parts of the control apparatus increases to make the apparatus complicate and expensive.
2) When a mechanical switch having metal contacts is employed as the voltage detection change-over switch in view of the current capacity as required for the switch, the contact resistance increases because of deterioration of the contacts in the course of time lapse, incurring unavoidably a voltage drop across the contacts. When such voltage drop becomes high, it is necessary to apply an increased rectifier output or terminal voltage of the battery across the divider resistors in order to ensure a turn-on voltage of the Zener diode which will ultimately incur a corresponding increase in the regulating voltage and hence the power consumption in both the normal operation mode and the high-voltage load operation mode.
3) Besides, when the contact resistance mentioned above becomes infinite due to destruction of the voltage detection change-over switch, the voltage drop will become infinitely large, rendering it impossible to feed back the rectified output and the terminal voltage of the battery to the voltage regulator, which in turn makes impossible the output voltage control of the AC generator. As a result, the output voltage of the rectifier will rise up abnormally to thereby overcharge the battery, which may thus suffer a damage which can not be remedied.
SUMMARY OF THE INVENTION
In the light of the state of the art described above, it is an object of the present invention to provide a control apparatus for an AC generator of a motor vehicle in which the voltage detection change-over switch of an output change-over means can be spared and which allows the control apparatus to be implemented inexpensively.
Another object of the present invention is to provide a control apparatus for an AC generator which is capable of suppressing variation of the regulating voltage which is brought about by deterioration of switch contacts, to thereby protect the battery and the high-voltage load from damage and which can thus ensure a high reliability.
In view of the above and other objects which will become apparent as the description proceeds, there is provided according to a general aspect of the present invention a control apparatus for an AC generator of a motor vehicle, which apparatus includes a rectifier circuit for rectifying an output of the AC generator including a field coil, an output change-over means for changing over an output of the rectifier circuit to either one of a battery and a high-voltage load mounted on the motor vehicle, and a voltage regulating means for regulating an exciting current supplied to the field coil in dependence on a terminal voltage of the battery as detected on a charging line connected to the battery by way of the output change-over means upon charging of the battery from the output of the rectifier circuit, to thereby regulate the output voltage of the AC generator.
With the arrangement of the AC generator control apparatus for the motor vehicle described above, the exciting current fed to the field coil is controlled in dependence on the terminal voltage of the battery when the output power of the rectifier circuit is supplied to the battery to thereby regulate or adjust the output voltage of the AC generator so that the terminal voltage of the battery can be maintained at a constant level.
In a preferred mode for carrying out the invention, the control apparatus mentioned above may further includes a high-voltage control means for detecting a terminal voltage of the high-voltage load upon switching of the output change-over means to the high-voltage load to thereby output a drive signal for controlling operation of the voltage regulating means upon detection of abnormality of the terminal voltage.
With the structure of the motor vehicle AC generator control apparatus described above, the exciting current fed to the field coil can be controlled in dependence on the terminal voltage of the high-voltage load when the output change-over means is switched to the high-voltage load, to thereby regulate or adjust correspondingly the output voltage of the AC generator for controlling the voltage supplied to the high-voltage load so that it remains constant. Thus, the circuit configuration can be simplified because the terminal voltage detection of the high-voltage load can be effectuated by detecting the terminal voltage of the battery without need for changing over the voltage detection lines.
In another preferred mode for carrying out the invention, the high-voltage control means may be so implemented as to invalidate the detecting operation of the voltage regulator for detecting the terminal voltage of the battery upon switching of the output change-over means to the high-voltage load and output a drive signal for driving/controlling the voltage regulating means in dependence on the result of abnormality detection of the terminal voltage of the high-voltage load.
With the arrangement of the motor vehicle AC generator control apparatus described above, operation for detecting change of the terminal voltage of the battery is invalidated when the output change-over means is switched to the high-voltage load so that the output voltage of the AC generator can be adjusted or regulated by controlling the exciting current fed to the field coil in dependence on only the variation of the terminal voltage of the high-voltage load, whereby the provision of the individual voltage detection change-over means is rendered unnecessary. Thus, the abnormal voltage detection can easily be realized because the terminal voltage abnormality detection is realized simultaneously with the switching of the output change-over means to the high-voltage load from the battery.
In yet another preferred mode for carrying out the invention, the high-voltage control means may include an exciting current interrupting means for interrupting temporarily the supply of the exciting current to the field coil from the voltage regulator upon switching of the output change-over means to the high-voltage load.
By virtue of the arrangement of the control apparatus for the AC generator of a motor vehicle described above, the exciting current fed to the field coil from the battery is interrupted for several seconds upon switching of the output power of the rectifier circuit to the high-voltage load from the battery by the output change-over means, whereby the output change-over means can be protected against damage due to a spark which may otherwise take place.
In still another preferred mode for carrying out the invention, the high-voltage control means may include an abnormality alarming means for outputting an abnormality alarm signal in response to an abnormality detection signal indicating abnormality of the output of the AC generator.
With the arrangement of the control apparatus for the AC generator of the motor vehicle described above, the abnormality event that the output power of the AC generator becomes abnormally low can be informed to the driver by the alarm means provided in association with the high-voltage control means. Thus, the safety of the apparatus can be enhanced because the abnormality of the AC generator can be detected regardless of whether the control apparatus is in the battery charge operation mode or in the high-voltage load operation mode, to another advantage of the invention.
In a further preferred mode for carrying out the invention, the abnormality detection signal may be derived from an output voltage of the AC generator rectified by a rectifier circuit and outputted from an additional rectifier output terminal thereof.
With the structure of the AC generator control apparatus described above, abnormality of the output power of the AC generator can be informed by the alarm means to the driver, when the output voltage generated from the second rectifier output terminal becomes abnormally low. Thus, the abnormality detection of the AC generator can easily be carried out at the DC voltage level.
In a yet further preferred mode for carrying out the invention, the abnormality detection signal may be derived from a smoothed voltage generated by rectifying and smoothing one phase output voltage of the AC generator.
With the arrangement of the control apparatus for the AC generator of a motor vehicle, one phase voltage of the AC generator is outputted to the alarm means after rectification thereof, wherein abnormality of the AC generator output is messaged by the alarming means when the output voltage of the AC generator lowers abnormally. Thus, the abnormality detection can effectively be realized with high reliability because it is carried out straightforwardly on the output voltage of the AC generator.
In a still further preferred mode for carrying out the invention, the abnormality detection signal may be applied to an input terminal of the voltage regulator to which a drive signal is inputted through a connecting line extending from the high-voltage control means and at the same time applied to an abnormality alarming means by way of the same connecting line.
With the arrangement of the control apparatus described above, the abnormality alarm signal is applied to the input terminal of the voltage regulator receiving the drive signal from the high voltage control circuit via the connecting line or conductor, wherein the abnormality alarm signal of the alarm means incorporated in the high-voltage control circuit is supplied by way of the same connecting line. Thus, the wiring length of the abnormality detection line can be shortened to a possible minimum, whereby the influence of noise to the abnormality detection signal can be suppressed to thereby assure an improvement of the signal quality.
The above and other objects, features and attendant advantages of the present invention will more easily be understood by reading the following description of the preferred embodiments thereof taken, only by way of example, in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of the description which follows, reference is made to the drawings, in which:
FIG. 1 shows a circuit configuration of a control apparatus for an AC generator of a motor vehicle according to a first embodiment of the present invention;
FIG. 2 is a block diagram showing a structure of the control apparatus for an AC generator of a motor vehicle according to a second embodiment of the present invention;
FIG. 3 is a block diagram showing a structure of the control apparatus for an AC generator of a motor vehicle according to a third embodiment of the invention;
FIG. 4 is a circuit diagram showing a structure of the control apparatus for an AC generator of a motor vehicle according to a fourth embodiment of the invention; and
FIG. 5 is a circuit diagram showing a structure of the conventional control apparatus for an AC generator of a motor vehicle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described in detail in conjunction with what is presently considered as preferred or typical embodiments thereof by reference to the drawings. In the following description, like reference characters designate like or corresponding parts throughout the several views.
Embodiment 1
FIG. 1 shows a circuit configuration of a control apparatus for an AC generator of a motor vehicle according to a first embodiment of the present invention. In the figure, like reference characters as those used in FIG. 5 denote components like as or equivalent to those shown in FIG. 5. Referring to FIG. 1, in a voltage regulator 3A according to the instant embodiment of the invention, the plus end (i.e., end having a positive polarity) of a series circuit of the voltage divider resistors 301 and 302 is connected directly to the plus terminal of the battery 4 by the excitation line L3. Similarly, the end of plus polarity of the field coil 102 is connected directly to the plus terminal of the battery 4 via the excitation line L3.
A high-voltage control circuit 8 is provided in place of the voltage detection change-over switch 73 employed in the conventional apparatus shown in FIG. 5. The high-voltage control circuit 8 is composed of a series circuit of a resistor 801 and a Zener diode 802 which cooperate to constitute a constant voltage source and to which a voltage of plus polarity is inputted from the battery 4 via the key switch 6, a comparator 805 having a plus input terminal to which a voltage generated across an onboard high-voltage electric load 5 is inputted via a high-voltage detection line L4 and a minus input terminal to which a reference voltage is inputted, and a transistor 806 having a base connected to an output terminal of the comparator 805 so that the transistor 806 is turned on in response to a high-level output of the comparator 805 and a collector to which connected is one end of a resistor 807 which serves to drive the output transistor 305. The other end of the resistor 807 is connected to a junction between the resistor 801 and the Zener diode 802 which cooperate to constitute a constant voltage source.
The collector of the transistor 806 is connected to the base of the output transistor 305 constituting a part of the voltage regulator 3A via a driving line L5. A one-shot multivibrator 806a is so implemented as to output a pulse signal having a pulse width or duration corresponding to about one second in response to switching of the output change-over switch 71 to the contact A1 from the contact B1. The output pulse signal of the one-shot multivibrator 806a is applied to a base of a transistor 806b which is turned on in response to the pulse signal and maintained in the conducting state (on state) during a period of about one second, whereby the driving line L5 is connected to the ground potential. Thus, the output transistor 305 is set to the nonconducting state (off state) about one second to thereby interrupt the exciting current.
At this juncture, it should be mentioned that the voltage regulator 3A is accommodated within a same unit together with the AC generator 1 and the rectifier circuit 2. On the other hand, the high-voltage control circuit 8 is disposed separately from the above-mentioned unit in view of the connections with the peripheral components such as the key switch 6, the onboard high-voltage electric load 5, etc., and is electrically connected to the voltage regulator 3A.
Next, description will turn to operations of the control apparatus according to the instant embodiment of the invention. When the common terminal C1 of the output change-over switch 71 is closed to the contact B1 in the battery charge operation mode (ordinary operation mode) for charging the battery 4, the plus terminal 201 of the rectifier circuit 2 is set to the charge-ready state. At this time point, the key switch 6 is in the off-state. Accordingly, the operation of the constant power supply source is inhibited. Thus, the output transistor 305 remains in the nonconducting state, whereby the exciting current supplied to the field coil 102 is interrupted.
When the key switch 6 is closed upon starting of the engine, the constant power supply source (801, 802) incorporated in the high-voltage control circuit 8 operates to generate a voltage across the resistor 807, which voltage is applied to the base of the output transistor 305 via the driving line L5. As result of this, the exciting current can flow through the field coil 102 of the AC generator 1 from the battery 4 by way of the output transistor 305.
As the engine operates, the field coil 102 rotates relative to the armature coil 101, as a result of which an AC voltage is induced in the armature coil 101. The induced AC voltage is rectified by the rectifier circuit 2. The DC voltage outputted from the rectifier circuit 2 makes appearance across the plus terminal 201 and the minus terminal 202 of the rectifier circuit 2. With this DC voltage, the battery 4 is charged by way of the rectifier output line L2 and the output change-over switch 71.
When the AC generator 1 continues to generate the electricity after operation of the engine has been started, there may occur an overcharge of the battery 4. Under the circumstances, the voltage of the plus terminal of the battery 4 is applied across the series circuit of the voltage divider resistors 301 and 302 via the excitation line L3. In that case, when the applied terminal voltage of the battery 4 increases beyond, for example, 14 volts, the divided voltage making appearance at the junction P1 between the voltage divider resistors 301 and 302 reaches a value at which the Zener diode 303 is turned on (i.e., set to the conducting state).
When the Zener diode 303 is turned on, the transistor 304 is switched to the conducting state, as a result of which the base potential of the output transistor 305 is lowered to the ground potential, resulting in that the output transistor 305 is turned off. Accordingly, the exciting current supplied to the field coil 102 from the battery 4 via the output transistor 305 is interrupted, as a result of which the potential at the plus terminal 201 of the rectifier circuit 2 becomes lowered with the terminal voltage of the battery 4 being restored to the predetermined constant level.
On the other hand, when the terminal voltage is lowered due to power supply to a load from the battery 4, the divided voltage appearing at the junction between the voltage divider resistors 301 and 302 lowers below the threshold voltage level of the Zener diode 303, which is then set to the off-state (nonconducting state), being accompanied with the turn-off of the transistor 304. A base voltage is applied to the base of the output transistor 305 from the constant power supply source, which results in that the exciting current again flows to the field coil 102 from the battery 4 via the output transistor 305 to thereby allow the AC generator 1 to restart the generation of electricity. The process of operations described above is repetitively executed every time the terminal voltage of the battery 4 lowers, for thereby regulating the terminal voltage of the battery 4 so that it assumes a constant level.
Next, description will turn to a high-voltage load operation mode in which a catalyst heating system or a defreezing system or the like high-voltage load is operated. At first, the output change-over switch 71 is changed over to thereby allow the output of the rectifier circuit 2 to be supplied to the onboard high-voltage electric load 5. At this time, the one-shot multivibrator 806a outputs a pulse signal having a temporal duration of about one second, which signal is applied to the base of the transistor 806b. Thus, the latter is set to the conducting state for about one second. As a result of this, the rectifier output line L2 is connected to the ground potential, which in turn means that the base of the output transistor 305 is connected to the ground potential with the output transistor 305 being turned off for about one second. Consequently, the exciting current flowing through the field coil 102 is attenuated. By virtue of this arrangement, the output change-over switch 71 is protected against damage due to spark which may otherwise be produced upon changing-over of the output change-over switch 71.
At this time, the terminal voltage appearing across the onboard high-voltage electric load 5 is applied to the plus terminal of the comparator 805 incorporated in the high-voltage control circuit 8 to be compared with the reference voltage applied to the minus terminal of the comparator 805.
When the terminal voltage mentioned above is lower than the reference voltage, the comparator 805 outputs a signal of low level, which is applied to the base of the transistor 806b to thereby turn off the latter. As a result of this, the voltage generated across the resistor 807 by the constant power supply source (801, 802) is applied to the base of the output transistor 305, which is then turned on to increase the exciting current flowing through the field coil 102. Thus, the output voltage of the AC generator 1 increases to thereby rise up the terminal voltage of the onboard high-voltage electric load 5.
However, when the terminal voltage of the onboard high-voltage electric load 5 increases beyond the reference voltage of the comparator 805, a high level voltage signal is outputted from the comparator 805 to be applied to the base of the transistor 806b, which responds thereto to be switched to the conducting state. When the transistor 806b turns on, the resistor 807 connected to the collector of the transistor 806b is coupled to the ground potential with application of the voltage to the base of the output transistor 305 being interrupted. Thus, the output transistor 305 is set to the nonconducting or off state.
When the output transistor 305 is turned off, the exciting current decreases, whereby the output voltage of the AC generator becomes lower. By carrying out repetitively the process or operation described above, the terminal voltage of the onboard high-voltage electric load 5 can be regulated to be constant at a predetermined value (reference voltage value).
At this juncture, it should be noted that the battery 4 is not discharged since it is disconnected from the output of the AC generator 1 and hence the terminal voltage of the battery 4 becomes lower. Consequently, the transistor 304 of the voltage regulator 3A is turned off to be invalidated with regards to the terminal voltage detecting function of the battery 4, whereby the transistor 304 is automatically changed over to the terminal voltage detecting function for the onboard high-voltage electric load 5.
As can be seen from the foregoing description, in the control apparatus according to the instant embodiment of the present invention, each of the plus polarity ends of the field coil 102 and the voltage divider resistor 301 is connected directly to the plus terminal of the battery 4 without intervention of the switch. Thus, the lowering of the output of the AC generator 1 in accompanying the lowering of the field current due to the contact voltage drop in the switch mentioned previously in conjunction of the conventional apparatus can successfully be avoided. Furthermore, the unwanted situation such as destruction of the battery 4 and/or the onboard high-voltage electric load 5 due to excessively large output of the AC generator 1 as brought about by variation in the regulating voltage can be evaded.
Embodiment 2
FIG. 2 shows a structure of the control apparatus for the AC generator of a motor vehicle according to a second embodiment of the present invention. In the figure, parts or components like as or equivalent to those described previously by reference to FIG. 1 are denoted by like reference characters, respectively. A voltage regulator 3B according to the instant embodiment of the invention includes a series circuit of a PNP-type transistor 308 and a base resistor 306 connected between the base of the transistor 305 and the plus terminal of the battery 4 via the excitation line L3.
Furthermore, a series circuit of a resistor 310 and a transistor 309 is inserted between the base of the transistor 308 and the ground potential, wherein the driving line L5 extending from the high voltage control circuit 8 is connected to the base of the transistor 309 by way of a resister 311.
Next, description will turn to operation of the control apparatus according to the instant embodiment of the invention. After the output change-over switch 71 has been closed to the contact B1 to thereby validate the battery charge operation mode, the key switch 6 is closed. Then, constant power supply source incorporated in the high-voltage control circuit 8 is put into operation, whereby a voltage is generated across the resistor 807. Due to this voltage, a base current flows to the transistor 309 of the voltage regulator 3B from the driving line L5 via the resistor 311. Thus, the transistor 309 is turned on.
In response to the switching of the transistor 309 to the on-state, the transistor 308 is turned on to apply a base voltage to the base of the output transistor 305 via the base resistor 306. As a result of this, an exciting current flows to the field coil 102 along a path extending from the plus terminal of the battery 4 through the field coil 102 and the output transistor 305 to the ground potential. As the field coil 102 rotates in accompanying the rotation of the engine, a voltage is induced in the armature coil 101 to be outputted to the plus terminal 201. After rectification of the output voltage of the AC generator, the DC voltage is fed to the battery 4 from the plus terminal 201 via the output line L2.
The charging voltage for the battery 4 is applied across both the ends of the series circuit of the voltage divider resistors 301 and 302 via the excitation line L3, wherein a divided voltage appearing as the junction P1 is applied to the cathode of the Zener diode 303. When the charging voltage increases to such a level that the divided voltage reaches a breakdown voltage of the Zener diode 303, the Zener diode 303 is switched to the conducting state, causing the transistor 304 to be turned on, whereby the base resistor 306 and hence the base of the output transistor 305 are connected to the ground with the output transistor 305 being turned off. Thus, the exciting current is interrupted. The operation mentioned so far is same as that of the control apparatus according to the first embodiment.
Now, it is supposed that the output change-over switch 71 is closed to the contact A1, whereby the output of the AC generator 1 is changed over from the battery 4 to the onboard high-voltage electric load 5 to thereby validate the high-voltage load operation mode, the one-shot multivibrator 806a generates a pulse signal having a duration of about 1 second which is applied to the base of the transistor 806b. As a result of this, the transistor 806b is set to the on-state about one second to thereby attenuate the exciting current flowing to the field coil 102.
After lapse of about one second, the transistors 309 and 308 and the output transistor 305 are again turned on, allowing the exciting current to flow through the output transistor 305. Initially, the terminal voltage of the onboard high-voltage electric load 5 is lower than the reference voltage inputted to the comparator 805. Consequently, the voltage generated across the resistor 807 due to the turn-off the transistor 806 causes the transistor 309 to be turned on, whereby the operation similar to that in the battery charge operation mode is effectuated.
When the terminal voltage of the onboard high-voltage electric load 5 increases beyond the reference voltage applied to the comparator 805 as the output voltage of the AC generator 1 increases, the transistor 806 is turned on to thereby connect the resistor 807 to the ground potential. As a result of this, the transistors 309 and 308 and the transistor 309 of the voltage regulator 3B are set to the off-state to interrupt the exciting current, whereby the terminal voltage of the onboard high-voltage electric load 5 is so regulated as to assume a predetermined constant value. However, when the terminal voltage of the onboard high-voltage electric load 5 becomes lower than the reference voltage, the transistors 309 and 308 and the output transistor 305 are again turned on to supply the exciting current for increasing the output voltage of the AC generator 1.
Embodiment 3
The instant embodiment of the invention is directed to the control apparatus for the AC generator of a motor vehicle which is equipped with a high voltage control circuit imparted with a function for detecting abnormality of the AG generator to thereby generate an alarm. FIG. 3 is a block diagram showing a structure of the control apparatus for the AC generator of a motor vehicle according to the instant embodiment of the invention. In FIG. 3, like reference characters as those used in FIG. 2 designate the parts or components same as or equivalent to those described hereinbefore by referring to FIG. 2. As can be seen in FIG. 3, a rectifier circuit 2A is provided with a second rectified current output terminal 203 for detecting an abnormality of the output voltage of the AC generator. The second rectified current output terminal 203 is isolated completely from the terminal of the battery 4. Consequently, even in the battery charge operation mode, the second rectified current output terminal 203 is prevented from the influence of the terminal voltage of the battery 4.
A voltage regulator 3C according to the instant embodiment of the present invention differs from the voltage regulator 3B described previously in conjunction with the second embodiment in that an abnormality detection line L6 is led from the second rectified current output terminal 203 and connected to the junction P2 of the driving line L5 by way of a resistor 321. Normally, there makes appearance at the junction P2 a voltage of a value corresponding to a value of the voltage generated across the resistor 807 divided by a resistance ratio between the resistors 311 and 321 plus an output voltage appearing at the second rectified current output terminal 203 and divided by a resistance ratio between the resistors 311 and 321.
A high-voltage control circuit 8A according to the instant embodiment of the invention differs from the structure of the high-voltage control circuit 8 according to the first and second embodiments in that a comparator 803 for detecting an abnormality of the output voltage of the AC generator, a transistor 804 which is turned on in response to a high level signal of the comparator 803, and an electric generation indicating lamp 9 which is lit when the transistor 804 is turned on are additionally provided.
The comparator 803 has a plus input terminal to which a reference voltage serving as a decision reference for determining an abnormal lowering of the output voltage of the AC generator 1. The minus input terminal of the comparator 803 is applied with a divided voltage from the junction P2 via the driving line L5. On the other hand, the transistor 804 has a base connected to the output terminal of the comparator 803, a collector connected to the key switch 6 by way of the electric generation indicating lamp 9 and an emitter connected to the ground.
Next, description will be directed to operations of the control apparatus according to the instant embodiment of the invention with emphasis being put on the operation for detecting the abnormality of the output voltage of the AC generator. The output voltage of the AC generator 1 appearing at the second rectified current output terminal 203 after rectification is inputted to the voltage regulator 3C via the abnormality detection line L6 and divided by the ratio between the resistance values of the resistors 311 and 321 to be outputted as the rectifier output voltage which makes appearance at the junction P2.
The rectified output voltage mentioned above is inputted to the minus input terminal of the comparator 803 via the driving line L5 to be compared with the reference voltage applied to the plus input terminal of the comparator 803. In that case, when the AC generator 1 operates normally with the value of the rectifier output voltage inputted to the minus input terminal of the comparator 803 being higher than the reference voltage applied to the plus input terminal thereof, the output signal of the comparator 803 assumes a low level. This signal is applied to the base of the transistor 804. Consequently, the transistor 804 is maintained in the off-state. Thus, the electric generation indicating lamp 9 remains unlit.
However, when the output voltage of the AC generator 1 becomes abnormally low for some reason to thereby lower the voltage appearing at the junction P2 than the reference voltage applied to the comparator 803, a high-level signal is outputted therefrom to be applied to the base of the transistor 804 which is then turned on. As a consequence, a current flows through the electric generation indicating lamp 9 and the transistor 804 to the ground, whereby the electric generation indicating lamp 9 is lit, alarming the driver of occurrence of abnormality in the AC generator. Parenthetically, operation of the voltage regulator and that of the high-voltage control circuit in the battery charge operation mode and the high-voltage operation mode are same as those of the control apparatus described hereinbefore in conjunction with the second embodiment.
Embodiment 4
In the case of the third embodiment, the abnormality diagnosis of the AC generator is performed on the basis of the output of the rectifier. However, such abnormality decision may be made on the basis of a voltage derived directly from one phase of the AC generator.
FIG. 4 is a circuit diagram showing a structure of the control apparatus for an AC generator of a motor vehicle according to a fourth embodiment of the invention. In this figure, like reference characters as those used in FIGS. 2 and 3 denote like or equivalent parts. A voltage regulator 3D differs from the voltage regulator 3B shown in FIG. 2 in that an abnormality detection line L6 is additionally provided branched from one phase output winding of the armature coil 101 of the AC generator 1.
The abnormality detection line L6 as led out is connected a series circuit of a resistor 313 and a diode 314, wherein the cathode of the diode 314 is connected to the driving line L5. Furthermore, a smoothing capacitor 315 is provided between the driving line L5 and the ground potential.
Next, operation of the control apparatus according to the instant embodiment of the invention will be described with emphasis being put on the operation for detecting abnormality of the output voltage of the AC generator 1. One of the three phase voltages of the AC generator 1 induced in the armature coil 101 during operation of the AC generator 1 is inputted to the voltage regulator 3D via the abnormality detection line L6 in the form of a rectangular voltage having a duty ratio of 50%. For rectifying the AC generator output voltage inputted to the voltage regulator 3D, there is provided a rectifying/smoothing circuitry which is constituted by the resistor 313, the diode 314 and the smoothing capacitor 315. Thus, the rectified output voltage of the AC generator 1 makes appearance at the junction P2.
When the output voltage of the AC generator 1 derived through the resistor 313 lowers to zero level, the electric charge stored in the smoothing capacitor 315 tends to be discharged. However, such discharge is prevented by the diode 314.
The output voltage of the AC generator 1 mentioned above is inputted to the minus input terminal of the comparator 803 via the driving line L5 to be compared with the reference voltage applied to the plus input terminal of the comparator 803. In that case, when the AC generator 1 operates normally with the output voltage of the AC generator 1 being higher than the reference voltage, the output signal of the comparator 803 assumes a low level. This signal is applied to the base of the transistor 804. Consequently, the transistor 804 is maintained in the off-state. Thus, the electric generation indicating lamp 9 remains unlit.
However, when the output voltage of the AC generator 1 becomes abnormally low for some reason and when the AC voltage 1 appearing at the junction P2 becomes lower than the reference voltage applied to the comparator 803, a high-level signal is outputted therefrom to be applied to the base of the transistor 804 which is then turned on. As a consequence, a current flows through the electric generation indicating lamp 9 and the transistor 804 to the ground, whereby the electric generation indicating lamp 9 is lit, alarming the driver of occurrence of abnormality in the AC generator. Parenthetically, operation of the voltage regulator and that of the high-voltage control circuit in the battery charge operation mode and the high-voltage operation mode are same as those of the control apparatus described hereinbefore in conjunction with the second and third embodiments.
Many features and advantages of the present invention are apparent form the detailed description and thus it is intended by the appended claims to cover all such features and advantages of the system which fall within the true spirit and scope of the invention. Further, since numerous modifications and combinations will readily occur to those skilled in the art, it is not intended to limit the invention to the exact construction and operation illustrated and described.
By way of example, although the detection of abnormality of the AC generator is alarmed by using a lamp, any other suitable alarm device such as a buzzer or the like may be employed.
Accordingly, all suitable modifications and equivalents may be resorted to, falling within the spirit and scope of the invention.
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A control apparatus for an AC generator of a motor vehicle of high reliability having substantially no adverse influence to an onboard battery and an onboard high-voltage load by suppressing to a passible minimum variation of a regulating voltage which may occur as contacts of a detection voltage change-over switch are degraded. An AC generator of a motor vehicle includes a rectifier circuit for rectifying an output of the AC generator including a field coil, an output change-over switch for changing over an output of the rectifier circuit to either one of a battery and a high-voltage electric load mounted on the motor vehicle, and a voltage regulator for regulating an exciting current supplied to the field coil in dependence on a terminal voltage of the battery as detected on a charging line connected to the battery by way of the output change-over switch upon charging of the battery from the output of the rectifier circuit, to thereby regulate the output voltage of the AC generator.
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PRIORITY INFORMATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/424,401, filed on Nov. 7, 2002.
FIELD OF THE INVENTION
[0002] The field of this invention relates to alternate paths for gravel during downhole gravel packing operations and more particularly to spirally shaped paths in the form of a surrounding hollow auger for a gravel pack screen assembly. Spirally wrapped shunt tubes are further contemplated.
BACKGROUND OF THE INVENTION
[0003] A common problem when gravel packing is that the gravel forms bridges and leaves gaping areas uncovered as the gravel that is subsequently delivered piles up behind the bridge or blockage. Another problem is the difficulty in delivering screen into long horizontal runs because of the limited weight available to advance the screen and the possibility that it may simply buckle in the wellbore and cease to further advance. Yet another issue is the need to centralize the screen as the gravel is delivered for deposition all around it. Another concern is damage to the screen assembly during run in. Gravel screens have been provided in the past with surrounding shrouds but the delivery to the desired location could still cause damage to the shroud and the underlying screen. Bridge formation is always a concern. Annular bridge formation can be aggravated by zones of low flow rates leading to deposition of undue amounts of gravel in concentrations in undesirable locations leading to a bridge ultimately forming.
[0004] In the past, a solid auger on a gravel pack screen has been used to insert the screen into the wellbore after the gravel has been earlier deposited. The auger helps to advance the screen into the borehole location that is already pre-charged with gravel. This method is illustrated in U.S. Pat. No. 5,036,920. Augers have been used on perforating guns to get them out after they are fired, as illustrated in U.S. Patent Re. 34,451.
[0005] Alternate paths for the gravel comprising longitudinally oriented narrow passages disposed parallel to each other have been used to try to deliver gravel beyond a sand bridge. Some examples are U.S. Pat. Nos.: 6,298,916; 5,161,618; 6,059,032; 5,842,516; 4,945,991; 5,161,613; 5,113,935; 5,419,394; 5,417,284; 5,435,391; 5,560,427; 5,848,645; 5,622,224; 5,588,487; 5,890,533; 6,227,303; 6,220,345; 5,476,143; 5,341.880; 5,515,915; 5,082,052; 6,409,219; 5,390,966; and 5,868,200. Also of interest is the Halliburton multiple path screen system called SurePac. Some of these references have shunt tubes that are internal and others feature external tubes. These designs address the specific problem of bridging but ignore some of the other issues such as protection of the screen, advancement of the screen into position and the potential damage to the shunt tubes when mounted externally.
[0006] The present invention addresses in a cohesive design several parameters. The hollow flight or flights of augers are structurally rigid to allow rotation to advance the screen. The passages in the flights are also protected by the rigidity of the auger design. The screen is better protected during run in. The auger allows gravel to enter and exit in multiple locations to allow gravel to bypass bridges. The spiral flow pattern in the interior and along the exterior of the auger is more turbulent due to the centrifugal force from going around the screen, making it less likely that gravel will deposit within the auger or prematurely in the annulus. The auger centralizes prior to gravel delivery.
[0007] The other advantages are offered by an alternative embodiment that features spirally wound shunt tubes. These tubes are open at discrete locations for escape of gravel. The spiral layout improves gravel distribution upon exit from the tubes.
[0008] These and other advantages of the present invention will be more apparent to those skilled in the art from a review of the description of the preferred embodiment and the claims, which appear below.
SUMMARY OF THE INVENTION
[0009] A gravel pack screen assembly has one or more hollow flight augers that a continuous or segmented with multiple upwardly oriented gravel entrances and multiple downwardly oriented gravel exits. The gravel passes through the auger and around any bridge. The auger helps advance the screen into position as well as to centralize it during gravel deposition. The auger protects the screen during run in as well as the internal passages that pass through it due to its structural rigidity. An alternative embodiment features spirally wound tubes with staggered exit locations for better distribution of the gravel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is an exterior view of a screen assembly with a single flight hollow auger mounted to it showing the flow of gravel through the hollow flight;
[0011] [0011]FIG. 2 is a section view of an alternative embodiment showing the spirally wrapped tubes;
[0012] [0012]FIG. 3 is the view along lines 3 - 3 of FIG. 2;
[0013] [0013]FIG. 4 shows an outer view of the jacket mounted over joints in the screen assembly; and
[0014] [0014]FIG. 5 is the view along lines 5 - 5 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIG. 1 the screen assembly 10 can be made up of multiple sections such as 12 and 14 that are connected by a coupling 16 . The actual screen, shown by dashed line 18 is below an outer protective jacket 20 . The protective jacket 20 stops short of each coupling 16 so that the proper length of the assembly 10 can be put together for a given application. The auger 22 is hollow and has an inlet 24 near the top where gravel, represented by arrow 26 can enter. There is a plurality of exits 28 on the auger underside for the gravel 26 to exit. The auger 22 may be made continuous over the couplings 16 such as by installing the segments that pass the coupling 16 after it is assembled. Alternatively, the auger 22 can stop before some or all of the couplings 16 and resume on the protective jacket 20 immediately below the coupling 16 . In this manner there can be multiple inlets 24 where each section of auger 22 begins. Additionally or alternatively, there can be additional inlets on the uphole side 30 of auger 22 for the purpose of letting in gravel 26 at multiple points along a length of continuous auger 22 .
[0016] The pitch and/or diameter of auger 22 can be constant or variable. There can be a single auger 22 or nested augers. Auger 22 may be made of the same metallic material as the protective jacket 20 and attached by a variety of techniques, although welding is preferred. Alternatively the auger 22 can be non-metallic as can be the protective jacket 20 . They can be made integrally or the auger 22 can be mounted separately to jacket 20 . The inlets 24 and outlets 28 can have a variety of shapes and sizes guided by the need to maintain the structural integrity of the auger 22 during conditions of its rotation to advance the screen assembly 10 into position before the gravel 26 is deposited in a known manner. All or less than all of the length of the screen assembly 10 can be covered with the hollow auger 22 . Periodically, short cut passages 32 can extend longitudinally from the underside of auger 22 to the uphole side 30 immediately below as yet another path for the gravel 26 to take if auger 22 starts to plug internally.
[0017] Those skilled in the art will appreciate that the presence of auger 22 creates turbulence around the screen assembly 10 so as to make it less likely in the first place that sand bridges will form. The presence of the hollow auger 22 allows the gravel alternate paths to enter at the start or along the way on each auger or segment thereof and to exit on the downhole side of the auger or its segments anywhere along the length where an outlet is provided and at all lower open ends of hollow auger 22 . The auger 22 acts as a centralizer on the trip downhole. It also protects the screen assembly 10 from mechanical damage during run in. The auger 22 also helps to advance the screen assembly into proper position. This can be useful in a nearly horizontal run where the ability to push the screen assembly 10 forward without buckling it may be severely limited. This problem can occur in regions of shale instability where contact by water based fluids makes the shale unconsolidated so that it can collapse into the wellbore. If this happens the alternate paths through the auger 22 allow gravel to also bypass the region of shale collapse. The auger 22 can be assembled to the protective jacket 20 such as by welding and then the assembly can be rolled over the screen material and secured to the base pipe underlying the screen material. Removal of the screen assembly 10 , should that become necessary, is made easier by just applying an uphole force to the screen assembly 10 . The auger 22 will put the screen assembly into rotation and the pitch of the auger 22 will drive the auger out of the gravel.
[0018] Accordingly, the auger 22 in its various embodiments described above addresses several potential problems involved in running gravel pack screens. The alternate paths create internal turbulence and centrifugal force that helps to minimize blockages internally in the flow paths. Externally, turbulence is also created by auger 22 to help fight sand bridging.
[0019] [0019]FIG. 2 illustrates an alternative embodiment of the present invention. The screen 30 is assembled in sections and connected by joints 32 . Illustratively, four shunt tubes 34 , 36 , 38 , and 40 as best seen in the section view of FIG. 5 are disposed on the outside of screen 30 . In the preferred embodiment, the shunt tubes 34 , 36 , 38 , and 40 are equally spaced and spirally wound on the same pitch over the length of the screen assembly. Mounted over each joint 32 is a jacket 42 . As shown in FIG. 2, at least one of the shunt tubes 34 , 36 , 38 , and 40 has an exit 44 under jacket 42 . It also has an entrance 46 under jacket 42 . Flow coming downhole through tube 34 exits and goes in three directions represented by arrows 46 , 48 , and 50 . Arrow 46 shows the gravel exiting above the jacket 42 , arrow 48 shows the gravel exiting below the jacket 42 and arrow 50 shows the gravel re-entering tube 34 under jacket 42 . Jacket 42 provides a jumper path for each other tube such as tubes 36 and 40 shown in FIG. 2. Jacket 42 can have a discrete path for an individual tube or it can provide a common manifold so that flow from a variety of tubes can mix within the jacket and exit a different tube from the tube that a particular flow entered the jacket 42 . At the next joint 52 , a different tube 38 is open for flow in three possible directions as indicated by arrows 54 , 56 , and 58 . In between joints 32 and 52 at least one tube such as 40 has open ends 60 and 62 to allow flow out from under open coupling 64 . Flow can go out above coupling 64 as indicated by arrows 66 and out below, as indicated by arrows 68 . Between joints such as 32 and 52 a single tube may have one or more couplings 64 . Alternatively more than one tube can have one or more couplings 64 between typical joints such as 32 and 52 . As another variation, more than one of tubes 34 , 36 , 38 , and 40 can have open ends under the jacket 42 . The jacket 42 can be made in pieces 70 and 72 and held together by one or more bolts 74 .
[0020] Those skilled in the art will appreciate that the spiral winding will increase the overall length of the shunt tubes 34 , 36 , 38 , and 40 as the wrap around the screen 30 but the fluid velocity will be higher as the spiral flow path will aid distribution of the gravel as it emerges from any openings in the shunt tubes 34 , 36 , 38 , and 40 . The spiral pattern will also better protect the screen 30 on insertion and help to better center it when it reaches the desired location. Those skilled in the art will also appreciate that the number of tubes can be varied as well as their initial spacing and pitch. The diameter of an individual tube can be varied along its length. In the preferred embodiment if there are four tubes equally spaced and spirally wound on the same pitch, each tube will have breaks over a fourth of the length of the screens 30 with no or minimal zone overlap. Alternatively, jacket 42 can be eliminated in favor of a jumper tube at a joint such as 32 for those tubes that have no openings at that location while the tubes with openings can have a coupling such as 64 at a joint such as 32 .
[0021] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below:
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A gravel pack screen assembly has one or more hollow flight augers that a continuous or segmented with multiple upwardly oriented gravel entrances and multiple downwardly oriented gravel exits. The gravel passes through the auger and around any bridge. The auger helps advance the screen into position as well as to centralize it during gravel deposition. The auger protects the screen during run in as well as the internal passages that pass through it due to its structural rigidity. An alternative embodiment features spirally wound tubes with staggered exit locations for better distribution of the gravel.
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BACKGROUND OF THE INVENTION
The invention concerns a device for the removable attachment of a work space dividing partition to an office work surface. These partitions, also known under the name of dividers or screens, are generally used in open-space environments, so as to create several work spaces.
These partitions thus allow a person's work space to be defined with respect to the work spaces of his neighboring colleagues.
Each person can then benefit from a more confined area affording more privacy and sometimes even soundproofing, and enabling, furthermore, better concentration.
Until now, these partitions have been attached to office work surfaces by clamping collets or have been placed on the work surfaces by clamping chucks, or have been supported by legs resting directly on the ground.
The solutions based on clamping chucks or legs are cumbersome, contrary to the solutions based on clamps.
The known clamping collets present the drawback of being limited to certain work surface thicknesses. Moreover, even though their installation does not require any tools, installation is sometimes awkward.
SUMMARY OF THE INVENTION
One aspect of the present invention is to provide a device that allows the attachment of a panel which is simple to use and adapted to any work surface thickness.
To this end, the invention concerns a space dividing panel resting via a lower edge on the top surface of a wall forming the work surface and incorporating a device for attaching the panel to the work surface. It is characterized principally in that the device comprises:
placement means comprising a translationary mobile branch forming with the lower edge of the panel a clamp type mechanism located on either side of an external overhang of the work surface, the branch being movable between a position in which it presses with contact against the underside of the work surface for attachment of the panel, and a position at a distance from the surface for releasing the panel; control means of the placement means, located in the vicinity of the overhang, and reproducing, in a direction running parallel to the work surface, the displacement and the positioning of the mobile branch with respect to the work surface.
Specifically, when the mobile branch is moved away from the work surface (respectively towards the work surface), the control device is also. There is a correspondence, therefore, between the movement of the mobile branch and the movement of the control means.
More precisely, the attachment device comprises:
at least one support surface at the level of the lower edge of the panel on the top face of the work surface; a vertical flange provide with a placement end corresponding to the mobile branch and angled at 90° with respect to the flange, the flange being mobile in vertical translation, bringing the placement end away from or against the underside of the work surface in order to respectively release the panel or to attach it to the work surface; an actuating member of the flange corresponding to the means of control, movable in horizontal translation between an actuating position at a distance from the work surface where the placement end of the flange is at a distance from the work surface, and a releasing position in the vicinity of the work surface where the placement end of the flange rests against the underside of the work surface; means for returning the actuating member from the actuating position to the release position; means for transforming the horizontal movement of the actuating member into the vertical movement of the flange.
This solution features the advantage that, due to these transformation means, the attachment of the panel is made by a simple actuating of the actuating member by the user.
Specifically, the user first pulls on the actuating member to displace it horizontally toward an actuating position, thus bringing about the descent of the flange. It is then possible to correctly position the panel in relation to the edge of the work surface. The user then releases the actuating member, the latter being returned toward a release position, bringing about the raising of the flange until its placement end comes to rest against the underside of the work surface. The work surface is then held tight between the support surface of the panel, on the one hand, and the placement end of the flange, on the other hand.
The support surface of the panel and the placement end of the flange act as a jaw controlled by the actuating member. The opening (respectively the closing) of this jaw is produced by the movement of the placement end of the flange downwards by pulling on the actuating member (respectively upward by releasing the actuating member).
The attachment of the panel is therefore nearly instantaneous and can be performed by one person easily, in a single movement, and without tools, for any type of work surface thickness.
More precisely, the actuating and releasing positions are defined relatively with respect to the thickness of the work surface. The thicker the work surface, the more the jaw must open up to grip the edge of the work surface, and therefore the more considerable the horizontal movement of the actuating member will be, and inversely. Consequently, the so-called actuating and releasing positions are different depending on whether the work surface is thicker or thinner.
In the absence of the work surface, the movement of the actuating member is limited by stops corresponding to the maximum actuating and the maximum releasing positions.
According to the invention, the transformation means consist of a ramp belonging to the actuating member, inclined at an angle of α=]0; π/2[ with respect to the horizontal, and inserted in the interior of an opening made in the flange, the horizontal displacement of the ramp causing the vertical displacement of the flange.
The ramp is of a uniform width and is mounted fitted in the opening of the flange, the opening being specially sized to receive this ramp width. The opening receives the upper portion of the ramp when the actuating member is in maximum releasing position with the flange in raised position, and receives the lower portion of the ramp when the actuating member is in the maximum actuating position with the flange in lowered position.
The actuating of the actuating member from its maximum releasing position to its maximum actuating position leads to the sliding of the ramp within the opening, from its upper portion towards its lower portion, the α angle being negative in this case. The intersection between the lower edge of the opening and the lower edge of the ramp brings the flange downward while the ramp is displaced horizontally, due to this negative inclination of the ramp with respect to the horizontal.
Upon the release of the actuating member, the ramp slides within the opening, from its lower portion towards its upper portion, the α angle being positive in this case. The intersection between the upper edge of the opening and the upper edge of the ramp brings the flange upwards while the ramp is displaced horizontally, due to this positive inclination of the ramp with respect to the horizontal.
In order for the system to work, the ramp must not be horizontal (α=0) in which case there would be no vertical movement of the flange. The ramp must not be vertical (α=π/2), in which case it could not be inserted into the opening of the flange.
In order to ensure the horizontal displacement of the actuating member, the attachment device features guiding means of the actuating member within the panel. In fact, if the actuating member is moved from an angle α with respect to the horizontal, there will be no vertical drive of the flange.
Preferably, these guiding means consist of slide links.
More precisely, the actuating member is composed of three parts:
A vertical part sliding horizontally in a groove made in a fixed lower support of the panel;
The ramp sliding inside of the opening made in the mobile flange;
A horizontal part featuring at least one horizontal slide inside of which at least two bolts of a fixed intermediate support of the panel are inserted, with the position of the bolts within the slide dependent on the horizontal movement of the actuating member.
The horizontality of the actuating member is ensured by the bolts/slide unit arranged horizontally. The bolts form two horizontal fixed points preventing any rotation of the actuating member, and limiting its movement in a horizontal direction by means of the slide.
Furthermore, to improve the sliding between the ramp and the flange, the flange features guide fins of the ramp, positioned at a same angle α with respect to the horizontal. These fins, featuring the same inclination as the ramp, increase the contact surface between the edges of the ramp and the flange, thus limiting friction localized at the upper and lower edges of the opening in the flange so as to prevent premature localized wear of the mechanism.
In addition to the guiding means of the actuating member within the panel, the attachment device per the invention features guiding means of the flange within the panel, allowing the verticality of the movement of the flange to be ensured.
These guiding means are located on both the upper and lower parts of the flange. In order to do this, the upper part of the flange passes through a guide opening made in the upper support of the panel, while the lower part of the flange is guided on either side between a vertical side of said lower support of the panel and a vertical side of a fixed element of the panel.
Optionally, a centering clip of the flange is inserted into the guide opening of the upper support of the panel. This clip may take any form possible.
Furthermore, the flange features a shoulder in its upper part, acting as a stop with respect to the upper support of the panel, thus limiting its vertical displacement towards the top of the panel, so that it doesn't strike against a finishing cover covering the upper support of the panel.
According to one possible configuration, the means for return of the actuating member consist of a spring of which a first end is attached to the actuating member and a second end is attached to a fixed element of the panel. Other return means could be used.
Generally, the panel is composed of two facing plates forming front and rear faces, the plates being connected by the upper and lower supports and by a first mount and a second mount arranged symmetrically at the lower ends of the panel in contact with the work surface, with the lower surfaces of the mounts corresponding to the support surfaces of the panel on the upper face of the work surface. Providing two support surfaces (rather than one) at the two ends of the panel allows it to be better stabilized on the work surface.
Practically, the first mount is located facing the placement end of the flange and constitutes the fixed element of the panel of which one of the vertical sides serves to guide the flange. This first mount thus fulfills two functions: a support function for the stability of the panel, and a guiding function for the flange.
The second mount constitutes the fixed element of the panel to which the second end of the spring is connected. It therefore also fulfills two functions: a support function for the stability of the panel, and an anchoring point function for the return means of the actuator member.
Advantageously, all of the support surfaces of the panel on the work surface are equipped with non-slip feet to prevent any sliding of the panel along the edge of the work surface and therefore to strengthen the attachment of the panel. Thus, the support surfaces of the mounts on the upper face of the work surface as well as the support surface of the placement end of the flange on the underside of the work surface are provided with non-slip feet.
According to one possibility, the free end of the vertical portion of the actuating member is provided with a gripping sleeve extending from the lower support for the manual actuating of the actuator member by a user. This gripping sleeve can take any form, with its ergonomics being adapted to the hand of the user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a represents the panel seen from the exterior, with the actuating member in the maximum release position, the flange being raised to its maximum position;
FIG. 1 b illustrates the panel with the actuating member in the actuating position and positioned in relation to a work surface;
FIG. 1 c shows the panel attached to the work surface with the actuating member in the release position;
FIG. 2 represents the attachment device with the actuating member in the maximum release position;
FIG. 3 illustrates the attachment device with the actuating member in the maximum actuating position;
FIG. 4 is an enlarged view of the attachment device;
FIG. 5 shows the insertion of the ramp in the flange;
FIG. 6 illustrates the attachment device viewed from another angle; and
FIG. 7 is an enlarged view of the centering device of the flange.
DETAILED DESCRIPTION
With reference to FIG. 1 a , the attachment device is incorporated in a panel ( 1 ). The two facing panels ( 2 ), forming the front and rear faces of the panel ( 1 ) hide a portion of the attachment device located inside of the panel ( 1 ).
This attachment device is actuated by an actuating member ( 8 ), which causes the raising and lowering of a flange ( 7 ) whose free end, called the placement end ( 4 ), as well as the gripping sleeve ( 3 ) of the actuating member ( 8 ), is visible from the exterior of the panel ( 1 ).
In the configuration presented in FIG. 1 a , the actuating member ( 8 ) is in a maximum release position, i.e., in coordination with its gripping sleeve ( 3 ) wholly adhering on its right to the placement end ( 4 ). In this position, the placement end ( 4 ) is in raised position.
In the configuration presented in FIG. 1 b , a user pulls the sleeve ( 3 ) of the actuating member ( 8 ) to move it towards a maximum actuating position, i.e. in coordination with its gripping sleeve ( 3 ) wholly adhering on its left to a corner of the panel ( 1 ). In this position, the placement end ( 4 ) is in lowered position, so as to be able to easily position the panel ( 1 ) on a work surface ( 9 ), with the placement end ( 4 ) of the flange ( 7 ) positioning itself under the work surface ( 9 ), close to its outer edge ( 9 a ). The panel ( 1 ) presents two supporting surfaces ( 5 , 6 ) at its lower edge ( 1 a ), visible in FIG. 1 a , capable of resting on the upper side of the work surface ( 9 ).
Once the panel ( 1 ) is correctly positioned with respect to the work surface ( 9 ), the user releases the sleeve ( 3 ) of the actuating member ( 8 ). The latter is then found in the release position as illustrated in FIG. 1 c , with the placement end ( 4 ) of the flange ( 7 ) coming to rest on the underside of the work surface ( 9 ). The panel ( 1 ) is then attached to the work surface ( 9 ).
The panel ( 1 ) has a generally rectangular shape, but it can be provided with an extension ( 10 ) located in its lower left corner as is the case on FIGS. 1 a to 1 c . In this case, the gripping sleeve ( 3 ) extends from the extension ( 10 ) in a downward direction in order to be easily accessible by the user, and the placement end ( 4 ) extends from the left side of the extension ( 10 ) which is facing the edge of the work surface ( 9 ).
The attachment device per the invention is illustrated in FIGS. 2 to 4 .
FIG. 2 makes reference to FIG. 1 a , with the actuating member ( 8 ) in the maximum release position and the flange ( 7 ) raised, while FIG. 3 makes reference to FIG. 1 b with the actuating member ( 8 ) in the maximum actuating position and the flange ( 7 ) lowered.
The ( 7 ) vertical flange is movable in vertical translation along an axis parallel to the (Y) axis, bringing its placement end ( 4 ), bent at 90° with respect to the flange ( 7 ), away from or against the underside of the work surface ( 9 ). The actuating member ( 8 ) is movable in horizontal translation along an axis parallel to the (X) axis, between a maximum actuating position (sleeve ( 3 ) at the left) and a maximum release position (sleeve ( 3 ) at the right).
The actuating member ( 8 ) and the flange ( 7 ) are arranged such that the horizontal movement of the actuating member ( 8 ) is transformed into the vertical movement of the flange ( 7 ).
More precisely, the actuating member ( 8 ) features a ramp ( 11 ) inclined at an angle of α=]0; π/2[ with respect to the horizontal and inserted inside of an opening ( 12 ) of the flange ( 7 ) in which it slides. The opening ( 12 ) is sized to receive the ramp ( 11 ) in a fitted manner, with a slight working clearance to allow sliding between the two parts. The ramp ( 11 ) is uniform in width.
Specifically, when the actuating member ( 8 ) is actuated, the ramp ( 11 ) is displaced by a horizontal movement with respect to the flange ( 7 ) which remains fixed horizontally and moves vertically along the ordinate of the inclination of the ramp ( 1 ).
When the actuating member ( 8 ) is moved from a release position (in FIG. 2 ) towards an actuating position (in FIG. 3 ), i.e., from the right towards to the left, the lower edge ( 40 ) of the ramp ( 11 ) slides and rests on the lower edge ( 14 ) of the opening ( 12 ) so as to cause the flange ( 7 ) to descend. In the reverse case, from the left towards the right, it is the upper edge ( 16 ) of the ramp ( 11 ) which slides and rests on the upper edge ( 15 ) of the opening ( 12 ) so as to cause the flange ( 7 ) to rise.
The flange ( 7 ) presents a larger section at the opening ( 12 ) to reinforce its mechanical strength in this area of high stress.
The actuating member ( 8 ) is composed principally of three parts:
A vertical part ( 39 ) sliding horizontally in a groove ( 18 ) made in a lower fixed support ( 17 ) of the panel ( 1 ), with the gripping sleeve ( 3 ) being attached at its free end;
The ramp ( 11 ) sliding in the opening ( 12 ) of the flange ( 7 ); A horizontal part ( 13 ) provided with two horizontal slides ( 19 , 20 ) inside of which are inserted bolts ( 21 , 22 ) belonging to an intermediate support ( 23 ) attached to one facing plate ( 2 ) of the panel ( 1 ).
When the actuating member ( 8 ) is displaced horizontally, the position of the bolts ( 21 , 22 ) varies within the slides ( 19 , 20 ). These bolts ( 21 , 22 ) and the slides ( 19 , 20 ) perform the translational guidance and ensure the horizontality of the actuating member ( 8 ) in any position. The arrangement of the bolts ( 21 , 22 ) between the intermediate support ( 23 ) and the part ( 13 ) of the actuating member ( 8 ) is visible in FIG. 6 .
Furthermore, the length of the slides ( 19 , 20 ) corresponds largely to the length of the groove ( 18 ) of the lower support ( 17 ). As a result, the ends of the slides ( 19 , 20 ) and/or of the groove ( 18 ) can be considered as stops limiting the movement of the actuating member ( 8 ).
A spring ( 24 ) allows the actuating member ( 8 ) to be returned from an actuating position to a release position. This spring ( 24 ) thus brings the actuating member ( 8 ) towards the right. In order to do this, the spring ( 24 ) features a first end ( 25 ) attached to the actuating member ( 8 ), or more precisely to an opening made in a spur ( 27 ) protruding from the actuating member ( 8 ), and a second end ( 26 ) attached to a fixed element of the panel ( 1 ), or more precisely to a mount ( 28 ) attached to the panel ( 1 ) at its lower right corner.
The bottom surface of this mount ( 28 ) corresponds to the supporting surface ( 6 ) mentioned previously.
Generally, the two facing panels ( 2 ) forming the front and rear faces are connected by the lower support ( 17 ), the mount ( 28 ), an upper support ( 31 ) and another mount ( 29 ).
This mount ( 29 ) is arranged symmetrically to the mount ( 28 ) at the level of the angle formed by the extension ( 10 ) of the panel ( 1 ). The lower surface of this mount ( 29 ) corresponds to the previously mentioned supporting surface ( 5 ). It is located across from the placement end ( 4 ) of the flange ( 7 ). All of the supporting surfaces on the work surface ( 9 ), namely surfaces ( 5 , 6 ) and the upper surface of the placement end ( 4 ), are provided with non-slip feet ( 33 ) visible in FIGS. 2 and 3 .
The upper support ( 31 ) extends over the entire length of the panel ( 1 ), and features an opening ( 32 ) inside of which the upper part of the flange ( 7 ) is inserted. This opening ( 32 ) thus also serves to guide the flange ( 7 ) at the time of its vertical movement. The flange ( 7 ) is also guided at its bottom portion between a vertical side of the lower support ( 17 ) and a vertical side of the mount ( 29 ), with these two sides coming to surround the lower part of the flange ( 7 ) located in the angle of extension ( 10 ) of the panel ( 1 ).
FIG. 5 shows precisely the insertion of the ramp ( 11 ) in the opening ( 12 ) of the flange ( 7 ). Advantageously, guiding fins ( 34 ) of the ramp ( 11 ) are provided at the top and bottom edges of the opening ( 12 ) of the flange ( 7 ). They offer a larger sliding surface between the ramp ( 11 ) and the flange ( 7 ), thus improving the sliding of the actuator member ( 8 ).
In the present case, these fins ( 34 ) correspond to the material removed from the flange in order to form the opening ( 12 ). They are in fact simply cut out and then bent at an angle α corresponding to the angle of inclination of the ramp ( 11 ).
Finally, FIG. 7 illustrates the insertion of the upper part of the flange ( 7 ) in the guiding opening ( 32 ) made in the upper support ( 31 ) of the panel ( 1 ). The flange ( 7 ) features an enlarged portion ( 35 ) with respect to its upper end ( 38 ), and of a width greater than the width of the opening ( 32 ). This enlarged portion ( 35 ) is located under the opening ( 32 ) and forms a shoulder acting as a stop to limit the upward displacement of the flange ( 7 ). This shoulder is located on the flange ( 7 ) in such a way that, when it is stopped with respect to the opening ( 32 ), the upper end ( 38 ) of the flange ( 7 ) remains under the finishing cover ( 30 ) of the upper support ( 31 ) of the panel ( 1 ).
A centering clip ( 43 ) of the flange ( 7 ) can be inserted in the guiding opening ( 32 ).
FIG. 7 shows a possible example of clip ( 43 ). It is comprised of a central portion inserted in the opening ( 32 ) and of two arms equipped with tenons ( 41 , 42 ) capable of being clipped in the two openings ( 36 , 37 ) located on either side of the opening ( 32 ). The central portion of the clip ( 43 ) features a through hole sized to receive the upper end ( 38 ) of the flange ( 7 ) in a fitted manner, with a slight working clearance to allow its vertical displacement. The tenons ( 41 , 42 ) act as a stop to prevent any upward movement of the clip ( 43 ), while the central portion features an overhang capable of pressing against the upper surface ( 31 ) to prevent any downward movement of the clip ( 43 ). The clip ( 43 ) is therefore held firmly in position.
Of course, the example above should not be regarded as exhaustive of the invention, which instead includes the set of variants of shape and configurations that are within the reach of ordinary skill in the art.
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Workspace dividing partition resting via a lower edge on the top face of a wall forming a work surface and incorporating a device for attaching the partition to the work surface. The partition includes placement means comprising a translationary mobile branch which with the lower edge of the partition forms a clamp type mechanism situated on either side of an external overhang of the work surface, wherein the branch is able to move between a position in which it presses with contact against the underside of the work surface in order to attach the partition, and a position distant from the underside in order to release the partition. The partition also includes placement control means, situated near the overhang and reproducing, in a direction appearing parallel to the work surface, the movement and positioning of the mobile branch with respect to the work surface.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from Argentina's Instituto Nacional de la Propiedad Industrial, patent application #20130103381, titled “CERRAMIENTO MULTIFUNCIONAL” (Multifunctional Enclosure, in English), filed on Sep. 20, 2013, based on the Paris Convention for the Protection of Industrial Property, subscribed by the Argentine Republic and the United States of America, the entire contents of which are herein incorporated by reference.
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
REFERENCES CITED
EP0253411A2
ES2063610A2
U.S. Pat. No. 3,845,591
U.S. Pat. No. 6,604,327
WO02072969A1
BACKGROUND OF INVENTION
Field of the Invention
The present invention refers to a “MULTIFUNCTIONAL ENCLOSURE”, appropriate for any surface to be enclosed, both external and internal, in which it comprises a cross-linked structure containing a set of profiles that fits in the field of telescopic retractable roof structures, in particular structures composed primarily of profiles used in the field of architecture and construction.
Background
Traditionally enclosure systems may be classified as those suitable for closed areas and outdoor areas. The first group comprises those enclosures that permit use and enjoyment every day of the year, regardless of weather conditions. The second group refers to all those enclosures that open wholly or partly to the open air. To this second group, the present invention is intended.
To make better use of the outdoor places, various enclosure systems were developed, generally consisting of roofs with partial openings that can be opened or closed in the manner of windows, fully or partially, that may be opened when weather conditions are favorable.
To this end, various systems have been developed and used, including:
Protective canvas or awnings; Tents, made of various materials such as canvas or plastic, with rigid or inflatable support structures (the whole tent is inflated, which requires monitoring its air leakage with the consequent continuous energy expenditure, or only the supporting structure is inflatable); Removable modules removable at will, which must be completely dismantled when not in use. Retractable module roofs that result in visible retracted structures at the ends of the area to be covered or have the need for providing a large enclosed space to hide them. Sliding covers that allow for a limited opening, always leaving a covered portion, since the entire structure (walls and/or roof) moves in modules, which are inserted one inside the other, to occupy one end portion thereof; being that in some cases the walls are fixed and only the corresponding portion of the roof moves leaving always a covered airspace.
All these solutions generally do not resolve the problem of dealing with the weight of the modules. Most sliding modules are difficult to move to a desired position because they employ mechanical means, pulleys and chains, which are used to manually move the modules. If the modules need to be moved by pushing there is a risk that they may lock.
As for pavilion type enclosures, there are a variety of models, fixed or telescopic, made of various materials, such as canvas or metal. Telescopic enclosures may be retracted and still occupy a fifth or a sixth of its original size.
In regards to the perimeter structures that support a sliding roof, they generally have multiple drawbacks. These structures have to bear the weight coupled with sliding modules' movements, thus they present a variety of construction issues such as tension, vibration, and possible deformation from buckling, all issues that require expensive systems because of materials used, resulting in increased weight and cost of the entire structure.
Enclosure systems that use rail tracks to displace themselves always have some possibility of locking on the tracks.
It must be noted that hereinafter when referring to a structure, module, or enclosure that it is closed, it implies that the modules are in position to total coverage of the surface, and when it is said to be open it implies that the modules are fully stored in underground chambers releasing all the space above ground.
The proposed invention solves all aforementioned problems, because there are no bearings circulating over rails and especially because once the structure is fully retracted it is hidden from view, freeing the space previously covered.
The process of opening and closing the enclosure may be effected mechanically. The use of counterweights for pivoting the structures makes manual operation of the enclosure possible. The simplicity of operation eliminates the need for trained personnel for their handling. It also allows for usage of the enclosure as often as desired.
Another possibility is the opening and closing of the enclosure by using a motor and a programmable computer that allows for scheduling and pre-defined frequencies of operation.
All the above mentioned problems can be solved by the present invention, whose opening and closing is accomplished telescopically, and may be used to cover areas such as: swimming pools, sports fields, greenhouses, gardens, patios, work areas, isolation areas, parking lots, and similar.
The following prior art is known to the inventor.
Spanish Patent ES2,063,610, discloses a fixed circular lattice structure, over which layered structures shaped as wedges are affixed to its perimeter, and pivot on it and lean to one side or the other causing the partial opening of the enclosure or its total closure. The problems presented by this invention are:
The segments tend to jam if they are not perfectly synchronized in their movement; Space around the enclosed area does become completely free; a portion of the structure is visible on the ground; The deformation of the segments due to temperature variations and use increases the chances of jamming; Its does not allow for placement of an enclosure in a small area.
U.S. Pat. No. 3,845,591 discloses a telescopic enclosure that extends horizontally. It consists of segments of different sizes such that upon retraction each segment is contained underneath the previous segment. The structure moves over side rails. The problems presented are:
The segments tend to jam while circulating over rails; Rails must be periodically maintained to prevent the bearings from locking; Not all space is liberated upon opening the enclosure, part of the structure remains visible and above ground; The structure is usable to enclose small areas since its configuration limits its elements to exceed certain size because of weight and maneuverability.
WIPO application WO0/2072969 discloses a telescopic rectangular enclosure that can be extended horizontally. It consists of segments of different sizes that may be retracted and stored below the previous segment. The segments move by rolling over side rails on the floor. The ends of the enclosure may be closed by means of a retractable semicircular dome formed by U-shaped modules united together at their pivoting points. The problems presented by this invention are:
The modules in movement tend to lock while circulating on the rails; Space above ground is not free, part of the structure remains visible; The structure is usable to enclose small areas.
U.S. Pat. No. 6,604,327 B1 discloses a telescopic enclosure that can extend horizontally. It consists of segments of different sizes that may be retracted and stored below the previous segment. The segments move by rolling over wheels over the floor. The problems presented by this invention are:
The modules in movement tend to lock easily since there is no guide to keep all wheels aligned; Space above ground is not free, part of the structure remains visible; Applicable only to small areas.
European Patent EP 0253411 discloses several enclosure options. Focusing on a relevant option, a telescopic rectangular enclosure may be extended horizontally and consist of segments of different sizes that may be retracted and stored below the previous segment. The structure circulates over wheels and its ends are retractable, closable by semicircular dome modules formed by inverted U shape wedges. The problems presented by this invention are:
The modules tend to lock while circulating on the rails; Space above ground is not free; part of the structure remains visible; The structure is usable to enclose small areas.
SUMMARY OF THE INVENTION
The object of the present invention is a to provide for a multifunctional enclosure, for covering outdoor and indoor areas, which comprises a set of components operatively linked together, forming an enclosure that can be retracted completely and be hidden out of sight; having features that solve the previously mentioned problems.
When the enclosure is retracted, it frees completely the area above ground as the entire structure is stored below ground level and out of sight; When the enclosure is deployed it covers the entire desired area, being suitable for large areas; The component modules do not travel over the ground, either on rails or wheels, rather the modules pivot on their axis, thereby eliminating the inconvenience caused by wear and jamming of wheels caused by the horizontal displacement of the modules; Module's movement is not hindered by obstacles as bearings maintain separation between modules and ensure smooth and fluid movements; Each half of the enclosure pivots on its own axis, therefore the total load is divided; It allows for the placing of openings, such as access doors and windows; The enclosure modular structure makes it ideal for manufacturing, transport, and installation at different locations.
The inventive enclosure is composed of a series of modules arranged in two parallel halves facing each other. Each one of the modules has a section of parabolic profile shape and the length of the area to be covered, and it is connected to an axis upon it rotates.
The number of modules in each half of the enclosure can vary according to the dimensions of the area to be covered. All modules in each half share the same horizontal axis; both axes are located below ground level, in parallel to each other.
The size of the modules varies from one another due to construction requirements, such as the location of an access door or opening, which requires certain modules to have an angle greater than others, whereby the wedge of the modules of each half does not always have the same angle as the opposite module. This means that each half module has different length and diameter that range from larger on the outside to smaller on the inside, also one side may have more modules than the other side.
The radius and length difference between modules is such that allows for a proper fit between them to open and close, while determining the clearance or gap light needed to allow for deformations provided in each case and the smooth functioning without trouble.
The rotational movement of the modules around their axes allows for a proper fit between each other in the perimetral underground housing, reducing the space required and at the same time offering the possibility for the total deployment of the structure to the deployed position.
Each module consists of two wedge-shaped panels, one in front and one on the rear, connected by its wider end (the side opposite the axis) through multiple beams, two of which connect the inside corners facing each other (hereinafter upper and lower beams) and the rest connecting the middle part (hereinafter middle beam) giving it structural stiffness and support to the laminar material that will be used to close the resulting intermediate spaces. On the inner facing sides of the beams, multiple perpendicular ribs are affixed thereto and spaced at equal distances, and upon which the laminar material mentioned above is interspersed, these ribs converging on at least one axis associated with a motor.
Each panel shaped wedge will consist of two radial profiles or studs attached at one end (the apex of the wedge), with another profile that will unite them at the other end giving the characteristic wedge shape to the whole module and can present in its middle part a section of arch or curved profile affixed to the internal face of the studs. The radial profile or attack stud of each module, which is the one closer to the middle of the deck to be deployed, or that remains at ground level when retracted, may present an extension to the opposite side of the axis to facilitate the rotation of the panel about its axis on the following ways:
By placing counterweights on the extension. These counterweights are located interspersed and sized not to interfere with their movement or with other modules in the opposite side; or by applying the necessary force to the end thereof to the lever advantage (such as by steel cables, gears, mechanical, elastic, or hydraulic devices).
By using a counterweight extension, it allows for the rotation of the modules by applying a small force on said extensions, which requires using a smaller motor and therefore less energy or the possibility to use manual force.
A bracket may be affixed to some joints between two profiles to ensure its squareness and to further strengthen the joints and the whole structure. Optionally, the brackets may be placed on internal corners or only on those unions that bear a higher load, to reduce the overall weight of the module.
Near the apex of the wedge-shaped panels is the opening where the axis is located. The external module, hereinafter drag module, may rest at 90 degrees to the ground, when in its deployed position, will be firmly fixed to said axis. The remaining modules will turn freely around said axis, linked to it through bearings to reduce the friction, so that turning the axis will turn the drag module and the module will drag the next module by a pulling action exerted by an abutment flange or stop. The flange runs through the longitudinal extension of the module and is disposed on the inner side of each lower beam (except for the lower module that does not having such a flange). The flange abuts against another like flange located on the outer side of each upper beam (except for the upper module that does not have such a flange).
The lower module that remains in contact with the ground surface may contain apertures, such as a door or a window.
The modules, which connect with each other in the deployed position, form a half cylinder that conforms the roof and sides of an enclosure, and the semicircular sections of each module complete the front and back faces of semicircular cover.
Each module is formed by cross-linking said beams and ribs with the resulting spaces in between them filled with foil material, either translucent or opaque.
Since modules are loaded on the same horizontal axis, each one can be moved from an angle that positions it below the ground line within underground housing (open or rest position when the cover is not in use) to a deployed position, in which the modules are located so that they connect to each other through their upper and/or lower edges by flanges or tabs above mentioned, completing each half an arch of 90 degrees.
As mentioned, there are three attack/contact beams in each module, which are positioned upside when the structure is opened.
The beams corresponding to the profile of the upper module are designed and positioned so as to ensure the tightness of the enclosure when, in the deployed position, makes contact with the other module. The beams corresponding to the profiles of the remaining modules are designed and positioned in such a way to ensure the tightness of the enclosure when deployed and to make contact with the studs and lower beams of the adjacent upper module through the said flange.
The design of the joints between different modules and the semicircular shaped enclosure guarantees a free water runoff adjacent to the lower module and the tightness of the joints of the profiles with laminar sealing material. In turn, the upper module has a slanting in the last part (the top) that facilitates the disposal of water, snow, ice, or other liquids.
The process of opening and closing the enclosure may be performed mechanically with the help of motors, but the use of counterweights for pivotal structures makes opening manually feasible. This simplicity of operation eliminates the need for trained personnel with special skills. It also allows the utilization as frequent as desired.
The deployment of the enclosure may be performed with the help of one or two synchronized motors, pulleys, or hydraulic pistons applied to the modules or beams.
If motors are used, the opening and closing of the structure may be automated, so it is possible to schedule and pre-defined operating frequencies.
In order to reduce structural stress caused by the operation of the enclosure, it is possible to apply forces to the end of the extensions designed to partially offset the weight of the modules, which can be static, linear, hydraulic, spring loaded, mechanical, or elastic, such as counterweights.
In a preferred embodiment shown, counterweights consist of a radial extension to the main radius of each module, with the radial development required (in the opposite direction to the module).
The dimensions of the counterweights, as shown in the embodiment, may vary depending on the soil type and the topography since it will determine the depth of the excavation.
The axes that serve for rotation of the modules (and corresponding counterweights) include bearings supported by a rigid structure affixed on a firm base on each side at the ends of each drag module.
Access to the interior of the structure, when deployed, is made through one or more openings located on the lower module of one or both principal sections.
In order to reduce any rubbing or friction, avoid obstacles, and maintain the necessary gap between the modules for the smooth running of the enclosure, bearings are disposed on the inner and outer faces.
The underground storage or housing is located on the perimeter of the area to be covered. It consists of a compartment closed on all sides except the necessary opening gap for the entry and exit of the modules and the maintenance access that may be required.
The sealing, total or partial, of the housing is achieved with the use of a perimeter rain cover and collector. In the embodiment, both elements, rain cover and rain collector, are part of the movable structure with the first connected to the upper beam of the main module and the second connected to the lower beam of the module, this greatly simplifies the operation of the structure.
In the case of covering large areas, a series of arches, fixed or telescopic, may be added to the enclosure structure to provide the necessary support while matching the curvature of the modules. For this, each module in the underside of the beams may have bearings to match and position the supporting arches used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the enclosure in the closed position.
FIG. 2 is a perspective view of the enclosure in open condition.
FIG. 3 is a top view of the enclosure in the closed condition.
FIGS. 4A, 4B, 4C, and 4D are a sequence of perspective views of the operational condition of the enclosure.
FIG. 5 is a longitudinal cross sectional view through the middle of the enclosure in a closed position, where the modules making up one half of the enclosure may be observed.
FIG. 6 is a cross sectional view of the enclosure in closed position and of the underground storage.
FIG. 7 is a view of a cross section of the enclosure retracted inside the lateral underground storage.
FIG. 8 is a top view of the retracted enclosure with the covers and the upper slabs of the underground storage removed.
FIG. 9 is a schematic view of the modules in cross section of an alternative enclosure of four modules where the arrangement of the modules can be seen in closed position.
FIG. 10 is a schematic view of the modules in cross section of an alternative enclosure of four modules where the arrangement of modules can be seen in open position.
FIG. 11 is a schematic view of the modules in cross section of an alternative enclosure of eight modules where the arrangement of modules can be seen in closed position.
FIG. 12 is a schematic view of the modules in cross section of an alternative enclosure of eight modules where the arrangement of modules can be seen in open position.
FIG. 13 is a top schematic view of an horizontal section of the back panels of the modules showing the location and of the axial profiles related modules being in open position.
FIG. 14 is an internal cross-sectional view of the upper module.
FIG. 15 is a cross sectional view of the front panel of the upper module.
FIG. 16 is a cross sectional view of the middle module.
FIG. 17 is a cross sectional view of the front of the middle module.
FIG. 18 is an internal cross sectional view of the lower module.
FIG. 19 is a cross sectional view of the lower front panel module.
FIG. 20 is a view of a cross section of the enclosure in an open position and the lateral underground storage.
FIG. 21 is an internal view of a cross section of the enclosure in closed condition with side underground chambers.
FIG. 22 is a schematic view of a cross section of half of the enclosure in closed position.
FIG. 23 is a schematic view of an approach of a cross section of half of the enclosure that shows how the beams of the modules are related in closed position.
FIG. 24 is a schematic view of an approach of a cross section of the axial profiles of the envelope in closed position showing how the axial sections of the panels of the modules are related.
FIG. 25 is a view of a cross section of one underground storage and the structure in open position.
FIG. 26 is a side view of an approach one to a bearing.
FIG. 27 is a lower view of one of the bearings.
FIG. 28 is a front view of the bearing hole through which passes one of the axes.
FIG. 29 is a perspective view showing the arrangement of the closed halves of the enclosure and a traverse cut for a better appreciation of the underground storage.
DETAILED DESCRIPTION OF THE INVENTION
In order that the present invention may be clearly understood and implemented the preferred embodiment is disclosed hereinafter. An accurate description of a preferred embodiment with reference to the same to the accompanying schematic drawings, given that in all figures the same reference numerals that indicate like or corresponding elements; the preferred embodiment is one of many and it is purely illustrative and in no way limiting of the invention.
FIG. 1 is a perspective view of the inventive enclosure in the deployed position where it may be observed that each half of the enclosure is made of upper module ( 1 ), medium module ( 2 ), and lower module ( 3 ). Each of the modules consist of a plurality of longitudinal beams, herein shown an upper beam ( 4 ), a middle beam ( 5 ), and a lower beam ( 6 ), and a plurality of transversal ribs ( 7 ). The spaces delimited by the beams and ribs are filled by foil material covering ( 8 ). A wedge-type front and rear panels are formed by an upper profile beam ( 9 ) and two lateral or axial profiles beams ( 10 , 11 ), a middle a curved profile rib ( 12 ) is used to strengthen the panels. Foil material covering ( 13 , 14 ) fills the spaces delimited by the various beams and ribs. Brackets ( 15 ) may be used to strengthen the enclosure structure. One or more modules or panels may have an opening, such as a door ( 16 ), shown at the lower module ( 3 ). The upper module ( 1 ) on each half of the enclosure is framed by a closing or attack beam ( 17 , 17 ′) that together function as underground housing covers, and the rainwater collectors ( 18 , 19 ) of the lower module ( 3 ).
FIG. 2 is a perspective view of the enclosure in the open position showing the underground housing covers ( 17 and 17 ′).
FIG. 3 is a top view of the inventive enclosure in the deployed position showing that each half of it is made by the upper module ( 1 ), middle module ( 2 ), and lower module ( 3 ). Each module consists of an upper beam ( 4 ), a middle beam ( 5 ), a bottom beam ( 6 ), a plurality of ribs or intermediate sections ( 7 ), foil material covering the spaces delimited by the beams and ribs ( 8 ), and two wedge type panels of which it can be seen the upper profile beam ( 9 , 9 ′). The attack beam of the upper module ( 1 ) forms the underground cover ( 17 ). Shown also are the rainwater collector ( 18 ) of the lower module ( 3 ), the front rain collector ( 19 ), the underground engine compartments ( 20 and 20 ′), and the structural supporting brackets ( 21 ). This figure shows clearly how the modules of one half are offset with respect to the modules of the other half, so that they may be interposed half on the modules of the other half, to allow proper rotation without interfering with its extensions or counterweights. In the event that counterweight extensions are not used, it is not necessary to maintain an offset of the modules.
FIG. 4 shows a sequence of perspective views of the evolution of the enclosure. Looking from top to bottom: 4 A: Enclosure completely deployed; 4 B: Partial opening; 4 C: Partial opening; 4 D: Enclosure fully open.
FIG. 5 shows a longitudinal sectional view of the deployed enclosure, so that the modules which make one half of the enclosure are observable. The upper module framed by underground cover ( 17 ) is appreciated, as are middle module ( 2 ), and lower module ( 3 ). The front and rear covers ( 19 and 19 ′), which are retractable, and the lower ( 22 ) and middle ( 23 ) beam from the middle module ( 2 ), as well as ribs or intermediate sections ( 24 ), and the foil material covering the space delimited by the beams and ribs ( 25 ). Counterweights ( 26 , 27 , 28 and 26 ′, 27 ′, 28 ′) used in this embodiment are observed as are the front and rear axles ( 29 and 29 ′) for this half of the enclosure and the front and back underground housing ( 30 and 30 ′).
FIG. 6 is a transversal cross-sectional view of the deployed enclosure and underground housing, where it can be observed: Upper modules ( 1 , 1 ′), middle modules ( 2 , 2 ′), and lower modules ( 3 , 3 ′) with its storm sewers ( 18 , 18 ′), the axes ( 29 , 29 ″), underground housing compartments ( 31 , 31 ′), and the group of counterweights ( 32 ) for each module.
FIG. 7 is a cross sectional view of an open enclosure where all modules are retracted into the lateral underground housings, appreciating: upper modules ( 1 , 1 ′), middle modules ( 2 , 2 ′), lower modules ( 3 , 3 ′) with its attached storm gutters ( 18 , 18 ′), covers ( 17 , 17 ′) for the upper modules ( 1 , 1 ′) of each half, the axes ( 29 , 29 ″), side underground housing ( 31 , 31 ′), and a group of counterweights ( 32 ) for each module.
FIG. 8 is a top view of the inventive enclosure in the open position with its covers removed to appreciate the disposition of the modules ( 1 , 2 , 3 , 1 ′, 2 ′, 3 ′) in the underground housing, engine compartments ( 20 , 20 ′), motors ( 33 , 33 ′), axis of each motor ( 34 , 34 ′), affixing and supporting structures ( 35 , 36 , 35 ′, 36 ′) for the axes corresponding to each side of the enclosure ( 29 , 29 ″, 29 ″′, 29 ″″), gearbox reductions for each motor ( 37 , 38 ), and frontal extensions of each module with its counterweights ( 26 , 27 , 28 , 26 ′, 27 ′, 28 ′).
FIG. 9 is a schematic cross sectional view an alternative embodiment of the inventive enclosure comprising four modules in a deployed mode.
FIG. 10 is a schematic cross sectional view an alternative embodiment of the inventive enclosure comprising four modules in an open mode.
FIG. 11 is a schematic cross sectional view yet another alternative embodiment of the inventive enclosure comprising eight modules in a deployed mode.
FIG. 12 is a schematic cross sectional view yet another alternative embodiment of the inventive enclosure comprising eight modules in an open mode.
FIG. 13 is a top schematic view of the horizontal section of the back panels of the modules showing, in the deployed position, the location and relationship amongst the axial panels of the modules. It can be appreciated the upper modules ( 1 , 1 ′), each with its two axial profiles or lateral beams ( 10 ′, 11 ′, 10 ″′, 11 ″′); middle modules ( 2 , 2 ′), each with its two axial profiles or lateral beams ( 39 ′, 40 ′, 39 ′″, 40 ′″), and lower modules ( 3 , 3 ′), each with its two axial profiles or lateral beams ( 41 ′, 42 ′, 41 ″′, 42 ′″).
FIG. 14 is an internal cross sectional view of the upper module where it can be observed the upper beam ( 4 ), middle beam ( 5 ), lower beam ( 6 ), foil material covering ( 43 ), and the wedge formed by an upper profile beam ( 9 ), two lateral or axial profiles beams ( 10 , 11 ), a middle curved profile rib ( 12 ), foil material covering ( 13 , 14 ), and supporting brackets ( 15 , 15 ′). The axis passage ( 44 ) and the counterweight ( 28 ) are shown.
FIG. 15 is a cross sectional view of the front panel of the upper module where it can be observed the internal face of one of the panels and the arrangement of the beams ( 10 , 11 ), the curved profile ( 12 ), the foil material covering ( 13 ), and the counterweight ( 28 ).
FIG. 16 is an internal cross sectional view of the middle module where it can be observed an upper beam ( 45 ), a middle beam ( 23 ), a lower beam ( 22 ), the foil material ( 46 ), and the wedge-type panel formed by a top rib or profile ( 47 ) and two lateral studs or profiles ( 48 , 49 ), a curved profile ( 50 ), foil material covering ( 51 , 52 ), and supporting brackets ( 53 , 53 ′). The axis passage ( 54 ) and the counterweight ( 59 ) are shown.
FIG. 17 is a cross sectional view of the front panel of the middle module where it is shown the arrangement of the studs ( 48 , 49 ), curved profile ( 50 ), foil material covering ( 51 ), and counterweight ( 27 ).
FIG. 18 is an internal cross sectional view of the lower module where it can be observed an upper beam ( 55 ), a middle beam ( 56 ), a lower beam ( 57 ), the foil material covering ( 58 ), and the wedge-type panel formed by a top rib or profile ( 59 ), two lateral studs or profiles ( 60 , 61 ), a curved profile ( 62 ), foil material covering ( 63 , 64 ). The axis passage ( 65 ), the counterweight ( 26 ), an opening represented by a door ( 16 ), and a gutter ( 18 ) are shown.
FIG. 19 is a cross sectional view of the lower module where it is shown the internal face of one panel and the arrangement of studs ( 60 , 61 ), the curved middle section ( 62 ), the foil material covering ( 63 ), and the counterweight ( 26 ).
FIG. 20 is a cross sectional view of the deployed enclosure showing the lateral underground housings ( 31 , 31 ′), the axes ( 29 , 29 ″), the group of counterweights ( 32 ), an internal reinforcement arch ( 66 ), and the sets of modules ( 67 , 67 ′) in their respective underground housing ( 31 , 31 ′), and gutters ( 18 , 18 ′).
FIG. 21 is an internal view of a cross section of the enclosure in the deployed position showing side underground housings ( 31 , 31 ′), a group of counterweights ( 32 ), one of the internal reinforcement arches ( 66 ) shown to appreciate the relative position with reference to the upper ( 1 , 1 ′), middle ( 2 , 2 ′) and lower ( 3 , 3 ′) modules for each half of the enclosure with their gutters ( 18 , 18 ′), and bearings ( 67 , 68 , 69 , 67 ′, 68 ′, 69 ′) located on the inside of the beams corresponding to each half modules and rolling on the upper face of the arch ( 66 ).
FIG. 22 is a schematic rear view of a cross section of one half of the deployed enclosure showing the upper beam ( 4 ), middle beam ( 5 ), and lower beam ( 6 ) of the upper module, the last one ( 6 ) having bearings ( 70 ) on its lower side; the middle module with an upper beam ( 45 ) presenting a bearing ( 71 ) on its upper side, a middle beam ( 23 ), and lower beam ( 22 ) presenting a bearing ( 72 ) on its lower side; lower module, presenting gutters ( 18 ), an upper beam ( 55 ) presenting a bearing ( 73 ) on its upper face, a middle beam ( 56 ), and lower beam ( 57 ); said bearings permit the modules to roll over the matching faces of the ribs or profiles that are perpendicular to the beams.
FIG. 23 is a detailed schematic view of a cross section of a joint of two modules showing how the beams of the modules, in this example the middle module's lower beam ( 22 ) with its flange, hook, or stop ( 74 ) and bearing ( 72 ), allow the pulling of the lower modules, with or without the help of bearings, from the lower module with his upper beam ( 55 ) with its flange, hook, or cap ( 75 ) and bearing ( 73 ), and the respective foil material covering ( 46 , 58 ).
FIG. 24 is a schematic view of a cross section of the axial profiles of the deployed enclosure showing how the axial sections of the panels of the modules are related when deployed. In this case, the upper module with its lower beam ( 11 ) and its flange, hook, or cap ( 76 ) meet middle module's upper beam ( 48 ) and its flange, hook, or cap ( 77 ) and the respective foil material coverings ( 13 , 51 ).
FIG. 25 is a view of a cross section of one underground housing ( 31 ) showing the upper module with an upper beam ( 4 ), a middle beam ( 5 ), a lower beam ( 6 ), the foil material covering ( 43 ), and an upper profile beam ( 9 ); the middle module with an upper beam ( 45 ), a middle beam ( 23 ), a lower beam ( 22 ), the foil material covering ( 46 ), and an upper profile beam ( 47 ); the lower module with an upper beam ( 55 ), a middle beam ( 56 ), a lower beam ( 57 ), the foil material covering ( 58 ), upper profile beam ( 59 ), and gutters ( 18 ).
FIG. 26 is a side view, in this case of the middle module's lower beam ( 22 ) with its flange, hook, or stop ( 74 ), in contact with lower module's upper beam ( 55 ) with its flange, hook, or cap ( 75 ), bearing ( 73 ), and the retaining bearing plate ( 78 ).
FIG. 27 is a bottom view of one of the bearings in which the bearing ( 73 ) and the retaining plate of the bearing ( 78 ) are shown.
FIG. 28 is a front view showing a bearing ( 79 ) in the axis passage ( 54 ) in the middle module, also shown two lateral studs or profiles ( 48 , 49 ).
FIG. 29 is a perspective view showing half of the enclosure deployed showing a transversal cut to the soil for better appreciation of the underground housings. It can be appreciated the upper module ( 1 ′) with its counterweight ( 28 ′), the middle module ( 2 ′) with its counterweight ( 27 ′), and the lower module ( 3 ′) with its counterweight ( 26 ′), the closure or attack beam ( 17 ′) corresponding to this half of the enclosure formed by the attack profiles, the engine compartment ( 20 ′) where a motor may be housed, the lateral underground housing ( 31 , 31 ′), the axis ( 29 ″), shown extended for a better visualization.
It is logical to assume that this invention may be implemented with modifications insofar as construction materials and number of modules, but without departing from the basic principles that are clearly specified in claims bellow.
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A manual or motor activated enclosure, appropriate for any surface to be enclosed, comprising matching opposite cross-linked structures containing a set of profiles that fits in the field of telescopic modular pivoting roof structures, that upon retraction it is housed underground such that none of its components are visible above ground, and upon deployment it achieves complete enclosure of the area while proving for openings.
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FIELD OF THE INVENTION
The present invention relates to a tool for greasing wheel bearings and more particularly to a grease dam for ensuring proper fill of grease within the hub cavity prior to installing the outer bearing.
DESCRIPTION OF THE PRIOR ART
Greasing a wheel hub assembly is well known in the art. Heretofore, it has been the practice to first pack the inner bearing with grease and position the inner bearing within the hub and mount the hub and inner bearing upon the spindle. Grease is spread by hand uniformly about the grease cavity within the hub which is manually positioned in alignment on the spindle to receive the grease uniformly prior to mounting the outer bearing. Once grease is installed within the grease cavity the outer bearings are installed and secured to the spindle. The nut assembly and hub cap are then secured. However, because [of] the consistency of the grease is much like molasses, it is impossible to fill the hub cavity more than 30%, as much of the grease will simply leak out of the end of the hub assembly prior to installing the outer bearing and hub cap. Such insufficient filling of grease within the hub cavity results in premature bearing failure due to a lack of lubrication. Current standards call for filling the hub cavity with grease to at least 50% of the cavity volume. The present invention provides a simple tool for proper filling of grease during assembly of the wheel hub/spindle assembly without the need for complicated wheel end arrangements or greasing tool devices.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a tool for properly filling a wheel hub cavity with grease as well as a method for its use that is superior to the prior art.
The present invention is directed to a removable grease dam tool to facilitate proper filling of grease within a wheel hub assembly. A grease dam is placed adjacent an outer surface of a wheel hub that is rotatably mounted to a spindle. The grease dam blocks at least 50% of the exposed area between the wheel hub and spindle and leaves a top portion open to allow grease to be injected into the inner cavity of the wheel hub. A portion of the grease dam is disposed within the wheel hub between the heel hub and spindle to simulate the presence of the outer bearing assembly. Once the inner cavity of the wheel hub is filled with grease beyond a 50% fill level, the grease dam is removed and the outer bearing assembly is immediately thereafter installed. The tool prevents leakage of grease during assembly to ensure at least a 50% fill level. A handle is provided to facilitate manipulation by a user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the grease dam tool according to the present invention.
FIG. 2 is a top plan view of the grease dam tool of FIG. 1 .
FIG. 3 is a top plan view of the grease dam tool according to an alternate embodiment of the present invention.
FIG. 4 is a cross section view of a partially assembled wheel hub spindle assembly.
FIG. 5 is a cross sectional view of the partially assembled wheel hub/spindle assembly of FIG. 4 utilizing the grease dam tool of the present invention.
FIG. 6 is a front view of a partially assembled wheel hub/spindle assembly.
FIG. 7 is a front view of the partially assembled wheel hub/spindle assembly of FIG. 6 with a mounted grease dam of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a perspective view of the grease dam tool 1 of the present invention to ensure proper grease fill of a wheel hub assembly. The tool 1 is rather simple in construction and its use in the wheel hub assembly ensures at least a 50% grease fill of the wheel hub inner cavity. The grease dam tool 1 has three primary parts. A main portion 3 is formed of a semi-disc shaped substantially planar member having a central semi-circular notch 6 to accommodate and engage a spindle. The main portion 3 does not completely circumscribe the central notch 6 but preferably circumscribes the central notch 6 more than 180°. Such an arrangement provides the ability to fill the inner cavity more the 50%. A dam portion 8 extends from the main portion and is shaped to engage the inner surface of a wheel hub and an outer peripheral surface of a spindle. Preferably the dam portion is semi-frustoconically shaped and extends orthoganally from the main portion 6 . The dam portion 8 has a recess 10 to accommodate and engage a wheel spindle. The semi-frustoconical shape of the dam portion 8 and the recess 10 allow the dam portion to be positioned between the wheel hub and the spindle thereby blocking egress of grease as will be later discussed in more detail. A handle 12 is provided to allow the tool to be manipulated by a user. The handle 12 simply extends from the main portion from an opposite side from which the dam portion 8 is provided.
As can be seen from FIG. 2, the main portion 6 , and the dam portion 8 are secured together by screws 14 which extend through the main portion 6 and engage the dam portion 8 to form an integral body. Other means to secure the main portion 6 and dam portion 8 may be employed such as by adhesive or other commonly known securing means. While it is preferred to form the main portion 6 and dam portion 8 of two separate pieces of plastic, they may be formed of a homogeneously formed single piece of plastic. As further depicted in FIG. 2, a pair of pegs 16 extend from the main portion 6 parallel to and adjacent the dam portion 8 . As will be later described in more detail, the pegs 16 are provided to engage bores formed in an outer face of the wheel hub to properly position and align the grease dam during use.
FIG. 3 depicts an alternative embodiment of the present invention. The recess 10 a formed in the dam portion is stepped to accommodate a different spindle end arrangement.
FIG. 4 depicts a partial section view of a conventional partially assembled wheel hub/spindle assembly. An inner bearing assembly 20 is packed with grease and pre-assembled to the wheel hub 22 as is conventionally known in the art. The wheel hub 22 and inner bearing assembly 20 are mounted to the spindle 24 which has be pre-coated with grease. As can be seen, the outer end 25 of the wheel hub/spindle assembly remains open. When grease is inserted into the inner cavity 23 of the wheel hub 22 , once the level reaches the inward most point of the wheel hub, the grease will simply leak out of the open end of 25 of the wheel hub/spindle assembly. Such an arrangement will not allow sufficient filling the hub cavity 23 with lubricating grease.
FIG. 5 depicts the same wheel hub arrangement of FIG. 4 with the application of the grease dam tool 1 of the present invention. As can be seen form FIG. 5, the grease dam tool 1 is installed on the outer end 25 of the wheel hub/spindle assembly. The main portion 6 is flush mounted to an outer face 26 of the wheel hub 22 and the dam portion 8 is inserted within the inner cavity 23 between the wheel hub 22 and the spindle 24 . This arrangement blocks the lower portion of the open end 25 of the wheel hub/spindle assembly. In essence the grease dam tool simulates the presence of an outer bearing assembly and blocks the egress of grease from the inner cavity 23 . A grease applicator 33 may then simply inject grease within the inner cavity 23 . Because the grease dam 1 blocks the open end 25 , the grease level may be filled up to the level of the grease dam tool. As previously discussed, the grease dam tool preferably circumscribes the spindle more than 180° and therefore blocks more than 50% of the exposed open end area. Consequently, a grease fill level of at least 50% is achieved. Note the grease level 30 that is located above the center line 31 of the spindle 24 and wheel hub 22 . Once the inner cavity 23 has been sufficiently filled with lubricating grease (at least 50%) the grease dam 1 may be removed and a pre-packed outer bearing assembly immediately installed between the wheel hub 22 and spindle 24 adjacent the outer face 26 . A securing nut may then be secured to the end of the spindle and end play of the wheel hub assembly set as conventionally known in the art.
FIG. 6 depicts a front view of the assembly of FIG. 4 . AS can bee seen there is an annular space 28 (corresponding to inner cavity 23 ) is disposed between the spindle 24 and the inner surface of the wheel hub 22 . A plurality of lugs nuts 29 are provided on the outer periphery of the hub 22 for securing a wheel thereto. Also, provided are a plurality of bores 27 formed on-the outer race 26 which are preferably threaded to receive securing bolts from a hub cap that will seal the entire inner cavity of the wheel hub 22 once filled with grease and fully assembled with the outer bearing assembly etc. As clearly seen the lower portion of the annular space 28 remains open at the end of the wheel hub assembly. Therefore, if grease were simply injected, it would simply leak out prior to achieving a sufficient fill level. FIG. 7 shows a front view of the assembly of FIG. 6 with the application of the grease dam 1 of the present invention. As clearly shown the grease dam 1 blocks the lower portion of the open end 25 of the wheel hub/spindle assembly. The pegs 16 are inserted into corresponding bores 27 to properly position and align the grease dam tool relative to the hub 22 . The engagement of the pegs 16 and bores 27 also serve to help maintain the contact with the outer face 26 of the wheel hub 22 during greasing. A user simply manipulates the handle 12 to align the pegs 16 with the corresponding bores 27 and applies pressure to maintain the main portion 6 flush against the outer face 26 . As previously discussed, lubricating grease is simply then inserted in the exposed portion of the annular space 28 adjacent the top portion of the wheel hub 28 . Once a proper grease fill level is achieved, the grease dam is removed and an outer bearing assembly is immediately installed and the securing nut threaded onto the spindle 24 and end play adjusted. The hub cap is then installed to seal the inner cavity 23 and ensure retainment of the grease within the inner cavity 23 .
While the foregoing description of the grease dam 1 and its use has been described, the specific method of assembling and lubricating of the wheel hub/spindle assembly will now be described with appropriate reference to the drawings.
First, an outer bearing assembly is packed with lubricating grease and is preferably packed with Mobil SHC=007 synthetic grease for ready installation in the wheel hub/spindle assembly. A wheel hub 22 is provided with a pre assembled pre-packed inner bearing assembly 20 as in known in the art. Or the inner bearing assembly 20 is packed with grease, as is the outer bearing assembly, and then mounted to the wheel hub 22 . The spindle 24 is then liberally coated with Mobil SHC=007 grease. The wheel hub 22 and inner bearing assembly 20 are then together installed onto the spindle 24 . The grease dam tool 1 is then aligned and positioned relative to the spindle 24 and wheel hub 22 by aligning the pegs 16 with the appropriate bore 27 . As can be seen in the drawing figures, the dam 8 portion is disposed between the wheel hub 22 and spindle 24 , and the main portion 6 . is preferably flush mounted with the outer face 26 of the wheel hub 22 so as to block the lower most portion of the open end 25 of the wheel hub/spindle assembly. Pressure is applied to the handle 12 to maintian the grease dam 1 in position. A grease applicator is the used to fill the inner cavity 23 with grease to at least 50%. The cavity being defined by the space between the inner bearing assembly 20 , wheel hub 22 , spindle 24 and dam portion 8 of the grease dam tool 1 . Once the inner cavity 23 is filled to at least 50%, the grease dam tool 1 is removed and the outer bearing assembly is immediately installed between the wheel hub 22 and spindle 24 . The securing nut is then applied and end play adjusted. An additional coating of grease is then applied to the outer surface of the outer bearing assembly and nut assembly. A hub cap is then installed to the outer face 26 of the wheel hub 22 as is known in the art taking care not to cover a vent hole in the hub cap.
While the foregoing invention has been shown and described with reference to a preferred embodiment, it will be understood by those possessing skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. For example while a specific configuration and shapes has been shown and described for the inner surface of the wheel hub 22 and outer surface of the spindle 24 and the corresponding inner and outer bearing race seats as well as the relative positions of the recited components, the grease dam 1 of the present invention can be so dimensioned to accommodate different wheel hub 22 and spindle 24 configurations so long as the grease dam is capable of blocking the lower portion of the exposed area of the assembly while allowing injection of grease within the inner cavity 23 . It is recognized that different profiles are used in the art to define the inner surface of the wheel hub 22 that defines the shape of the inner cavity 23 and the bearing race seats. Use of the present invention for different spindle profiles and end nut assemblies are also contemplated.
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A removable grease dam tool to facilitate proper filling of grease within a wheel hub assembly and a method of using the same. A grease dam is placed adjacent an outer surface of a wheel hub mounted to a spindle. The grease dam blocks at least 50% of the exposed area between the wheel hub and spindle and leaves a top portion open to allow greased to be injected into the inner cavity of the wheel hub. A portion of the grease dam is disposed within the wheel hub between the wheel hub and spindle to simulate the presence of the outer bearing. Once the inner cavity of the wheel hub is filled beyond a 50% fill level, the grease dam is removed and the outer bearing assembly is immediately thereafter installed. The tool prevents leakage of grease during assembly to ensure at least a 50% fill level. A handle is provided to facilitate manipulation by a user.
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This application is a 371 of PCT/EP97/07242, filed on Dec. 22, 1997.
TECHNICAL FIELD OF THE INVENTION
The invention relates to novel S-aryl-dithiazine dioxides, to processes for their preparation and to the use in crop protection and in the protection of materials.
BACKGROUND OF THE INVENTION
Dithiazine dioxides having alkyl substitution at the S have already been described, a biological activity has not been mentioned (see Nakahashi, K. et al., Bull. Chem. Soc. Jpn. 45, 3217 (1972); Masegawa, K. et al., Bull. Chem. Soc. Jpn. 45, 1567 (1972)).
DETAILED DESCRIPTION OF THE INVENTION
Surprisingly, it has now been found that the novel compounds of the general formula (I) ##STR1## in which R 1 , R 2 , R 3 , R 4 independently of one another each represent hydrogen, optionally substituted alkyl, alkenyl, alkinyl or aryl and
Ar represents optionally substituted aryl
are outstandingly suitable for the protection of plants and materials.
The formula (I) provides a general definition of the compounds according to the invention. Preference is given to compounds of the formula (1) in which
R 1 , R 2 , R 3 and R 4 independently of one another each represent hydrogen, straight-chain and branched alkyl having 1 is 10 carbon atoms, straight-chain or branched alkenyl having 2 to 10 carbon atoms or straight-chain or branched alkinyl having 2 to 10 carbon atoms, which is optionally mono- to polysubstituted by identical or different substituents selected from the group consisting of halogen, alkoxy having 1 to 6 carbon atoms, halogenoalkoxy having 1 to 6 carbon atoms and 1 to 9 identical or different halogen atoms, alkylthio having 1 to 6 carbon atoms, halogenoalkylthio having 1 to 6 carbon atoms and 1 to 9 identical or different halogen atoms, acyl having 1 to 6 carbon atoms, acyloxy having 1 to 6 carbon atoms, (alkoxy)carbonyl having 1 to 6 carbon atoms, amino, which is optionally substituted by identical or different substituents selected from the group consisting of alkyl and aryl, optionally substituted phenoxy, aryl, pyridyl or pyridyloxy, nitro or cyano, or
represent aryl, which is optionally mono- to pentasubstituted by halogen, alkyl having 1 to 10 carbon atoms, halogenoalkyl having 1 to 8 carbon atoms and 1 to 8 identical or different halogen atoms, alkoxy having 1 to 10 carbon atoms, halogenoalkoxy having 1 to 8 carbon atoms and 1 to 8 identical or different halogen atoms, alkylthio having 1 to 10 carbon atoms, halogenoalkylthio having 1 to 8 carbon atoms and 1 to 8 identical or different halogen atoms, amino, monoalkylamino having straight-chain or branched alkyl radicals having to 1 to 6 carbon atoms, dialkylamino having identical or different, straight-chain or branched alkyl radicals having in each case 1 to 6 carbon atoms, cycloalkyl having 1 to 6 carbon atoms, methylenedioxy, difluoromethylenedioxy, chlorofluoromethylenedioxy, dichloromethylenedioxy, nitro or cyano
and
Ar represents aryl, which is optionally mono- to pentasubstituted by halogen, alkyl having 1 to 10 carbon atoms, halogenoalkyl having 1 to 8 carbon atoms and 1 to 8 identical or different halogen atoms, alkoxy having 1 to 10 carbon atoms, halogenoalkoxy having 1 to 8 carbon atoms and 1 to 8 identical or different halogen atoms, alkylthio having 1 to 10 carbon atoms, halogenoalkylthio having 1 to 8 carbon atoms and 1 to 8 identical or different halogen atoms, amino, monoalkylamino having straight-chain or branched alkyl radicals having 1 to 6 carbon atoms, dialkylamino having identical or different, straight-chain or branched alkyl radicals having in each case 1 to 6 carbon atoms, cycloalkyl having to 1 to 6 carbon atoms, methylenedioxy, difluoromethylenedioxy, chlorofluoromethylenedioxy, dichloromethylenedioxy, nitro or cyano.
Particular preference is given to compounds of the formula (I) in which
R 1 , R 2 , R 3 and R 4 independently of one another each represent hydrogen, straight-chain or branched alkyl having 1 to 8 carbon atoms, straight-chain or branched alkenyl having 2 to 8 carbon atoms or straight-chain or branched alkinyl having 2 to 8 carbon atoms, which is optionally mono- to tetrasubstituted by identical or different substituents selected from the group consisting of fluorine, chlorine, alkoxy having 1 to 5 carbon atoms, halogenoalkoxy having 1 to 5 carbon atoms and 1 to 5 fluorine and/or chlorine atoms, alkylthio having 1 to 5 carbon atoms, halogenoalkylthio having 1 to 5 carbon atoms and 1 to 5 fluorine and/or chlorine atoms, acyl having 1 to 5 carbon atoms, acyloxy having 1 to 5 carbon atoms, alkoxycarbonyl having 1 to 5 carbon atoms, amino, which is optionally substituted by identical or different substituents selected from the group consisting of alkyl having 1 to 4 carbon atoms and phenyl, optionally substituted phenoxy, aryl, pyridyl, pyridyloxy, nitro or cyano, or represent phenyl, which is optionally mono- to tetrasubstituted by fluorine, chlorine, alkyl having 1 to 8 carbon atoms, halogenoalkyl having 1 to 6 carbon atoms and 1 to 6 fluorine and/or chlorine atoms, alkoxy having 1 to 8 carbon atoms, halogenoalkoxy having 1 to 6 carbon atoms and 1 to 6 fluorine and/or chlorine atoms, alkylthio having 1 to 8 carbon atoms, halogenoalkylthio having 1 to 6 carbon atoms and 1 to 6 fluorine and/or chlorine atoms, amino, monoalkylamino having alkyl radicals of 1 to 4 carbon atoms, dialkylamino having identical or different alkyl radicals having in each case 1 to 4 carbon atoms, cycloalkyl having 1 to 6 carbon atoms, methylenedioxy, difluoromethylenedioxy, chlorofluoromethylenedioxy, dichloromethylenedioxy, nitro or cyano,
and
Ar represents phenyl, which is optionally mono- to tetrasubstituted, preferably mono- to disubstituted, by fluorine, chlorine, bromine, alkyl having 1 to 8 carbon atoms, such as preferably methyl, ethyl, n- or i-propyl, n-, i-, s- or t-butyl, halogenoalkyl having 1 to 6 carbon atoms and 1 to 6 fluorine and/or chlorine atoms, such as preferably trifluoromethyl, trifluoroethyl, difluorochloromethyl, alkoxy having 1 to 8 carbon atoms, such as preferably methoxy, ethoxy, n- or i-propoxy, n-, i-, s- or t-butoxy, halogenoalkoxy having 1 to 6 carbon atoms and 1 to 6 fluorine and/or chlorine atoms, such as preferably difluoromethoxy, trifluoromethoxy, difluorochloromethoxy, trifluoroethoxy, alkylthio having 1 to 8 carbon atoms, halogenoalkylthio having 1 to 6 carbon atoms and 1 to 6 fluorine and/or chlorine atoms, amino, monoalkylamino having alkyl radicals of 1 to 4 carbon atoms, dialkylamino having identical or different alkyl radicals having in each case 1 to 4 carbon atoms, cycloalkyl having 1 to 6 carbon atoms, methylenedioxy, difluoromethylenedioxy, chlorofluoromethylenedioxy, dichloromethylenedioxy, nitro or cyano.
R 1 , R 2 , R 3 and R 4 each particularly preferably represent hydrogen and/or methyl.
The particular radical definitions given for the radicals in the respective combinations or preferred combinations of radicals are, independently of the particular combination given, also replaced at will by radical definitions of other preferred ranges.
Moreover, it has been found that the compounds of the formula (I) are obtained if the salts of the general formula (II) ##STR2## in which R 1 , R 2 , R 3 and R 4 are each as defined above and
M.sup.⊕ represents an alkali metal ion or alkaline earth metal ion, in particular Na + , K + ,
are reacted with diazonium salts of the general formula (III)
Ar--N.tbd.N.sup.⊕ A.sup.74 (III)
in which
Ar is as defined above and
A.sup.θ represents the anion of a mineral acid, in aqueous/alkaline solution, if appropriate in the presence of a catalyst.
Preferably, a base and, if appropriate, a catalyst, and then the diazonium salt solution (III) are added to a solution of (II). Preferred bases employed are alkali metal hydroxides such as, for example, potassium hydroxide or sodium hydroxide.
Suitable catalysts are all catalysts which promotes the exchange of the diazonium function for sulphur-containing radicals.
Preference is given to using Cu(I) salts or copper powder. The temperature during the addition of the diazonium salt solution can be varied within a wide range. In general, the reaction is carried out between -30° C. and +60° C., preferably between -20° C. and +40° C. The preparation of the diazonium salt solution from anilines is carried out by literature methods.
Some of the salts of the general formula (II) are known, or they can be prepared by methods similar to those known from the literature (see literature references p.1). It is possible to use either salts of the formula (II) which have been isolated in solid form, or solutions which have been prepared in situ.
The active compounds according to the invention have a strong microbicidal action and can be used for controlling undesirable microorganisms, preferably fungi and bacteria, in crop protection and in the protection of materials.
In the present context, the term industrial materials refers to non-living materials which have been prepared for use in industry. Possible examples are industrial materials which are to be protected by active compounds according to the invention against microbial alteration or destruction, adhesives, sizes, paper and card, textiles, leather, wood, coating compositions and plastics articles, cooling lubricants and other materials which can be attacked or decomposed by microorganisms. In the context of the materials to be protected mention may also be made of parts of production plants, for example cooling water circuits, which may be adversely affected by reproduction of microorganisms. Preferred industrial materials in the context of the present invention are adhesives, sizes, papers and cards, leather, wood, coating compositions, cooling lubricants and heat transfer fluids.
Examples of microorganisms which can bring about degradation or an alteration in the industrial materials are bacteria, fungi, yeasts, algae and slime organisms. The active compounds or compositions according to the invention preferably act against bacteria, fungi, especially mould fungi, and also against slime organisms and algae.
By way of example, mention may be made of microorganisms of the following genera:
Alternaria, such as Alternaria tenuis,
Aspergillus, such as Aspergillus niger,
Chaetomium, such as Chaetomium globosum,
Coniophora, such as Coniophora puetana,
Lentinus, such as Lentinus tigrinus,
Penicillium, such as Penicillium glaucum,
Polyporus, such as Polyporus versicolor,
Aureobasidium, such as Aureobasidium pullulans,
Sclerophoma, such as Sclerophoma pityophila,
Trichoderma, such as Trichoderma viride,
Escherichia, such as Escherichia coli,
Pseudomonas, such as Pseudomonas aeruginosa,
Staphylococcus, such as Staphylococcus aureus.
Fungicidal compositions in crop protection are employed for controlling Plasmodiophoromycetes, Oomycetes, Chytridiomycetes, Zygomycetes, Ascomycetes, Basidiomycetes, Deuteromycetes.
Some causative organisms of fungal diseases which come under the abovementioned generic term may be mentioned by way of example, but not by way of limitation:
Pythium species, such as, for example, Pythium ultimum;
Phytophthora species, such as, for example, Phytophthora infestans;
Pseudoperonospora species, such as, for example, Pseudoperonospora humuli or Pseudoperonospora cubense;
Plasmopara species, such as, for example, Plasmopara viticola;
Peronospora species, such as, for example, Peronospora pisi or Peronospora brassicae;
Erysiphe species, such as, for example, Erysiphe graminis;
Spaaerotheca species, such as, for example, Sphaeroteca fuliginea;
Podosphaera species, such as, for example, Podosphaera leucotricha;
Venturia species, such as, for example, Venturia inaequalis;
Pyrenophora species, such as, for example, Pyrenophora teres or Pyrenophora graminea (conidia form: Drechslera, synonym: Helminthosporium);
Cochliobolus species, such as, for example, Cochliobolus sativus (conidia form: Drechslera, synonym: Helminthosporium);
Uromyces species, such as, for example, Uromyces appendiculatus;
Puccinia species, such as, for example, Puccinia recondita;
Tilletia species, such as, for example, Tilletia caries;
Ustilago species, such as, for example, Ustilago nuda or Ustilago avenae;
Pellicularia speciies, such as, for example, Pellicularia sasakii;
Pyyricularia species, such as, for example, Pyricularia oryzae;
Fusarium species, such as, for example, Fusarium culmorum;
Botrytis species, such as, for example, Botrytis cinerea;
Septoria species, such as, for example, Septoria nodorum;
Leptosphaeria species, such as, for example, Leptosphaeria nodorum;
Cercospora species, such as, for example, Cercospora canescens;
Alternaria species, such as, for example, Alternaria brassicae;
Pseudocercosporella species, such as, for example, Pseudocercosporella herpotrichoides.
The fact that the active compounds are well tolerated by plants also permits treatment of plants at the concentrations required for controlling plant diseases, it being possible to carry out treatment of above-ground parts of plants, and also treatment of planting stock and seeds and of the soil.
Depending on their respective physical and/or chemical properties, the active compounds of the formula (I) can be converted into customary formulations, such as solutions, emulsions, suspensions, powders, foams, pastes, granules, aerosols and very fine capsules in polymeric substances.
These formulations and compositions are prepared in a known manner, for example by mixing the active compounds with extenders, that is, liquid solvents, liquefied gases under pressure, and/or solid carriers, if appropriate with the use of surfactants, that is, emulsifiers and/or dispersants and/or foam-formers. If the extender used is water, it is also possible to use for example organic solvents as auxiliary solvents. Essentially, suitable liquid solvents are: aromatics, such as xylene, toluene and alkylnaphthalenes, chlorinated aromatics or chlorinated aliphatic hydrocarbons, such as chlorobenzenes, chloroethylenes, or methylene chloride, aliphatic hydrocarbons, such as cyclohexane or paraffins, for example mineral oil fractions, alcohols, such as butanol or glycol and their ethers and esters, ketones, such as acetone, methyl ethyl ketone, methyl isobutyl ketone or cyclohexanone, strongly polar solvents, such as dimethylformamide or dimethyl sulphoxide, and water; by liquefied gaseous extenders or carriers are meant liquids which are gaseous at ambient temperature and under atmospheric pressure, for example aerosol propellants, such as halogenated hydrocarbons and butane, propane, nitrogen and carbon dioxide; suitable solid carriers are: for example ground natural minerals, such as kaolins, clays, talc, chalk, quartz, attapulgite, montmorillonite or diatomaceous earth, and ground synthetic minerals, such as finely divided silica, alumina and silicates; suitable solid carriers for granules are: for example crushed and fractionated natural rocks such as calcite, marble, pumice, sepiolite and dolomite, and synthetic granules of inorganic and organic meals, and granules of organic material such as sawdust, coconut shells, maize cobs and tobacco stalks; suitable emulsifiers and/or foam-formers are: for example nonionic and anionic emulsifiers, such as polyoxyethylene fatty acid esters, polyoxyethylene fatty alcohol ethers, for example alkylaryl polyglycol ethers, alkylsulphonates, alkyl sulphates, arylsulphonates and protein hydrolysates; suitable dispersants are: for example lignosulphite waste liquors and methylcellulose.
Tackifiers such as carboxymethylcellulose, natural and synthetic polymers in the form of powders, granules or latices, such as gum arabic, polyvinyl alcohol, polyvinyl acetate, and natural phospholipids, such as cephalins and lecithins, and synthetic phospholipids, can be used in the formulations. Possible further additives are mineral and vegetable oils.
It is possible to use colorants such as inorganic pigments, for example iron oxide, titanium oxide and Prussian blue, and organic dyestuffs, such as alizarin dyestuffs, azo dyestuffs and metal phthalocyanine dyestuffs, and trace nutrients such as salts of iron, manganese, boron, copper, cobalt, molybdenum and zinc.
The efficacy and the activity spectrum of the active compounds of the formula (I) and of the compositions preparable therefrom, of precursors or of formulations in general can be increased by adding, if appropriate, further antimicrobial compounds, fungicides, bactericides, herbicides, insecticides or other active compounds, so as to widen the spectrum of activity or to obtain particular effects such as, for example, additional protection against insects. These mixtures may have a wider activity spectrum than the compounds according to the invention.
In many cases, synergistic effects are obtained, i.e. the activity of the mixture is greater than the activity of the individual components. Particularly suitable co-components are, for example, the following compounds:
Triazoles, such as:
azocyclotin, bitertanol, bromuconazole, diclobutrazole, difenoconazole, diniconazole, epoxyconazole, etaconazole, fenbuconazole, fenchlorazole, fenethanil, fluquinconazole, flusilazole, flutriafol, furconazole, hexaconazole, imibenconazole, ipconazole, isozofos, myclobutanil, metconazole, paclobutrazol, penconazole, propioconazole, (±)-cis-1-(4-chlorophenyl)-2-(1H-1,2,4-triazol-1-yl)-cycloheptanol, 2-(1-tert-butyl)-1-(2-chlorophenyl)-3-(1,2,4-triazol-1-yl)-propan-2-ol, tetraconazole, triadimefon, triadimenol, triapenthenol, triflumizole, triticonazole, uniconazole and their metal salts and acid adducts;
Imidazoles, such as:
clotrimazole, bifonazole, climbazole, econazole, fenapamil, imazalil, isoconazole, ketoconazole, lombazole, miconazole, pefurazoate, prochloraz, triflumizole, thiazolcar, 1-imidazolyl-1-(4'-chlorophenoxy)-3,3-dimethylbutan-2-one and their metal salts and acid adducts;
Pyridines and pyrimidines, such as:
ancymidol, buthiobate, fenarimol, nuarimol, triamirol;
Succinate dehydrogenase inhibitors, such as:
benodanil, carboxim, carboxim sulphoxide, cyclafluramid, fenfuram, flutanil, furcarbanil, furmecyclox, mebenil, mepronil, methfuroxam, metsulfovax, pyrocarbolid, oxycarboxin, shirlan, seedvax;
Naphthalene derivatives, such as:
terbinafine, naftifine, butenafine, 3-chloro-7-(2-aza-2,7,7-trimethyl-oct-3-en-5-ine);
Sulfenamides, such as:
dichlorfluanid, tolylfluanid, folpet, fluorfolpet; captan, captofol;
Benzimidazoles, such as:
carbendazim, benomyl, fuberidazole, thiabendazole or their salts;
Morpholine derivatives, such as:
aldimorph, dimethomorph, dodemorph, falimorph, fenpropidin fenpropimorph, tridemorph, trimorphamid and their arylsulphonates, such as, for example, p-toluenesulphonic acid and p-dodecylphenyl-sulphonic acid;
Benzothiazoles, such as:
2-mercaptobenzothiazole;
Benzothiophene dioxides, such as:
N-cyclohexyl-benzo[b]thiophenecarboxamide S,S-dioxide;
Benzamides, such as:
2,6-dichloro-N-(4-trifluoromethylbenzyl)-benzamide, tecloftalam;
Boron compounds, such as:
boric acid, boric esters, borax;
Formaldehyde and formaldehyde-releasing compounds, such as:
benzyl alcohol mono-(poly)-hemiformal, n-butanol hemiformal, dazomet, ethylene glycol hemiformal, hexa-hydro-S-triazines, hexamethylenetetramine, N-hydroxymethyl-N'-methylthiourea, N-methylolchloroacetamide, oxazolidines, paraformaldehyde, taurolin, tetrahydro-1,3-oxazine, N-(2-hydroxypropyl)-aminemethanol;
Isothiazolinones, such as:
N-methylisothiazolin-3-one, 5-chloro-N-methylisothiazolin-3-one, 4,5-dichloro-N-octylisothiazolin-3-one, 5-chloro-N-octylisothiazolinone, N-octylisothiazolin-3-one, 4,5-trimethylene-isothiazolinones, 4,5-benzisothiazolinones;
Aldehydes, such as:
cinnamaldehyde, formaldehyde, glutaraldehyde, β-bromocinnamaldehyde;
Thiocyanates, such as:
thiocyanatomethylthiobenzothiazole, methylenebisthiocyanate;
Quaternary ammonium compounds, such as:
benzalkonium chloride, benzyldimethyltetradecylammonium chloride, benzyldimethyldodecylammonium chloride, dichlorobenzyl-dimethyl-alkyl-ammonium chloride, didecyldimethylammonium chloride, dioctyl-dimethyl-ammonium chloride, N-hexadecyl-trimethyl-ammonium chloride, 1-hexadecyl-pyridinium chloride;
Iodine derivatives, such as:
diiodomethyl p-tolyl sulphone, 3-iodo-2-propinyl alcohol, 4-chlorophenyl-3-iodopropargyl formal, 3-bromo-2,3-diiodo-2-propenyl ethylcarbamate, 2,3,3-triiodoallyl alcohol, 3-bromo-2,3-diiodo-2-propenyl alcohol, 3-iodo-2-propinyl n-butylcarbamate, 3-iodo-2-propinyl n-hexylcarbamate, 3-iodo-2-propinyl cyclohexylcarbamate, 3-iodo-2-propinyl phenylcarbamate;
Phenols, such as:
tribromophenol, tetrachlorophenol, 3-methyl-4-chlorophenol, 3,5-dimethyl-4-chlorophenol, phenoxyethanol, dichlorophen, 2-benzyl-4-chlorophenol, 5-chloro-2-(2,4-dichlorophenoxy)-phenol, hexachlorophene, p-hydroxybenzoic ester, o-phenylphenol, m-phenylphenol, p-phenylphenol and their alkali metal and alkaline earth metal salts;
Microbicides having an activated halogen group, such as:
bronopol, bronidox, 2-bromo-2-nitro-1,3-propanediol, 2-bromo-4'-hydroxy-acetophenone, 1-bromo-3-chloro-4,4,5,5-tetramethyl-2-imidazoledinone, β-bromo-β-nitrostyrene, chloroacetamide, chloramine T, 1,3-dibromo-4,4,5,5-tetrametyl-2-imidazoldinone, dichloramine T, 3,4-dichloro-(3H)-1,2-dithiol-3-one, 2,2-dibromo-3-nitrile-propionamide, 1,2-dibromo-2,4-dicyanobutane, halane, halazone, mucochloric acid, phenyl(2-chloro-cyano-vinyl)sulphone, phenyl(1,2-dichloro-2-cyanovinyl)sulphone trichloroisocyanuric acid;
Pyridines, such as:
1-hydroxy-2-pyridinethione (and its Na, Fe, Mn, Zn salts), tetrachloro-4-methylsulphonylpyridine, pyrimethanol, mepanipyrim, dipyrithion, 1-hydroxy-4-methyl-6-(2,4,4-trimethylpentyl)-2(1H)-pyridine;
Methoxyacrylates or the like, such as:
methyl (E)-methoximino[alpha-(o-tolyloxy)-o-tolyl]acetate, (E)-2-methoxyimino-N-methyl-2-(2-phenoxyphenyl)acetamide, (E)-2-{2-[6-(2-cyanophenoxy)pyrimidin-4-yloxy]phenyl}-3-methoxyacrylate, O-methyl-2-[([3-methoximino-2-butyl)imino]oxy)o-tolyl]-2-methoximinoacetimidate,
2-[[[[1-(2,5-dimethylphenyl)ethylidene]amino]oxy]methyl]-α-(methoximino)-N-metyl-benzeneacetamide,
alpha-(methoxyimino)-N-methyl-2-[[[[1-[3-(trifluoromethyl)phenyl]ethylidene]amino]oxy]methyl]-benzeneacetamide,
methyl alpha-(methoxyimino)-2-[[[[1-[3-(trifluoromethyl)phenyl]ethylidene]amino]oxy]methyl]-benzeneacetate,
methyl alpha-(methoxymethylene)-2-[[[[1-[3-(trifluoromethyl)phenyl]ethylidene]amino]oxy]methyl]-benzeneacetate,
2-[[[5-chloro-3-(trifluormethyl)-2-pyridinyl]oxy]methyl]-α-(methoxyimino)-N-methyl-benzeneacetamide,
methyl 2-[[[cyclopropyl[(4-ethoxyphenyl)imino]methyl]thio]methyl]-α-(methoxyimino)benzeneacetate,
alpha-(methoxyimino)-N-methyl-2-(4-methyl-5-phenyl-2,7-dioxa-3,6-diazaocta-3,5-dien-1-yl)-benzeneacetamide,
methyl alpha-(methoxymethylene)-2-(4-methyl-5-phenyl-2,7-dioxa-3,6-diazaocta-3,5-dien-1-yl)-benzeneacetate,
alpha-(methoxyimino)-N-methyl-2-[[[1-[3-(trifluoromethyl)phenyl]ethoxy]imino]methyl]-benzeneacetamide,
2-[[(3,5-dichloro-2-pyridinyl)oxy]methyl]-α-(methoxyimino)-N-methylbenzeneacetamide,
methyl 2-[4,5-dimethyl-9-(4-morpholinyl)-2,7-dioxa-3,6-diazanona-3,5-dien-1-yl]-.alpha.-(methoxymethylene)-benzeneacetate;
Metal soaps, such as:
tin naphtenate, copper naphtenate, zinc naphtenate, tin octoate, copper octoate, zinc octoate, tin 2-ethylhexanoate, copper 2-ethylhexanoate, zinc 2-ethylhexanoate, tin oleate, copper oleate, zinc oleate, tin phosphate, copper phosphate, zinc phosphate, tin benzoate, copper benzoate, zinc benzoate;
Metal salts, such as:
copper hydroxycarbonate, sodium dichromate, potassium dichromate, potassium chromate, copper sulphate, copper chloride, copper borate, zinc fluorosilicate, copper fluorosilicate;
Oxides, such as:
tributyltin oxide, Cu 2 O, CuO, ZnO;
Dithiocarbamates, such as:
cufraneb, ferban, potassium N-hydroxymethyl-N'-methyl-dithiobarbamate, Na or K dimethyldithiocarbamate, macozeb, maneb, metam, metiram, thiram, zineb, ziram;
Nitriles, such as:
2,4,5,6-tetrachloroisophthalodinitrile, disodium cyano-dithioimidocarbamate;
Quinolines, such as:
8-hydroxyquinoline and their Cu salts;
Other fungicides and bactericides, such as:
5-hydroxy-2(5H)-furanone; 4,5-benzodithiazolinone, 4,5-trimethylenedithiazolinone, N-(2-p-chlorobenzoylethyl)-hexaminium chloride, 2-oxo-2-(4-hydroxy-phenyl)acethydroximic chloride, tris-N-(cyclohexyldiazeniumdioxy)-aluminium, N-(cyclohexyldiazeniumdioxy)-tributyltin or K salts, bis-N-(cyclohexyldiazenium-dioxy)copper,
Ag, Zn or Cu-containing zeolites alone or enclosed in polymeric materials.
Very particularly preferred mixtures are those with
azaconazole, bromuconazole, cyproconazole, dichlobutrazol, diniconazole, hexaconazole, metaconazole, penconazole, propiconazole, tebuconazole, dichlofluanid, tolylfluanid, fluorfolpet, methfuroxam, carboxin, N-cyclohexylbenzo[b]-thiophenecarboxamide S,S-dioxide, fenpiclonil, 4-(2,2-difluoro- 1,3-benzodioxol-4-yl)-1H-pyrrole-3-carbonitrile, butenafine, imazalil, N-methylisothiazolin-3-one, 5-chloro-N-methylisothiazolin-3-one, N-octylisothiazolin-3-one, dichloro-N-octylisothiazolinone, mercaptobenthiazole, thiocyanatomethylthiobenzothiazole benzisothiazolinones, N-(2-hydroxypropyl)-amino-methanol, benzyl alcohol (hemi)-formal, N-methylolchloroacetamide, N-(2-hydroxypropyl)-aminemethanol, glutaraldehyde, omadine, dimethyl dicarbonate, and/or 3-iodo-2-propinyl n-butylcarbamate.
Furthermore, in addition to the abovementioned fungicides and bactericides, highly active mixtures are also prepared with other active compounds:
Insecticides/acaricides/nematicides:
abamectin, acephat, acetamiprid, acrinathrin, alanycarb, aldicarb, aldoxycarb, aldrin, allethrin, alpha-cypermethrin, amitraz, avermectin, AZ 60541, azadirachtin, azinphos A, azinphos M, azocyclotin,
Bacillus thuringiensis, barthrin, 4-bromo-2(4-chlorophenyl)-1-(ethoxymethyl)-5-(trifluoromethyl)-1H-pyrrole-3-carbonitrile, bendiocarb, benfuracarb, bensultap, betacyfluthrin, bifenthrin, bioresmethrin, bioallethrin, bromophos A, bromophos M, bufencarb, buprofezin, butathiophos, butocarboxin, butoxycarboxim,
cadusafos, carbaryl, carbofuran, carbophenothion, carbosulfan, cartap, quinomethionate, cloethocarb, chlordane, chlorethoxyfos, chlorfenvinphos, chlorfluazuron, chlormephos, N-[(6-chloro-3-pyridinyl)-methyl]-N'-cyano-N-methylethanimidamide, chlorpicrin, chlorpyrifos A, chlorpyrifos M, cis-resmethrin, clocythrin, cypophenothrin clofentezin, coumaphos, cyanophos, cycloprothrin, cyfluthrin, cyhalothrin, cyhexatin, cypermethrin, cyromazin,
decamethrin, deltamethrin, demeton M, demeton S, demeton-S-methyl, diafenthiuron, dialiphos, diazinon, 1,2-dibenzoyl-1(1,1-dimethyl)-hydrazine, DNOC, dichlofenthion, dichlorvos, dicliphos, dicrotophos, diflubenzuron, dimethoate, dimethyl-(phenyl)-silyl-methyl 3-phenoxybenzyl ether, dimethyl-(4-ethoxyphenyl)silylmethyl 3-phenoxybenzyl ether, dimethylvinphos, dioxathion, disulfoton,
eflusilanate, emamectin, empenthrin, endosulfan, EPN, esfenvalerate, ethiofencarb, ethion, ethofenprox, etrimphos,
fenamiphos, fenazaquin, fenbutatin oxide, fenfluthrin, fenitrothion, fenobucarb, fenothiocarb, fenoxycarb, fenpropathrin, fenpyrad, fenpyroximat, fensulfothion, fenthion, fenvalerate, fipronil, fluazuron, flucycloxuron, flucythrinate, flufenoxuron, flumethrin flufenprox, fluvalinate, fonophos, formethanate, formothion, fosmethilan fosthiazat, fubfenprox, furathiocarb,
HCH, heptenophos, hexaflumuron, hexythiazox, hydramethylnon, hydroprene,
imidacloprid, iodfenfos, iprobenfos, isazophos, isoamidophos, isofenphos, isoprocarb, isoprothiolane, isoxathion, ivermectin, lama-cyhalothrin, lufenuron,
kadedrin
lambda-cyhalothrin, lufenuron,
malathion, mecarbam, mervinphos, mesulfenphos, metaldehyde, methacrifos, methamidophos, methidathion, methiocarb, methomyl, metalcarb, milbemectin, monocrotophos, moxiectin,
naled, NC 184, NI 125, nicotine, nitenpyram,
omethoate, oxamyl, oxydemethon M, oxydeprofos,
parathion A, parathion M, penfluron, permethrin, 2-(4-phenoxyphenoxy)-ethyl ethylcarbamate, phenthoat, phorat, phosalon, phosmet, phosphamidon, phoxim, pirimicarb, pirimiphos M, pirimiphos A, prallethrin, profenophos, promecarb, propaphos, propoxur, prothiophos, prothoat, pymetrozin, pyrachlophos, pyridaphenthion, pyresmethrin, pyrethrum, pyridaben, pyrimidifen, pyriproxifen,
quinalphos,
resmethrin, RH-7988, rotenone,
salithion, sebufos, silafluofen, sulfotep, sulprofos,
tau-fluvalinate, taroils, tebufenozide, tebufenpyrad, tebupirimphos, teflubenzuron, tefluthrin, temephos, terbam, terbufos, tetrachlorvinphos, tetramethrin, tetramethacarb, thiafenox, thiapronil, thiodicarb, thiofanox, thiazophos, thiocyclam, thiomethon, thionazin, thuringiensin, tralomethrin, triarathen, triazophos, triazamate, triazuron, trichlorfon, triflumuron, trimethacarb,
vamidothion, XMC, xylylcarb, zetamethrin;
Molluscicides:
fentin acetate, metaldehyde, methiocarb. niclosamide;
Herbicides and algicides
acetochlor, acifluorfen, aclonifen, acrolein, alachlor, alloxydim, ametryn, amidosulfuron, amitrole, ammonium sulphamate, anilofos, asulam, atrazine, aziptrotryne, azimsulfuron,
benazolin, benfluralin, benfuresate, bensulfuron, bensulfide, bentazone, benzofencap, benzthiazuron, bifenox, borax, bromacil, bromobutide, bromofenoxim, bromoxynil, butachlor, butamifos, butralin, butylate, bialaphos, benzoyl-prop, bromobutide,
carbetamide, chlomethoxyfen, chloramben, chlorbromuron, chlorflurenol, chloridazon, chlorimuron, chlornitrofen, chloroacetic acid, chlorotoluron, chloroxuron, chlorpropham, chlorsulfuron, chlorthal, chlorthiamid, cinmethylin, cinofulsuron, clethodim, clomazone, chlomeprop, clopyralid, cyanamide, cyanazine, cycloate, cycloxydim, chloroxynil, clodinafop-propargyl, cumyluron, CGA 248757, clometoxyfen, cyhalofop, clopyrasuluron, cyclosulfamuron,
dichlorprop, dichlorprop-P, diclofop, diethatyl, difenoxuron, difenzoquat, diflufenican, dimefuron, dimepiperate, dimethachlor, dimethipin, dinitramine, dinoseb, dinoseb acetate, dinoterb, diphenamid, dipropetryn, diquat, dithiopyr, diduron, DNOC, DSMA, 2,4-D, daimuron, dalapon, dazomet, 2,4-DB, desmedipham, desmetryn, dicamba, dichlobenil, dimethamid, dithiopyr, dimethametryn,
eglinazine, endothal, EPTC, esprocarb, ethalfluralin, ethidimuron, ethofumesate, ethobenzanid, ethoxyfen, ET 751, ethametsulfuron,
fenoxaprop, fenoxaprop-P, fenuron, flamprop, flamprop-M, flazasulfuron, fluazifop, fluazifop-P, fuenachlor, fluchloralin, flumeturon, fluorocglycofen, fluoronitrofen, flupropanate, flurenol, fluridone, flurochloridone, fluroxypyr, fomesafen, fosamine, flamprop-isopropyl, flamprop-isopropyl-L, flumiclorac-pentyl, flumipropyn, flumioxzim, flurtatone, flumioxzim,
glyphosate, glufosinate-ammonium
haloxyfop, hexazinone,
imazamethabenz, isoproturon, isoxaben, isoxapyrifop, imazapyr, imazaquin, imazethapyr, ioxynil, isopropalin, imazosulfuron,
KUH 911, KUH 920
lactofen, lenacil, linuron, LS830556,
MCPA, MCPA-thioethyl, MCPB, mecoprop, mecoprop-P, mefenacet, mefluidide, metam, metamitron, metazachlor, methabenzthiazuron, methazole, methoroptryne, methyldymron, methyl isothiocyanate, metobromuron, metoxuron, metribuzin, metsulfuron, molinate, monalide, monolinuron, MSMA, metolachlor, metosulam, metobenzuron,
naproanilide, napropamide, naptalam, neburon, nicosulfuron, norflurazon, sodium chlorate,
oxadiazon, oxyfluorfen, orbencarb, oryzalin, quinchlorac, quinmerac,
propyzamide, prosulfocarb, pyrazolate, pyrazolsulfuron, pyrazoxyfen, pyributicarb, pyridate, paraquat, pebulate, pendimethalin, pentachlorophenol, pentanochlor, petroleum oils, phenmedipham, picloram, piperophos, pretilachlor, primisulfuron, prodiamine, prometryn, propachlor, propanil, propaquizafob, propazine, propham, pyrithiobac,
quinmerac, quinocloamine, quizalofop, quizalofop-P,
rimsulfuron
sethoxydim, sifuron, simazine, simetryn, sulfometuron, sulfentrazone, sulcotrione, sulfosate,
tar oils, TCA, tebutam, tebuthiuron, terbacil, terbumeton, terbuthylazine, terbutryn, thiazafluoron, thifensulfuron, thiobencarb, thiocarbazil, tralkoxydim, triallate, triasulfuron, tribenuron, triclopyr, tridiphane, trietazine, trifluralin, tycor, thdiazimin, thiazopyr, triflusulfuron,
vernolate.
The weight ratios of the active compounds in these active compound combinations can be varied within relatively large ranges.
The combinations of active compounds preferably obtain the active compound in an amount of from 0.1 to 99.9%, in particular from 1 to 75%, particularly preferably from 5 to 50%, the remainder up to 100% being made up by one or more of the abovementioned co-components.
The microbicidal compositions or concentrates used for protecting industrial materials comprise the active compound or the active compound combination in a concentration of from 0.01 to 95% by weight, in particular from 0.1 to 60% by weight.
The use concentrations of the active compounds or the active compound combinations to be used depends on the kind and the occurrence of the microorganisms to be controlled and on the composition of the material to be protected. The optimum application rate can be determined by test series. The use concentrations are generally in the range of from 0.001 to 5% by weight, preferably of from 0.05 to 1.0% by weight, based on the material to be protected.
The active compounds or compositions according to the invention allow, in an advantageous manner, the replacement of the microbicidal compositions which are currently available by more effective compositions. They have good stability and, in an advantageous manner, a wide activity spectrum.
The examples below serve to illustrate the invention. The invention is not limited to the examples.
EXAMPLE 1 ##STR3## 4.97 g (0.024 mol) of 1,1-dioxo-(1,4,2)dithiazinane-3-thione sodium salt are initially charged in 26 ml of H 2 O and 130 ml of acetone and cooled to 0° C. The diazonium salt solution I is added dropwise over a period of 8 min. to this mixture. The mixture is initially stirred at 0° C. for 0.5 h and then at room temperature for 2 h. The mixture is extracted with CH 2 Cl 2 , and the organic phase is washed with IN HCl and H 2 O, dried and concentrated. The residue is chromatographed over silica gel.
Yield 2.6 g (=÷% of theory).
m.p.:=166° C.
Diazonium salt solution I
4.97 g (0.024 mol) of 4-chloroaniline are initially charged in 46.8 ml of H 2 O and 6.5 ml of HCl (conc.), cooled to 0° C., and a solution of 1.9 g of NaNO 2 in 15.6 ml of H 2 O is added dropwise. The mixture is stirred for 1 h and adjusted to pH 4.5 using 6.3 g of sodium acetate.
The compounds of the formula (I) listed in Table 1 are prepared in a similar manner. ##STR4##
TABLE 1__________________________________________________________________________Ex.No. R.sup.1R.sup.2 R.sup.3 R.sup.4 Ar Physical constants__________________________________________________________________________1 H H H H m.p. = 166° C.2 H H H H ##STR5## m.p. = 143° C.3 H H H H ##STR6## m.p. = 152° C.4 H H H H ##STR7## m.p. = 175° C.5 H H H H ##STR8## m.p. = 136° C.6 H H H H ##STR9## m.p. = 124° C.7 H H H H ##STR10## m.p. = 128° C.8 H H H H ##STR11## m.p. = 184° C.9 H H H H ##STR12## m.p. = 179° C.10 H H H H ##STR13## m.p. = 161° C.11 H H H H ##STR14## m.p. = 132° C.12 H H H H ##STR15## m.p. = 162° C.13 H H H H ##STR16## m.p. = 166° C.14 H H H H ##STR17## .sup.1 H-NMR (CDCl.sub.3) δ = 3.37 (2H, m), 3.57 (2H, m), 7.16 (2H,d), 7.55 (2H,d)15 H H H H ##STR18## .sup.1 H-NMR (CDCl.sub.3) δ = 3.44 (2H, m), 3.61 (2H, m), 7.4-7.5 (2H, m), 7.65 (1H,d).16 H H H H ##STR19## .sup.1 H-NMR (CDCl.sub.3 /DMSO) δ = 3.45 (2H, m), 3.59 (2H, m), 7.0-7.8 (9H, m)17 H H H H ##STR20## .sup.1 H-NMR (CDCl.sub.3) δ=18 H H H H ##STR21## Oil__________________________________________________________________________
Use Example A
To demonstrate the efficacy against fungi, the minimum inhibitory concentrations (MIC) of agents according to the invention are determined:
An agar which is prepared using malt extract is admixed with active compounds according to the invention at concentrations of from 0.1 mg/l to 5,000 mg/l. After the agar has solidified, it is contaminated with pure cultures of the test organisms listed in Table 2. The MIC is determined after 2 weeks of storage at 28° C. and from 60 to 70% relative atmospheric humidity. The MIC is the lowest concentration of active compound at which no colonization by the microbial species used is observed, it is stated in Table 2 below.
TABLE 2______________________________________Minimum inhibitory concentrations (ppm) of compoundsof the formula (I) according to the inventionExample No. 1 2 5______________________________________Penicillium <40 <40 <40brevicauleChaetomium <40 <40 <40globosumAspergillus niger <40 200 <40______________________________________
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The invention relates to novel S-aryl-dithiazine dioxides, to processes for their preparation and to the use in crop protection and in the protection of materials.
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CROSS-REFERENCE OF RELATED APPLICATION
The present invention claims the priority under 35 U.S.C. §119 of German Patent Application No. 196 03 029.3 filed on Jan. 29, 1996, the disclosure of which is expressly incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention may relate to an exchange device for a transport belt used, e.g., within a dryer section of a machine for producing of a web of material, e.g., paper or cardboard. The exchange device may include a spooler for removing a used transport belt and for inserting a new transport belt. The spooler may be supported by a mobile carrier device which may be moved to a predetermined location for the transport belt exchange.
The present invention may also be directed to a method for exchanging a used transport belt, e.g., in the dryer section of a machine for the production of a paper or cardboard web, for a new transport belt.
2. Discussion of Background Information
Exchange devices are generally utilized in the prior art. These devices are used in, for example, paper or cardboard production machines to enable exchanging of a transport belt, e.g., dryer screen or felt. At certain locations within the paper production machine, special foundations have been installed on which the exchange device is mounted to enable exchange the transport belt or the felt. The space requirements for such prior art exchange devices is relatively large. Further, it is expensive to install such exchange device foundations within the paper production machine.
SUMMARY OF THE INVENTION
For this reason, it is an object of the present invention to provide an exchange device for a transport belt, and a method for exchanging transport belts of the type discussed above, that does not suffer from the above-noted disadvantages.
Accordingly, the present invention may be directed to an exchange device for a transport belt utilized in, e.g., a dryer section of a machine for the production of a web of material. The exchange device may include a spooler that removes a used transport belt and that inserts a new transport belt. The spooler may be supported by a mobile carrier device that moves the spooler to a predetermined location for exchanging the transport belt. This particular arrangement obviates the need for a separate installation to serve the exchange device within the machine using the transport belt. Thus, the machine according to the present invention may be constructed to use up less space and be more cost efficient than the prior art devices.
In a particular embodiment of the present invention, an exchange device may include a carrier device having at least two carrier elements that can be shifted relative to each other. Thus, the carrier device may be constructed rather simply. One of the at least two carrier elements may be guided into the machine and anchored. This one carrier element may serve as a guide for a second of the at least two elements which may also be anchored in the machine. The at least two carrier elements may be utilized as a base for the spooler.
The present invention may also be directed to a method for exchanging a transport belt in a web production machine including spooler that removes a used transport belt and that inserts a new transport belt. The spooler may be supported by a roller device that moves the spooler to a predetermined location for exchanging the transport belt. The method may include moving a carrier device to a predetermined location for the transport belt exchange, moving the carrier device into the web production machine, moving the spooler into the machine by the roller device, rolling up the used transport belt, and inserting the new transport belt. Because the carrier device may be brought to a predetermined site where the transport belt exchange is to occur, foundations specifically dedicated to an exchange device within the web production machine are no longer necessary. Thus, according to the present invention, the spooler may be guided into the machine to roll up the used transport belt, and to install a new transport belt in the machine.
According to a preferred method, during the rolling up of the used transport belt, the new transport belt may be simultaneously rolled out and threaded in the machine by the used transport belt.
Accordingly, the present invention may be directed to an exchange device for replacing a transport belt in a dryer section of a web production machine. The exchange device may include a spooler device that removes a used transport belt and inserts a new transport belt and a mobile carrier device, supporting the spooler, movable to an exchange location for replacing the transport belt exchange.
In accordance with another feature of the present invention, the spooler and the mobile carrier device may be movable relative to each other.
In accordance with still another feature of the present invention, the spooler may move along a portion of the mobile carrier device.
In accordance with a further feature of the present invention, the exchange device may also include a roller device associated with the spooler.
In accordance with a still further feature of the present invention, the roller device may vary in height with respect to the mobile carrier device.
In accordance with another feature of the present invention, the mobile carrier device may include at least two carrier elements that are movable relative to each other.
In accordance with still another feature of the present invention, at least one of the at least two carrier elements may include at least two carriers.
In accordance with yet another feature of the present invention, the mobile carrier device may include at least one carrier guide device permitting the relative movement of the carrier elements.
In accordance with still another feature of the present invention, the carrier guide device may include at least one roll and at least one rail. The at least one roll may move along the at least one rail.
In accordance with a further feature of the present invention, the spooler may include at least one spooler guide device.
In accordance with another feature of the present invention, the spooler guide device may be associated with the at least one carrier guide device.
The present invention may also be directed to a procedure for exchanging an old transport belt for a new transport belt in a dryer section of a web production machine. The procedure may include moving a carrier device to an exchange location adjacent the web production machine, extending the carrier device into the web production machine, guiding, via a roller device, a spooler into the web production machine, rolling up of the old transport belt, and inserting the new transport belt.
In accordance with another feature of the present invention, extending the carrier device may include extending at least one carrier element into the web production machine.
In accordance with a further feature of the present invention, the process may further include guiding a second carrier element into the web production machine along the first carrier element.
In accordance with still another feature of the present invention, the procedure may include relaxing the old transport belt and placing the relaxed old transport belt on a surface of the extended carrier device.
In accordance with a still further feature of the present invention, the guiding of the spooler may include coupling the spooler to the roller device and rolling the rolling device along a surface of the carrier device.
In accordance with yet another feature of the present invention, the procedure may further include relaxing the tension in the old transport belt, ripping open a seam in the old transport belt, and connecting each end of the old transport belt to the spooler.
In accordance with another feature of the present invention, the procedure may also include simultaneously rolling up the old transport belt and unrolling the new transport belt. The simultaneous rolling and unrolling may thread the new transport belt in the web production machine.
The present invention may also be directed to a device for replacing an old transport belt in a web production machine. The device may include a spooler device for simultaneously removing the old transport belt and threading a new transport belt in the web production machine and a carrier device for positioning the spooler device at a predetermined exchange location within the web production machine.
In accordance with a further feature of the present invention, the carrier may include at least a first and second carrier element telescopically movable relative to each other. The spooler device may traverse an extent of the first carrier element.
In accordance with another feature of the present invention, the first carrier device and the spooler may be located on opposite sides of the old transport belt.
In accordance with still another feature of the present invention, a roller device may move the spooler device perpendicular to a surface of the carrier device.
In accordance with a still further feature of the present invention, the carrier device may include at least two guides and the spooler device may include at least two rolls. The at least two rolls and at least two guides may couple the carrier device and the spooler device.
In accordance with a further feature of the present invention, the carrier device may include at least a first and second carrier element movable relative to each other, a first drive device for extending one of the first and second carrier element into the web production machine, and a second drive device for extending an other of the first and second carrier element into the web production machine. The other carrier element may be guided by the one carrier element.
In accordance with another feature of the present invention, the device may include a device for anchoring the one carrier element after extension into the web production machine, a device for anchoring the other carrier element after extension into the web production machine, and a roller device for moving the spooler along a surface of one of the first and second carrier element and into the web production machine.
In accordance with still another feature of the present invention, the device may also include a device for ripping a seam in the old transport belt. The spooler may include a first winding reel, containing the new transport belt, and a second winding reel. A coupling element may couple a first end of the ripped old transport belt to an end of the new transport belt and a coupling element coupling the second end of the ripped old transport belt to the second winding reel.
In accordance with yet another feature of the present invention, the device may include a reel driver driving at least the second winding reel to remove the old transport belt and to thread the new transport belt.
Further embodiments and advantages can be seen from the detailed description of the present invention and the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of preferred embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
FIG. 1 illustrates a schematic lateral view of an exchange device in working position;
FIG. 2 illustrates a part of the exchange device shown in FIG. 1; and
FIG. 3 illustrates a part of the exchange device in resting position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The particulars shown herein are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for the fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
An exchange device as described herein may be utilized in, e.g., a web production machine in which the web, e.g., paper or cardboard, may be formed and guided therethrough. To guide the web through the machine, transport belts, e.g., screen belts or felts, may be utilized to carry the web in a meandering (winding) path across and around dryer cylinders and guide rolls.
Exchange device 1, as shown in FIG. 1, may include a spooler 3 comprising two winding shafts 5 and 7. On a first winding shaft, e.g., winding shaft 5, a new rolled transport belt may be located at a position designated as a beginning of the transport belt exchange. A second winding shaft, e.g., winding shaft 7, may be initially empty and utilized to receive the used (replaced) transport belt.
Each winding shaft 5 and 7 may be attached by a suitable bearing 9 to an essentially U-shaped carrying frame 11 and coupled to a respective suitable drive 13 and 13'. It is conceivable that only one of the winding shafts may be provided with a drive. In this manner, the drive may be used to pull the used transport belt from the paper production machine and simultaneously roll off a new transport belt for the machine.
A roller device 15, which may include suitable rolls 17, may be rollably supported on a carrier device 19 and effect movement of carrier frame 11.
The device may include at least two carrier arms 21 and 23. Guide devices 25 and 27 may be provided on carrier arms 21 and 23 of spooler 3. Guide devices 25 and 27 may include rolls, that, as more fully described below, may work in conjunction with guide devices associated with carrier device 19.
Roller device 15 may be variably adjustable with respect to height, i.e., in a direction parallel to the slots 17a, 17b, 29a, 29b in roll device 15. Roller device 15 may also include rolls 17 which may be rolled in a direction relative to a base 29 of the roll device 15, i.e., guided by slots 17a, 17b. In this manner, spooler 3, which may be supported by roller device 15, may be raised or lowered with respect to rolls 17.
At a predetermined location within the paper production machine, i.e., where the transport belt exchange is to occur, a stabilizer device 31 may be provided which prevents a jamming of spooler 3.
As shown in FIG. 2, a carrier device 19 may include two parts. For example, carrier device 19 may include a first, e.g., lower carrier element 33 and a second, e.g., upper carrier element 35. The length of carrier device 19 may be, e.g., sufficiently long to extend across an entire width of the paper production machine run or the width of the transport belt. When the exchange of the transport belt begins, exchange device 1 and carrier device 19 may be brought (guided) to an exchange location and placed adjacent to the transport belt to be exchanged and perpendicular to the transport belt running direction. Carrier elements 33 and 35, shown from an end view of the elements in a longitudinal direction of carrier device 19, may be longitudinally shifted relative to each other through suitable guide devices 37, 39 and 41. For example, carrier element 35 may be extended (rolled) into the paper production machine, i.e., beneath an underside of the transport belt to be changed, and locked in place (anchored). Then, carrier element 33 may be extended (rolled) into the paper production machine under the guidance of carrier element 35 and locked in place. As shown in FIG. 2, carrier elements 33 and 35 may be provided with a driver 43, 45 in order to simplify the shifting or extending of the carrier elements into the paper production machine. Respective drivers 43, 45 may include drive devices 47 and 49 and/or shaft stumps 51 and 53 which may be attached to a suitable driver.
Guide devices 37, 39 and 41 may include rails 55, 57 and 59, respectively, that may extend along an entire length of carrier device 19. Guide devices 37, 39, and 41 may also include a plurality of roll pairs 61. Each roll in roll pair 61 may be disposed on opposing sides of rails 55, 57, and 59, i.e., an upper and lower side, the upper and lower side designated with respect to the upper and lower carrier. This arrangement may be utilized to ensure optimal guidance and stabilization of carrier elements 33 and 35 relative to each other. Each roll of roll pair 61 may include a substantially V-shaped indentation formed within its circumference to receive a complementarily formed protrusion of a respective rail. Accordingly, guidance in the lengthwise direction of carrier device 19 may be ensured and cross-wise shifting of the carrier elements relative to each other may be effectively prevented. Thus, the above-discussed arrangement of the present invention stabilizes carrier device 19 throughout its extension and subsequent retraction from the web production machine.
Rails 55 and 59 may extend beyond the side lateral walls of carrier device 19. These rails may be utilized in conjunction with rolls associated with guide devices 25 and 27 formed on an inside surface of carrier arms 21 and 23 of the carrier frame 11.
Referring now to FIG. 3 only a left half of exchange device 1 is shown. Exchange device 1 may be compactly arranged when spooler 3 is located directly on top of carrier device 19. In this arrangement, guide devices 25 and 27 may engage rails 55 and 59 of carrier device 19. This position of spooler 3 and carrier device 19 may be selected when exchange device 1 is not in operation. To arrange the spooler atop carrier device 19, rolls 17 may be guided via slots 17a, 17b and rolled completely into base 29 of roller device 15 and base 29 may be returned completely into its top most starting position via slots 29a, 29b. By comparing FIGS. 1 and 3, it is apparent that, in FIG. 1, base 29 is set in a lowest working position, i.e., most extended position, while, in FIG. 3, base 29 is arranged in its most compressed arrangement.
Upper carrier element 35 may be constructed of, e.g., two U-shaped carriers 67 and 69, and U-shaped carriers 67 and 69 may be arranged such that their respective inner legs are coupled together. Lower carrier element 33 may be constructed of, e.g., two U-shaped carriers 63 and 65. As shown in FIG. 2, guide devices 37 and 41 may be mounted to outer legs of U-shaped carriers 63 and 65, respectively, and guide device 39 may be mounted to inner legs of U-shaped carriers 67 and 69. Roll pairs 61 may be mounted on an outer leg of U-shaped carriers 67 and 69 to run along guide devices 37 and 41, respectively, and roll pairs 61 may be mounted on inner legs of U-shaped carriers 63 and 65 to run along guide device 39. The engagement of the U-shaped carrier legs and guide devices provide a relatively light but highly stable carrier device 19. Atop the upper surface of carriers 67 and 69, the present invention may include a support surface, e.g., a needle or nail board 71, to be more fully discussed below. Further, rolls 17 of roller device 15 may be utilized to roll along the longitudinal direction of carriers 67 and 69. Accordingly, spooler 3 may be moved or oriented in any desired longitudinal direction relative to carrier device 19.
In accordance with the present invention, a description of an exemplary method or procedure for exchanging a transport belt within a paper or cardboard production machine will now be provided. For example, exchange device 1 may be stored in its compressed state, i.e., in a rest position, in an arrangement similar to that depicted in FIG. 3.
In the off position, exchange device 1 may be used for rewinding or off winding of new and old transport belts or felts. That is, if winding shaft 5 is empty, new transport belt material may be loaded onto the shaft; if winding shaft 7 is full, the old transport belt material may be unrolled from the shaft. This off position is of particular importance when the paper side is supposed to be reversed.
When exchanging a transport belt or felt within a paper production machine, carrier device 19 may be guided to a predetermined exchange location and adjacent the existing transport belt to be replaced and positioned perpendicular to the paper production machine run, i.e., perpendicular to the running direction of the transport belt. A first carrier element, e.g., lower carrier element 33, may be telescopically extended about halfway into the paper production machine run, e.g., below the felt run. Then lower carrier 33 and upper carrier 35 may be concurrently extended into the paper production machine until the entire extent of lower carrier 33 has been extended. Once fully extended, lower carrier 33 may be firmly anchored on its opposite side, e.g., on a drive side. Upper carrier element 35 may now be fully extended and inserted into the paper production machine. Each carrier elements 33 and 35 may be securely guided into the paper production machine relative to each other along guide devices 37, 39 and 41. Upon full extension, upper carrier element 35 may also be fastened in the paper production machine. Alternatively, the upper and lower carrier elements may be reversed such that the upper carrier is first extended into the machine.
By extending and anchoring upper and lower carrier elements 35 and 33, a secure base may be provide on which spooler 3 may be moved into the paper production machine. However, before spooler 3 may be inserted, the felt or transport belt to be exchanged should be relaxed to such an extent that the transport belt rests atop the base of the carriers 67 and 69. Spooler 3 may be moved into the paper production machine, e.g., above the felt or transport belt relative to the carrier device 19 positioned below the felt. The insertion of spooler 3 may be greatly simplified by utilizing roller device 15. Specifically, rolls 17 may be used to longitudinally roll out spooler 3 along carriers 67 and 69 and carrier arm 11 with the possible stabilization device 31 may be raised.
After spooler 3 is fully extended (inserted) into the paper production machine, roller device 15 may be moved, via rolls 17, so that carrier frame 11 of the spooler 3 may rest upon suitable abutments of stabilizing device 31.
As noted above, a nail board 71 may be mounted atop carriers 67 and 69. Nail board 71 may be utilized for fastening the felt running across the carrier device 19 and may provide a safe and secure retention of the felt until the exchange procedure begins.
Once the felt is secured to nail board 71, the felt may be ripped, in a known manner, e.g., along an existing seam extending perpendicularly across the width of the paper production machine run. Preferably, the existing seam may be placed adjacent a middle portion of the carrier device 19, e.g., where carriers 67 and 69 are joined together. The respective ends of the ripped felt may be connected to respective winding shafts of exchange device 1. For example, a right-hand portion of the ripped felt may be coupled to winding shaft 7, which may be initially empty and a left-hand portion of the ripped felt may be coupled to winding shaft 5, or more specifically, coupled to an end of the new felt or transport belt to be inserted. Thus, at this point in the insertion process, the new felt on winding shaft 5 may be coupled to the old felt which meanders or winds through the web production machine and may be coupled, at its opposite end, to the empty winding shaft 7. Drive 13', which may include, e.g., a chain drive, may actuate empty winding shaft to rotate, i.e., to begin winding up the old felt or transport belt by pulling the belt out of the production machine. Because the end of the old felt, i.e., opposite winding shaft 7, is coupled to the new felt, the new felt is simultaneously threaded into place as the old belt is removed from the production machine.
As soon as the old transport belt is fully wound up on, e.g., winding shaft 7, and the new transport belt has been threaded into the paper production machine, the ends of the new transport belt may be joined to each other in a conventional manner. Exchange device 1 may include a device that securely joins the ends of the new felt in the running direction. It may also be possible to slacken the ends of the transport belt by shifting, in the direction of the seam, to ease the joining. As spooler 3 sits on rolls 17, the lateral edges of the transport belt can be precisely adjusted towards each other.
After the ends of the transport belt have been joined, roller device 15 may be, e.g., used again (assuming sufficient new felt remains on winding shaft) in a similar manner. However, roller device 15 should also be retracted from the web production device via rolls 17. Thus, roller device 15 may be removed from the machine such that spooler 3 may be freely arranged on the base formed by carriers 67 and 69, and may be moved out to carrier device 19.
Once spooler 3 has been retracted out of the web production machine, carrier elements 33 and 35 may be loosened and retracted or moved out of the paper production machine.
For storing exchange device 1 and for transporting exchange device 1 to respective exchange locations within the paper production machine, spooler 3 and carrier device 19 may be preferably pushed on top of each other, i.e., in the compressed arrangement, as explained in FIG. 3. Thus, exchange device 1 would exhibit its most compact and space saving structure.
In view of the foregoing discussion of the exchange device or the disclosed procedure for exchanging a transport belt, an exchange device for a fixed carrier mounted in the paper production machine, as required by the prior art, may be eliminated. Further, considerable space savings and reduced construction costs may be realized. The construction and arrangement of the exchange device may relatively simple and easy to use. Consequently, the exchange procedure, as disclosed above, may likewise be simple to execute. As carrier elements 33 and 35 of carrier device 19 provide for stable and secure guidance of each other, these elements also provide for stable and secure movement of spooler 3 along carrier device 19. Thus, the danger of accidents, compared to conventional procedures, is greatly reduced.
It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the invention has been described with reference to a preferred embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in its aspects. Although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein; rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.
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An exchange device for replacing an old transport belt in, e.g., a dryer section of a machine producing a web, e.g., paper or cardboard. The device may include a spooler for simultaneously removing the old transport belt and inserting new transport belt. The exchange device may also include a mobile carrier device that supports the spooler and may guide the spooler to an exchange location within the web production machine.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of International Patent Application Serial No. PCT/NL2008/050821, entitled “A Method for Generating Information of a 3-Dimensional Molecular Structure of a Molecule”, to Technische Universiteit Delft, filed on Dec. 19, 2008, which is a continuation of Netherlands Patent Application Serial No. 2001101, entitled “A Method for Generating Information of a 3-Dimensional Molecular Structure of a Molecule”, to Technische Universiteit Delft, filed on Dec. 19, 2007, and the specification and claims thereof are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable,
COPYRIGHTED MATERIAL
[0004] Not Applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention (Technical Field)
[0006] The present invention relates to a method for generating information of a 3-dimensional molecular structure of a molecule as mentioned in the preamble of claim 1 . The invention also relates to a computing device and a computer program as mentioned in the independent claims 8 and 9 .
[0007] 2. Description of Related Art
[0008] A method as identified above is known from EP 1 226 528. Said method is generally known in the art since many-years (the “Faster” method). This publication EP 1 226 528 relates to a method for generating information related to the molecular structure of a biomolecule, the method being executable by a computer under the control of a program stored in the computer and comprising the steps of: (a) receiving a three-dimensional representation of the molecular structure of said biomolecule, the said representation comprising a first set of residue portions and a template; (b) modifying the representation of step (a) by at least one optimization cycle; wherein each optimization cycle comprises the steps of: (b1) perturbing a first representation of the molecular structure by modifying the structure of one or more of the first, set of residue portions by means of a supplemental force field acting on at least said first set of residue portions; (b2) relaxing the perturbed representation by disabling the supplemental force field; (b3) evaluating the perturbed and relaxed representation of the molecular structure by using an energetic cost function and replacing the first representation by the perturbed and relaxed representation if the latter's global energy is more optimal than that of the first representation; and (c) terminating the optimization process according to step (b) when a predetermined termination criterion is reached; and (d) outputting to a storage medium or to a consecutive method a data structure comprising information extracted from step (b). The contents of EP 1 226 528 are herewith incorporated by reference in its entirety.
[0009] This known method has several disadvantages. For example, only the main chain (the template) and the side chains are taken into account for calculating the energy value of different conformational structures. Upon bending the molecular structure, only the energy values of these main chain and side chains are calculated. With the Faster method, the main chain will never move during the search calculation, since the backbone atoms positions are fixed without exception and provide the essential information to position the side chains within the main chain frame. In molecular dynamics, all atoms are in constant motion, possessing kinetic energy (at for example 300 Kelvin) and experiencing potential energy described by a Hamiltonian function. During the cycles there is no (0 Kelvin) energy minimization (as is used frequently in other methods to obtain acceptable molecular conformations) but excess energy in the system as a result of the cyclic intervention is removed as excess heat through the thermostatic (300 Kelvin) coupling of the Berendsen bath.
BRIEF SUMMARY OF THE INVENTION
[0010] The present, invention aims at providing an improved method. The improvement concerns the use of MD as basic and physical reliable simulation engine and is guided by the potentials that are imposed by interactive and cyclic intervention of a hydrogen bond search algorithm. This search algorithm is able to detect possible hydrogen bond formation and breaking within a wider range then is possible with MD. Guiding forces are not represented by spring-like harmonic forces which increase quadratically with the distance but by applying forces that increase during time cycles and are driven by crossing barrier events. The enhancement of correctly recognized hydrogen bond networks accelerates MD simulation and increases the production of molecular events (for example formation of a hydrogen bond) with a factor up to 1000 times over classical simulation. Another very important feature is that the recognition of optimal hydrogen bond networks and the guiding directives to the realization of these networks helps the MD to follow very efficiently the high-dimensional pathway of least resistance towards the global energy minimum.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] Not Applicable.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present, invention aims at providing an improved method. The improvement concerns the use of MD as basic and physical reliable simulation engine and is guided by the potentials that are imposed by interactive and cyclic intervention of a hydrogen bond search algorithm. This search algorithm is able to detect possible hydrogen bond formation and breaking within a wider range then is possible with MD. Guiding forces are not represented by spring-like harmonic forces which increase quadratically with the distance but by applying forces that increase during time cycles and are driven by crossing barrier events. The enhancement of correctly recognized hydrogen bond networks accelerates MD simulation and increases the production of molecular events (for example formation of a hydrogen bond) with a factor up to 1000 times over classical simulation. Another very important feature is that the recognition of optimal hydrogen bond networks and the guiding directives to the realization of these networks helps the MD to follow very efficiently the high-dimensional pathway of least resistance towards the global energy minimum.
[0013] The invention also aims at providing a more accurate and more reliable method.
[0014] Finally, the invention aims at providing a faster method for generating information of a 3-dimensional molecular structure of a molecule.
[0015] To obtain at least one of the aforementioned goals, the invention provides a method comprising the steps as indicated in claim 1 . It has shown that using hydrogen bridge energy for calculating the energy value of the structure of the molecule provides an improved method. It has also shown that the method reaches said predetermined criterion faster and more accurately.
[0016] The method has become more reliable with the steps according to the present invention.
[0017] Preferably, this is obtainable when the following steps (b2) and (b3) are performed in the method as generally indicated above: (b2) thermodynamically relaxing atomic motions of the perturbed representation by disabling the supplemental force field while maintaining the running of the simulation by a classical molecular dynamics engine; and (b3) evaluating the perturbed and molecular dynamics relaxed representation of the molecular structure by using an energetic cost function (derived from the Hamiltonian equations of motion that governs the atomic motions over time) and replacing the first representation by the perturbed and relaxed representation if the latter's global energy is more optimal than that of the first representation. Then steps (c) and further are continued, as have already been described above.
[0018] As a matter of fact, the hydrogen atoms that will form hydrogen bridges are those attached to oxygen or nitrogen atoms.
[0019] According to the invention, a hydrogen bond potential V hb is introduced as a supplemental force to the standard (gromos 96) force field (for example, the Amber or Charmm force field used in the method of EP 1 226 528), which acts on the atoms involved in hydrogen bonding in order to accelerate protein folding in MD simulations. This is implemented as a staged molecular dynamics protocol, where according to the present invention three stages are distinguished: the repulsive stage (“R”), the attractive stage (“A”) and the relaxation stage (“E”). These three stages each treat hydrogen bonds differently. In “R” a potential stimulates hydrogen bond breakage, in “A” a potential facilitates hydrogen bond formation and in “E” the system is allowed to relax thermodynamically at about 300 Kelvin by removing all forces derived from the supplementary force field and running the MD simulation stand-alone. In the present simulations each stage is active for, for example, 0,5 ps in the order-(-R-E-A-E-)- n .
[0020] When a stage is active (for example 0,1 ps), all intramolecular donor-acceptor pairs of a protein are evaluated in every time frame. The relevant pairs are selected and potentials are introduced that will result in a force acting on the atoms. A pair is excluded from selection if it (a) is a strong hydrogen bond (characterized by a donor-acceptor distance less than for example 0.35 nm and a donor-hydrogen-acceptor angle larger than for example 120°), (b) the atoms of the pair are involved in another strong hydrogen bond and (c) the atoms in the pair are already targeted in another hydrogen bond potential (e.g. from a previous evaluation). For the remaining donor-acceptor pairs those with the largest hydrogen bond potential energy (eq. 1) are selected, with the rule that the atoms in a pair may only be selected once.
[0021] Regarding the potential used, please note as follows:
[0022] The hydrogen bond potential V hb (q,t) is given in (eq. 1).
[0000] V hb ( q,t )= fc ( q,t )· E d ( q ( t ev ))· E θ ( q ( t ev )) (eq. 1)
[0023] It is a function of time t and consists of a distance potential E d (q(t ev )), an angle potential E d (q(t ev )) a time-dependent force constant f c(q,t) and the positions of the atoms in the hydrogen bonds q.
[0024] In the repulsive stage the distance potential E d (q(t ev )) is determined by the distance d (nm) between donor and acceptor (FIG. 1) at the evaluation time t ev . Cutoff distances d min and d max of (for example) 0.35 and 0.40 nm are used respectively. For the attractive stage the distance between hydrogen and acceptor (FIG. 1) is considered and the cutoff distances d rain and d max are (for example) 0.35 and 0.40 nm, respectively. For the attractive stage the distance between hydrogen and acceptor (FIG. 1) is considered and the cutoff distances d min and d max , are (for example) 0.23 and 40 nm, respectively. The values of the cutoff distances ensure that only weak to very weak hydrogen bonds are targeted.
[0000]
E
d
(
q
(
t
ev
)
)
=
{
1
d
(
t
ev
)
<
d
min
1
-
(
t
ev
)
-
d
min
max
-
d
min
d
min
≤
d
(
t
ev
)
<
d
max
0
d
max
≤
d
(
t
ev
)
(
eq
.
2
)
[0025] The angle potential E θ (q(t ev )) depends on the angle θ (degrees) of the donor hydrogen acceptor (FIG. 1) at activation time t ev . The cutoff angle θ bound in the repulsive stage is in this case set to 120°, which ensures targeting all weak hydrogen bonds, and in the attractive stage to 60° (although other values may be chosen as well), allowing generation of many hydrogen bonds.
[0000]
E
θ
(
q
(
t
ev
)
)
=
{
1
θ
(
t
ev
)
≥
θ
bound
0
θ
bound
>
θ
(
t
ev
)
(
eq
.
3
)
[0026] An important concept of the present invention is that the individual forces, applied in each selected donor-acceptor atom pair in the thermodynamic system may increase gradually during a cycle, until a barrier crossing event is received at. Then, the forces (potentials) will diminish and they will be set to a value “zero” at the end of said cycle.
[0027] The time-dependent force constant ensures a gradual introduction of the forces in the system. It is a function of the maximum force constant fc max (kJ mol −1 nm −1 ) and the gradual force introduction time t grad (ps)·t grad initially has the value zero. It is increased by one every timestep as long as the hydrogen bond it acts upon is within the distance potential cutoff, i.e., d min ≦d t <d max . When outside this range, one is subtracted. If this sum becomes smaller than 0 t grad is set to 0. t grad ensures that when the hydrogen bond is within the distance potential boundaries the force is introduced within 50 timesteps (division factor in (eq. 4)) to its maximum value and when outside these boundaries it is slowly decreased to zero. The division factor is chosen arbitrarily, within the idea of gradually introducing the forces in the system to its maximum. To obtain the maximum force constant several values were tested and the values showing a good response, i.e. many unfolding and folding events, were used.
[0000]
fc
(
q
,
t
)
=
fc
max
·
min
{
1
,
t
grad
50
}
(
eq
.
4
)
[0028] The hydrogen bond potential leads to the introduction of the following force acting on the acceptor atom (FIG. 1).
[0000]
F
A
=
fc
(
q
,
t
)
·
{
1
d
max
-
d
min
XA
(
t
ev
)
XA
(
t
ev
)
d
min
≤
d
(
t
ev
)
<
d
max
;
θ
(
t
ev
)
≥
θ
bound
0
rest
(
eq
.
5
)
[0029] The balancing force is F X =-F A . In these equations the X refers to the donor atom in the repulsive stage and to the hydrogen atom in the attractive stage (FIG. 1).
[0030] Preferred embodiments are specifically identified in the dependent claims. The advantages of said embodiments will become clear after the extensive discussion of the invention, given below.
[0031] As a matter of fact, EP 1 226 528 mentions the use of the contribution of hydrogen bonds in the molecule. However, this is only for determining the energy values between the atoms in the main chain and side chains, since the presence of a hydrogen atom on a side chain or a main chain influences the energy value between atoms in the main chain and side chains. The energy contribution of hydrogen bridges is in general not taken into account. According to the above identified European patent publication EP 1 226 528 the conformation of the main chain is not amended when alterations in the hydrogen bonds or hydrogen bridges are obtained. Furthermore, when the method according to said European patent advances, single residues are removed from the optimization cycle whereas portions (clusters of residues) only are used for calculating the global energy of the molecule.
[0032] In general terms, the present invention accelerates protein folding in all atom molecular dynamics simulations by introducing alternating hydrogen bond potentials as a supplement to the force field. The alternating hydrogen bond potentials result in accelerated hydrogen bond reordering, which lead to quick formation of secondary structure elements. The method does not require knowledge of the native state, but generates the potentials based on the development of the tertiary structure in the simulation. In protein folding the formation of secondary structure elements, especially a-helix and n-sheet, is very important and we show that our method can fold both efficiently and with great speed.
[0033] Folding of a protein into the native state cannot be described by a random search through all the degrees of freedom, but is believed to be a guided process.
[0034] The method according to the invention is applicable not only to interactions within the same biomolecule, but also to interactions with one or more different molecules, optionally as a complex of said biomolecule with a different molecule.
[0035] Here we propose a novel computational method based on the idea that occasional (partial) unfolding of a protein enhances the frequency of barrier crossing and the folding rate of proteins. We perform molecular dynamics (hereinafter identified as MD) simulations during which we periodically introduce temporary supplemental (additional) forces that alternatingly stimulate unfolding and folding. These forces act on the intramolecular hydrogen bonds. The first reason for this is because distinct hydrogen bonds in a similar context contribute equally to the free energy, but a free energy barrier separates all the possible hydrogen bonds. In other words, hydrogen bonds provide kinetic stability both in the global minimum and in local minima rather than thermodynamic stability. This has important implications: unfolding and folding can be stimulated by reimbursing the activation energy set by the kinetic barrier of a hydrogen bond. In addition the hydrogen bonds provide specificity rather than stability with respect to the tertiary structure of a protein, which means that the interactions that provide thermodynamic stability are unaltered and still guide the folding process of the protein into its native state, while the time in free-energy minima is decreased. A second more technical reason for influencing the intramolecular hydrogen bonds is that the number of required additional forces is minimal. This is because the number of donor-acceptor pair combinations in a protein is limited and the hydrogen bonds are orientation dependent, requiring introduction of only a few relevant hydrogen bond potentials.
[0036] The manipulation of the hydrogen bonds is performed within a single MD simulation, where alternatingly attractive or repulsive hydrogen bond potentials are introduced in addition to the standard force field potentials. The repulsive potential destabilizes the hydrogen bonds and lifts the protein to a higher free-energy level. The attractive potential in turn facilitates hydrogen bond formation to enable a fast identification of the conformational regions of free-energy minima. Such local unfolding/folding mechanism would be comparable with the barrier crossing effect of a chaperone protein. In this method we do not need a priori information on the native state; rather we use the structure of the protein as it develops during the simulation to determine which potentials are introduced.
[0037] We show that manipulation of hydrogen bonds during an MD simulation can accelerate the folding of a protein. The two secondary structure elements appearing most, a-helix and β-sheet, can be folded efficiently. This is demonstrated by the folding of a 16 residue polyalanine to the a-helical native state and the 16 residue C-terminal of the 1 GB1 protein to the β-hairpin native state.
[0038] The method presented above aims to accelerate in silico protein folding. This is achieved by manipulating the intramolecular hydrogen bonds, leading to an increase in the number of barrier transitions. To show that this is indeed the case, the time behavior of a 16-residue polyalanine was examined with standard MD (4 simulations of 30 ns) and with AHBP-MD (5 simulations of 10 ns). The simulations were started from a collapsed coil, which represent a structure in a local minimum possessing many hydrogen bonds. The maximum force constant used in the MD simulation including AHBP were −600 kJ mol −l nm −1 for the attractive potential and 450 kJ mol −1 nm −1 for the repulsive potential.
[0039] To test if the faster and broader sampling of the conformational space of a protein by the AHBP-MD simulations leads to fast formation of secondary structure elements two systems were tested. The polyalanine simulations used to show enhanced barrier crossing in AHBP-MD were also used to test the ability of the AHBP method to form a-helical secondary structure. To test the 13-sheet secondary structure formation we investigated the folding of the 16 residue C-terminus of the protein G (PDB-code 1 GB1), which adopts β-hairpin conformation in an aqueous environment. We performed 10 standard MD simulations of 50 ns and 10 AHBP-MD simulations of 30 ns, which all started from an extended conformation. In these AHBP-MD simulations of the β-hairpin we used a maximum force constant of −300 and 900 kJ mol −1 nm' for the attractive and the repulsive potential respectively.
[0040] For the polyalanine simulations the average number of residues in an a-helical conformation is determined. The N- and C-terminus are not taken into account since they are too mobile. From this, it is clear that within the very short time of the AHBP simulation fast formation of a-helix secondary structure occurs. The fastest formation of a full helix is observed within 6 ns and all simulations show formation of a-helical structure elements. In our four standard MD simulations we observe only one short instance of a-helix formation, confirming that a-helix formation is much faster and more abundant when AHBP is turned on.
[0041] To test for β-sheet formation in the simulation of the folding of 1 GB1 β-hairpin, we determined the average number of residues in a n-sheet conformation versus simulation time. In the AHBP-MD simulations a steady rise of the number of residues in a n-sheet conformation is observed, while in the standard MD simulations this number is not as high and not as consistent. So in addition to a-helix formation, AHBP-MD simulations can also lead to fast formation of β-sheet secondary structure.
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A method for generating information of a 3-dimensional molecular structure of a molecule, said method being executable by a computer under the control of a program stored in the computer, said method comprising the steps of: (a) receiving a 3-dimensional representation of the molecular structure of said molecule, comprising a first set of residue portions and a template; (b) repeating an optimization cycle, wherein a set of (b1) modifying the molecular structure of one or more of the first set of residue portions, (b2) relaxing said modified structure, and (b3) calculating an energy value of the structure and comparing said calculated value with a prestored base value or with a value calculated in a previously performed step (b3), is repeated; (c) until a predetermined criterion is fulfilled; and (d) outputting a data structure comprising information extracted from any of these steps to a storage medium or to a consecutive method. Preferably the 3-dimensional representation of said molecule comprises a set of hydrogen residues and step (b3) comprises the step of calculating the energy value of hydrogen bridges in the structure, and wherein said criterion of step (c) is comprised of a difference between the calculated value and the prestored base value or the previously calculated value.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national phase of PCT Appln. No. PCT/EP2011/052493 filed Feb. 21, 2011, which claims priority to German Patent Application No. 2010 002 234.9 filed Feb. 23, 2010, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a process for deaerating liquids, especially for deaerating aqueous suspensions as obtained, for example, in textile treatment or pulp and paper production.
[0004] 2. Description of the Related Art
[0005] In many liquid systems, especially aqueous systems, which contain surface-active compounds as desired or else as undesired constituents, problems can occur with entrapped air bubbles when these systems are brought into more or less intensive contact with gaseous substances, for example in the sparging of waste waters, in the intensive stirring of liquids, and in distillation, washing or dyeing operations. Especially liquids containing particles in fine distribution which can attract air bubbles, for example fibers, tend to entrap air.
[0006] In pulp production, the entrapped air prevents, for example, rapid drainage of the water and thus lowers quality and productivity.
[0007] Surface foam can be controlled with known defoamers. These consist, for example, of polyorganosiloxanes as described in U.S. Pat. No. 3,235,509 A, of polyorganosiloxanes in combination with polyoxyalkylenes as described in U.S. Pat. No. 3,984,347 A, or else of polyoxyalkylenes alone as described in “Antifoaming action of polyoxyethylene-polyoxypropylene-polyoxyethylene-type triblock copolymers on BSA foams”, Nemeth, Zs.; Racz, Gy.; Koczo, K. Colloids Surf., A, 127(1-3), 151-162, 1997.
[0008] DE 1444442 A1 discloses that foam destruction in hydraulic fluids containing approx. 50% glycols and polyglycols can be improved by the chemically related polypropylene glycol.
[0009] Conventional defoamers are known to be suitable for the control of “dry” surface foam, in which large gas bubbles are separated by thin liquid films (as described in Langmuir 2004, 20, 9463-9505). However, they are ineffective for deaeration of liquid-gas mixtures consisting mainly of liquid, with or without suspended solids.
[0010] This is because the surface properties and the solubility of defoamers which destroy the surface foam, which is also referred to as “macrofoam”, necessarily differ from the properties of deaerators (see Adams, J. W. et al. Verfkroniek, 68 (10) 1996 p. 43-45). Defoamers must be incompatible and migrate rapidly to the surface. Deaerators which, in contrast, are supposed to control the microfoam must have better compatibility since they are supposed to be effective not at the surface but in the liquid phase. It is therefore impossible to infer deaerator efficacy from a good defoamer efficacy (cf. EP 257 356 B1, page 2, lines 28-31).
[0011] Therefore, specific formulations are proposed for these applications. GB 2 350 117 A proposes, for better deaeration, use of linear or cyclic siloxanes bearing Si—C— or Si—O—C-bonded polyether groups. EP 257 356 B1 claims siloxanes with (isobutyryloxy)isopropyldimethyl-propoxy groups, which are said to enable better deaeration of plastisols than polyethersiloxanes.
[0012] There is still a need for better and more economic deaerating agents for various applications, especially for the production of pulp.
SUMMARY OF THE INVENTION
[0013] It has now been surprisingly discovered that specific polyoxyalkylenes have superior deaeration efficacy.
[0014] The invention provides a process for deaerating liquids containing at least 50% by weight and especially at least 70% by weight of water,
[0000] by adding 0.0001 to 1.0% by weight, preferably 0.0005 to 0.1% by weight, of polyoxyalkylenes of the formula
[0000] R—[O—CH 2 —CH(CH 3 )] x —[O—CH 2 —CH 2 ] y —O—R (I)
[0000] in which R may be the same or different and is a hydrogen atom, a C 1 -C 30 -alkyl radical, a C 1 -C 30 -alkenyl radical or a radical of the formula
[0000] R 1 —C(O)— (II)
[0000] in which R 1 is a C 1 -C 22 -alkyl radical,
x has a value of 6 to 300 and
y has a value of 0 to 30
and the y/x ratio is 0 to 1, and specific, branched polyether-polysiloxane copolymers
to these liquids.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Examples of R radicals in formula (I) are hydrogen and the methyl, allyl and butyl radicals. The R radical is preferably a hydrogen atom.
[0016] Examples of the radicals of the formula R 1 are the methyl and butyl radicals.
[0017] In the formula (I), the index x is preferably 15 to 150, more preferably 25 to 100. The y/x ratio is preferably 0 to 0.75, more preferably 0 to 0.25 and especially 0 to 0.1. In a particularly preferred variant, y=0.
[0018] The polyoxyalkylenes of the formula (I) preferably have a mean molar mass (number average M n ) of 600 to 20,000, preferably 800 to 12,000.
[0019] The polyoxyalkylenes used are preferably polypropylene glycols having a mean molar mass (number average M n ) of 1000 to 8000 g/mol.
[0020] It is possible to use one kind of polyoxyalkylene or two or more kinds of polyoxyalkylenes.
[0021] The oxyalkylene groups may be in random distribution in the polyoxyalkylenes of the formula (I), or may be present as block copolymers.
[0022] Polyoxyalkylenes of the formula (I) are known commercial products. According to the values of x and y, the polyoxyalkylenes are liquids or waxy products, preference being given to liquid products having a viscosity (at 25° C. and 1013 hPa) of 400 to 1500 mm 2 /s.
[0023] The solubility of the polyoxyalkylenes in water is determined by the ratio of y/x. Preference is given to using polyoxyalkylenes which are soluble to an extent of less than 2% in water at 25° C. and 1013 hPa, or have a cloud point (measured to EN 1890 Variant A) of less than 35° C., especially less than 25° C.
[0024] Deaeration in the context of this invention is a process in which the gas content of a liquid containing gas in dispersed form, i.e. containing a microfoam in which the proportion by volume of the liquid in the microfoam is higher than the proportion by volume of gas, is reduced.
[0025] A process for deaerating liquids is understood in the context of the invention to mean, more particularly, a process in which the gas content of a liquid phase containing preferably at most 50% by volume, more preferably at most 20% by volume and especially at most 10% by volume of gas in dispersed form is significantly reduced, such that preferably a gas content of less than 5% by volume and especially of less than 2% by volume is attained.
[0026] The invention more preferably provides a process for deaeration of the liquids obtained in pulp production, preferably aqueous fiber-containing suspensions having a water content of at least 70% by weight.
[0027] The liquids to be deaerated contain, aside from the inventive addition of polyoxyalkylenes of the formula (I), preferably less than 1% by weight and more preferably less than 0.1% by weight of further glycols or polyglycols, and more preferably no further glycols or polyglycols.
[0028] In the production of pulp, which is a cellulose product containing a greater or lesser level of impurities, from cellulosic materials such as wood, different digestion solutions are used to dissolve the other constituents such as lignin. In a subsequent washing and sieving operation, the pulp obtained is separated from the digestion solution and purified.
[0029] Probably the most important digestion process is the alkaline sulfate or Kraft process, in which a digestion solution containing NaOH/NaS is used to obtain what is called the sulfate or Kraft pulp. A further product obtained is black liquor which, as well as the digestion solution, contains the other constituents of cellulosic materials such as wood.
[0030] The inventive polyoxyalkylenes can be used directly or, owing to better distribution and handling, as a solution in suitable organic substances, or as an emulsion.
[0031] Suitable organic additives to the inventive polyoxyalkylenes of the formula (I) are mineral oils, native oils, isoparaffins, polyisobutylenes, residues from oxoalcohol synthesis, esters of low molecular weight synthetic carboxylic acids, for example 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, fatty acid esters, for example dodecyl palmitate or isopropyl myristate, fatty alcohols, ethers of alcohols, phthalates and esters of phosphoric acid.
[0032] Suitable further additives to the inventive polyoxyalkylenes of the formula (I) are polyether-polysiloxane copolymers, which may be linear or branched.
[0033] It is possible to use one kind of polyether-polysiloxane copolymers or two or more kinds of polyether-polysiloxane copolymers.
[0034] A preferred embodiment of the invention is a process for deaerating liquids containing at least 50% by weight and especially at least 70% by weight of water by adding 0.0001 to 1.0% by weight and preferably 0.0005 to 0.1% by weight of a mixture of 100 parts by weight of polyoxyalkylenes of the formula
[0000] R—[O—CH 2 —CH(CH 3 )] x ·[O—CH 2 —CH 2 ] y —O—R (I)
[0000] especially polypropylene glycols having a mean molar mass (number average M n ) of 1000 to 8000 g/mol,
and 1 to 200 parts by weight, preferably 2 to 100 parts by weight, of polyether-polysiloxane copolymers.
[0035] Such polyether-polysiloxane copolymers form part of the prior art and are known to those skilled in the art.
[0036] Examples of linear polyether-polysiloxane copolymers are those in which the polyether radicals are laterally SiC-bonded to linear siloxane chains via hydrocarbyl radicals, preferably divalent hydrocarbyl radicals. Such linear polyether-polysiloxane copolymers are described, for example, in GB 2 350 117 A.
[0037] Examples of branched polyether-polysiloxane copolymers are those in which the polyether radicals are SiC-bonded laterally to linear siloxane chains via hydrocarbyl radicals, preferably divalent hydrocarbyl radicals, and where these linear siloxane chains are bonded to one another via lateral organic bridges. Examples of these organic bridges are SiC-bonded linear or branched organic radicals, preferably divalent hydrocarbyl radicals, which may contain one or more heteroatoms selected from the group of oxygen and nitrogen atoms, such as alkylene radicals, SiC-bonded polyether radicals which are bonded via alkylene radicals to siloxane chains, and SiC-bonded divalent hydrocarbyl radicals such as alkylene radicals, containing polyether and urethane groups.
[0038] Of particularly good suitability are branched polyether-polysiloxane copolymers as described, for example, in EP 1 076 073 A1, EP 1 424 117 A2 or WO 2006/128624 A1, as a component of defoamers.
[0039] The branched polyether-polysiloxane copolymers used are preferably those in which the siloxane chains are bonded to one another via lateral divalent SiC-bonded hydrocarbyl radicals containing polyether radicals and urethane groups.
[0040] These polyether-polysiloxane copolymers and the preparation thereof are described in WO 2006/128624 A1, especially on page 3 line 8 to page 13 line 38 (incorporated by reference).
[0041] The inventive polyether-polysiloxane copolymers preferably have a viscosity of 50 to 100,000,000 mPa·s at 25° C., more preferably 100 to 1,000,000 mPa·s at 25° C. and most preferably 1000 to 100,000 mPa·s at 25° C.
Description of the Deaeration Experiments:
[0042] 350 ml of black liquor from the pulp process (hard- and softwood from UPM Kymmene Oy Kuusankoski, Finland, having a water content of greater than 80% by weight) are heated to 80° C. under constant conditions with stirring in a beaker for 15 minutes, then 220 ml thereof are transferred into a stirred glass autoclave likewise thermostated at 80° C.
Determination of D 0 :
[0043] The autoclave is closed without adding deaerator and, after a wait time of 3 seconds, the outlet valve at the base of the autoclave is opened for 5 seconds.
[0044] The black liquor is then discharged into a measuring cylinder under pressure 3 bar and, immediately thereafter, the mass and the volume for the density calculation are determined.
Determination of D 2 :
[0045] The autoclave is closed without adding a deaerator and the black liquor present is stirred at 800 rpm under a compressed air pressure of 3 bar for 10 minutes. After a wait time of 3 seconds, the outlet valve at the base of the autoclave is opened for 5 seconds.
[0046] The black liquor is then discharged into a measuring cylinder under pressure 3 bar and, immediately thereafter, the mass and the volume for the density calculation are determined.
Determination of D 1 :
[0047] The autoclave is closed after adding the amount of a deaerator specified in the table below and the black liquor present is stirred at 800 rpm under a compressed air pressure of 3 bar for 10 minutes. After a wait time of 3 seconds, the outlet valve at the base of the autoclave is opened for 5 seconds.
[0048] The black liquor is then discharged into a measuring cylinder under pressure 3 bar and, immediately thereafter, the mass and the volume for the density calculation are determined.
D 0 =density of the black liquor at 80° C. without deaerator; without stirring D 2 =density of the black liquor at 80° C. without deaerator; after stirring D 1 =density of the black liquor at 80° C. with deaerator; after stirring
[0000] Deaeration in %=100×( D 1 −D 2 )/( D 0 −D 2 )
D 0 (hardwood): 1.01 g/cm 3 and D 2 (hardwood): 0.83 g/cm 3 . D 0 (softwood): 1.03 g/cm 3 and D 2 (softwood): 0.77 g/cm 3 .
[0054] Examples 1 and 2 (with polymers 1 and 2),
[0055] Example 3 (mixture of 70% polymer 1 and 30% polymer C1),
[0056] Example 4 (mixture of 70% polymer 1 and 30% polymer C3),
[0057] Comparative Experiments 1 and 2 (with polymers C1 and C2),
[0058] Comparative Experiment 3 (mixture of 70% polymer 1 and 30% polymer C4).
[0059] For use as deaerators, polymers 1 and 2 in examples 1 and 2 and polymers C1 and C2 in comparative experiments and 2 are metered directly into the black liquor without any further additive.
Polymer 1:
[0060] Polymer 1 is a polypropylene glycol with a mean molar mass (number average M n ) of 2000.
Polymer 2:
[0061] Polymer 2 is a copolymer of ethylene oxide and propylene oxide in which polyethylene oxide forms the central molecular moiety with the general structural formula
[0000] H—[O—CH(CH 3 ) —CH 2 ] m —[O—CH 2 —CH 2 ] n —[O—CH(CH 3 )—CH 2 )] o —OH
[0062] The mean molar mass (number average M n ) is 3500 g/mol, the molar proportion by mass of polypropylene oxide being approx. 3100 g/mol.
Polymer C1:
[0063] In comparative experiment 1, the deaerator used is a linear polyether-polysiloxane copolymer according to the prior art, as per GB 2 350 117 A. This was prepared as follows:
[0064] 67 g of a siloxane terminated with methyl groups, composed of dimethylsiloxy and hydromethylsiloxy units and having an active hydrogen content of 0.133% and a viscosity of 72 mm 2 /s (25° C.) are mixed by stirring vigorously with 408 g of an allyl polyether (H 2 O content 560 ppm) having a PO/EO ratio of 4.0 and an iodine number of 11.2, and the mixture was heated to 100° C. Addition of 0.5 ml of a 2% solution of hexachloroplatinic acid in isopropanol starts the hydrosilylation, which is manifested in a weakly exothermic reaction. The reaction mixture is kept at 100 to 110° C. until a clear copolymer is obtained and no active hydrogen is detectable any longer. The polysiloxane with lateral polyether groups has a viscosity of 870 mm 2 /s (25° C.)
Polymer C2:
[0065] In comparative experiment 2, a polypropylene oxide with a mean molar mass (number average M n ) of 400 g/mol, which is not in accordance with the invention, is used.
Polymer C3 (According to WO 2006/128624 A1):
[0066] Polymer C1 is heated to 130° C., and water traces are removed at 1 hPa. Thereafter, 7 g of hexamethylene diisocyanate are metered in and the mixture is homogenized for 20 minutes. The isocyanate reaction is started with 1 drop of dibutyltin laurate (DBTL). After two hours, the NCO content has fallen below the detection limit (IR: 20 ppm), and so 120 g of a surfactant (commercially available under the Emulan® HE 50 from BASF SE, Ludwigshafen, Germany) are metered in. After cooling to 25° C., the 80% copolymer solution has a viscosity of 2100 mm 2 /s and a urethane content of 0.139 meq/g.
Polymer C4:
[0067] Polymer C4 is a polydimethylsiloxane having a chain length of approx. 200, as described in claim 1 in DE 1444442.
[0068] The amounts of the polymers or mixtures thereof added to the black liquor are reported in the table.
[0069] The results of the testing of the efficacy in deaeration are compiled in the table.
[0000]
TABLE
Dearation
Dearation
in black
in black
liquor
liquor
Examples/
Amount
from
from
Comparative
added
hardwood
softwood
Examples
Deaerator
in μl
in %
in %
Example 1
polymer 1
8
53.0
83.2
Example 2
polymer 2
8
52.9
78.5
Example 3
70% polymer
8
55.8
85.6
1 and 30%
polymer C1
Example 4
70% polymer
8
58.1
88.9
C1 and 30%
polymer C3
Comparative
polymer C1
8
43.9
69.2
Example C1
Comparative
polymer C2
8
0
0
Example C2
Comparative
70% polymer
n.a.
n.a.
n.a.
Example C3
1 and 30%
polymer C4.
The two
polymers
are not
homogeneously
miscible,
and so no
deaeration
experiments
were
conducted.
[0070] As can be inferred from the table, deaeration in comparative experiments 1 and 2 is much poorer than in examples 1 to 4.
[0071] In comparative experiment 1, an unbranched linear polyether-polysiloxane copolymer analogous to GB 2 350 117 A is used; in comparative experiment 2, a noninventive polypropylene glycol is used.
[0072] In example 3, a homogeneous mixture of 70% polymer 1 and 30% polymer C1, a linear polyether-polysiloxane copolymer, is used. Addition of 30% of polymer C1 makes polymer 1 water-dispersible.
[0073] Surprisingly, the mixture of 70% polymer 1 and 30% polymer C1 in black liquor from hard- and softwood shows better deaeration than the two individual polymers.
[0074] In example 4, a homogeneous mixture of 70% polymer 1 and 30% polymer C3, a branched polyether-polysiloxane copolymer, is used as a deaerator. Addition of 30% of polymer C3 improves the efficacy of polymer 1 once again.
[0075] In comparative example C3, a mixture of 70% polymer 1 and 30% polymer C4, a dimethylpolysiloxane, according to DE 1444442 A is used. The mixture is unstable and separates into 2 phases within a few minutes. Since a homogeneous mixture which is stable over a prolonged period is of crucial importance for the later practical handling and use as a deaerator, no deaeration experiments were conducted.
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Efficient deaeration of aqueous suspensions such as those obtained during textile treatment or pulp and paper production is achieved by use of a combination of a polyoxypropylene polyether polymer or copolymer and branched polyether-polysiloxane copolymers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to synchronizing signal detecting apparatus for circular knitting machines or more in particular to a mechanical synchronizing signal detecting apparatus for circular knitting machines having an electronic pattern-forming command circuit.
2. Description of the Prior Art
In conventional circular knitting machines having an electronic pattern-forming command circuit, a control signal processed electronically in accordance with a desired pattern is applied to a needle selecting system in synchronism with the movement of the needle track of the machine. In order to detect the movement of this needle track of the machine, a needle track detector produces a sine-wave signal in synchronism with the pitches of the needle track. At the time point when this sine-wave signal passes the zero level from negative to positive side, a control signal indicating "Knit" or "Don't knit" is applied to the needle selecting system of the machine.
A minute backward motion of the machine has so far been unavoidable immediately following the stoppage thereof from a normal operating condition. In the event that the position of such a stoppage happens to be immediately after the passing of the zero level by the detected sine-wave signal, the sine-wave signal passes the same zero level again at the time of reactuation or restarting of the machine, thus erroneously producing one superfluous pulse of the synchronizing signal, with the result that a control signal displaced by one step is applied to the needle selecting system. This erroneous operation has been one of the causes for the reduction in quality due to dispersion of pattern.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to improve the quality of knitting patterns by obviating the knitting error which occurs at the time of reactuation of the machine.
In other words, a phase condition memory unit is newly provided for storing the phase condition of the sine-wave signal at the time when it passes the zero level, the sine-wave signal being obtained from the needle track detector and associated with the passage of the needle along the needle track. Only when an output is produced from this phase-condition memory unit is the synchronizing signal produced from the synchronizing signal detector made effective.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of the invention.
FIG. 2 shows waveforms of inputs and outputs of various circuits included in FIG. 1.
FIG. 3 is a diagram comparing the synchronizing signal (H) produced in the conventional knitting machines with the synchronizing signal (J) produced in the apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 showing an embodiment of the invention, reference numeral 1 shows a non-volatile memory device for storing pattern signals representing desired knitting patterns and the outputs of flip-flops 12 and 16 described later, in the form of binary numbers or other codes. Numeral 2 shows a command circuit for processing a knitting pattern signal currently in use for knitting operations, among those pattern signals representing the knitting patterns stored in the non-volatile memory device 1. Numeral 3 shows a circular knitting machine having a needle-selecting system receiving the pattern signal thus processed in the command circuit 2. Numeral 4 shows a needle track detector disposed in proximity to the front surface of the needle track on the periphery of the rotating cylinder of the circular knitting machine. This needle track detector detects the movement of the needle track and produces a signal for synchronizing the processing of the pattern signal with the knitting speed of the circular knitting machine. Numeral 5 shows an amplifier for amplifying the output A produced by the needle track detector 4. Numeral 6 shows a waveform shaping circuit for converting the sine-wave signal of output B amplified by the amplifier 5 into a rectangular wave signal. Numeral 7 shows a differentiating circuit for differentiating the output L produced from the waveform shaping circuit 6, and numeral 8 shows a negative pulse clamp circuit for eliminating negative pulses from the output K of the differentiating circuit 7. The synchronizing signal detector 9 is made up of the circuits 6, 7 and 8.
In conventional apparatuses, the output H of the synchronizing signal detector 9 is used as a synchronizing signal. Since the conventional apparatuses do not employ any means for checking the above-mentioned backward motion of the machine, however, one superfluous pulse of synchronizing signal is erroneously produced depending on the position of stoppage of the machine.
As such checking means, the present invention employs a phase condition memory unit 18 for storing the phase condition at a point prior to the passing of the zero level by the sine-wave signal produced from the needle track detector 4. Numeral 10 shows a comparator for comparing the sine-wave signal B produced from the needle track detector 4 with a setting V 1 to check whether or not the signal B has passed the predetermined high level V 1 prior to the time point when the signal B passes the zero level. Output C of the comparator 10 is set in the flip-flop 12 through an OR circuit 11. Numeral 14 shows a similar comparator for comparing the signal B with a setting V 2 to check whether or not the signal B has passed the predetermined low level V 2 . The output D of the comparator 14 is applied as one input to an AND circuit 13. The output E of the flip-flop 12 is applied as the other input to the AND circuit 13, the output of which is applied to and set in the flip-flop 16 through the OR circuit 15. Numeral 17 shows a delay circuit for delaying the output F of the flip-flop 16 slightly behind the synchronizing signal H. The output E of the flip-flop 12 and the output F of the flip-flop 16 are kept stored in the non-volatile memory device 1, so that the states of such outputs can be set again in the flip-flop 12 and 16 through the OR circuits 11 and 15 at the time of reclosing the power switch. Further, the flip-flops 12 and 16 are reset by the output J of the AND circuit 19. The foregoing is the construction of the phase condition memory unit 18. The output G of the phase condition memory unit and the output H of the synchronizing signal detector are applied to the AND circuit 19 to obtain a logical product thereof. The output J of the AND circuit 19 is applied to a command circuit 2 as a complete and correct synchronizing signal. The relation of operation between the various elements will be made apparent further by reference to the output waveforms produced therefrom as shown in FIG. 2. Next, assume that the position of stoppage of the machine causes an erroneous operation thereof, for example, that a machine stop command is issued immediately after the sine-wave signal has passed the zero level. In such a case, the output signal B from the amplifier 5 takes the waveform as shown in FIG. 3. The comparison between the synchronizing signal H in the conventional apparatuses and the synchronizing signal J produced in the apparatus according to the invention clearly shows that the conventional synchronizing signal H is produced undesirably once again at the time of the restarting of the machine, thus causing a knitting error.
In the apparatus according to the invention, by contrast, the output G of the phase condition memory unit 18 is not produced at the time of machine restarting. Therefore, by obtaining a logical product of the output G and the synchronizing signal H which is an output of the synchronizing signal detector 9, it is possible to entirely prevent an unnecessary synchronizing signal which otherwise might be generated by the backward motion of the machine at the time of stoppage thereof. In other words, erroneous generation of a synchronizing signal is eliminated thereby to prevent the knitting error at the time of machine restart. Thus the product pattern is not dispersed, making possible products always of a high quality.
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In order to prevent the dispersion of knitting patterns which otherwise might result from backward motion when a circular knitting machine stops, a phase condition memory unit is provided for storing the phase condition of a sine-wave signal from a needle track detector of the circular knitting machine before the sine-wave signal passes the zero level. On condition that an output is produced from the phase condition memory unit, a synchronizing signal obtained from a synchronizing signal detector is made effective.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/308,457 entitled “Roof with Ridge Vent Brace” filed Feb. 26, 2010.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention pertains to the building industry and, more particularly, to bracing for use in securing roof decking adjacent a roof ridge vent.
[0004] 2. Discussion of the Prior Art
[0005] In the construction of various types of buildings, wood products are widely used as a base layer for a roof. That is, sheets of OSB sheathing or plywood are generally nailed or screwed to roof trusses or rafters to establish decking for the roof, typically followed by shingles being secured upon the sheets. Particularly when constructing a residential home, it is also common to form the roof with a peak and provide venting of an attic space at the peak or ridge of the roof. Typically, a gap is established along the peak, with the gap opening directly into an attic space of the residence. A ridge vent assembly, typically formed of various elongated, perforated metal members arranged in an overlapping manner, is then mounted over the gap along the entire peak. More specifically, the ridge vent assembly includes side flanges mounted along each side of the peak, with the flanges sitting atop the shingles. With this construction, heated air that collects in the attic space is permitted to escape from the residence through the ridge vent assembly, thereby providing for a more energy efficient, configuration, particularly during summer months when an owner may be trying to cool the air in the, home while the attic space contains rather hot air.
[0006] Certainly, the roof needs to be constructed in a manner which prevents the ingress of rain water. One factor that can seriously compromise these features is warping of the sheets establishing the roof decking along lines adjacent the peek. To address this potential flaw, it is known to mount blocks, such as pieces of 2×4 wood studs, between the roof trusses or rafters, thereby providing support directly beneath the uppermost edges of the decking. Unfortunately, mounting these blocks can be fairly time consuming. In addition, the blocks do not allow for an unobstructed flow of ventilation air from between the rafters to the ridge vent assembly.
[0007] Based on these and other perceived construction drawbacks associated with the typical, construction of buildings with vented peaks, it is considered desirable to provide an arrangement which eases aspects of the overall construction, substantially prevents roof decking from warping along lines adjacent a ridge roof assembly and allows unobstructed flow of ventilation air moving under the sheathing and exiting the ridge vent.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a brace for securing a roof deck adjacent a roof ridge'vent. More specifically, the brace takes the form of an elongated metal, preferably J-shaped channel, with the brace being wrapped around the upper edge portion of the roof decking, such as OSB sheathing or plywood, at the roof ridge. The brace stiffens and carries the weight of the roof decking between the roof trusses or rafters, allowing an unobstructed flow of ventilation air under the decking and preventing bowing of the roof decking. In the winter, this unobstructed air flow exists from the soffit to the ridge vent which aids in preventing ice damming. The brace is at least partially covered by a line of shingles and then mounting flange portions of a ridge vent extend over each of the brace, decking edge and shingles.
[0009] Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a partial perspective and exploded view of a residential building employing a ridge vent brace in accordance with the invention;
[0011] FIG. 2 is a cross-sectional side view of a roof ridge with ridge vent brace according to the invention; and
[0012] FIG. 3 is a perspective view of a preferred embodiment of the ridge vent brace of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] With initial reference to FIG. 1 , a portion of a building constructed utilizing the ridge vent brace of the invention is generally indicated at 2 . Based on the illustrated angle of building 2 , which, can be a residential or commercial building, both a first upstanding side wall 5 and a second upstanding side wall 6 are shown, along with a roof 8 . As depicted, roof 8 constitutes a gable-style roof, although it should be understood that the invention can also be employed in connection with other types of known roofing constructions, including hip and Gambrel roofs. As also shown in this figure, side walls 5 and 6 are provided with siding 14 , such as aluminum, vinyl or wood planks, as well as associated corner trim. 16 . Of course, it, should be realized that other types of known exterior finishes could be used, including brick, stone and the like.
[0014] In a similar manner, roof 8 can be constructed of various materials. As shown, roof 8 includes roof decking 20 , such as OSB sheathing or plywood which are held in place by various, fasteners 24 , such as nails or screws. Roof decking 20 is mounted up to a peak or ridge 27 and has mounted thereon roofing or tar paper 29 , as well as shingles 30 or other known weatherguard roofing members. At the peak 27 , in a manner known in the field, roof decking 20 and shingles 30 stop short of peak 27 and an elongated ridge vent 34 is provided to cover this portion of roof 8 from the ingress of rain and the like, while also permitting heated air to escape from an uppermost portion, such as an attic space (not labeled) of building 2 , thereby enhancing the overall energy efficiency of the construction. At this point, it should be noted that these details of building 2 are provided for the sake of completeness and are not intended to be limiting to the invention. Instead, the invention is more specifically concerned with the inclusion and structure of a ridge vent brace 38 in the overall construction.
[0015] As shown in FIG. 2 , a cross-sectional side view of the uppermost portion of gable roof 8 depicts rafters 42 and 43 , which can be separately mounted or formed as part of a pre-assembled truss structure. A connecting plate or truss gusset 46 is shown connecting rafters 42 and 43 , although a ridge board-type construction is also common in the field. Most, importantly, this figure illustrates the mounting of various ridge vent braces 38 in accordance with the invention. However, before detailing this mounting, the preferred construction of ridge vent brace 38 will now be described with reference to FIG. 3 .
[0016] The perspective view of FIG. 3 shows each ridge vent brace 38 including a base leg 55 , an upper leg 58 and a connecting leg 61 . In the most preferred embodiment, connecting leg 61 extends substantially perpendicular to and spaces base and upper legs 55 and 58 , thereby establishing a channel 64 between base leg 55 and upper leg 58 . Base leg 55 preferably projects from connecting leg 61 a distance substantially greater than upper leg 58 such that ridge vent brace 38 assumes a J-shape from an end view. Although ridge vent brace 38 could be made of various stiff and substantially inflexible materials, the invention preferably employs metal, such as galvanized steel or other metal of sufficient thickness, such as 18-25 gauge. In the most preferred form of the invention, ridge vent brace 38 is, provided in a length and channel dimension matching roof decking 20 . Therefore, if roof decking 20 constitutes ½″ thick, 4′×8′ plywood sheets, each ridge vent brace 38 is 8 feet long and base leg 55 is spaced from upper leg 58 by a distance just slightly greater than ½″, such as 9/32″ or 5/16″. In accordance with the invention, the width of base and upper legs 55 and 58 can vary, with base leg 55 preferably being more than twice the dimension of upper leg 55 to establish the J-shape. For instance, base leg 55 can be made approximately 2 inches wide, while upper leg 58 is approximately ¾″ wide, as measured projecting from connecting leg 61 . If desired, greater dimensions can be employed, such as base leg 55 being approximately 6 inches wide and upper leg being approximately 2″ wide.
[0017] Given this construction, as shown best in. FIG. 2 , each ridge vent brace 38 is adapted to slip over an uppermost edge 68 of a respective sheet of roof decking 20 , with each ridge vent brace 38 extend rig along, yet being spaced from, peak 27 . Given the dimensioning of ridge vent brace 38 relative to roof decking 20 , the uppermost edge of roof decking 20 is snugly received in channel 64 , with ridge vent brace 38 being held down by the mounting of roof decking 20 to the respective rafter 42 , 43 . Thereafter, ridge vent 34 is mounted along peak 27 and extends over the upper leg 58 of each ridge vent brace 38 . More particularly, ridge vent 34 is shown to-include interconnected, angled panels 78 and 79 , each of which leads to a respective in-turned portion 82 , 83 and a mounting flange 86 , 87 . It is mounting flanges 86 and 87 which extend beyond the respective upper legs 58 and atop portions of shingles 30 , then are used to secure ridge vent 34 to roof decking 20 with mechanical fasteners (not shown).
[0018] Due to the use of the ridge vent braces of the invention, the number of which will depend on the actual length of the roof, the uppermost edge portions of the roof decking will not be able to warp or otherwise deform in a manner which could lead to leaking of the roof adjacent the ridge vent. That is, the uppermost edge portions are snugly captured in the base channels and, since the braces are stiff and substantially inflexible, the shape of the uppermost edge portions are maintained. Therefore, in accordance with the invention, it should be recognized that the ridge vent braces function to stiffen and carry the weight of the roof decking between the rafters, preventing bowing of the roof decking. In addition, the use of the ridge vent braces, avoids the need to install boards or studs between the rafters in order to directly nail down the uppermost edge of the roof decking such that employing the ridge vent bracing of the invention also ensures the unobstructed and efficient flow of ventilation air moving under the decking to the ridge vent. In the winter, this unobstructed flow of air occurs from the soffit to the ridge vent, keeping the underside of the roof sheeting at a modified temperature to aid in preventing ice damming.
[0019] Although described with reference to preferred embodiments of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. In general, the invention is only intended to be limited by the scope of the following claims.
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A brace for securing roof decking adjacent a roof ridge vent takes the than of an elongated channel, preferably a metal J-shaped channel, with the brace being wrapped around the upper edge portion of the roof decking at the roof ridge. The brace stiffens and carries the weight of the roof decking between the roof trusses or rafters, allowing an unobstructed flow of ventilation air under the decking and preventing bowing of the roof decking. The brace is at least partially covered by a line of shingles and then mounting flange portions of a ridge vent extend over each of the brace, decking edge and shingles.
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TECHNICAL FIELD
This invention relates generally to ion beam handling and more particularly to a gate for use in time-of-flight mass spectrometry.
BACKGROUND ART
This invention relates in general to ion beam handling in mass spectrometers and more particularly to ion gating in time-of-flight mass spectrometers (TOFMS). The apparatus and method of mass analysis described herein is an enhancement of the techniques that are referred to in the literature relating to mass spectrometry.
The analysis of ions by mass spectrometers is important, as mass spectrometers are instruments that are used to determine the chemical structures of molecules. In these instruments, molecules become positively or negatively charged in an ionization source and the masses of the resultant ions are determined in vacuum by a mass analyzer that measures their mass/charge (m/z) ratio. Mass analyzers come in a variety of types, including magnetic field (B), combined (double-focusing) electrical (E) and magnetic field (B), quadrupole (Q), ion cyclotron resonance (ICR), quadrupole ion storage trap, and time-of-flight (TOF) mass analyzers, which are of particular importance with respect to the invention disclosed herein. Each mass spectrometric method has a unique set of attributes. Thus, TOFMS is one mass spectrometric method that arose out of the evolution of the larger field of mass spectrometry.
The analysis of ions by TOFMS is, as the name suggests, based on the measurement of the flight times of ions from an initial position to a final position. Ions which have the same initial kinetic energy but different masses will separate when allowed to drift through a field free region.
Ions are conventionally extracted from an ion source in small packets. The ions acquire different velocities according to the mass-to-charge ratio of the ions. Lighter ions will arrive at a detector prior to high mass ions. Determining the time-of-flight of the ions across a propagation path permits the determination of the masses of different ions. The propagation path may be circular or helical, as in cyclotron resonance spectrometry, but typically linear propagation paths are used for TOFMS applications.
TOFMS is used to form a mass spectrum for ions contained in a sample of interest. Conventionally, the sample is divided into packets of ions that are launched along the propagation path using a pulse-and-wait approach. In releasing packets, one concern is that the lighter and faster ions of a trailing packet will pass the heavier and slower ions of a preceding packet. Using the traditional pulse-and-wait approach, the release of an ion packet as timed to ensure that the ions of a preceding packet reach the detector before any overlap can occur. Thus, the periods between packets is relatively long. If ions are being generated continuously, only a small percentage of the ions undergo detection. A significant amount of sample material is thereby wasted. The loss in efficiency and sensitivity can be reduced by storing ions that are generated between the launching of individual packets, but the storage approach carries some disadvantages.
Resolution is an important consideration in the design and operation of a mass spectrometer for ion analysis. The traditional pulse-and-wait approach in releasing packets of ions enables resolution of ions of different masses by separating the ions into discernible groups. However, other factors are also involved in determining the resolution of a mass spectrometry system. "Space resolution" is the ability of the system to resolve ions of different masses despite an initial spatial position distribution within an ion source from which the packets are extracted. Differences in starting position will affect the time required for traversing a propagation path. "Energy resolution" is the ability of the system to resolve ions of different mass despite an initial velocity distribution. Different starting velocities will affect the time required for traversing the propagation path.
In addition, two or more mass analyzers may be combined in a single instrument to form a tandem mass spectrometer (MS/MS, MS/MS/MS, etc.). The most common MS/MS instruments are four sector instruments (EBEB or BEEB), triple quadrupoles (QQQ), and hybrid instruments (EBQQ or BEQQ). The mass/charge ratio measured for a molecular ion is used to determine the molecular weight of a compound. In addition, molecular ions may dissociate at specific chemical bonds to form fragment ions. Mass/charge ratios of these fragment ions are used to elucidate the chemical structure of the molecule. Tandem mass spectrometers have a particular advantage for structural analysis in that the first mass analyzer (MS1) can be used to measure and select molecular ion from a mixture of molecules, while the second mass analyzer (MS2) can be used to record the structural fragments. In tandem instruments, a means is provided to induce fragmentation in the region between the two mass analyzers. The most common method employs a collision chamber filled with an inert gas, and is known as collision induced dissociation CID. Such collisions can be carried out at high (5-10 keV) or low (10-100 eV) kinetic energies, or may involve specific chemical (ion-molecule) reactions. Fragmentation may also be induced using laser beams (photodissociation), electron beams (electron induced dissociation), or through collisions with surfaces (surface induced dissociation). It is possible to perform such an analysis using a variety of types of mass analyzers including TOF mass analysis.
In a TOFMS instrument, molecular and fragment ions formed in the source are accelerated to a kinetic energy: ##EQU1## where e is the elemental charge, V is the potential across the source/accelerating region, m is the ion mass, and v is the ion velocity. These ions pass through a field-free drift region of length L with velocities given by equation 1. The time required for a particular ion to traverse the drift region is directly proportional to the square root of the mass/charge ratio: ##EQU2## Conversely, the mass/charge ratios of ions can be determined from their flight times according to the equation: ##EQU3## where a and b are constants which can be determined experimentally from the flight times of two or more ions of known mass/charge ratios.
Generally, TOF mass spectrometers have limited mass resolution. This arises because there may be uncertainties in the time that the ions were formed (time distribution), in their location in the accelerating field at the time they were formed (spatial distribution), and in their initial kinetic energy distributions prior to acceleration (energy distribution).
The first commercially successful TOFMS was based on an instrument described by Wiley and McLaren in 1955 (Wiley, W. C.; McLaren, I. H., Rev. Sci. Instrumen. 26 1150 (1955)). That instrument utilized electron impact (EI) ionization (which is limited to volatile samples) and a method for spatial and energy focusing known as time-lag focusing. In brief, molecules are first ionized by a pulsed (1-5 microsecond) electron beam. Spatial focusing was accomplished using multiple-stage acceleration of the ions. In the first stage, a low voltage (-150 V) drawout pulse is applied to the source region that compensates for ions formed at different locations, while the second (and other) stages complete the acceleration of the ions to their final kinetic energy (-3 keV ). A short time-delay (1-7 microseconds) between the ionization and drawout pulses compensates for different initial kinetic energies of the ions, and is designed to improve mass resolution. Because this method required a very fast (40 ns) rise time pulse in the source region, it was convenient to place the ion source at ground potential, while the drift region floats at -3 kV. The instrument was commercialized by Bendix Corporation as the model NA-2, and later by CVC Products (Rochester, N.Y.) as the model CVC-2000 mass spectrometer. The instrument has a practical mass range of 400 daltons and a mass resolution of 1/300, and is still commercially available.
There have been a number of variations on this instrument. Muga (TOFTEC, Gainsville) has described a velocity compaction technique for improving the mass resolution (Muga velocity compaction). Chatfield et al. (Chatfield FT-TOF) described a method for frequency modulation of gates placed at either end of the flight tube, and Fourier transformation to the time domain to obtain mass spectra. This method was designed to improve the duty cycle.
Cotter et al. (VanBreeman, R. B.: Snow, M.: Cotter, R. J., Int. J. Mass Spectrom. Ion Phys. 49 (1983) 35.; Tabet, J. C.; Cotter, R. J., Anal. Chem. 56 (1984) 1662; Olthoff, J. K.; Lys, I.: Demirev, P.: Cotter, R. J., Anal. Instrumen. 16 (1987) 93, modified a CVC 2000 time-of-flight mass spectrometer for infrared laser desorption of involatile biomolecules, using a Tachisto (Needham, Mass.) model 215G pulsed carbon dioxide laser. This group also constructed a pulsed liquid secondary time-of-flight mass spectrometer (liquid SIMS-TOF) utilizing a pulsed (1-5 microsecond) beam of 5 keV cesium ions, a liquid sample matrix, a symmetric push/pull arrangement for pulsed ion extraction (Olthoff, J. K.; Cotter, R. J., Anal. Chem. 59 (1987) 999-1002.; Olthoff, J. K.; Cotter, R. J., Nucl. Instrum. Meth. Phys. Res. B-26 (1987) 566-570. In both of these instruments, the time delay range between ion formation and extraction was extended to 5-50 microseconds, and was used to permit metastable fragmentation of large molecules prior to extraction from the source. This in turn reveals more structural information in the mass spectra.
The plasma desorption technique introduced by Macfarlane and Torgerson in 1974 (Macfarlane, R. D.; Skowronski, R. P.; Torgerson, D. F., Biochem. Biophys. Res Commoun. 60 (1974) 616.) formed ions on a planar surface placed at a voltage of 20 kV. Since there are no spatial uncertainties, ions are accelerated promptly to their final kinetic energies toward a parallel, grounded extraction grid, and then travel through a grounded drift region. High voltages are used, since mass resolution is proportional to U o /;eV, where the initial kinetic energy, U 0 / is of the order of a few electron volts. Plasma desorption mass spectrometers have been constructed at Rockefeller (Chait, B. T.; Field, F. H., J. Amer. Chem. Soc. 106 (1984) 193), Orsay (LeBeyec, Y.; Della Negra, S.; Deprun, C.; Vigny, P.; Giont, Y. M., Rev. Phys. Appl 15 (1980) 1631), Paris (Viari, A.; Ballini, J. P.; Vigny, P.; Shire, D.; Dousset, P., Biomed. Environ. Mass Spectrom, 14 (1987) 83), Upsalla (Hakansson, P.; Sundqvist B., Radiat. Eff. 61 (1982) 179) and Darmstadt (Becker, O.; Furstenau, N.; Krueger, F. R.; Weiss, G.; Wein, K., Nucl. Instrum. Methods 139 (1976) 195). A plasma desorption time-of-flight mass spectrometer has bee commercialized by BIO-ION Nordic (Upsalla, Sweden). Plasma desorption utilizes primary ion particles with kinetic energies in the MeV range to induce desorption/ionization. A similar instrument was constructed at Manitobe (Chain, B. T.; Standing, K. G., Int. J. Mass Spectrum. Ion Phys. 40 (198.1) 185) using primary ions in the keV range, but has not been commercialized.
Matrix-assited laser desorption, introduced by Tanaka et al. (Tanaka, K.; Waki, H.; Ido, Y.; Akita, S.; Yoshida, Y.; Yoshica, T., Rapid Commun. Mass Spectrom. 2 (1988) 151) and by Karas and Hillenkamp (Karas, M.; Hillenkamp, F., Anal. Chem. 60 (1988) 2299) utilizes TOFMS to measure the molecular weights of proteins in excess of 100,000 daltons. An instrument constructed at Rockefeller (Beavis, R. C.; Chait, B. T., Rapid Commun. Mass Spectrom. 3 (1989) 233) has been commercialized by VESTEC (Houston, Tex.), and employs prompt two-stage extraction of ions to an energy of 30 keV.
Time-of-flight instruments with a constant extraction field have also been utilized with multi-photon ionization, using short pulse lasers.
The instruments described thus far are linear time-of-flights, that is: there is no additional focusing after the ions are accelerated and allowed to enter the drift region. Two approaches to additional energy focusing have been utilized: those which pass the ion beam through an electrostatic energy filter.
The reflectron (or ion mirror) was first described by Mamyrin (Mamyrin, B. A.; Karatajev. V. J.; Shmikk, D. V.; Zagulin, V. A., Sov. Phys., JETP 37 (1973) 45). At the end of the drift region, ions enter a retarding field from which they are reflected back through the drift region at a slight angle. Improved mass resolution results from the fact that ions with larger kinetic energies must penetrate the reflecting field more deeply before being turned around. These faster ions than catch up with the slower ions at the detector and are focused. Reflectrons were used on the laser microprobe instrument introduced by Hillenkamp et al. (Hillenkamp, F.; Kaufmann, R.; Nitsche, R.; Unsold, E., Appl. Phys. 8 (1975) 341) and commercialized by Leybold Hereaus as the LAMMA (LAser Microprobe Mass Analyzer). A similar instrument was also commercialized by Cambridge Instruments as the IA ( Laser Ionization Mass Analyzer). Benninghoven (Benninghoven reflectron) has described a SIMS (secondary ion mass spectrometer) instrument that also utilizes a reflectron, and is currently being commercialized by Leybold Hereaus. A reflecting SIMS instrument has also been constructed by Standing (Standing, K. G.; Beavis, R.; Bollbach, G.; Ens, W.; Lafortune, F.; Main, D.; Schueler, B.; Tang, X.; Westmore, J. B., Anal. Instrumen. 16 (1987) 173).
Lebeyec (Della-Negra, S.; Lebeyec, Y., in Ion Formation from Organic Solids IFOS III, ed. by A. Benninghoven, pp 42-45, Springer-Verlag, Berlin (1986)) described a coaxial reflectron time-of-flight that reflects ions along the same path in the drift tube as the incoming ions, and records their arrival times on a channelplate detector with a centered hole that allows passage of the initial (unreflected) beam. This geometry was also utilized by Tanaka et al. (Tanaka, K.; Waki, H.; Ido, Y.; Akita, S.; Yoshida, T., Rapid Comun. Mass Spectrom. 2 (1988) 151) for matrix assisted laser desorption. Schlag et al. (Grotemeyer, J.; Schlag, E. W., Org. Mass Spectrom. 22 (1987) 758) have used a reflectron on a two-laser instrument. The first laser is used to ablate solid samples, while the second laser forms ions by multiphoton ionization. This instrument is currently available from Bruker. Wollnik et al. (Grix., R.; Kutscher, R.; Li, G.; Gruner, U.; Wollnik, H., Rapid Commun. Mass Spectrom. 2 (1988) 83) have described the use of reflectrons in combination with pulsed ion extraction, and achieved mass resolutions as high as 20,000 for small ions produced by electron impact ionization.
An alternative to reflectrons is the passage of ions through an electrostatic energy filter, similar to that used in double-focusing sector instruments. This approach was first described by Poschenroeder (Poschenroeder, W., Int. J. Mass Spectrom. Ion Phys. 6 (1971) 413). Sakurai et al. (Sakuri, T.; Fujita, Y; Matsuo, T.; Matsuda, H; Katakuse, I., Int. J. Mass Spectrom. Ion Processes 66 (1985) 283) have developed a time-of-flight instrument employing four electrostatic energy analyzers (ESA) in the time-of-flight path. At Michigan State, an instrument known as the ETOF was described that utilizes a standard ESA in the TOF analyzer (Michigan ETOF).
Lebeyec et al. (Della-Negra, S.; Lebeyec, Y., in Ion Formation from Organic Solids IFOS III, ed. by A. Benninghoven, pp 42-45, Springer-Verlag, Berlin (1986)) have described a technique known as correlated reflex spectra, which can provide information on the fragment ion arising from a selected molecular ion. In this technique, the neutral species arising from fragmentation in the flight tube are recorded by a detector behind the reflectron at the same flight time as their parent masses. Reflected ions are registered only when a neutral species is recorded within a preselected time window. Thus, the resultant spectra provide fragment ion (structural) information for a particular molecular ion. This technique has also been utilized by Standing (Standing, K. G.; Beavis, R.; Bollbach, G.; Ens, W.; Lafortune, F.; Main, D.; Schueler, B.; Tang, X.; Westmore, J. B., Anal. Instrumen. 16 (1987) 173).
Although TOF mass spectrometers do not scan the mass range, but record ions of all masses following each ionization event, this mode of operation has some analogy with the linked scans obtained on double-focusing sector instruments. In both instruments, MS/MS information is obtained at the expense of high resolution. In addition correlated reflex spectra can be obtained only on instruments which record single ions on each TOF cycle, and are therefore not compatible with methods (such as laser desorption) which produce high ion currents following each laser pulse.
New ionization techniques, such as plasma desorption (Macfarlane, R. D.; Skowronski, R. P.; Torgerson, D. F.; Biochem. Bios. Res. Commun. 60 (1974) 616), laser desorption (VanBreemen, R. B.; Snow, M.; Cotter, R. J., Int. J. Mass Spectrom. Ion Phys. 49 (1983) 35; Van der Peyl, G.J.Q.; Isa, K.; Haverkamp, J.; Kistemaker, P. G., Org. Mass Spectrom. 16 (1981) 416), fast atom bombardment (Barber, M.; Bordoli, R. S.; Sedwick, R. D.; Tyler, A. N., J. Chem. Soc., Chem. Commun. (1981) 325-326) and electrospray (Meng, C. K.; Mann, M.; Fenn, J. B., Z. Phys. D10 (1988) 361), have made it possible to examine the chemical structures of proteins and peptides, glycopeptides, glycolipids and other biological compounds without chemical derivatization. The molecular weights of intact proteins can be determined using matrix assisted laser desorption ionization (MALDI) on a TOF mass spectrometer or electrospray ionization. For more detailed structural analysis, proteins are generally cleaved chemically using CNBr or enzymatically using trypsinor other proteases. The resultant fragments, depending upon size, can be mapped using MALDI, plasma desorption or fast atom bombardment. In this case, the mixture of peptide fragments (digest) is examined directly resulting in a mass spectrum with a collection of molecular ion corresponding to the masses of each of the peptides. Finally, the amino acid sequences of the individual peptides which make up the whole protein can be determined by fractionation of the digest, followed by mass spectral analysis of each peptide to observe fragment ions that correspond to its sequence.
It is the sequencing of peptides for which tandem mass spectrometry has its major advantages. Generally, most of the new ionization techniques are successful in producing intact molecular ions, but not in producing fragmentation. In a tandem instrument the first mass analyzer passes parent ions (also referred to as "reactant ions") corresponding to molecules of the peptide of interest. These ions are activated toward fragmented in a collision chamber, and their fragmentation products extracted and focused into the second mass analyzer which records a fragment ion (or daughter ion) spectrum.
A conventional tandem TOFMS consists of two TOF analysis regions with an ion gate and a collision chamber between the two regions. Ions of interest may be selected with the ion gate before being activated in the collision cell. As in conventional TOFMS, ions of increasing mass have decreasing velocities and increasing flight times. Thus, the arrival time of ions at the ion gate at the end of the first TOF analysis region is dependent on the mass-to-charge ratio of the ions. If one opens the ion gate only at the arrival time of the ion mass of interest, then only ions of that mass-to-charge will be passed into the collision cell and the second TOF analysis region.
The arrival times of product ions at the end of the second TOF analysis region is dependent on the product ion mass because a reflectron is used. Because the flight time of an ion through a reflectron is dependent on the kinetic energy of the ion, and the kinetic energy of the product ions are dependent on their masses, the flight time of the product ions through the reflectron is dependent on their masses.
SUMMARY OF THE INVENTION
One of the advantages in using tandem TOFMS in a collisionally activated dissociation (CAD) type of experiment is that the molecular ions may fragment over a long period of time following activation. Useful fragmentations may occur for up to 10 us or even 100 us after activation in tandem TOFMS rather than typically 1 us in other types of tandem spectrometers. As a result, a lower activation energy is required and a greater percentage of the parent ions are observed to fragment. This results in a higher signal intensity in the daughter ion spectrum. To obtain such long useful fragmentation times, the activation step (which occurs in the collision cell) should occur near the source. Because the molecular ion is selected before collisional activation in a typical tandem spectrometer, the selector must also be near the source. This limits the ion selection resolution which can be obtained because in TOFMS the resolution is directly related to the distance between the ion source and the selector.
In tandem TOFMS, molecular ion selection is typically achieved by the use of pulsed deflection plates. However, the mass resolution of such selection is typically low (.sup.˜ 25). The term resolution as it is used here refers to the ability of the selector to pass a given mass ion--without perturbing its trajectory or flight time--while deflecting ions of greater or lesser mass out of the ion beam.
The purpose of the present invention is to achieve higher mass resolution selection than is available by conventional means without reduction in sensitivity. The present invention places the pulsed deflection plates at a position after the collision cell (as encountered by the ions). The products of an ion dissociation that occurs after the molecular ion has left the source will have the same velocity as the original ion. The product ions will therefore arrive at the ion selector at the same time as the original ion and will be passed by the gate (or not) just as the original ion would have been. Thus, it is not required that the ion selector be placed before the collision cell, but only that it be placed after the exit of the source. By placing the selector at a greater distance from the source, the resolution of molecular ion selection is increased and the long useful fragmentation time inherent to TOFMS is retained.
The invention is a specific design for a tandem TOF mass spectrometer incorporating two analyzers. This instrument incorporates Einsel lens focusing, a collision cell, and a patented (U.S. Pat. No. 4,731,532) two stage gridless reflector.
Other objects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description with reference to the accompanying drawings, all of which form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of prior art commonly referred to as a REFLEX spectrometer;
FIG. 2 is a diagram of an ion source, as used with the present invention;
FIG. 3 is a graph of the mass spectrum of angiotensin II showing the molecular ion at mass 1047 amu, using a prior art TOF system;
FIG. 4 is a view of the plate arrangement according to a conventional ion deflector, used in TOFMS;
FIG. 5A is a cross sectional view of a collision cell as used with a time-of-flight mass spectrometer;
FIG. 5B is an end view of the collision cell as used with a time-of-flight mass spectrometer;
FIG. 6A is a plot of the resolution of molecular ion selection as a function of length (l) of the deflection plates;
FIG. 6B is a plot of the resolution of molecular ion selection as a function of the length, L, between the ion source and the deflection plates;
FIG. 7 is a schematic view of the REFLEX spectrometer including the postselector;
FIG. 8 is an example timing diagram of the use of the postselector in the REFLEX spectrometer; and
FIG. 9 is a graph of a daughter ion spectrum of angiotensin II, obtained using a postselector according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With respect to FIG. 1, a prior art TOFMS 1 is shown, with a laser system 2, ion source 3, deflector 4, collision cell 16, reflector 5, linear detector 6, reflector detector 7 and a data acquisition unit 8. In FIG. 1, laser system 2 produces short (.sup.˜ 3 ns wide) pulses of laser radiation. The laser pulses generate ion packets from a solid sample in the source. These ion packets are accelerated through, and out of, the ion source 3 by an electrostatic field.
The molecular ion of interest can be selected using the deflector 4. While deflector 4 is energized, ions passing through it are deflected to a path which does not lead to detection. When deflector 4 is deenergized, ions may pass through it without being perturbed. As given by equation 2, the ions require some time to travel the distance L between the point of generation and the deflector. This time is dependent on the ion mass according to equation 2. Thus, by energizing and deenergizing deflector at appropriate times after the laser pulse, a given mass ion may be passed unperturbed whereas ions of greater or lesser mass are deflected out of the beam. Alternatively, all or a range of ion masses may be selected.
Selected ions enter collision cell 16. If desired, collision cell 16 is filled to some pressure with a collision gas. In such a case, the selected ions undergo collisions with the collision gas molecules and may become activated toward fragmentation. Selected ions and their fragments then drift through the spectrometer until they arrive at the linear detector 6. Alternatively, the reflector 5 may be used to reflect the ions so that they travel to the reflector detector 7. The mass and abundance of the ions is measured via the data acquisition system 8 as the flight time of the ions from the source 2 to one of the detectors 6 or 7 and the signal intensity at the detectors respectively.
With respect to FIG. 2, a diagram of an ion source 3 as used with the present invention is shown. Ion packets are generated by a laser pulse at the surface of the sample plate 9 which is biased to a high voltage (e.g. 20 kV). Extraction plate 10 is held at ground potential. The electric field resulting from the potential difference between elements 9 and 10 accelerates the generated ions toward extraction plate 10. Ions are focused by the electrostatic lens system 11, and steered in two dimensions by plates 12. Finally, deflection plates 4 are used to select ions of interest.
With respect to FIG. 3, a graph of the mass spectrum of angiotensin II showing the molecular ion at mass 1047 amu, using a prior art TOF system (REFLEX) is shown. This spectrum was recorded using reflector 5 and detector 7. As a result, it is possible to observe some ions (at apparent masses 902, 933, and 1030 amu) which are products of the dissociation of the molecular ions.
FIG. 4 is a view of the deflection plate arrangement according to the present invention. In TOFMS, ions of greater or lesser masses than the ion of interest are removed from the ion beam by deflecting these ions from the principal beam axis 15. This is accomplished by using deflection plates 13 and 14. In the deflection plate arrangement, two metal plates 13 and 14 are adjacent to one another, on opposite sides of the ion beam, and approximately parallel to the ion beam, to form the complete deflector assembly as shown in FIG. 4. By energizing plates 13 to +V and plate 14 to -V, ion packets are deflected from path 15 to path 15'. Ions deflected to path 15' are not detected and so are considered to be deselected. Ions which continue along path 15 are eventually detected and so are considered to be selected.
Ions passing between plates 13 and 14 are deflected by an angle: ##EQU4## where θ is the angle of deflection (as shown in FIG. 4), V is the voltage on the plates, and l is the length of the plates in the flight direction 15, q is the elemental charge, d is the distance between plates 13 and 14, and ε is the kinetic energy of the ion. Note that under a given set of conditions, one can obtain the same degree of deflection at, for example, half the voltage by doubling l or decreasing d by a factor of 2.
Typically, the values of these variables may be, q=1 elemental charge, V=700 V, l=10 mm, d=5 mm, and ε=20 keV. This leads to an angle of deflection from the energized device of 4°. This is the angle by which deselected ions are deflected. When the deflector is deenergized, V=0 V, thus the angle of deflection produced by the deenergized device is 0°. So, selected ions continue unperturbed and are eventually detected.
As discussed regarding FIG. 1, in prior art spectrometer 1, the deflection plates 4 are located between the source and collision cell 16. FIG. 5A is a cross sectional view of collision cell 16. As depicted in FIG. 5A, ions pass through collision cell 16 along a path which is parallel to path 19. Collision gas is fed into the collision cell through inlet 20 and exits the collision cell through orifices 17 and 18. Ions passing through the collision cell may have collisions with the collision gas in accordance with the collisional cross section of the ions and the pressure of the collision gas. The average number of collisions experienced by an ion can be estimated by: ##EQU5## where N c is the average number of collisions, r is the cross sectional radius of the ion, x is the length of the collision cell, P is the pressure in the collision cell, N is Avagadro's number, R is the universal gas constant, and T is the temperature of the gas. At a pressure, P, of 0.1 mbar, N c , would be about 6 collision depending on the cross section of the ion and the length, x, of the collision cell.
As a result of these collisions, some of the kinetic energy of the ions is converted into internal energy. Depending on the mass of the collision gas molecules and the kinetic energy and mass of the ion, on the order of 100 eV of kinetic energy may be converted to internal energy per collision. If enough internal energy is gained an ion may become activated toward fragmentation. Activated ions may later fragment to form product ions.
The kinetic energy lost by the ions is an important issue because this will affect the flight time of the ions and therefore their apparent masses. As a result, while there is some loss of mass resolution in collisionally activated dissociation (CAD) experiments, it is not typically of consequence in performing a tandem TOFMS analysis.
Once through the collision cell, ions continue to drift through the spectrometer until arriving at a detector. Activated ions may undergo fragmentation at some point between the collision cell and the detector. Fragmentation of an ion will typically lead to the production of one ion and one neutral species. The process of fragmentation will release a few eV of kinetic energy, so the product species may move somewhat faster or slower in the time of flight direction. However, because the molecular ions typically have a kinetic energy of 5-30 keV the few eV of kinetic energy released via fragmentation will have no practical influence on the mass analysis of the products. That is, the product species will have practically the same velocity as the molecular ion from which they were formed. Because they have the same velocity, product species will travel the same distance in the same amount of time as the parent ion and they will arrive at the deflector at the same time. If the deflector is deenergized at the time of arrival of the parent ion, both the parent and the daughter ions will pass through the deflector unperturbed. In this way, both the daughter ions and the parents from which they are formed are simultaneously selected or deselected.
As a result, the ion selector may be inserted into any position in a TOFMS system, between the source and analyzer region. For example, such a gate may be located in the position of deflection plates 4 at the end of source 3 or anywhere between collision cell 16 and reflector 5.
The advantages of using a postselector of the present invention over conventional preselectors are demonstrated in FIGS. 6A and 6B. FIGS. 6A and 6B shows plots relating the resolution of molecular ion selection to the length, l, of the selector deflection plates, and to the distance, L, between the source and the selector, respectively. When using deflection plates to select ions, the resolution of molecular ion selection can be approximated as: ##EQU6## where R is the mass resolution of the gating device, L is the distance from the source to the gating device, and l is the effective length of the deflection plates--including its associated electric field--in the direction of ion motion. Thus, as shown in FIG. 6A, the resolution decreases rapidly with increasing deflection plate length. In contrast as depicted in FIG. 6B, the resolution increases linearly with the distance between the source and deflector. Clearly from FIG. 6B and equation 6, if the position of the collision cell is to remain fixed, improved ion selection resolution can be achieved only by postselecting ions--i.e. by placing the deflector after the collision cell--rather than by preselecting the ions--i.e. by placing the deflector before the collision cell.
With respect to FIG. 7, the previously described REFLEX instrument 1 now including a postselector 100 according to the present invention. Postselector 100 is located between two TOF analysis regions 200 and 201. In the first of the TOF analysis regions 200, the parent ions--the original ions produced from the source 3--are collisionally activated and mass analyzed. Although deflector 4 is still present, it remains inactive or is used only for coarse ion gating. The parent ion of interest is selected by gating the ion beam using postselector 100. Using postselector 100 it is possible to allow only those parent ions of interest to pass from the first to the second analysis region. In analysis region 201, the daughter ions--generated by the dissociation of the selected parent ion--are mass analyzed and recorded via reflector 5, detector 7, and data acquisition system 8.
In prior art instrument 1, the preselector was located before the collision cell at a distance from the source of about 25 cm. Also, the effective length l of the device was about 5 mm. As a result, the resolution of the device was only about 25. As depicted in FIG. 7, the postselector is positioned farther from the source than the collision cell 16. By placing the postselector about 60 cm from the source and decreasing its effective length to about 3 mm, a molecular ion selection resolution of better than 110 is obtained.
With respect to FIG. 8, an example timing diagram is shown. From the time of ion generation until a short time before the ion of interest enters the postselector 100, the potentials on the plates 13 and 14 are held at +700 V and -700 V respectively as discussed with respect to FIG. 4. This causes all ions of lower mass than the ions of interest to be deflected out of the beam. At time tin the ions of interest arrive at the gate 100 and at time tout, the ions exit the gate. Some time td before the ions of interest arrive at gate 100, the potential on plates 13 and 14 are brought to ground potential. Plates 13 and 14 are held at ground potential until some short time td after the ions of interest leave the gate. Thereafter, the potentials on the plates 13 and 14 are maintained at +/-700 V. This causes all ions of higher mass than the ions of interest to be deflected out of the beam.
With respect to FIG. 9, a graph of a daughter ion spectrum of angiotensin II, obtained using a postselector in a similar manner as described above is shown. The mass of the daughter ions are determined via their flight time from source 2 to detector 7. When a single stage reflectron is used, the relationship between parent ion mass, daughter ion mass, and total daughter ion flight time is given by: ##EQU7## where L 1 is the distance from the source to the reflectron, L 2 is the length of the reflectron, L 3 is the distance from the reflectron to the detector, V 1 is the source potential, V 2 is the reflectron potential, M is the parent ion mass, m is the daughter ion mass, and q is the elemental charge. A similar relationship holds when a two stage reflector such as that of the REFLEX spectrometer is used. Using such an equation, it is possible to calibrate a spectrum like that of FIG. 9 and thereby assign masses to the observed signals.
While the foregoing embodiments of the invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention.
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A method and apparatus for analyzing ions by determining times of flight including using a collision cell to activate ions toward fragmentation and a deflector to direct ions away from their otherwise intended or parallel course. Deflectors are used as gates, so that particular ions may be selected for deflection, while others are allowed to continue along their parallel or otherwise straight path, from the ion source, through a flight tube, and eventually, to a detector. According to the present invention, a postselector, in the form of two deflection plates is used as an ion deflector and is encountered by ions after the collision cell as they progress through the spectrometer.
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BACKGROUND OF THE INVENTION
Quarry blasting for rock, such as limestone, granite, and other igneous rocks conventionally uses ANFO as the explosive. ANFO is a mixture of approximately 94% ammonium nitrate and 6% fuel oil.
In quarry blasting, a plurality of boreholes are drilled in a predetermined pattern or array. For example, the holes are drilled in a 10 foot by 10 foot pattern, with 3-9 inch diameters and depths of 20-90 feet. A cast booster with a blasting cap is placed in the bottom of the hole, and ANFO is added into the hole up to level approximately eight feet from the surface. Small rock chips from 1/4-1/2 inch in size, commonly called stemming, is placed in the top of the hole to confine the ANFO. The boreholes are detonated sequentially so as to provide free faces toward which the broken rock moves.
The energy and power factors vary, depending upon the geological structures being blasted. For example, limestone requires a power factor of 2-5 pounds per ton.
ANFO is also used in open pit mining, for such minerals as coal, taconite, copper and gold. In open pit mines, the boreholes are typically 10-15 inches in diameter, drilled in a 28×28 feet pattern to produce 40-60 feet faces.
ANFO is a popular explosive in both quarry mining and open pit mining due to its low cost. However, ANFO has several limitations. When the boreholes are filled with solid columns of ANFO, only 60-70% efficiency is achieved as the detonation rises in the borehole. Accordingly, in such a straight ANFO shot, the 30-40% waste must be considered to avoid oversize material which is detrimental to the digging and crushing equipment used after the blast to process the shot rock. Also, such waste increases the cost of producing the shot rock.
Methods for overcoming the inefficiencies of solid ANFO shot and to enhance its action in the borehole have been developed. One such method is the use of solid AP propellant which has typically been used as a rocket fuel. Because of various nuclear disarmament treaties and the requirements that missiles be disarmed, this material has essentially become an excess material. It must be disposed of and traditionally has been disposed of as a waste by open air firing of the propellant motors or open burning of the propellant. However, these disposal methods are no longer viable because of environmental considerations.
U.S. Pat. No. 5,261,327 proposes the use of such solid AP propellant with ANFO as a blasting composition for quarry blasting. As disclosed therein, the solid AP propellant is a mixture of about 70% ammonium perchlorate, 20% aluminum and 10% binder.
However, the use of such solid propellant has become problematic because, firstly, the amount of the solid propellant remaining has diminished significantly. In addition, it is relatively expensive. Thus, even if one were to formulate additional solid propellant, its cost lends against its desirability for use in quarry blasting.
SUMMARY OF THE INVENTION
We have discovered a new and improved blasting composition and a method for surface mine blasting. In particular, the present invention provides a composition which provides results as good as or better than the conventional combination of ANFO with AP propellant and it is substantially less expensive.
Specifically, the present composition comprises from about 13 to 15 weight percent unrefined petroleum wax, from about 15 to 25 weight percent aluminum powder, from about 10 to 52 weight percent sodium perchlorate and from about 10 to 52 weight percent ammonium nitrate. As used herein, all weights and percent by weight are based on the total weight of the composition.
The inventive blasting composition is used in combination with ANFO in essentially a conventional manner, for example, as described in U.S. Pat. No. 5,261,327 in place of the solid AP propellant as described in this patent.
Also disclosed is a blasting system comprising ANFO as a first component and the inventive composition as a second component. The relative amounts of first to second components is from about 70:30 to 30:70 and, preferably, from about 40±2:60±2 to 60±2:40±2.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 5 show test configuration and FIGS. 2 through 4 and 6 are graphical depictions of the results of the tests performed.
DETAILED DESCRIPTION OF THE INVENTION
The propellant of the present invention is preferably a hot melt type composition comprising petroleum wax, atomized aluminum powder, sodium perchlorate and aluminum nitrate. The wax operates as a binder which consolidates the propellant. The aluminum powder increases the thermochemical heat release during explosion, the sodium perchlorate and ammonium nitrate act as oxidizers.
The composition may be prepared by first melting the petroleum wax, generally at a temperature of from about 140° to 150° F. The aluminum powder is admixed into the melted wax with stirring. The sodium perchlorate is then added with stirring. Finally, the ammonium nitrate is added into the mixture with stirring. All of these operations may be carried out at atmospheric pressure.
After mixing, the propellant may be cooled on a continuous belt, granulated, and packaged, or poured into appropriate molds, e.g., plastic bags and the like and allowed to cool and harden.
In use, for example, in using the explosive composition in a quarry or open pit mine, a plurality of bore holes having predetermined diameters and depths are drilled in a predetermined pattern or array. A primary charge, such as, a cast booster is lowered into the bottom of the hole and wire leads from the primary charge extend upwardly to the top of the hole and are secured to prevent the wires from falling into the hole.
ANFO is then poured into the hole to cover the primary charge to a desired depth, e.g., for example, 12 inches. The inventive propellant packaged either in stick or crushed form is placed in the hole and an additional layer of ANFO is added on top of the propellant. The layering of the additional ANFO is then added and layering of ANFO and the inventive propellant is repeated until the bore hole is filled to approximately 10 feet from the surface. A layer of ANFO may then be added into the hole.
Generally, bore holes are wired in series and after the normal and appropriate safety precautions are taken, the blast is initiated by actuating the primary charge or charges. Specific details of such use as noted are conventional and are described in U.S. Pat. No. 5,261,327.
A series of tests were carried out to evaluate the inventive composition as follows:
Four different compositions of the inventive propellant were prepared containing varying amounts of the ingredients. The composition was prepared by first melting the petroleum wax at 140° F. to 150° F. Aluminum powder was then added and the mixture was stirred at 20 rpm for 5 minutes at atmospheric pressure. Then, the specified amount of sodium perchlorate was added and the mixture again stirred at 20 rpm for 5 minutes at atmospheric pressure. One half of the specified amount of ammonium nitrate was added the mixture again stirred at 20 rpm for 10 minutes at atmospheric pressure. Thereafter, the remaining half of the specified amount of ammonium nitrate was stirred into the mixture at 20 rpm for 10 minutes. The mixture temperature was maintained at 140° to 150° F. The propellant was then cast into the polyethylene bags while hot and allowed to cool and harden.
The wax used was an unrefined petroleum wax designated 142N from Chevron Corporation. It exhibited a congealing point of 129° F. per ASTI-D938, a case penetration value of 71 at 77° F. per ASTI-D937, an oil content of 469 0 +399 0 per ASTI-D3235 and ASTI-D721, respectively, and a color of <4.5 per ASTI-D1500. The end paraffin weight of the wax determined by gas chromatography was 349 0 , and average molecular weight is 461. This is an unrefined wax having a light brown to dark color. It contains organic sulfur compounds as impurities. The specific gravity is about 0.92 g/cc at 77° F. The wax is a non-elastomeric relatively small molecule as compared, for example, to a cured organic polymer. In addition, in contrast to the conventional cured polymer which exhibits well defined viscoelastic properties, the wax merely softens and melts to a liquid. In addition, the cured polymer conventionally used for solid AP propellant as commercially available, costs anywhere from 10 to 50 times that of the wax.
The aluminum powder used was Alan-Togo America ATA 101. This is a free-flowing, atomized aluminum powder having a regular particle size with a specific gravity of about 2.7 g/cc. It is substantially pure metallic aluminum having an average particle diameter of 18 microns. This material was formerly known as Alan MD101. Its main purpose is to raise the heat of combustion, enhance fluidity and increase the density of the propellant composition.
The sodium perchlorate used was from Western Electro Chemical Company (WECCO) NaC104. It has a specific gravity of 2.54 and an approximate particle size of 300 microns. Sodium perchlorate is the most economical perchlorate commercially available today and is about one third the cost of ammonium perchlorate. Sodium perchlorate is also more dense than ammonium perchlorate, i.e., 2.54 g/cc versus 1.95 g/cc. While sodium perchlorate is hygroscopic, this hygroscopicity is counteracted to an extent by the mixing with hot wax.
The ammonium nitrate used (NaH 4 NO 3 ) has a specific gravity of 1.725 g/cc, an approximate drill size of 1,000-2,000 microns. It is readily available because of its use as agricultural fertilizer. While the pure material is hygroscopic, the drilling coating process renders it free flowing. The grade used in the present test was E-2 grade manufactured by Northern California Fertilizer Company.
Five different explosive tests were carried out and crater blast evaluations made thereof. The compositions were as follows:
Composition 1 ANFO;
Composition 2 equals a 40/60 blend of composition number 722/ANFO;
Composition 3 a 40/60 blend of composition number 724/ANFO;
Composition 4 a 40/60 blend of composition number 726/ANFO;
Composition 5 a 40/60 blend of composition number 727/ANFO.
The blasting compositions used in the tests were as follows:
______________________________________ Composition NumberIngredient 722 724 726 727______________________________________Wax 15% 15% 13% 13%Aluminum powder 25% 15% 25% 25%Sodium perchlorate 10% 10% 10% 52%Ammonium nitrate 50% 60% 52% 10%______________________________________
In commercial explosive applications, three factors are generally of primary importance to the user, namely, rock mass fragmentation, rock mass displacement and excessive ground vibration. A series of tests using the inventive composition in combination with ANFO were evaluated. Generally, a direct indication of the power of an explosive is its ability to displace the rock mass. High vibration levels can be an indication of overconfinement or inability of an explosive to displace the rock mass generally low vibration levels are desirable in all types of blasting.
A series of individual hole crater blasts were carried out in order to evaluate the inventive composition as described above. Single hole crater tests were conducted to compare the strength of the various test explosives. In each test, a control hole of ANFO was used to establish a base line for comparison. For each test, the charge, weight and depth of burial was constant.
FIG. 1 shows the crater test configuration.
The crater displacement of each of the compositions compared to ANFO is depicted in FIG. 2.
A comparison of crater vibration is shown in FIG. 3.
FIG. 4 depicts an overall comparison of crater displacement for two runs of each of the inventive compositions.
As can be seen from the data depicted in these figures, the inventive compositions performed equivalent to or at least as good as ANFO alone.
The displacement was determined using high speed cameras set up appropriately to provide face movement, ground swell and stemming ejection data. The cameras had a framing rate of up to 400 frames/second and produced a picture every 2.5 ms. Accurate calculations of face movement and ground swell velocity were obtained by positioning targets on the face, bench top and pit floor at specific locations. Development of the film and linkage to a computer allowed precise calculations and raw data.
Face displacement evaluations were then carried out to evaluate the inventive composition. Generally, in most explosive applications for breaking rock, it is advantageous to blast to a free face. The free face ideally is parallel to the axis of the explosive column for optimum energy distribution. Under such conditions, the explosive functions in a different manner than it does in crater blasting. When the explosive column detonates, the energy is directed toward the free face. The face bends out from the middle of the column and breaks. Breakage occurs from high compressional stress intensities within the rock mass and as stress waves rebound off the free rock face, the rock is placed under tension and if the intensity is sufficiently high, the rock fails. Once the rock has been broken, it is pushed out by the high pressure gases from the detonation. The displacement velocity and range is directly related to the gas production characteristics of the explosive. Single hole face displacement trials were conducted to evaluate the test explosives when shooting to a free face. FIG. 5 shows a typical test configuration for face displacement evaluation as used.
FIG. 6 shows a comparison of the displacements of the various inventive compositions with the ANFO standard. As shown in FIG. 6, the displaced volume for each of the inventive compositions was substantially the same or somewhat better than that for ANFO alone.
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An improved blasting composition comprising from about 13 to 15 weight percent unrefined petroleum wax, from about 15 to 20 weight percent aluminum powder, from about 10 to 52 weight percent sodium perchlorate and from about 10 to 52 weight percent ammonium nitrate. The blasting composition may be used in combination with ANFO and in place of conventional solid AP propellants and represents an economical alternative thereto.
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BACKGROUND OF THE INVENTION
The present invention relates to a system for automatically regulating the engine speed of an internal combustion engine for automobiles, and more particularly to a system for regulating the idling speed.
The idling speed of the engine is initially regulated to a predetermined set speed in the manufacturing shop. Thereafter, the idling speed increases gradually, because the friction of the engine decreases as the mileage of the automobile increases. Therefore, the idling speed must be regulated to the set speed by operating the regulating screw according to the variation of the idling speed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a system which automatically regulates the idling speed to a predetermined set speed.
Another object of the present invention is to provide a system for automatically regulating the idling speed which may also have effects of the throttle opener and the dash pot.
According to the present invention, there is provided a system for regulating the engine speed of an internal combustion engine having a carburetor and a throttle valve in the carburetor, comprising an electro-mechanical actuator comprising an electric motor for maintaining said throttle valve to an open state, a speed sensor for detecting the speed of the engine, comparing circuit means connected to the speed sensor, setting circuit means for applying a standard level to the comparing circuit means for comparing the output of the speed sensor with the standard level, detecting means for detecting the number of revolutions of the electric motor, control circuit means for producing a pair of output signals for a time period in dependency on outputs of the comparing circuit means and of the detecting means, driving circuit means for driving the electric motor for increasing and decreasing the open state of the throttle valve in dependency on the output signals of the control circuit means.
Other objects and features of the present invention will become apparent from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a system of the present invention;
FIG. 2 is a block diagram showing a brush pulse sensor;
FIG. 3 is a perspective view showing an actuator and a carburetor;
FIG. 4 is a perspective view showing the actuator in detail;
FIGS. 5 I-5 V shows waveforms at various locations of the brush pulse sensor;
FIG. 6 is a chart showing an operation of the actuator;
FIG. 7 is a graph showing a range of misfiring of an engine;
FIGS. 8 and 9 are graphs showing relations between a rod of the actuator, the throttle valve and the engine speed; and
FIGS. 10a and 10b show an example of the control circuit in the system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, an internal combustion engine 1 is provided with a speed sensor 2 which is connected to the crank shaft of the engine by pulleys 3 and 4 and a belt 5. A carburetor 6 has a throttle valve 7 and an air cleaner 8. The shaft of the throttle valve 7 is adapted to be operated by an actuator 9. The output terminal of the speed sensor 2 is connected to a comparator 11 of a control circuit 10.
A standard idling speed setting circuit 12 is connected to the comparator 11 for comparing the idling speed of the engine 1 with the standard idling speed. The comparator 11 is connected to a control circuit 13 which is in turn connected to a driving circuit 14. The driving circuit 14 is connected to the actuator 9 and connected to the ground through a resistor 16. A brush pulse sensor 17 is connected between the driving circuit 14 and the resistor 16. The output of the brush pulse sensor 17 is connected to the control circuit 13.
An air-conditioner sensor 18 for detecting the operation of the air-conditioner is connected to the standard idling speed setting circuit 12. An ignition sensor 20 and a car speed sensor 21 are connected to the control circuit 13.
Referring to FIG. 2, the brush pulse sensor 17 comprises a filter 22, amplifier 23, comparator 24, and one-shot multivibrator 25 which is connected to a counter 15 (FIG. 10a) of the control circuit 13.
Referring to FIG. 3, throttle levers 31 and 32 are secured to the shaft 30 of the throttle valve 7. The throttle lever 31 is connected to an accelerator pedal through an accelerator cable 33 and biased by a spring 35 connected between a hole 34 and the carburetor body so as to close the throttle valve 7. The lever 32 abuts on the end of a rod 36 of the actuator 9.
As shown in FIG. 4, the rod 36 is secured to a gear 41 and supported by a bearing 38. The rod 36 has an actuating plate 53 and a screw portion 37 which is threaded into a stationary fixed nut 39. A pair of limit switches 51 and 52 are provided on opposite sides of the plate. A feeder roller 40 is engaged with the rod 36 to feed a current. The gear 41 is made of plastic and the rod 36 is insulated from the housing. Accordingly, when the rod 36 is in contact with the lever 32, the current flows through the rod 36 and lever 32, so that the contact may be electrically detected. The gear 41 engages with a small gear 42 secured to a shaft 43 of a large gear 44. The gear 44 engages with a small gear 45 secured to a shaft 47 of a direct current motor 46.
The motor 46 operates to rotate the shaft 47 in one direction or in the opposite direction according to signals which will be hereinafter described. The rotation of the shaft 47 is transmitted to the rod 36 through gears 45, 44, 42 and 41. The gear 41 always engages the gear 42 since the gear 41 is sufficiently elongated in the axial direction. The rod 36 moves in the axial direction because of the engagement of the screw portion 37 with the nut 39. Thus, the rod 36 projects or retracts by the signals. Projection of the rod 36 causes the shaft 30 of the throttle valve 7 to rotate in the throttle valve open direction. Thus, the engine speed increases. To the contrary, when the rod 36 is retracted, the throttle valve 7 is closed by the spring 35, so that the engine speed decreases.
The plate 53 of the rod 36 actuates to open the limit switch 51 or 52 at the limit stroke end, which means the limitation of the operation of the throttle valve 7 for the idling speed. The switches 51 and 52 are provided disposed in a motor driving circuit for the motor 46. Accordingly, the motor stops on the opening of one of the switches and the operation of the throttle valve 7 stops.
The operation of the system will be hereinafter described with reference to FIGS. 6, 10a and 10b. When an ignition switch 54 (FIG. 10a) is opened, the rod 36 of the actuator 9 is in the retracted position F and the throttle lever 32 abuts on a stopper 50 as shown in FIG. 6. The limit switch 52 is opened by the plate 53. When the ignition switch 54 is closed, a starting circuit 55 operates to produce an output signal for a predetermined time. The signal is applied to the driving circuit 14 by a lead 56 to operate the circuit. A driving current flows through the switch 51, motor 46 and diode 57, so that the motor 46 rotates to project the rod 36. As shown in FIG. 6 at modes 2 and 3, the rod 36 is projected to a position C which is beyond a normal idling position D, whereby the throttle valve 7 is opened greater than the normal idling opening degree for starting the engine. The mode 3 shows the cold engine start condition where a choke valve is closed. Since the throttle valve is opened according to the closing of the choke valve, the lever 32 is spaced apart from the rod 36.
When the engine speed is higher than a predetermined rate n 1 in the stopping condition of the car, the output voltage of the speed sensor 2 exceeds a predetermined standard level, so that the output of a comparator 58 changes to a high level. The output is applied to an AND gate 60 by a lead 61. On the other hand, the output of the speed sensor 2 is converted to digital signals by an A/D converter 62 in dependency on the output voltage. The outputs of the A/D converter 62 are applied to a logic circuit 63 having the operation of a truth table.
Describing the operation of the brush pulse sensor 17, the direct current passing through the motor 46 varies according to the variation of the resistance between brushes and slip-rings of the commutator of the motor 46. The variation of the current is detected by the resistor 16 and applied to the brush pulse sensor 17. For example, in the case that the inner resistance of the motor 46 is 20 ohm, the resistance of the resistor 16 is 1 ohm and the current flowing the motor is 0.3 A, the voltage at the resistance 16 is 0.3 V. The variation at the position I in FIG. 2 is shown in FIG. 5 I. The waveform is changed to the waveform of FIG. 5 II by the filter 22. The waveform is further dealt with by the amplifier 23, comparator 24 and one-shot multivibrator 25, so that the waveform is changed as shown in FIG. 5 III, FIG. 5 IV and FIG. 5 V. By counting output pulses FIG. 5 V of the sensor 17, the number of revolutions of the motor 46, that is the amount of the projection of the rod 36 may be detected.
The counter 15 counts the pulses from the brush pulse sensor 17 to produce time signals Q 1 , Q 2 , Q 3 and Q 4 which have different time periods respectively. The time signals Q 1 to Q 4 are applied to gates in the logic circuit 63 for opening the gates for the respective time period. The logic circuit 63 operates to change the output signal on a lead 64 to a 1 for a time period which is determined by the outputs of the A/D converter 62, that is the idling speed of the engine. Thus, the output of the AND gate 60 goes to a high level which is applied to the driving circuit 14 through an AND gate 65. The driving current flows through the switch 52, motor 46 and diode 66, so that the motor 46 rotates reversely. Thus, the rod 36 is retracted. When the count of the counter 15 reaches a predetermined amount and the output Q 3 changes to a high level, a transistor Tr 1 becomes conducting. Thus, the AND gate 65 is closed, so that the motor 46 stops. By such an operation, the idling speed is decreased to the standard speed n 1 .
If the idling speed is lower than the idling speed n 1 , the output of a comparator 68 changes to a high level which is applied to an AND gate 70 by a lead 71a. The output of the AND gate 70 changes to a 1 for a predetermined time by signals from the logic circuit 63 and comparator 68 in a manner similar to the above described operation. The output of the AND gate 70 is applied to the driving circuit 14 through an AND gate 71. Thus, the motor 46 rotates so as to project the rod 36. When the output Q 3 of the counter 15 changes to a high lever, a transistor Tr 2 becomes conducting. Therefore, the AND gate 71 is closed, so that the idling speed can be controlled to the idling speed n 1 .
Modes 4 and 5 show such control operations. In the mode 4, the lever 32 rotated together with the choke valve is gradually returned to the position D as the warming up of the engine progresses.
When the car is started and the output of a car speed sensor 72 exceeds a predetermined level, the output of a car speed detecting circuit 73 changes to 0 for a predetermined time thereby closing AND gates 65 and 71. When the throttle valve 7 is opened, the lever 32 separates from the rod 36. Thus, the contact switch 74 composed of the roller 40, rod 36 and lever 32 is opened. The contact switch 74 is connected to a rod projecting circuit 75 for the dash pot. The output on lead 76 of the circuit 75 goes to a high level by the signal of the switch 74. When the engine speed exceeds a predetermined speed n 2 , an output on a lead 78 of a comparator 77 changes to a high level. Thus, an output of a rod projecting circuit 75a (FIG. 10b) changes to a high level for a predetermined time, and the output of an AND gate 78a goes to a high level, so that the motor 46 is operated so as to project the rod 36 to the middle position C. Mode 6 shows this operation. The Roman numerals in FIGS. 10a and 10b indicate corresponding connection of the lines; that is the same numeral indicates that those lines are connected to each other.
When the car speed n 2 decreases below the predetermined speed, the output on the lead 78 is inverted. The inverted signal is sent to a rod retracting circuit 80. The circuit 80 produces an intermittent output on a lead 81 for a predetermined time. The motor 46 is intermittently operated, so that the rod 36 is slowly retracted to the position D. Thus, dash pot effect may be provided. Mode 8 of FIG. 6 and FIG. 8 show the dash pot operation.
When the engine speed exceeds a predetermined speed n 3 , an output of a comparator 82 changes to a high level, which is applied to a throttle opener control circuit 83. A rod projecting circuit 84 operates to generate an output signal for a predetermined time. The output signal is applied to an AND gate 85 and to a control circuit 86 through a semiconductor switch 87. The output of the AND gate 85 is applied to the driving circuit 14. Thus, the rod 36 is projected. When the output Q 3 changes to a low level, the switch 87 is opened. Thus, the control circuit 86 produces an output, which renders a transistor Tr 3 conductive. Therefore, the motor 46 stops and the rod 36 is at the projected position B as shown at mode 7 in FIG. 6. When the engine speed decreases below the speed n 3 , the output of the comparator 82 is inverted. By such an inversion of the output, a rod retracting circuit 88 of the throttle opener control circuit 83 operates to produce an output for a predetermined time. The output is applied to an AND gate 90 and to the control circuit 86 through the switch 87. Thus, the driving circuit 14 is operated to retract the rod 36. The motor 46 is stopped by the output Q 3 and the conduction of the transistor Tr 3 . Accordingly, the rod 36 is retracted to the position C. Thereafter, by the signal of the contact switch 74, the rod retracting circuit 88 operates to retract slowly the rod 36 to the position D as described above. Mode 9 and FIG. 9 show such a throttle opener effect.
The throttle opener effects to prevent misfiring of the engine. Misfiring occurs in the negative torque condition of the engine, such a condition as where the throttle valve 7 is closed on the descent. FIG. 7 shows the range in which the misfiring will occur. Since the throttle opener keeps the throttle valve 7 in an open condition for a predetermined time at a deceleration, misfiring may be prevented.
Now hereinafter describing the operation for an air-conditioner, the air-conditioner 91 is operated by closing an air-conditioner switch 92. By closing the switch 92, semiconductor switches 93, 94 and 95 are closed, so that each set value of the comparators 58,68 and the A/D converter 62 is raised. Therefore, the motor 46 is operated to project the rod 36 so as to increase the idling speed to a raised level. When the switch 92 is opened, the rod 36 is retracted to the position D. Modes 10 and 11 show such an operation.
When the ignition switch 54 is opened, a running-on preventing circuit 96 operates to produce an output, which is applied to the AND gate 65 by a lead 97. The output of the AND gate actuates the driving circuit 14, so that the rod 36 is further retracted to the initial position F as shown in mode 12. The lever 32 abuts on the stopper 50. Since the rod 36 is separated from the lever 32 and the lever abuts the stopper, the throttle valve is kept in the closed position. Thus, the running-on of the engine may be prevented.
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A system for regulating the engine speed of an internal combustion engine having a carburetor and a throttle valve in the carburetor. The system comprises an electro-mechanical actuator having an electric motor and a push rod engaged with a throttle lever for maintaining the throttle valve to an open state, a speed sensor for detecting the speed of the engine, and an electronic control circuit. A detecting means is provided for producing a pulse train according to the number of the rotations of the electric motor. The electronic control circuit comprises a comparing circuit connected to the speed sensor, a level setting circuit for applying a standard level to the comparing circuit for comparing the output of the speed sensor with the standard level, a counter for counting the output of the detecting means, and a control circuit for producing a pair of output signals in dependency on the outputs of the comparing circuit and of the counter. Output signals of the control circuit are applied to a driving circuit for driving the electric motor for projecting or retracting the push rod, so that the throttle valve is opened or closed in dependency on the output signals of the speed sensor for controlling the engine speed to the standard level.
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This is a continuation of application Ser. No. 07/747,024, filed Aug. 19, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of manufacturing a laminated transparent substrate, and more particularly to a method manufacturing a laminated transparent substrate having a controlled optical property.
2. Description of the Related Art
Laminated transparent substrates formed by sandwiching thermo-plastic resin between a pair of transparent substrates, such as glass plates, are used for several usages. One of the producing methods therefor is adhering a plurality of glass plates with a resin layer or layers. Another of the producing methods is applying pressure from both sides of a resin layer to develop uniaxial compression, for example by rolling, to provide a controlled optical property such as birefringence.
Autoclaving is employed for manufacturing laminated safety glass plate for use as a front glass in automobiles, etc. In autoclaving, a workpiece is heated under pressure application. Heating is clone by an oil bath or an electric furnace.
Some color superhomeotropic (CSH) liquid crystal display devices use an optical compensation plate having a negative optical anisotropy for compensating the birefringence (positive optical anisotropy) of the liquid crystal layer for compensating the optical anisotropy of a liquid crystal layer formed of a certain liquid crystal and having a certain thickness, a transparent birefringence plate having the opposite optical anisotropy is desired as the compensation plate. It is, however, not easy to produce a birefringence plate having the desired optical anisotropy.
SUMMARY OF THE INVENTION
An object of this invention is to provide a method of manufacturing a laminated transparent substrate having a controlled optical property such as birefringence.
According to an aspect of this invention, there is provided a method of manufacturing a laminated transparent substrate comprising the steps of: sandwiching between transparent substrates ionomer resin to form a laminated structure and sealing it in a reduced pressure atmosphere; applying heat and pressure to said laminated structure; and rapidly decreasing the pressure applied to said laminated structure, and then rapidly decreasing the temperature of said laminated structure.
According to this method, a laminated transparent substrate having a desired optical property can be easily provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing patterns of temperature and pressure control for explaining a method of manufacturing a laminated transparent substrate according to an embodiment of this invention.
FIG. 2 is a schematic cross sectional diagram showing the structure off lamination to be loaded in an autoclave apparatus.
FIG. 3 is a graph showing pattern of temperature and pressure control in a conventional autoclaving method.
FIG. 4 is a schematic diagram showing a liquid crystal display device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before describing the embodiments of this invention, autoclaving will be described referring to FIGS. 2 and 3.
As shown in FIG. 2, a thermo-plastic resin film 3 such as a polyvinylbutyral resin film is sandwiched between a pair of glass plates 1 and 2 to form a laminated structure. This laminated structure is loaded in an evacuatable hermetic bag 4. The glass plates 1 and 2 are, for example, made of reinforced glass plates. The material of the resin film 3 is selected from transparent resins having high strength. The inside of the bag 4 is evacuated through an open end 5 then the open end 5 is sealed. The laminated structure which is vacuum-packed in the bag 4 in this way is then loaded in an autoclave apparatus. The temperature and pressure in the autoclave apparatus are then controlled to vary as shown in FIG. 3. Namely, at the same time as the commencement of pressure application, the temperature is raised. When the pressure arrives at a predetermined value, it is kept at the constant pressure. When the temperature then arrives at a predetermined value, it is kept at the constant temperature.
When a predetermined time period has passed while keeping the predetermined pressure and temperature, first the temperature is lowered. When the temperature has decreased to a predetermined temperature, then the pressure is rapidly decreased to zero. A pair of glass plates are adhered by a resin film by such process.
There is a method of forming a uniaxial anisotropic optical medium having the principal axis in the thickness direction of the film, by sandwiching a resin film between a pair of transparent substrates such as glass plates and applying pressure and temperature thereto.
For example ionomer resins known as HI-MILAN (trade name), available from Mitsui Du-pont Polychemical, Japan, which are formed by bridging ethylene acryl acid or ethylene metacryl acid copolymer molecules with metal ions have such property.
Thus, it can be considered to manufacture a transparent optical medium having a desired anisotropic refractive index distribution by sandwiching a HI-MILAN resin film between a pair of glass plates and subjecting it to pressure and heat treatment. When a HI-MILAN resin is treated by the autoclave method, however, the resin film may become opaque and it is difficult to obtain a transparent optical medium.
In case of an optical compensation plate for use in a liquid crystal display utilizing polarizers, when milky opaque, i.e. scattering of light, occurs, the contrast becomes significantly low. Also, when the thickness of the resin film is thick, such as 0.5 mm, the processed film may become a white film.
When a resin film having been subjected to pressure and heat treatment is gradually cooled, it can be considered that the alignment state of the molecules become disturbed during the gradual cooling. Thus, the optical property of the resin film obtained after the gradual lowering of the temperature and the pressure becomes different from those when the pressure and the heat application treatment has done.
It is considered that when the resin film is quenched from a heated state to a low temperature, the molecular alignment at a high temperature state can be conserved. However, it is not easy to rapidly lower the temperature when the pressure is kept at a high value. If such an apparatus is made, the cost of it will become very high.
Thus, first the pressure is rapidly lowered and then the temperature is rapidly lowered. It can be considered that the alignment state of the molecules obtained by the pressure and heat application treatment can be substantially quenched as it is by such a treatment.
When the temperature is rapidly cooled after the pressure is rapidly lowered, it is considered that the alignment state of the molecules in the treated film may not be significantly varied, and may be conserved.
Hereinunder, embodiments of this invention will be described, which treats an ionomer resin film by applying pressure and heal, to obtain a laminated transparent substrate. The ionomer resin is Formed by bridging ethylene acryl acid or ethylene metacryl acid copolymer molecules with metal ions such as sodium ions.
As shown in FIG. 2, a HI-MILAN film 3 is sandwiched between a pair glass plates i and 2 and loaded in an evacuatable bag 4. Then, the bag 4 is sealed after evacuation. The bag 4 thus vacuum-packed is then loaded in an autoclave apparatus.
The temperature and the pressure in the autoclave apparatus are then controlled as shown in FIG. 1. Namely, the temperature is gradually raised from the room temperature to a predetermined temperature of 100-150° C., and also the pressure in the autoclave apparatus is raised to a predetermined pressure of 1-5 atms. In this step, first the pressure reaches the predetermined value of 1-5 atms, and then the gradually heated temperature reaches the predetermined value of 100-150° C. When the temperature and the pressure reach the predetermined values, they are kept constant at these constant values thereafter. When treatment at the predetermined temperature and pressure has been done for a predetermined time period (for example, for about 30 min.), first the pressure is lowered rapidly. For example, the pressure in the autoclave apparatus is rapidly lowered while the temperature is kept at the high temperature. After the pressure has been decreased, the temperature is then rapidly decreased. For example, the vacuum packed lamination structure is taken out from the pressure-lowered autoclave apparatus, and then it is swiftly transferred into a circulation type low temperature furnace kept at -20° C. The laminated structure is kept in the low temperature furnace for about 30 minutes or more.
The laminated transparent substrate thus treated shows the predetermined optical property, while keeping the transparent state.
It can be considered that molecules in the film realize the predetermined aligned state in the predetermined pressure and heat application step. If this state can be quenched, an optical device having the desired anisotropy can be obtained.
Occurrence of milky opaque of the transparent substrate can be suppressed by the manufacturing methods as described above.
Examples of the above embodiment will be described below. Laminated transparent substrate are made under the following conditions.
______________________________________thickness of the HI-MILAN sheet 0.5 mmthickness of glass plate (per one plate) 0.7 mmautoclaving temperature 120° C.autoclaving pressure 3 kg/cm.sup.2temperature before quenchingafter unloading from autoclaving furnace ca 100° C.temperature of low temperature furnace -20° C.______________________________________
The optical anisotropy Δn obtained were -1.4×10 -3 for HI-MILAN 1601 (Na ion type), -0.9×10 -3 for HI-MILAN 1605 (Na ion type), -1.3×10 -3 for HI-MILAN 1555 (Na ion type), -0.9×10 -3 for HI-MILAN 0707 (Na ion type) and -0.9×10 -3 for HI-MILAN AM 7311 (Mg ion type). The haze of the manufactured laminated transparent substrate was about 0.2%.
For comparison, laminated transparent substrate which were cooled naturally to the room temperature without quenching according to the conventional method were also made. The haze of the conventionally made laminated transparent substrates was about 1.5%.
Accordingly, a clear improvement was found in the examples of the present embodiment.
Further, it is possible to anneal the treated laminated substrate at a temperature higher than the use temperature, e.g. room temperature, and lower than the treatment temperature before quench, e.g. ca 100° C.
FIG. 4 shows a liquid crystal display device. A homeotropic liquid crystal layer 13 is sandwiched between a pair of glass substrates 12 and 14 provided with electrodes. A pair of crossed polarizers 11 and 16 having crossed polarization axes P1 and P2 are positioned outside the liquid crystal cell. An optical compensator film 15 manufactured according to the above-described embodiment is inserted between the liquid crystal cell 12, 13, 14 and one of the polarizers 16.
When the liquid crystal molecules in the liquid crystal layer 13 is aligned perpendicular to the substrates. A positive optical anisotropy is established. The compensator plate 15 has a negative optical anisotropy to compensate the positive optical anisotropy of the liquid crystal layer 13.
Although description has been made along the embodiment of this invention, the present invention is not limited thereto. For example, such ionomer resin films utilizing metal ions other than sodium ion can be employed and processed in a similar manner. Here, however, the ionomer resin film using sodium ion has a larger difference in the magnitudes of the refractive indice for the ordinary ray and extraordinary ray, than the ionomer resin films using other metal ions such as magnesium ion. Therefore, the ionomer resin film utilizing sodium ion can realize a predetermined refractive index difference by a thinner thickness. The ionomer resin film utilizing sodium ion has a tendency of lowering the transparency. Thus, the method of the above embodiments is particularly effective.
It will be obvious for those skilled in the art that various changes, alterations, combinations and improvements are possible within the scope of this invention.
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A method of manufacturing a laminated transparent substrate comprising the steps of sandwiching between transparent glass substrates ionomer resin formed by bridging ethylenemetacryl acid copolymars with sodium ions, to form a laminated structure and sealing it in a reduced pressure atmosphere; applying heat and pressure to said laminated structure; rapidly decreasing the pressure applied to said laminated structure; and then rapidly decreasing the temperature of said laminated structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an electric road motor vehicle with a switchable winding electric motor propulsion system. The present invention also generally relates to an electric motor propulsion system for a vehicle, in particular for a vehicle which does not travel on rails, and the electric motor of which has a rotary field winding with a switchable winding.
2. Background Information
DE-A-41 33 059 and the publication "VDI Berichte" (No. 878, 1991, Pages 611-622) describe vehicles which do not travel on rails and are driven by electric motors, where the wheels of the vehicle are propelled individually by electric motors. The electric motors are rotary field motors with a rotary field winding, the rotary field winding being divided into several phase windings which are fed from a common converter or from several converters corresponding to the individual motors with phase-shifted, pulsating driver currents. The pulsating driver currents can be alternating currents, but they can also be direct currents generated with a pulse wave shape. The converters, which are electronic converters which control the pulsation rate and possibly also the amplitude of the driver currents by means of electric semiconductor valves, are for their part controlled by the vehicle control system, e.g. by means of an accelerator pedal or a similar device. The converters are powered by an on-board direct current system which, as described in the above referenced publications, can be a generator powered by an internal combustion engine, but can also be a rechargeable storage battery.
The electric motors in question must generally be designed for comparatively high levels of performance when they are used for vehicle propulsion. But the electric motors must generally simultaneously be designed so that they are as compact as possible. The pulsation frequency at which the driver currents are generated by the converter must also generally be relatively high (e.g. 2 KHz), so that they can regulate both the traction operation of the vehicle and the motor currents with sufficient accuracy. Although rotary field motors of any type can be used for the electric propulsion of a motor vehicle as described above, permanent magnet external-rotor motors have been found to be particularly well-suited to the task. DE-A-42 44 721, for example, discloses that a permanent magnet external-rotor motor can be cooled by an integrated cooling circuit, and the output stage solid state switching device of the converter can be located near the rotary field winding of the internal stator of the motor. Such motors have approximately the shape of a flat circular cylinder, whereby the connecting elements of the windings and of the solid state switching device are located on an axial end wall of the stator.
The operating characteristics, e.g. the torque and speed of rotation, are a function of the electric loading generated by the driver currents in the rotary field winding. EP-A-340 686 discloses that there can be separate converters corresponding to the phase windings of a rotary field motor, to which different numbers of phase windings and different circuit configurations can be connected by means of a number of controllable switches. By changing the number of phase windings connected in series, the torque and the maximum speed of rotation which can be achieved by the motor can be adjusted to the operating conditions. The system disclosed in EP-A-340 686 of course makes possible the desired optimization of the efficiency of the propulsion system, but it is comparatively complex and expensive.
OBJECT OF THE INVENTION
An object of the present invention is to provide an electric motor propulsion system for a vehicle in which the circuit configuration in which the phase windings of an electric motor with a rotary field winding are fed by driver currents can also be modified during operation. The manufacturing costs in terms of parts for this system should also be kept as low as possible.
SUMMARY OF THE INVENTION
The present invention, in accordance with at least one preferred embodiment, is based on an electric motor propulsion system for a vehicle, comprising:
at least one electric motor with a rotary field winding which is divided into several phase windings,
an electronic converter system which delivers pulsating driver currents of different phases to several output terminal connections,
a system of mechanical switches connecting the phase windings of the electric motor to the output terminal connections, by means of which the number of phase windings connected to each of the output terminal connections can be changed,
an actuator system for the actuation of the switches, and
a control circuit which controls the actuator system.
On such an electric motor propulsion system, the present invention teaches, in accordance with at least one preferred embodiment, that the control circuit also controls the converter system and reduces the amplitude of the driver currents supplied to the output terminal connections, while the control circuit changes the position of the switches by controlling the actuator system.
The present invention makes it possible to distribute the driver currents to a changeable number of phase windings, and thus to optimize the efficiency of the electric motor over a rather wide range of operating parameters. For example, by splitting the driver currents supplied by the converter system over two or more phase windings, the maximum speed of rotation of the motor can be increased at the expense of its torque by the reduction of the electric loading which occurs when the currents are split.
On the other hand, by connecting the phase windings in series, the torque can be increased at the expense of the maximum achievable speed of rotation. On a rotary field motor designed for three phases, this can be achieved by a switchover of the phase windings between a delta connection and a star connection, whereby a higher torque can be achieved in a star or "wye" connection of the phase windings, while higher maximum speeds of rotation can be achieved with the delta connection. Preferably, the switchover is appropriately performed automatically by the control circuit, e.g. as a function of the instantaneous speed of vehicle travel. For example, the motor can be operated in a star connection at a lower speed of travel, and in a delta connection at a higher speed of travel.
The switchover of the switching system preferably occurs during operation of the vehicle, and as a rule preferably during an acceleration phase. Since the switches of the switching system are also carrying the driver currents during traction operation, the switches should preferably be designed so that they are appropriate to the power levels which have to be switched, i.e. for voltages on the order of magnitude of 1,000 V and currents on the order of magnitude of 100 A, using conventional technology. Such switches would be expensive and bulky, which would run contrary to the stated requirement for small drive units. The present invention proceeds on the assumption that with the electronic semiconductor valves of the converters, components are already available which can switch the required electric power. The control circuit provided in the context of the invention guarantees that the semiconductor valves of the converters deactivate the driver currents while the switches also controlled by the control circuit switch the phase windings, for example, during the switchover between the star connection and the delta connection. In this manner, the switches can be designed so that they are smaller and more lightweight, since they need only be sized for stationary flowing currents, and their contacts are not exposed to any arcing wear or similar phenomena.
Theoretically, to reduce the contact load, it is sufficient if the current and/or voltage amplitude at the outputs of the converters is reduced for the duration of the switchover process, so that the driver power or current is reduced only for the duration of the switchover. But it has been determined that the period of time during which the switchover process reduces the traction of the electric motor can be kept so short (e.g. 20 to 30 msec), that the interruption of traction is not noticeable in the operation of the vehicle. Therefore the driver currents can be appropriately deactivated completely for the duration of the switching of the switches.
The actuator system not only tends to require a specified period of time to switch the switches, but it also tends to require a setup time or lead time, on account of the spring excursions in the switch contacts and the inertia of the switch contacts. The duration of the interruption of traction can be reduced if the control circuit delays the deactivation of the driver currents by the converter system in relation to the activation of the actuator system. That makes it possible for the actuator system to compensate for idle motions, spring excursions etc., before the driver currents are actually deactivated.
In one preferred embodiment of the present invention, the switching system connected to the phase windings of the electric motor and the actuator system intended for the activation of the switching system are mounted directly on the electric motor. In this manner, the number of connecting lines to which the motor module must be connected can be reduced. Such connecting lines can generally require detachable connections, and therefore increase the complexity of manufacture, assembly and installation.
The actuator system can comprise an actuator which is common to all the switches of the switching system, and is in particular combined with all the switches into a single component. But it can also be constructed of several modular units, each of which has a separate actuator of the actuator system. In this latter version, the invention also teaches that it is appropriate to connect or combine the actuator with the modular unit into a separate unit which can be mounted on the electric motor. Both versions have the advantage that they can be installed easily.
The switches of the switching system described above each preferably have a moving contact which is driven by the actuator system, and at least one stationary contact with which the moving contact can be brought into contact. To form transfer switches, pairs of stationary contacts with which the moving contact can be placed in contact in alternation can also be provided. The stationary contacts can be components of the units combined with the actuators described above. But since, under some circumstances, this can require additional detachable connections between the stationary contacts and the phase windings of the motor, the invention teaches that in one preferred embodiment, the stationary contacts of each switch are mounted directly on the electric motor, so that the switch units comprise only the moving contacts, and in addition to the actuator, they may also include a connection element for a detachable connection to the output terminal connections of the converter system.
The actuators provided for the actuation of the individual switches or of all the switches can have different designs, and can be selected primarily as a function of the available space and the required actuation speed. For example, the actuators can have an output mechanism which rotates, but in particular one which pivots in an oscillating fashion, and on which the moving contact is mounted. Alternatively, the actuator can have an output mechanism which is connected to the moving contact and which executes a linear actuation motion. The latter variant in particular is very easy to construct with simple and reliable means, e.g. in the form of a toothed rack which forms the output mechanism and is engaged with a pinion which is driven in rotation. An electric motor or an electromagnet with a rotating armature, for example, is particularly appropriate for driving such a pinion.
To guarantee reliable operation, the contacts in the closed position of the switch should preferably be held in contact with one another under a predetermined minimum force. The application forces can be generated by suitable spring systems, and instead or in addition to the springs, can be generated by the actuators, which in this case are permanently excited by the control circuit. If there are spring means to generate the application forces, the actuator for the reaction forces exerted by the switch is preferably designed to be irreversible, or self-locking. When the actuator is designed as an electric motor, it can be realized in a simple manner by an irreversible transmission, e.g. in the form of a worm gear transmission. The actuator can be locked in position mechanically in the closed position of the switch, but the locking can also be accomplished by permanent excitation of the actuator. Hydraulic or pneumatic actuators can be locked in position by sealing their pressure medium work chambers. A variant in which the contact application forces are applied by spring means, but which still makes do without a actuator which absorbs the reaction forces, takes advantage of the bidirectional top dead center characteristics of a bistable spring which, starting from an unstable middle position, generates spring forces toward both directions of movement. Bistable springs of this type can be used both for on-off switches and for transfer switches.
In addition to electric motors and electromagnets as auxiliary power sources, cylinder-piston units which are actuated by fluid overpressure or underpressure can also be provided. Both pneumatic and hydraulic units are suitable.
The control circuit can control the actuator system in an open-loop control circuit. To prevent inadvertent wrong operation and any short circuits which may result from such wrong operation, the invention teaches that in one preferred embodiment, corresponding to the output mechanism there is a displacement sensor which detects the position of the output mechanism, and the control sensor responds to the displacement sensor. The displacement sensor can be designed as a simple limit switch, but it can also be a displacement sensor which determines distance coordinates, and which then makes it possible for the control circuit to regulate the position of the output mechanism.
The mechanical switches can be appropriately utilized as safety switches, in addition to the electronic solenoid valves of the converter system, so that in the event of possible defects or malfunctions of the electronic system, they can cut the power supply to the drive motor. If the switches are designed as transfer switches, it is therefore appropriate to provide measures whereby they can be switched by means of the control circuit into a neutral position in which no contact is closed. The neutral position can be defined by a mechanical stop or a similar arrangement. But a position regulation action of the type described above can also be used to define the middle position.
The above discussed embodiments of the present invention will be described further hereinbelow with reference to the accompanying figures. When the word "invention" is used in this specification, the word "invention" includes "inventions", that is, the plural of "invention". By stating "invention", the Applicant does not in any way admit that the present application does not include more than one patentably and non-obviously distinct invention, and maintains that this application may include more than one patentably and non-obviously distinct invention. The Applicant hereby asserts that the disclosure of this application may include more than one invention, and, in the event that there is more than one invention, that these inventions may be patentable and non-obvious one with respect to the other.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained below in greater detail with reference to the embodiments illustrated in the accompanying figures.
FIG. 1 is a block diagram of an electric motor propulsion system for an automotive vehicle;
FIG. 2 is a diagram showing a switching system which switches the rotary field winding of an electric motor of the propulsion system illustrated in FIG. 1 between the star connection and the delta connection;
FIG. 3 is a block diagram of a variant of the electric motor propulsion system illustrated in FIG. 1;
FIG. 4 is a schematic view in cross section of a switch which can be actuated by an electric motor, as it can be used in the electric motor propulsion systems illustrated in FIGS. 1 to 3;
FIG. 5 is a schematic overhead view of the transfer switch illustrated in FIG. 4;
FIG. 6 is a variant of the transfer switch illustrated in FIG. 4 which can be actuated by en electric motor;
FIG. 7 is a schematic overhead view of the transfer switch illustrated in FIG. 6;
FIG. 8 shows an additional variant of a transfer switch which can be used in the electric motor propulsion systems illustrated in FIGS. 1 and 2, and is driven by an electromagnet, and
FIG. 9 shows yet another variant of an transfer switch which can be used in the electric motor propulsion systems illustrated in FIGS. 1 to 3, and which is driven by a pneumatic or hydraulic piston-cylinder unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The electric motor propulsion system illustrated by means of the block diagram in FIG. 1 for an automotive vehicle can comprise an electric motor 1, the multi-phase winding 5 of which, here composed of three phase windings 3, is preferably connected by means of a switching system 7 to a converter 9. The converter 9 is preferably connected to an energy source 11 on board the vehicle, e.g. a rechargeable battery or a generator driven by an internal combustion engine, and at its output terminal connections L1, L2 and L3, which are preferably phase-shifted from one another by 120 degrees, it generates pulsed driver currents for the excitation of the phase windings 3 of the electric motor 1. The driver currents generated by the converter 9 can be alternating currents or pulse-shaped direct currents. The energy source 11 can supply direct currents or alternating currents, which are preferably converted by semiconductor valves of the converter 9 into the pulsed driver currents with changeable pulsation frequency, and preferably also with changeable amplitude. A vehicle control system not shown in any greater detail, and which can be influenced by means of an accelerator pedal which is operated by the driver of the vehicle, for example, can preferably determine the frequency and amplitude of the driver currents.
Although it is possible to drive several wheels of a drive axle of the vehicle, possibly by means of a differential transmission or a similar system, using only a single electric motor, preference is given to the use of separate electric motors for the individual wheels of the vehicle. For their part, these electric motors are preferably fed by a common converter or separate converters which correspond to the individual electric motors by means of likewise separate switching systems. The electric motor can be a conventional rotary field motor, which can also have separate exciter windings in addition to the rotary field winding. But it is particularly appropriate, as illustrated in FIG. 1, to use a permanent magnet external-rotor motor with a stator 13 carrying the rotary field winding 5 and a rotor 15, e.g. a pot-shaped rotor, which on its circumference surrounding the stator 13 has a number of permanent magnets 16 located next to one another with alternating polarity. The permanent magnets 16 preferably lie opposite radially opposite poles of the rotary field winding 5 which are not illustrated in any further detail. Such an electric motor has a comparatively high output with small dimensions, and conventionally has at least approximately the shape of a flat circular cylinder.
To optimize the efficiency of the electric motor 1, the rotary field winding 5 can be switched by means of the switching system 7 between a star (or "wye") connection and a delta connection. As a result of the operation of one and the same electric motor 1, alternately in a star connection and in a delta connection, the electric motor 1 can be more efficiently adjusted to meet the demands of the current operating conditions. When operated in the star connection, the electric motor can generally achieve a higher torque, but the higher torque essentially comes at the expense of a reduction in the maximum speed which can be reached. On the other hand, when the motor is operated in the delta connection, it can reach a higher maximum speed, but at the expense of reduced torque. The transfer switch of the switching system can operate as a function of the vehicle speed for example, so that the electric motor 1 is operated in the star connection up to a specified vehicle speed, and in the delta connection above that speed. Other control strategies, which result in the switchover of the switching system 7 as a function of the torque, are also conceivable.
FIG. 2 shows details of the schematic diagram of the switching system 7. L1, L2 and L3 designate respectively the output terminal connections, and thus the phases, of the converter 9. M designates a connection of the converter 9 which is connected to frame (i.e. possibly earth or ground) potential for the connection to a neutral point of the rotary field winding which is formed in the star connection. The winding terminal connections of the phase winding 3 connected to the output terminal connection L1 are designated U1 and U2. The phase winding connected to the output terminal connection L2 has the winding terminal connections V1 and V2, while the phase winding connected to the output terminal connection L3 has the winding terminal connections W1 and W2. In the illustrated embodiment, the switching system 7 has three mechanical transfer switches S1, S2 and S3, each of which has one moving contact 17 and two stationary contacts 19, 21. The moving contacts 17 of each of the three switches S1, S2 and S3 are preferably connected in cyclic interchange with each one of the winding terminal connections, in this case the winding terminal connections W2, U2 and V2. The stationary contacts corresponding to the moving contacts 17 of the individual switches S1, S2 and S3 are preferably connected to respective other phase windings 3, and namely to their winding terminal connections U1, V1 and W1 not connected to the moving contacts 17.
The stationary contacts 21 of two of the switches, in this case the switches S2 and S3, are preferably connected together with the stationary connections 19 of these switches to each of the phase windings 3, and namely to the winding terminal connection V2 or W2 not connected to the stationary contact 19. The stationary contact 21 of the remaining switch, in this case of the switch S1, is preferably connected to the frame potential M. FIG. 2 shows the moving contacts 17 in the delta connection, in which they are in contact with the stationary contacts 19 which are connected to the winding terminal connections U1, V1 and W1 and to the output connections L1, L2 and L3. When the moving contacts 17 in contact with the stationary contacts 21 are switched, the phase windings 3 in the star connection are connected to the output terminal connections L1, L2 and L3 and the frame potential M is simultaneously connected to the neutral point of this star connection.
In the embodiment illustrated in FIG. 1, the switches S1, S2 and S3 of the switching system 7, including an actuator 25 which drives the moving contacts 17, are preferably attached to the stator 13 of the electric motor 1, and therefore essentially form a single unit with the electric motor 1. The connection elements 27, e.g. plug contacts or terminal screws for the detachable connection with the output terminal connections L1, L2 and L3 of the converter 9, are also a component of this unit. The switches S1, S2 and S3 can all be combined into one unit. But the unit of the switching system 7, as shown at 29 in FIG. 1, can also be composed of several switch modules. Regardless of the design and construction of the switching system 7, however, the actuator 25 is preferably common to all the switches S1, S2 and S3, and is preferably connected by means of suitable force transmission means, indicated at 31 in FIG. 1, to the moving contacts 17 of the switches S1, S2 and S3. The force transmission means 31 can be rods, cams, flexible cables or similar devices.
The actuator 25 is preferably controlled by a control circuit 33 which can be a component of the above-mentioned vehicle control system. The control system 33 preferably responds to sensors 35 which, for their part, measure the parameters which describe the condition of the vehicle. For example, the sensors 35 can supply information which represents the actual or requested torque, or the vehicle speed or similar characteristics. The control circuit 33 switches the actuator 25, as a function of this information, as explained above, to the delta connection position or to the star connection position of the switching system 7.
But the control circuit 33 also includes the converter 9. Simultaneously with the control signal which effects the switchover of the actuator 25, the control circuit 33 transmits an additional control signal to the converter 9, which signal deactivates all the driver currents to the output connections L1, L2 and L3 for the duration of the control signal fed to the actuator 25, and thus for the duration of the switchover process, during which the moving contacts 17 are moved between the stationary contacts. The electrical semiconductor valves which are already present in the converter 9 are preferably used for the deactivation of the driver currents. The mechanical contacts of the switching system 7 therefore need only be designed for the stationary current load of the driver currents. In particular, the contacts of the switching system 7 need only be sized for significantly lower contact wear.
There can be some idle motion in the actuation displacement of the actuator 25 toward the moving contacts, and the actuator 25 can be subjected to certain inertia effects which delay the beginning of the actual movement of the moving contacts 17 with respect to the initiation of the control signal by the control circuit 33 which controls the actuator 25. The control circuit 33 preferably comprises delaying means which accordingly delay the control signal which is transmitted to the converter and deactivates the driver currents with respect to the control signal transmitted to the actuator 25. Although the interruption of the traction of the electric motor 1 caused by the switchover of the switching system 7 is comparatively brief and is thus negligible, in this manner the duration of the interruption of traction can be reduced even further.
As shown at 37, there can be a position sensor which corresponds to the actuator 25, and the task of which is to detect the current position of the output mechanism 31. The sensor 37 preferably supplies the control circuit 33 with feedback signals which make it possible to monitor the current setting of the switching system 7. The sensor 37 can be a simple limit switch, but the sensor can also be designed as a continuously operating displacement sensor, one which can supply current position signals as part of a position regulating loop of the control circuit 33.
The switches S1, S2 and S3 of the switching system 7 can also preferably be set by means of the control circuit 33, possibly using the signal supplied by the sensor 37, to a middle position, in which the moving contact 17 does not contact any of the stationary contacts 19, 21. In the middle position, the electric motor 1 is essentially completely separated from the output terminal connections L1, L2 and L3 and from the connection M. The switching system 7 can thus be used as a mechanical disconnector, in addition to the electrical semiconductor valves of the converter 9 as safety switches, which make it possible to disconnect the electric motor 1 completely from the converter 9, e.g. in the event of a defect or malfunction of the converter 9.
FIG. 3 illustrates a variant of the electric motor propulsion system illustrated in FIG. 1, which also makes possible a switchover from star to delta connections as illustrated in FIG. 2. Components which are functionally equivalent are identified by the same reference numbers used in FIGS. 1 and 2, and are further identified by the letter "a" for clarity. Reference is also made to the description of FIGS. 1 and 2 to explain the construction and function of the system.
While in the propulsion system illustrated in FIG. 1, all the switches of the switching system correspond to a common actuator, in the embodiment illustrated in FIG. 3, the switches S1, S2 and S3 are designed as module 29a, each of which comprises a separate actuator. Accordingly, the moving contacts 17a of these switches are connected to the actuator 25a by means of separate force transmission means 31a. The modules 29a, including the corresponding actuators 25a, are preferably assembled together with detachable connection elements 27a into a single unit, and are located on the stator 13a of the electric motor 1a. Although not shown in FIG. 3, each of the actuators 25a can comprise a position sensor, like the one shown at 37 on the propulsion system illustrated in FIG. 1.
Embodiments of actuators are explained below, as they can be used to advantage in the vehicle propulsion systems described above and illustrated in FIGS. 1 to 3. In the actuators explained below, functionally equivalent components are identified with the same reference numbers, and a letter is added to the number for clarity. The explanation also refers to the preceding explanation of these components.
FIGS. 4 and 5 illustrate a switch module 29b which is attached to a base part 39 of the stator of the electric motor. The stationary contacts 19b, 21b of the module 29b are mounted directly on the base part 39 by means of insulating mounts 41, while the moving contact 17b is provided on a resilient contact arm 43 which projects radially in relation to the axis of rotation of an output shaft 45 of the actuator 25b from the output shaft 45. The actuator 25b comprises a small electric motor 47 with a downstream transmission 49 which drives the output shaft 45 and which can pivot or rotate around the axis of the output shaft 45. The connection terminal element 27b for the detachable connection of the converter is attached to a housing 51 which encloses the actuator 25b and the contacts 17b, 19b and 21b so that it accessible from outside. For the connection of the moving contact 17b to the phase windings of the electric motor, an additional terminal connection element 53 is attached with insulation in the base part 39, which additional connection element is connected to the contact 17b by means of a flexible lead 55 or similar device so that it is electrically conductive, but still movable.
The actuator 25b provides sufficient application forces in the closed positions of the switch, in which the moving contact 17b is alternately in contact with one of the stationary contacts 19b or 21b. For this purpose, the electric motor 47 is either continuously excited by means of the control circuit (33 in FIG. 1) which controls it, or the transmission 49 is designed as an irreversible transmission in relation to the reaction forces of the output shaft 45, so that the spring forces of the spring element 54 press the contacts against one another without any reverse rotation of the output shaft 45.
FIGS. 4 and 5 illustrate a module of the type explained with reference to FIG. 3. It is apparent that the output shaft 45 can be extended to activate several switches, so that the actuator 25b can also be used for the version of the vehicle propulsion system illustrated in FIG. 1.
FIGS. 6 and 7 illustrate a variant of a switch module 29c which differs from the version illustrated in FIGS. 4 and 5 primarily in that the actuator 25c, instead of an output shaft driven in rotational motion, drives the moving switch contact 17c by means of an output rod 53 which moves in a linear fashion. The output rod 53 in turn preferably bears the moving contact 17c on a resilient arm 43c, while the stationary contacts 19c, 21c are mounted by means of insulator elements 41c directly on the base part 39c of the stator of the electric motor. The actuator 25c is preferably designed as an electric motor propulsion unit, and comprises, for example, an electric motor or an electromagnet with a rotating armature which drives a pinion 57 engaged with the teeth 55 of the output rod 53. Stable limit positions of the output rod 53 can be guaranteed by a bistable spring 59, which preferably snaps out of a middle, unstable position resiliently in both directions into stable limit positions. In the stable limit positions, one of which is illustrated in FIG. 7, the resilient arm 43c which supports the moving contact 17c and projects from the output rod 53 provides defined contact application pressures. It goes without saying that the application forces which create a rigid contact between the contact 17c and the output rod 53 can also generate elastic application forces. Since the stable limit position of the output rod 53 is essentially guaranteed by the bistable spring 59, there is essentially no need for a limit position looking by the electric motor propulsion system of the actuator 25c. Instead of the bistable spring 59, however, a position locking can also be achieved by the electric motor propulsion system, as illustrated and explained with reference to FIGS. 4 and 5. There can also be bistable position locks of the type explained with reference to the version illustrated in FIGS. 4 and 5. In the version illustrated in FIGS. 6 and 7, the actuator 25c can also be common to several switches and/or modules, e.g. so that the output rod 53 carries several moving contacts 17c.
FIG. 8 illustrates an additional variant in which, in contrast to the variant illustrated in FIGS. 6 and 7, there is an electromagnet 61 for the actuation of the output rod 53d which bears the moving contact 17d. The electromagnet 61 of this actuator 25d has an armature 63 mounted on the output rod 53d, which armature 63 presses a moving contact 17d mounted on an arm 43d of the actuator rod 53d and acted upon by a return spring 65 in one of the stationary contacts, in this case the contact 21d, in opposition to the force of the return spring 65, against the other contact 19d, as long as the electromagnet 61 is excited.
An additional variant of a actuator 25e is illustrated in FIG. 9, which differs from the actuator illustrated in FIG. 8 essentially only in that, instead of the electromagnet-armature unit, there is a piston-cylinder unit with a stationary pressure cylinder 67 and a piston 69 connected to the output rod 53e and which can be displaced in the pressure cylinder 67. The unit can be actuated pneumatically or hydraulically, if fluid at an overpressure is introduced at 71. With a suitable arrangement of the pressure chamber, the unit can also be used for systems which operate on underpressure. The system illustrated in FIG. 9 has been designed so that the moving contact 17e is biased by the return spring 65e in one of the limit positions. When double-acting cylinders are used, the return spring 65e can be eliminated. The output rod 53e can be stopped in the limit positions by closing the pressurized pressure chamber.
One feature of the invention resides broadly in the electric motor propulsion system for a motor vehicle, comprising at least one electric motor 1 with a rotary field winding 5 divided into several phase windings 3, an electronic converter system 9 which supplies pulsating driver currents of different phase to several output terminal connections L1, L2, L3, a system 7 of mechanical switches S1, S2, S3 which connects the phase windings 3 of the electric motor 1 to the output terminal connections L1, L2, L3, and by means of which the number of the phase windings 3 connected to each of the output terminal connections L1, L2, L3 can be changed, an actuator system 25 for the actuation of the switches S1, S2, S3, and a control circuit 33 which controls the actuator system 25, characterized by the fact that the control circuit 33 also controls the converter system 9 and reduces the amplitude of the driver currents supplied to the output terminal connections L1, L2, L3, while the control circuit 33 changes the position of the switches S1, S2, S3 by controlling the actuator system 25.
Another feature of the invention resides broadly in the propulsion system characterized by the fact that the control circuit 33 essentially completely deactivates the driver currents supplied to the output terminal connections L1, L2, L3 during the change of the position of the switches S1, S2, S3.
Yet another feature of the invention resides broadly in the propulsion system characterized by the fact that the control circuit 33 delays the deactivation of the driver currents in relation to the activation of the actuator system 25.
Still another feature of the invention resides broadly in the propulsion system characterized by the fact that the switching system 7 connected to the phase windings 3 of the electric motor 1 and the actuator system 25 designed for the actuation of the switching system 7 are mounted on the electric motor 1.
A further feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system comprises a actuator 25 which is common to all the switches S1, S2, S3 of the switching system, and in particular is combined with all the switches S1, S2, S3 into a unit.
Another feature of the invention resides broadly in the propulsion system characterized by the fact that the switching system comprises several modular units 29a, each of which has a separate actuator 25a of the actuator system, in particular actuators 25a which are connected to each of the modular units 29a to form a separate unit which is mounted on the electric motor.
Yet another feature of the invention resides broadly in the propulsion system characterized by the fact that each switch S1, S2, S3 has a moving contact 17 which is driven by the actuator system 25, and at least one stationary contact 19, 21 with which the moving contact 17 can be placed in contact, in particular two stationary contacts 19, 21 which can be alternately contacted by the moving contact 17, and that at least one of the stationary contacts 19, 21 of each switch S1, S2, S3, in particular both stationary contacts 19, 21, are mounted directly on the electric motor.
Still another feature of the invention resides broadly in the propulsion system characterized by the fact that the switches S1, S2, S3, together with the actuator system 25 designed to actuate them, and with terminal connecting elements 27 for a detachable connection to the output terminal connections L1, L2, L3 of the converter system 9, are combined into at least one unit which is mounted on the electric motor 1.
A further feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system has at least one actuator 25b with an output mechanism 45 which rotates around an axis of rotation, and in particular pivots in an oscillating fashion, for the actuation of at least one of the switches.
Another feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system has at least one actuator 25c-e with an output mechanism 53; 53d, e which executes a linear actuation movement for the actuation of at least one of the switches.
Yet another feature of the invention resides broadly in the propulsion system characterized by the fact that the output mechanism 53 is designed as a toothed rack which is engaged with a pinion 57 which is driven in rotation.
Still another feature of the invention resides broadly in the propulsion system characterized by the fact that for the actuation of the switches, the actuator system has at least one irreversible actuator for reaction forces exerted by the switch.
A further feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system for the actuation of the switches has at least one actuator which can be locked at least in its limit position which closes the switches.
Another feature of the invention resides broadly in the propulsion system characterized by the fact that the control circuit 33 for the generation of the locking in position keeps the actuator actuated in the limit position.
Yet another feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system for the actuation of the switches S1, S2, S3 has at least one actuator 25b, c, the output mechanism 45; 53 of which interacts, at least in this limit position closing the switches S1, S2, S3, with a spring element 43; 59 which applies pressure to the output mechanism 45; 53 and/or to the switch to place it in the closed position.
Still another feature of the invention resides broadly in the propulsion system characterized by the fact that the spring element is designed as a bistable spring 59.
A further feature of the invention resides broadly in the propulsion system characterized by the fact that the switch S1, S2, S3 is designed as a transfer switch, and the actuator 25c propels the output mechanism 53 in both limit positions of the switch.
Another feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system 25b for the actuation of the switches S1, S2, S3 has at least one electric motor 47, in particular a geared motor 47; 49, and preferably an irreversible or self-locking geared motor.
Yet another feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system 25a for the actuation of the switches S1, S2, S3 has at least one electromagnet 61, 63.
Still another feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system 25e for the actuation of the switches S1, S2, S3 has at least one cylinder-piston unit 67, 69 which can be actuated by fluid at an overpressure or an underpressure.
A further feature of the invention resides broadly in the propulsion system characterized by the fact that the actuator system for the actuation of the switches S1, S2, S3 has at least one actuator 25, the output mechanism 31 of which corresponds to the displacement sensor 37 which detects the position of the output mechanism 31, and that the control circuit 33 responds to the displacement sensor 37.
Another feature of the invention resides broadly in the propulsion system characterized by the fact that at least some of the switches S1, S2, S3 are designed as transfer switches, and can be switched by means of the control circuit 33 into a neutral position in which none of the contacts are closed.
Yet another feature of the invention resides broadly in the propulsion system characterized by the fact that the electric motor 1 has a three-phase rotary field winding 5, and the switching system 7 is designed as a star-delta switching system.
Examples of flexplate components, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,323,665, which issued to Rediker on Jun. 28, 1994; No. 5,184,524, which issued to Senia on Feb. 9, 1993; No. 5,121,821, which issued to Poorman et al. on Jun. 16, 1992; and No. 4,672,867, which issued to Rodriguez on Jun. 16, 1987.
Examples of hybrid drive arrangements, such as internal combustion engine-electric generator arrangements, and components associated therewith, such as control arrangements and individual motors for driving corresponding wheels, may be found in the following U.S. Pat. Nos.: No. 5,327,987, which issued to Abdelmalek on Jul. 12, 1994; No. 5,318,142, which issued to Bates et al. on Jun. 7, 1994; No. 5,301,764, which issued to Gardner on Apr. 12, 1994; No. 5,249,637, which issued to Heidl et al. on Oct. 5, 1993; No. 5,176,213, which issued to Kawai et al. on Jan. 5, 1993; No. 5,327,992, which issued to Boll on Jul. 12, 1994; No. 5,291,960, which issued to Brandenburg et al. on Mar. 8, 1994; and No. 5,264,764, which issued to Kuang on Nov. 23, 1993.
Examples of electric and hybrid vehicles, and related components, may be or are disclosed in the following U.S. Pat. Nos.: No. 5,251,721 entitled "Semi-hybrid Electric Automobile" to Ortenheim; No. 5,004,061 entitled "Electrically Powered Motor Vehicle" to Andruet; No. 5,289,100 entitled "System for Powering, Speed Control, Steering, and Braking" to Joseph; No. 5,265,486 entitled "Portable External Drive Assembly" to AAMCO Corporation; No. 5,289,890 entitled "Drive Unit for Electric Motor Vehicle" to Aisin; and No. 5,310,387 entitled "Differential Motor Drive" to Hughes Aircraft Company.
Additional examples of electric vehicles in which the present invention my be utilized may be or are disclosed in the following U.S. Pat. Nos.: No. 5,166,584 entitled "Electric Vehicle" to Nissan; No. 5,161,634 entitled "Electric Vehicle" to Kubota Corporation; and No. 5,150,045 entitled "Electric Automobile" to Kaisha.
Examples of coolant pumps, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 4,643,135, which issued to Wunsche on Feb. 17, 1987; No. 4,677,943, which issued to Skinner on Jul. 7, 1987; No. 4,827,589, which issued to Friedriches on May 9, 1989; No. 4,886,989, which issued to Britt on Dec. 12, 1989; and No. 4,728,840, which issued to Newhouse on Mar. 1, 1988.
Examples of electronic commutation devices, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,164,623 entitled "Independent-drive Wheel for a Wheel-mounted Vehicle"; No. 5,117,167 entitled "Commutating Energy Suppression Circuit for an Electronically Commutated DC Motor" to Rotron; No. 5,258,679 entitled "Structure of DC Motor with Electronic Commutation" to ECIA; and No. 5,117,167 entitled "Commutating Energy Suppression Circuit for an Electronically Commutated DC Motor" to Rotron.
Examples of kinetic seals, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 4,989,883 entitled "Static and Dynamic Shaft Seal Assembly" to Inpro; No. 5,088,385 entitled "Actuator Apparatus With Secondary Seal Motion" to Westinghouse; No. 5,192,085 entitled "Rubber Drive System Mechanical Seal"; No. 5,226,837 entitled "Environmentally Protected Connection" to Raychem; and No. 5,286,063 entitled "Ball and Socket Floating Seal Assembly" to Babcock & Wilcox.
Examples of Phase angle sensors, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,203,290 entitled "Intake and/or Exhaust-valve Timing Control System for Internal Combustion Engine" to Atsugi Unisia; No. 5,277,063 entitled "Single Plane Trim Balancing" to General Electric; No. 5,353,636 entitled "Device for Determining Misfiring of Cylinders in Multi-cylinder Engines" to Toyota; No. 5,068,876 entitled "Phase Shift Angle Detector" to Sharp; No. 5,097,220 entitled "Circuit for Demodulating PSK Modulated Signal by Differential-Defection to Japan Radio"; and No. 5,063,332 entitled "Feedback Control System for a High-efficiency Class-D Power Amplifier Circuit".
Examples of three-phase motors for use with electric or hybrid vehicles, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,182,508, which issued to Schauder on Jan. 26, 1993; No. 5,194,800, which issued to Conzelmann et al. on Mar. 16, 1993; No. 5,216,212, which issued to Golowash et al. on Jun. 1, 1993; No. 5,230,402, which issued to Clark. et al. on Jul. 27, 1993; and No. 5,294,853, which issued to Schluter et al. on Mar. 15, 1994.
Examples of sensors, such as speed and/or torque sensors, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,294,871, which issued to Imaseki on Mar. 15, 1994; No. 5,345,154, which issued to King on Sep. 6, 1994; No. 5,359,269,which issued to Wedeen on Oct. 25, 1994; No. 5,182,711, which issued to Takahashi et al. on Jan. 26, 1993; No. 5,245,966, which issued to Zhang et al. on Sep. 21, 1993; and No. 5,332,059, which issued to Shirakawa et al. on Mar. 15, 1994.
Examples of high-current semiconductors, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,253,613, which issued to Bailey et al. on Oct. 19, 1993; No. 5,361,022, which issued to Brown on Nov. 1, 1994; No. 5,365,116, which issued to Lohss on Nov. 15, 1994; No. 5,274,287, which issued to Bahn on Dec. 28, 1993.
Examples of other media having components which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,277,063, which issued to Thomas on Jan. 11, 1994; No. 5,373,630, which issued to Lucier et al. on Dec. 20, 1994; No. 5,373,632, which issued to Lucier et al. on Dec. 20, 1994.
Examples of battery-operated electric vehicles, having components, such as batteries for providing electrical power, which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,229,703, which issued to Harris on Jul. 20, 1993; No. 5,325,912, which issued to Hotta et al. on Jul. 5, 1994; No. 5,332,630, which issued to Hsu on Jul. 26, 1994; No. 5,369,540, which issued to Konrad et al. on Nov. 29, 1994; No. 5,373,910, which issued to Nixon on Dec. 20, 1994.
Examples of converter arrangements, having components which may be utilized in accordance with the embodiments of the present invention, may be found in the following U.S. Pat. Nos.: No. 5,309,073, which issued to Kaneko et al. on May 3, 1994; No. 5,321,231, which issued to Schmalzriedt on Jun. 14, 1994; No. 5,341,083, which issued to Klontz et al. on Aug. 23, 1994; No. 5,350,994, which issued to Kinoshita et al. on Sep. 27, 1994; and No. 5,368,116, which issued to Iijima et al. on Nov. 29, 1994.
The components disclosed in the various publications, disclosed or incorporated by reference herein, may be used in the embodiments of the present invention, as well as, equivalents thereof.
The appended drawings in their entirety, including all dimensions, proportions and/or shapes in at least one embodiment of the invention, are accurate and to scale and are hereby included by reference into this specification.
All, or substantially all, of the components and methods of the various embodiments may be used with at least one embodiment or all of the embodiments, if more than one embodiment is described herein.
All of the patents, patent applications and publications recited herein, and in the Declaration attached hereto, are hereby incorporated by reference as if set forth in their entirety herein.
The corresponding foreign patent publication applications, namely, Federal Republic of Germany Patent Application No. P 44 31 347.0, filed on Sep. 2, 1994, having inventor Hans Fliege, and DE-OS P 44 31 347.0 and DE-PS P 44 31 347.0, as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere, and the references cited in any of the documents cited herein, are hereby incorporated by reference as if set forth in their entirety herein.
The details in the patents, patent applications and publications may be considered to be incorporable, at applicant's option, into the claims during prosecution as further limitations in the claims to patentably distinguish any amended claims from any applied prior art.
The invention as described hereinabove in the context of the preferred embodiments is not to be taken as limited to all of the provided details thereof, since modifications and variations thereof may be made without departing from the spirit and scope of the invention.
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An electric road motor vehicle with a switchable winding electric motor propulsion system, a switchable winding electric motor propulsion system in an electric road motor vehicle, and a switchable winding electric motor propulsion system for a motor vehicle. For the optimization of an electric motor propulsion system of a vehicle, the electric motor equipped with a rotary field winding is connected through a switching system to an electronic converter, so that due to the switching system, the number of phase windings of the rotary field winding to be connected to the individual output connections can be changed. The switching system is controlled by a control circuit through a actuator. The control circuit also controls the converter and deactivates the driver currents fed to the rotary field winding, while it switches over the switching system through the actuator. The switching system can thereby be made simpler and smaller. The switching system including the actuator is combined into a unit with the electric motor.
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[0001] This application claims the benefit of U.S. Provisional Application No. 60/819,186 filed on Jul. 7, 2006.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of generating numerical models for computer simulation of diffusive processes (processes described mathematically by the diffusion equation), such as fluid flow in porous media. More particularly, a method of upscaling from a fine-scale geologic model of an underground formation to a set of grids suitable for computer simulation is provided.
BACKGROUND OF THE INVENTION
[0003] Computer simulation of fluid flow in porous media is widely used in the oil industry, in hydrology, and in environmental studies for remediation of contaminated groundwater. Simulation predictions often have a significant impact on the economic valuation of assets, plans for depletion of hydrocarbon assets and government policies.
[0004] Hydrocarbon deposits, such as oil and gas, are found in nature in complex underground structures known as “reservoirs.” Reservoirs are comprised of various types of porous media (rocks) with different physical properties, such as porosity and permeability. These properties may vary widely over short distances. Fluid flow in a reservoir is determined by the physical properties.
[0005] The development of stochastic geologic property modeling techniques by geologists has allowed modelers to create subsurface models with a tremendous amount of data, which is represented in a three-dimensional “grid” that overlays the subsurface volume. It is not practical to perform reservoir simulations for the various situations of interest at geologic model scale, because of the large number of cells in the geologic model grid. Also, complex property distributions have made simple permeability averaging techniques obsolete. Therefore, “upscaling” (the formation of coarser grids for flow calculations) has become an integral part of reservoir simulation.
[0006] Assembling data describing rock properties and geologic structures is a crucial step toward accurate simulations of fluid flow in reservoirs. The geo-cellular models that assemble the data include rock properties (e.g., porosity and permeability) defined in each cell. The geologic cells form a non-overlapping partition of a reservoir.
[0007] The geo-cellular model may include millions of geologic cells to describe a reservoir, so direct simulation of reservoir fluid movement for the many cases of interest is cost-prohibitive. Thus, from an economic standpoint it is necessary to transform a detailed geologic model into a coarse simulation model with fewer degrees of freedom, so that reservoir simulation can be performed at an acceptable cost. This transformation is called both “scaleup” and “upscaling.” Recent reviews of scaleup have been published by D. Stern (“Practical Aspects of Scaleup of Simulation Models,” J. Pet. Tech., September 2005, pp. 74-82) and L. J. Durlofsky (“Upscaling and Gridding of Fine Scale Geologic Models for Flow Simulation,” paper presented at 8 th Int'l Forum on Reservoir Simulation, Stressa, Italy, June, 2005) (See: http://ekofisk.stanford.edu/faculty/durlofskypub12.html).
[0008] Upscaling involves building a simulation grid that is coarser than the geologic grid and converting properties defined on the geologic grid to the simulation grid. Once a simulation grid is defined, converting geologic properties typically requires that certain averages of the geologic properties be calculated to populate the simulation grid. For some of the properties, such as porosity, simple averages with suitable weights are sufficient. To scaleup permeability, flow-based averaging procedures have proven to be the best way. Durlofsky (2005) reviews such procedures and a recent mathematical analysis of flow-based permeability-scaleup is given by Wu et al. (“Analysis of Upscaling Absolute Permeability,” Discrete and Continuous Dynamical Systems - Series B , Vol. 2, No. 2, 2002).
[0009] Flow-based scaleup requires solving single-phase Darcy flow equations on a fine-scale grid. Most of the existing methods require the fine grid to be aligned with the coarse simulation grid. Recently, a method of upscaling simulation grid transmissibility using flow solutions defined on a fine grid that is not aligned with the simulation grid was described by He (C. He, “Structured Flow-based Gridding and Upscaling for Reservoir Simulation,” PhD Thesis, Stanford University, Stanford Calif., December, 2004). White and Horne present an algorithm to compute scaled-up values of transmissibility when there is permeability heterogeneity and anisotropy at the fine-grid scale (“Computing Absolute Transmissibility in the Presence of Fine-Scale Heterogeneity,” paper SPE 16011, Ninth SPE Symposium on Reservoir Simulation, Society of Petroleum Engineers, 209-220 (1987)).
[0010] As discussed by Stern (2005) and Durlofsky (2005), a successful scaleup often requires a simulation grid that is capable of capturing correlated heterogeneities directly. An iterative procedure is often required, which involves building multiple simulation grids to determine the “optimum” grid. This process is called grid optimization. Building multiple simulation grids requires repeated scaleup of the geologic model. For permeability scaleup, generating flow solutions on a fine-scale grid is the most time-consuming and costly step. Due to its high cost, automatic grid optimization is not feasible; in fact, even manual changes of simulation grids are seldom done in practice. As a result, simulation models often do not have the best accuracy, and they may produce predictions that are not consistent with the geologic models. What is needed is a method that allows faster and lower cost grid optimization.
SUMMARY OF INVENTION
[0011] This invention provides faster and lower cost grid optimization during scaleup. A key feature of the invention is to reuse flow solutions computed directly on the geologic models and thereby to avoid repeating this most computationally intensive part of the scaleup process. These flow solutions are repeatedly used to scale up permeability for different simulation grids. By reusing the flow solutions, the scaleup of different simulation grids can be performed more efficiently. Thus, manual change of simulation grids is no longer prohibitively time-consuming, and automatic grid optimization can become a reality. The method may be used when the physical model is described by linear partial differential equations or when the physical problem may require a mathematical model based on non-linear equations, as in the case of multi-phase fluid flow in porous media.
[0000] A computer-implemented method for scale-up of a physical property of a region of interest from a fine-scale grid where values of the property are known to multiple coarse grids, said property being associated with a diffusive process in the region of interest, said method comprising:
[0012] (a) selecting a volume of the region of interest, said volume being at least a portion of the region of interest;
[0013] (b) subdividing the volume into a plurality of fine grid cells to form a fine-scale grid for the volume, and obtaining a value of the physical property for each of the plurality of fine grid cells;
[0014] (c) solving a diffusion equation representing a diffusive process on the fine-scale grid over the selected volume, using the fine-scale values of the physical property, thus generating a global solution;
[0015] (d) saving the global solution;
[0016] (e) subdividing the selected volume into a first coarse grid having at least one coarse grid cell, wherein the plurality of fine grid cells is greater than the at least one coarse grid cells;
[0017] (f) selecting a coarse-grid cell, and determining which of the plurality of fine grid cells are included, in whole or in part, in the selected coarse grid cell, using a pre-selected criterion for partial inclusion;
[0018] (g) calculating a scaled-up value of the physical property for the selected coarse grid cell by retrieving and using the global solution for the fine grid cells included within the selected coarse-grid cell;
[0019] (h) repeating steps (f)-(g) to calculate scaled-up values of the physical property for at least one other coarse grid cell selected from the at least one coarse grid cell in the selected volume of the region of interest; and
[0020] (i) repeating steps (e)-(h) for at least one more coarse grid, using the global solution for each coarse grid.
[0021] In some embodiments of the invention, the global solution is generated by sub-dividing the selected volume into two or more parts which may overlap, and solving the diffusion equation separately in each sub-volume, wherein the solutions are compatible between sub-volumes. Furthermore, the present inventive method does not have to be applied to scale up to a coarse grid, but instead may be used to scale up to two or more scale-up volumes of any description.
[0022] In another embodiment of the invention, a computer-implemented method for scaling a physical property of a subsurface region from values known at cells in a fine grid to multiple different cells, said property being associated with a diffusive process in the region is provided. The method for scaling includes: (a) selecting a volume of the subsurface region, said volume being at least a portion of the subsurface region; (b) subdividing the volume into fine scale cells to form a fine-scale grid for the volume, and obtaining a value of the physical property for each fine scale cell; (c) solving a diffusion equation on the fine-scale grid over the selected volume, thus generating a global solution, wherein the global solution is generated by sub-dividing the volume into two or more sub-volumes, solving the diffusion equation separately in each sub-volume, and matching the solutions at sub-volume boundaries; (d) saving the global solution in computer memory or data storage; (e) defining a different cell within one of the two or more sub-volumes, said different cell being different in size or shape than the fine scale cells; (i) determining which fine scale cells are included, in whole or in part, in the different cell, using a pre-selected criterion for partial inclusion; (g) calculating a scaled value of the physical property for the different cell by retrieving and using the global solution for the fine scale cells included within the different cell; and (h) repeating steps (e)-(g) to calculate a scaled value of the physical property for at least one more different cell in the selected volume of the subsurface region, using the global solution recalled from computer memory or data storage for each different cell.
[0023] In yet another alternative embodiment of the present invention, a method for producing hydrocarbons from a subsurface formation is provided. The method includes: obtaining a geologic model of the subsurface region, said model providing discrete values of a physical property of a medium for a fine-scale grid covering a selected volume constituting at least a part of the subsurface region; and obtaining a scaled-up model of the physical property suitable for use in a reservoir simulation program. The scaled-up model is made by: (i) solving a diffusion equation representing a diffusive process on the fine-scale grid over the selected volume, using the fine-scale values of the physical property, thus generating a global solution; (ii) saving the global solution in computer memory or data storage; (iii) subdividing the volume into a first coarse grid, said coarse grid having fewer cells than the fine-scale grid; (iv) selecting a coarse-grid cell, and determining which fine-grid cells are included, in whole or in part, in the selected coarse-grid cell, using a pre-selected criterion for partial inclusion; (v) calculating a scaled-up value of the physical property for the selected coarse-grid cell by retrieving and using the global solution for the fine-grid cells included within the selected coarse-grid cell; (vi) repeating steps (iv)-(v) to calculate scaled-up values of the physical property for selected other coarse-grid cells in the selected volume of the subsurface region; (vii) repeating steps (iii)-(vi) for at least one more coarse grid, using the global solution retrieved from computer memory or data storage for each coarse grid; and (viii) selecting a preferred coarse grid based on pre-determined grid optimization criteria. The method of producing further includes producing hydrocarbons from the subsurface region at least partially based on reservoir simulations made using the scaled-up model of the physical property on the preferred coarse grid.
[0024] In still another embodiment of the present invention, a method for scale-up of a physical property is provided. The method includes: (a) calculating fine-scale solutions to at least one equation describing the physics of a diffusive process in a media of interest, wherein the fine-scale solutions are determined for each fine-scale cell in a fine-scale grid and the fine-scale solutions are stored in a memory; (b) constructing a coarse grid for at least a portion of the media of interest, wherein the coarse grid comprises a plurality of cells; (c) forming at least one scaleup volume in the media of interest, wherein the scaleup volume is used to calculate the physics of a diffusive process in the media of interest on the coarse grid; (d) constructing a mapping between the set of fine-scale solutions and the at least one coarse grid, wherein the mapping comprises relating at least one fine-scale cell to one of the plurality of coarse grid cells; (e) retrieving the fine-scale solutions from the memory for each fine-scale cell relating to a coarse grid cell; (f) calculating an upscaled physical property for the coarse grid using the fine-scale solutions; (g) constructing at least one additional coarse grid for an additional portion of the media of interest, wherein the additional coarse grid comprises a plurality of cells; (h) iteratively repeating steps (c) to (f) for the at least one additional coarse grid using the fine-scale solutions from step (a).
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The present invention and its advantages will be better understood by referring to the following detailed description and the attached drawings in which:
[0026] FIG. 1 shows a diagram of an exemplary method for upscaling physical properties;
[0027] FIG. 2 illustrates a fine-scaled geologic model for performing flow calculations;
[0028] FIG. 3A illustrates a coarse structured grid having two layers;
[0029] FIG. 3B shows a structured, orthogonal fine grid and coarse grid cells aligned with the fine grid;
[0030] FIGS. 4A-4C illustrate unstructured scaleup volumes;
[0031] FIG. 4A shows traditional cell-based scaleup volumes, where the scaleup volumes are simply the coarse grid cells;
[0032] FIG. 4B shows a diamond-shaped scale-up volume for a horizontal connection designed to model the connection between two cells;
[0033] FIG. 4C shows a vertical-connection scale-up volume surrounding the connection between adjacent cells;
[0034] FIG. 5A illustrates an irregular coarse scaleup volume superimposed on a fine grid; and
[0035] FIG. 5B illustrates that the centers of the fine grid cells may be used to associate a fine grid cell with a particular scaleup volume.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] The invention will be described in connection with its preferred embodiments. However, to the extent that the following detailed description is specific to a particular embodiment or a particular use of the invention, this is intended to be illustrative only, and is not to be construed as limiting the scope of the invention. On the contrary, it is intended to cover all alternatives, modifications and equivalents that may be included within the spirit and scope of the invention, as defined by the appended claims.
[0037] The invention disclosed herein is a new scaleup process to allow the reuse of fine-scale (global) solutions for multiple coarse-scale grids. Referring to FIG. 1 , the process includes the following steps:
[0038] Step 1 . Calculate a set of fine-scale solutions to the appropriate equations describing the physics of a diffusive process in a region of interest. Linear pressure boundary conditions may be used for generating the flow solutions. Other boundary conditions can be used, as discussed by Wu et al. (2002).
[0039] Step 2 . Construct a coarse grid suited to each region of interest.
[0040] Step 3 . From this coarse grid, form scaleup volumes to calculate particular physical properties of interest on the coarse grid.
[0041] Step 4 . Construct a mapping between the fine-scale model and the scaleup volumes.
[0042] Step 5 . For each scaleup volume, retrieve the fine-scale solutions for each fine-scale cell that is associated with the scaleup volume through the mapping.
[0043] Step 6 . Using these fine-scale solutions, calculate the upscaled property for each scaleup volume.
[0044] Step 7 . Repeat steps 2 to 6 for a new coarse grid. To perform a scaleup on a new coarse grid, the fine scale solution is not recalculated. Rather, it is retrieved from a storage device, such as a computer memory or disc.
[0045] One difference between the approach disclosed herein and previous approaches is the ability to reuse the fine-scale (global) solutions on different coarse grids. Previous approaches calculate a fine-scale solution for each new coarse grid.
[0046] In one exemplary embodiment of the present invention, the upscaling of permeability in a model of Darcy flow through a porous media is described. It should be understood that though the method is applied to permeability and fluid flow, it is applicable to other physical processes described by the diffusion equation, which is:
[0000]
a
∂
u
∂
t
+
∇
·
(
b
⇀
u
)
+
cu
=
∇
·
(
D
=
∇
u
)
,
[
Eq
.
1
]
[0000] where a, {right arrow over (b)}, c, and D are known functions of space and time. The physical meaning of the coefficients depend on the context in which the equation is used. For Darcy flows, a is related to rock compressibility and porosity and D is the permeability tensor. The variable u in Eq. 1 is the unknown to be solved from the equation; it corresponds to pressure, saturation, or concentration in porous media flows.
[0047] FIG. 2 demonstrates Step 1 —the calculation of the fine-scale solutions for a model of fluid flow through porous media in three directions. Fine grid or geo-cellular model 20 includes rock properties of porosity and permeability for each cell. Results of flow calculations for three directions are illustrated at 21 , 22 and 23 . For the three dimensional (“3-D”) model of Darcy flow, three solutions are necessary to calculate the upscaled permeability. These flow solutions can be calculated through any method desired, although often numerical methods such as finite difference or finite element are used, both of which are well known in the art of reservoir simulation. In this case, the region of interest is the entire model, but it may be desirable to divide the model into several regions to make the computations feasible. The solutions for the parts of the volume are combined through the use of appropriate boundary conditions to form a global solution covering the entire volume, i.e. the model or region of interest. The fine-scale solutions are then stored for later use.
[0048] The method disclosed herein will work in its most efficient mode if the fine grid is structured and orthogonal. Structured grids allow simpler and more efficient ways for manipulating the information compared to unstructured grids. In particular, the mapping algorithm used in Step 4 can be simplified and made more efficient. If the fine grid is both structured and orthogonal, one can take advantage of simpler and more efficient methods for obtaining the solution to the physical problem. The importance of these considerations rapidly increases with the number of cells (i.e. the resolution) of the fine grid, especially in 3-D applications.
[0049] As stated previously, if the size of fine grid representation of the physical process is so big that it becomes impractical to compute the solution on the entire model, then the model may be split into several regions and solutions may be obtained on each region separately. Preferably, regions overlap and the size of the regions will be chosen much bigger than the size of a coarse grid cell. Such choice will help reduce the effect of the boundary conditions on the local (regional) solutions and also will enable the regions to encompass features of larger scale (Wu et al. 2002). The coarse grid may also be an unstructured grid.
[0050] FIGS. 3A-3B illustrate an embodiment of Step 2 —construction of a coarse structured grid for the fine-scale geologic model shown in FIG. 2 . In FIG. 3A , coarse grid 30 is made up of coarse grid cells 31 , which could simply be defined as the union of a specific set of structured and orthogonal fine grid cells.
[0051] FIG. 3B shows a structured, rectangular fine grid 35 and two coarse grid cells 37 that are aligned with the fine grid 35 . For this simple case, there exists an efficient discretization, namely the two-point flux finite volume approximation. Also, because of the grid structure, a solver will be more efficient. Since the coarse grid cells are aligned with the fine grid, the mapping between coarse and fine grids is trivial and will not produce sampling errors.
[0052] In Step 3 , scaleup volumes are calculated for the coarse grid. The scale-up volumes are a particular volume of interest for the problem being solved. For reservoir simulations, these volumes are typically associated with coarse grid cells or connections.
[0053] The methods of this invention work equally well for either structured or unstructured grids. FIGS. 4A-4C illustrate exemplary embodiments of Step 3 —forming of scaleup volumes in a coarse unstructured grid. FIG. 4A shows traditional cell-based scaleup volume 40 and fine grid cells 41 within it. Coarse volume 40 within which the upscaled property is calculated is an approximation of the coarse grid cells. For a coarse unstructured grid with unstructured or Vornoi areal grid but a layered structure in the vertical dimension, if the finite difference method is used to obtain the flow solutions on the coarse grid, then the scale-up volumes 44 in FIGS. 4B and 45 in FIG. 4C are preferred. However, for the finite difference method on general unstructured grids, scale-up volumes based on cells or the unions of two neighboring cells can be used. The scaleup volume allows the direct calculation of the transmissibility, a key parameter in the finite difference method. The approach disclosed in U.S. Pat. No. 6,826,520 may be used to calculate transmissibility. Persons skilled in the art will know other approaches. For other numerical discretization schemes, different scale-up volumes may be required.
[0054] FIGS. 5A-5B illustrate an exemplary embodiment of Step 4 —a mapping to determine which fine grid cells are associated with each scaleup volume. In FIG. 5A coarse scaleup volume 51 is shown superimposed on fine-scale grid 50 . In FIG. 5B , a preferred method is depicted for determining if fine grid cell 52 , for example, is associated with (i.e., will be considered to be included within) coarse scaleup volume 51 . In this method, fine grid cell 52 is associated with scaleup volume 51 if its cell center 53 lies within the coarse scaleup volume 51 . This method or criterion for partial inclusion is discussed in Durlofsky (2005) and in U.S. Pat. No. 6,826,520. Other methods may be used, as is known in the art. The mapping between the fine and coarse grid can be constructed in many different ways. For example, one could use geometric algorithms that are well known in the art of computational geometry and grid generation.
[0055] U.S. Pat. No. 6,106,561 teaches a suitable method for creating a grid. Other methods of gridding may be used, as is well known in the art. There are many references on the subject, such as the Handbook of Grid Generation (J. F. Thompson et al., CRC Press, 1999).
[0056] As an example of Step 6 of FIG. 1 , the case of permeability of a porous medium, which is so important in the simulation of petroleum reservoirs to facilitate production of hydrocarbons from them, may be considered. In this case, both velocity and pressure gradient are components of the fine scale (i.e., global) solution for Darcy flow in porous media. Therefore, both pressure gradient and velocity are retrieved from data storage (Step 5 ) for each of the three solutions calculated in Step 1 . For the permeability property of the Darcy flow equations, it has been shown by Wen and Gomez-Hernandez (“Upscaling Hydraulic Conductivity in Heterogeneous Media,” J Hydrology 183, 9-32 (1996)) that the coarse grid permeability property can be represented by:
[0000] {right arrow over ( v )} =− K * ∇ P , [Eq. 2]
[0000] where {right arrow over (v)} is the volume-weighted average of the fine-scale velocity in the scaleup volume, ∇P is the volume weighted average of the fine-scale pressure gradient, and K * is the coarse scale permeability. These averages are calculated for each flow solution. It should be noted that the velocity and pressure gradient are vectors and the permeability is represented as a tensor. This is why three different solutions are preferred; three solutions and three equations per solution (one for each component of the vector) allow the calculation of the nine components of the coarse-scale permeability tensor.
[0057] There are several methods for computing the coarse-grid effective property once the fine grid solution is available. These methods are discussed by Durlofsky (2005). A preferred method is to use the volume-average approach and Eq. 2.
[0058] If a new coarse grid is desired to improve performance, the fine-scale solution is not re-calculated in the present inventive method. As shown in FIG. 1 , the scaleup volumes and their mapping to the fine grid must be reconstructed, and the fine scale solution is simply re-sampled on the new scaleup volumes defined based on the new coarse grid. Results of calculations with the new coarse grid can then be compared with results of calculations with the first coarse grid. Results of linear or single-phase flow calculations from the different coarse grids may be compared with the global flow solutions based on a geo-cellular model to select the preferred coarse grid. This process can be repeated until the most preferred coarse grid is found. The preferred coarse grid from these comparisons may then be used in a mathematical model based on non-linear equations, as in the case of multi-phase fluid flow in porous media.
Example 1
[0059] A fine grid calculation was performed using a geologic model having 14 million cells, of which 580,000 were active cells. A global solution for velocity and pressure was obtained for single phase Darcy flow within the model. Using one embodiment of the present inventive method, an initial scaleup to a coarse grid required 60 minutes computing time and, by retrieving and re-using results of the fine scale solution, only 7 minutes were required to scale up to a re-gridded model. In contrast, a typical method previously used required 125 minutes to scale up both the initial model and the re-gridded model. Both coarse grids had 40,500 active cells.
Example 2
[0060] A fine grid calculation was performed using a geologic model having 7.5 million cells, almost all of which were active. A global solution for velocity and pressure was obtained for single phase Darcy flow within the model. Using the present inventive method, an initial scaleup to a coarse grid required 390 minutes computing time and, by retrieving and re-using results of the fine scale solution, only 20 minutes were required to scale up to a re-gridded model. In contrast, methods previously used required 150 minutes to scale up both the initial model and the re-gridded model. Both coarse grids had 87,000 active cells.
[0061] The model size of Example 1 is more commonly encountered in current practice. For either size model, optimizing the methods disclosed herein will further improve the advantage in reduced time and cost over presently used methods. Using the disclosed methods, it is clear that the greatly reduced time required for re-gridded solutions makes practical a series of manually re-gridded solutions or the application of automatically re-gridded solutions.
[0062] Although the invention has been described in terms of scaling up simulation grids, it should be understood that the methods described herein apply equally well to sets of sample volumes that do not form grids, i.e., these volumes do not form a non-overlapping partition of the subsurface region. The sample volumes may be selected randomly or according to a regular pattern. The invention allows faster and lower cost determination of statistics from different sets of sample volumes. It should also be noted that the present inventive method does not require that the sample volume be larger than the fine-scale grid cells. The invention works equally for coarse grid cells (scaleup volumes) that are smaller than the fine-scale grid cells.
[0063] Although the invention has been described in terms of fluid flow in porous media, it should be understood that simulation of other physical phenomena described by the diffusion equation may also be practiced using the methods described herein. For example, thermal diffusion in solids and molecular diffusion in liquids may be simulated using the inventive method. In those cases, a physical property analogous to permeability may be upscaled from a fine grid calculation to a coarse grid calculation using the steps set out above.
[0064] The foregoing application is directed to particular embodiments of the present invention for the purpose of illustrating it. It will be apparent, however, to one skilled in the art, that many modifications and variations to the embodiments described herein are possible. All such modifications and variations are intended to be within the scope of the present invention, as defined in the appended claims.
REFERENCES
[0000]
1. D. Stern, “Practical Aspects of Scaleup of Simulation Models,” JPT (September, 2005) 74.
2. L. J. Durlofsky, “Upscaling and Gridding of Fine Scale Geological Models for Flow Simulation,” Proceedings of the 8 th International Forum on Reservoir Simulation (Jun. 20-25, 2005), Stresa, Italy.
3. Ph. Renard and G. de Marily, “Calculating Effective Permeability: A Review,” Advances in Water Resources, 20 (1997), 253-278.
4. X. H. Wen and J. J. Gomez-Hernandez, “Upscaling Hydraulic Conductivity in Heterogeneous Media,” Journal of Hydrology, 183 (1996), 9-32.
5. X. H. Wu, Y. Efendiev, and T. Y. Hou, “Analysis of Upscaling Absolute Permeability,” Discrete and Continuous Dyanmical Systems - Series B, 2 (2002), 185-204.
6. S. A. Khan and A. G. Dawson, “Method of Upscaling Permeability for Unstructured Grids,” U.S. Pat. No. 6,826,520, B1 (30 Nov. 2004).
7. C. He, “Structured Flow-based Gridding and Upscaling for Reservoir Simulation,” Ph. D. Thesis (2004), Stanford University, Stanford, Calif.
8. M. de Berg, M. van Kreveld, M. Overmars and O. Schwarzkopf, “Computational Geometry: Algorithms and Applications,” Springer, 1997.
9. P. G. Ciarlet, “The Finite Element Method for Elliptic Problems,” North-Holland, 1978.
10. K. Aziz and A. Settari, “Petroleum Reservoir Simulation,” Elsevier, 1979.
11. C. L. Farmer. “Simulation Gridding Method and Apparatus Including a Structured Areal Gridder Adapted for Use by a Reservoir Simulator.” U.S. Pat. No. 6,106,561 (22 Aug. 2000).
12. J. F. Thompson, B. K. Soni, and N. P. Weatherill. “Handbook of Grid Generation.” CRC Press, 1999.
13. C. D. White and R. N. Horne, “Computing Absolute Transmissibility in the Presence of Fine-Scale Heterogeneity,” paper SPE 16011, Ninth SPE Symposium on Reservoir Simulation, Society of Petroleum Engineers, 209-220 (1987).
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Method is provided for simulating a physical process such as fluid flow in porous media by performing a fine-grid calculation of the process in a medium and re-using the fine grid solution in subsequent coarse-grid calculations. For fluid flow in subsurface formations, the method may be applied to optimize upscaled calculation grids formed from geologic models. The method decreases the cost of optimizing a grid to simulate a physical process that is mathematically described by the diffusion equation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/741,809 entitled RUNWAY DIGITAL WIND INDICATOR SYSTEM and filed on Jul. 27, 2012, which is specifically incorporated by reference herein for all that it discloses and teaches.
TECHNICAL FIELD
[0002] The invention relates generally to the field of aviation, and more particularly to a runway digital wind indicator system.
BACKGROUND
[0003] Human beings have been successfully flying powered aircraft for slightly more than one hundred years. During that time, there have been radical improvements in all areas of the field of aviation. However, despite ongoing herculean efforts to improve the safety and reliability of air-travel, incidents and accidents continue to occur. Given the sheer complexity of the aircraft, airports, flight control, piloting methods, meteorology, and other factors that can seriously impact safety, there continue to be many potential causes for accidents and incidents (hereinafter, collectively “accidents”).
[0004] One of the major causes of aircraft accidents across the world are wind conditions occurring in proximity to a runway as a pilot attempts to land or take-off using that runway. Ideally, calm air conditions or a constant headwind (i.e., a wind blowing towards an airplane out of the direction of travel of the airplane) would be present whenever a plane lands or takes-off from a runway. This is because as wind flows over an aircraft's wings, lift is generated. If the airflow is not directly opposite the direction the aircraft is moving, then lift is reduced. In order to maintain proper flight control, a pilot therefore needs to be aware of the wind conditions along a runway. In response to this need, there are a number of current information systems being used in the art to monitor and report basic wind conditions near airports. Although somewhat minimal in nature, this basic wind information is still quite helpful for pilots attempting to take-off or land their planes. Nevertheless, if wind conditions are rapidly changing, gusting, or varying along different points of a given runway (or along different runways), a pilot can find the basic wind information inadequate at best and woefully misleading and extremely dangerous at worst.
[0005] For example, as the airflow of wind over a wing rapidly changes speed or direction, there is a correspondingly rapid change in the lift being generated by the wing. A pilot must then quickly compensate for these changes or risk an accident. If a pilot is informed that the winds at an airport are ten knots (kt) out of the west, he or she may be very surprised to find that at one end of the runway winds are gusting at twenty knots out of the southwest, at ten knots per hour out of the west in the middle of the runway, and fifteen knots per hour from the northwest at the other end of the runway. The sheer size of today's airports can further exacerbate this problem. If a pilot is told that winds are out of the west at twenty knots at Denver International Airport (DIA), for example, he or she must wonder how much the wind information varies along the many runways spread across the fifty three square miles that make up DIA. Thus, current minimal wind conditions information systems are insufficient to properly inform a pilot in order that he or she can maintain control over their aircraft and land or take-off safely.
[0006] To further complicate matters, wind information can often change not only from point to point along a runway, but also can quickly change in time as well. For example, the winds can be a generally constant ten knots from the east at one time and then switch to gusting ten to twenty knots from the west minutes later. As current minimal wind indicator systems are often slow to update and rarely provide up to the minute information, additional problems can develop for a pilot relying on such untimely, out-of-date information. In fact, current automated weather detection sites such as Surface Weather Observation Stations (ASOS) or Automated Weather Observation Stations (AWOS) can provide as little as a single reading within an hour and may be located miles from a given runway.
[0007] What is needed is a real-time runway digital wind indicator system that can sense and report wind information from multiple locations along a runway as well as from the centerfield location (near a center point for a given airport) in a constantly updating, real-time manner without burying pilots with too much information.
SUMMARY
[0008] One embodiment of the present invention comprises a system for sensing wind conditions at multiple locations, aggregating this data, and communicating up-to-date information to pilots. For example, meteorological information including wind speed, direction, and change (i.e., gustiness) plus temperature, humidity, barometric pressure, etc. can be sensed by three or more sensor pods placed along a runway (at least one at each end and another in the middle of a given runway). Data from these pods is then transferred to a computer receiver that processes the information into a concise, usable format that can be displayed to air traffic control, sent to runway digital display signs placed in proximity to runways for direct pilot reference, or posted to websites/internet locations that can then be used to wirelessly relay the information to any of a plethora of digital devices that can be accessed directly by a pilot.
[0009] For example, before beginning a final approach to land his airplane, a pilot could examine his tablet computer and reference a webpage for a given airport and runway. The runway digital wind indicator system will have sensed the wind information at the approach, midpoint and departure locations (i.e., both ends and the middle of a runway) plus at the centerfield of the airport. The system then aggregates and processes this data into a concise, easily readable information set that is posted real-time, up to the second, on the webpage that the pilot can view on his tablet computer. He then has a much-enhanced understanding of the wind conditions along his runway and can then be prepared for the wind environment he and his plane will experience upon landing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a perspective view of an exemplary embodiment of a runway digital wind indicator system;
[0011] FIG. 2 illustrates a perspective view of an additional exemplary embodiment of a runway digital wind indicator system;
[0012] FIG. 3A illustrates a front elevation view of an exemplary embodiment of a runway digital display sign; and
[0013] FIG. 3B illustrates a side elevation view of an exemplary embodiment of a runway digital display sign.
DETAILED DESCRIPTION
[0014] Referring now to the drawings, FIG. 1 shows a perspective view of an exemplary embodiment of a runway digital wind indicator system 100 . In the center of FIG. 1 , the runway 110 is shown with a representation of an aircraft 120 awaiting clearance for departure at one end of the runway 110 . In another embodiment, the aircraft 120 can already be in the air and planning on landing on the runway 110 . In either case, a plurality of wind sensors 130 is placed in proximity to the runway 110 . In the embodiment shown in FIG. 1 , there are three wind sensors 130 , in other embodiments the plurality of wind sensors 130 can be greater than three. Additionally, a centerfield wind sensor 160 can also be incorporated in the system. Such a sensor is preferably located at a point near the center of the airport, i.e., the centerfield location 161 . In FIG. 1 , the centerfield location 161 is near the representation of the air traffic control tower 115 , as such an edifice is often centrally located.
[0015] The wind sensors 130 are preferably placed in elevated positions (for example, on poles) in order to be in the optimum position to properly sense current meteorological information. At a minimum, the plurality of wind sensors 130 should measure the wind speed and direction. Whenever the term “wind sensor” 130 is used herein, it should be understood to encompass at least wind speed and direction sensing, and can also include additional sensors to determine temperature, humidity, pressure, wind shear, rate of change (change in readings/speed/direction, etc. over time), and other data points. The plurality of wind sensors 130 can be linked (i.e., in electronic communication) either wirelessly or wired (or both) with a central computer receiver 140 . In the embodiment in FIG. 1 , wireless transceivers are illustrated as antennas.
[0016] The central computer receiver 140 receives sensor data from the plurality of wind sensors 130 . In another embodiment, the computer receiver 140 can also receive data from existing sensors/systems and integrate the data into the new runway digital wind indicator system. The computer then processes this data and aggregates it into concise, easily digestible information that is ready to be displayed via a communications network 150 (e.g., the internet) using internet data, websites, webpages, apps, etc., (collectively, “internet communications”), on a hand-held computing device 104 (such as a tablet computer, mobile smart phone, etc.), a laptop computer 106 , or other computing device 108 in a constantly updating, real-time manner. Additionally, the computer receiver 140 can route the information to an air traffic controller in the control tower 115 and to a runway digital display sign 180 . This can be accomplished wirelessly or over physical lines. The information can be made available not just to air traffic controllers (or other tower/airport personnel) but to anyone else that could utilize the information via one or more communications networks 150 . In the case of utilizing existing wind systems, the communications network 150 will take the Air Traffic Control wind information and display it on the hand-held computing device 104 , a laptop computer 106 , or other computing device 108 and/or the runway digital display sign 180 .
[0017] As shown in FIG. 1 , an exemplary runway digital display sign (RDDS) 180 can display real-time information such as wind direction: “301” (degrees), and speed: “015” (knots, or kt) at the departure location 131 on the runway 110 . Also shown on the RDDS 180 in the embodiment of FIG. 1 , are wind speed and direction at the midfield location 132 , centerfield location 161 , and arrival location 133 ; temperature at the centerfield; and barometric pressure reading (i.e., Altimeter) at the centerfield. Note that the wind speed and direction line item for the Centerfield location also displays wind gust information: winds are from 310 degrees at 15 knots, gusting to 25 knots. In other embodiments, the wind gust information is available for other locations. In yet other embodiments, the RDDS 180 can display other information. Furthermore, the number of runway digital display signs 180 can be two or more (one at each end of each runway 110 , for example).
[0018] It is important to understand that although the embodiment illustrated in FIG. 1 only shows a single runway, the system is designed to handle multi-runway airports as well. In such a case, the number of runway digital display signs, wind sensors, etc. would be increased to accommodate additional runways. The central computer receiver 140 may need to be expanded or upgraded to handle the additional load; alternatively, additional computer receivers 140 can be added to the system. The computer receiver 140 processes the raw data inputs from all the wind sensors into constantly updated, usable, actionable information. Calculations are made on an ongoing basis to provide smooth data that is easily readable and yet up-to-date.
[0019] FIG. 2 illustrates a perspective view of an additional exemplary embodiment of a runway digital wind indicator system 200 . In the center of FIG. 2 , the runway 210 is shown with a representation of an aircraft 220 waiting to depart from one end of the runway 210 . In this embodiment, the pilot can view the wind information on the RDDS 280 or on his or her electronic device 207 in the cockpit of the airplane 220 . Alternatively, a plurality of instruments 205 can be installed or placed in the cockpit to display the information (in the example illustrated in FIG. 1 , a round display instrument shows an arrow to indicate the direction in which the wind is blowing, the degrees from which the wind is blowing: 301, and the speed: 15 knots). The information displayed is based on data gathered by a plurality of wind sensors 230 . In other embodiments, additional instruments or more complex instruments would be used to display the data from all the wind sensors; or as requested by the pilot.
[0020] The plurality of wind sensors 230 is placed in proximity to the runway 210 . In the embodiment shown in FIG. 2 , there are three wind sensors 230 in proximity to the runway 210 , in other embodiments the plurality of wind sensors 230 can be greater than three. Additionally, a centerfield wind sensor 260 can also be incorporated in the system. Such a sensor is ideally located at a centerfield location 261 near the center of the airport. In FIG. 2 it is near the representation of the control tower 215 .
[0021] At a minimum, the plurality of wind sensors 230 should measure the wind speed and direction. Additional sensors can be incorporated in the wind sensor 230 pods to include temperature, humidity, barometric pressure (and rate of change thereof, or at least whether it is rising or falling), rate of change in wind speed/direction, etc. The plurality of wind sensors 230 can be linked either wirelessly or wired (or both) to a central computer receiver 240 .
[0022] The central computer receiver 240 receives sensor data from the plurality of wind sensors 230 (including the centerfield sensor 260 ). In another embodiment, the computer receiver 240 can also receive data from existing sensors/systems and integrate the data into the new runway digital wind indicator system. The computer than processes this data and aggregates it into concise, easily digestible information that is ready to be displayed in real-time via an electronic device 207 (e.g., an IPad® or other tablet computing device) and/or to a runway digital display sign 280 .
[0023] As shown in FIG. 2 , an exemplary runway digital display sign (RDDS) 280 can display real-time information such as wind direction: “301” (degrees), and speed: “015” (knots) take from the departure location 231 on the runway 210 . Also shown on the RDDS 280 in the embodiment of FIG. 2 , are wind speed and direction at the midfield location 232 (301 degrees and 12 knots), centerfield location 261 , and arrival location 233 ; temperature at the centerfield location 261 ; and barometric pressure reading (altimeter) at the centerfield location 261 . Note that the wind speed and direction line item for the Centerfield location 261 also displays wind gust information: winds are from 310 degrees at 15 knots, gusting to 25 knots. In other embodiments, the RDDS 280 can display other information (for example, gusts can be displayed for locations other than centerfield, midfield, arrival, or departure; as another example, wind shear information can be displayed). Furthermore, the number of runway digital display signs 280 can be two or more (one at each end of the runway 210 , for example).
[0024] FIG. 3A illustrates a front elevation view of an exemplary embodiment of a runway digital display sign 380 . As in FIGS. 1 and 2 above, the RDDS 380 can display the wind direction, speed, and even gusts for departure, midfield, centerfield, and arrival locations; plus temperature; barometric pressure (Altimeter), wind shear, etc. In the views shown in FIG. 3 , an exemplary size and shape RDDS 380 are illustrated. The dimensions of the RDDS 380 can vary in other embodiments.
[0025] The RDDS has a main support body 386 comprising the structure and frame of the RDDS. It is secured to the ground or other solid surface by a plurality of stanchions 381 , 382 , 383 , and 384 . FIG. 3A illustrates four stanchions 381 - 384 , in other embodiments, other numbers and types of stanchions can be employed. Although not shown in FIG. 3A , the stanchions 381 - 384 can be attached to, or embedded in, a concrete footer or other support structure.
[0026] The main support body 386 enfolds the display 389 . The display 389 shows the airplane's pilot(s) information from the computer receiver. Although there are many possible ways to display the information, that shown in FIG. 3A is a two column 387 and 388 format with the first column 387 listing the fields and the second column 388 displaying the associated data for each field. For example, the first row contains the field “Departure” and the data point “310015”. This is a short-hand way of stating that at the departure location on this runway, the wind is from 310 degrees and is blowing at 15 knots. Although no delineator is shown in FIG. 3A , a period, dash, space, comma, etc. could be used to separate the degrees from the knots. Also, the text could be displayed in different colors. For example, if the winds are strengthening, the “015” could be in red, and if they are weakening, the “015” could be green. As another example, if the knots reading is between zero and ten, it could be displayed in green, between 10 and 20 it could be displayed in yellow, and winds over 20 knots could be displayed in red. Additional information such as increasing or decreasing trends could be displayed as a plus sign or minus sign, respectively, after the knots number. Furthermore, the information could be displayed graphically rather than numerically (for example, an arrow pointing in the direction the wind is blowing and colored as above). Such graphical representations could also be used on computing devices, websites, etc. and the individual pilot or user could customize the type of graph, text, graphical representation, etc. he or she likes to use.
[0027] FIG. 3B illustrates a side elevation view of an exemplary embodiment of a runway digital display sign 380 . The main support body 386 and one stanchion 381 are visible.
[0028] While particular embodiments of the invention have been described and disclosed in the present application, it should be understood that any number of permutations, modifications, or embodiments may be made without departing from the spirit and scope of this invention. Accordingly, it is not the intention of this application to limit this invention in any way except as by the appended claims.
[0029] Particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the invention.
[0030] The above detailed description of the embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise embodiment or form disclosed herein or to the particular field of usage mentioned in this disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. Also, the teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.
[0031] In light of the above “Detailed Description,” the Inventor may make changes to the invention. While the detailed description outlines possible embodiments of the invention and discloses the best mode contemplated, no matter how detailed the above appears in text, the invention may be practiced in a myriad of ways. Thus, implementation details may vary considerably while still being encompassed by the spirit of the invention as disclosed by the inventor. As discussed herein, specific terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated.
[0032] While certain aspects of the invention are presented below in certain claim forms, the inventor contemplates the various aspects of the invention in any number of claim forms. Accordingly, the inventor reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention.
[0033] The above specification, examples and data provide a description of the structure and use of exemplary implementations of the described articles of manufacture and methods. It is important to note that many implementations can be made without departing from the spirit and scope of the invention.
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A runway digital wind indicator system senses wind conditions at multiple locations, aggregates this data, and communicates up-to-date, usable information to pilots. Meteorological information, including wind speed, direction, and change (i.e., gustiness) plus temperature, humidity, barometer, wind shear, etc., can be sensed by three or more sensor pods placed along a runway (at least one at each end and another in the middle of a given runway). Data from these pods is then transferred to a computer receiver that processes the information into a real-time, concise, readable format that can be displayed to air traffic control, sent to runway digital display signs placed in proximity to runways for direct pilot reference, and/or posted to websites/internet locations that can then be used to wirelessly relay the information to any of a plethora of digital devices that can be accessed directly by a pilot.
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REFERENCE TO RELATED APPLICATIONS
This application claims priority to Provisional Patent Application U.S. Ser. No. 60/619,407, entitled “Resettable Latching MEMS Temperature Sensor” and filed on Oct. 15, 2004, which is fully incorporated herein by reference.
GOVERNMENT LICENSE RIGHTS
This invention was made with Government support under contract MDA972-03-C-0010, awarded by the Defense Advanced Research Projects Agency (“DARPA”). The Government has certain rights in the invention.
BACKGROUND
1. Field of the Invention
The present invention relates generally to a thermal bimorph. More particularly, the present invention relates to a micromachined thermal bimorph that displaces laterally.
2. Background of the Invention
Current battery-powered embedded sensor systems often require a low power method of determining when a certain level of temperature has been reached. Typical applications, such as in transportation and shipping monitoring, heating and air conditioning, and food storage, would benefit from the ability to monitor the temperature environment with a completely unpowered sensor. In addition, these applications would benefit from the ability to poll that sensor to determine if a temperature extreme was reached, and then reset the sensor for later use. In either case, an ultra-low power sensor, or even a sensor that consumes no quiescent power, would reduce the overall system power consumption enough to allow embedded sensors to operate for decades in portable battery powered applications, or in systems that scavenge small amounts of power from the environment.
A micromachined thermal bimorph can perform the function of moving a set of miniature contacts into intimate contact when a certain level of temperature is achieved. The resulting device can be used as a temperature trigger sensor that does not require quiescent power to operate. The thermal bimorph could be based on a standard vertical thermal bimorph that moves out-of-plane under temperature loading. However, the temperature trigger sensor for such a device may require complex processing to make contacts and other structures out-of-plane of the microchip. Achieving useful, functional, and complex contact, latching, actuating, and other structures is much simpler on a microchip if performed in the plane of the chip. In order to use those functional structures, a thermal bimorph that moves laterally in the plane of the microchip is required. The present invention is that lateral-moving thermal bimorph. The present invention may be used as a temperature sensitive switch, or in other actuator applications in which lateral movement in response to temperature variation is desired.
Prior inventions have disclosed micro-machined bimorph devices, but none have had the advantages of the present invention in providing lateral movement of a thermal bimorph in response to ambient temperature changes.
For example, US 2004/0084997 A1 discloses a piezoelectric bimorph actuator comprised of two electrorestrictive materials that change length in response to an applied electrical field. This invention claims to provide lateral motion, but the motion is in fact perpendicular to the plane of the materials comprising the bimorph (i.e. vertical rather than in the plane of the surfaces). Also, the components of the bimorph are separately fabricated and then assembled and bonded together, rather than being micromachined in a one-piece structure as is the present invention. This prior art bimorph also requires electrical power to operate.
U.S. Pat. No. 5,382,864 and applications U.S. 2002/0074901 and 2002/0149296 also disclose piezoelectric bimorph actuators that displace vertically in response to an applied electrical field.
Another vertically-moving bimorph is disclosed in US 2004/0164649 A1, which describes a piezoelectric micromachined bimorph in which the two bimorph materials are fabricated separately on separate substrates and then are bonded together.
U.S. Pat. No. 5,463,233 discloses a micromachined thermal switch that uses a thermal bimorph as an electrical switch, but the movement of the thermal bimorph in this invention is also in a vertical direction rather than in the plane of the substrate. Similarly, U.S. Pat. No. 5,917,226 discloses micromachined thermal sensor comprising a thermal bimorph that displaces in a vertical direction.
Finally, U.S. Pat. No. 6,044,646 discloses a micromachined thermal actuator that can move in a direction either in the plane of or normal to the substrate. This actuator, however, does not use a simple bimorph device but employs independently-controllable heaters that require the application of external power to operate
In sum, none of the prior art patents discloses a micromachined thermal bimorph that displaces in a lateral direction in response to ambient temperature changes.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a laterally-moving micromachined thermal bimorph constructed utilizing semiconductor fabrication techniques.
It is a further object of the invention to provide a no-power or low-power thermal bimorph that displaces laterally in response to ambient temperature changes.
It is a further object of the invention to provide a laterally-moving thermal bimorph fabricated as a one-piece micromachined structure, without requiring separately-constructed elements that are then bonded together.
The present invention employs a micromachined thermal bimorph structure. A thermal bimorph is a thin film consisting of two layers of different materials that expand at different rates when exposed to heat, so that one layer expands more than the other upon a temperature increase, and the bimorph bends. In one embodiment of the invention, the thermal bimorph deflects and latches under a temperature load of sufficient magnitude, closing an electrical contact. External circuitry can then be used to poll the temperature sensor. A thermal, capacitive, or other actuator can be used to reset the temperature sensor by disengaging the latch and returning the bimorph to its original position. The sensor will use nearly zero power except when actually providing the trigger signal to the microcontroller or during any reset operation. The sensor can remain latched for interrogation at a later date, even if system power is lost, and the sensor can be reset to detect the next event.
For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
These and other embodiments of the present invention will also become readily apparent to those skilled in the art from the following detailed description of the embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is top view of one embodiment of the invention.
FIG. 2 is a side view of one embodiment of the invention.
FIG. 3 is a perspective view of the end of one embodiment of the thermal bimorph.
FIG. 4A is a high-level flowchart of an embodiment of a process according to the present invention.
FIGS. 4B-4H illustrate steps in the process of fabricating one embodiment of the present invention.
FIG. 5 is a partial top view of the invention illustrating the dovetail dimensions for one embodiment of the thermal bimorph.
FIG. 6 is a partial top view of the invention illustrating the dimensions of one embodiment of the silicon/polymide layers of the bimorph.
FIG. 7 is a schematic diagram of one embodiment of the bimorph used as a temperature sensor.
FIG. 8 is a top view of the illustrated embodiment of the sensor in its normal state and ready to sense temperature extremes.
FIG. 9 is a diagram of one embodiment of the sensor in its latched and contacted state after a temperature extreme has been reached.
FIG. 10 shows the definition of parameters used in the design of the sensor.
FIG. 11 is a diagram of the electrical interconnection of one embodiment of the sensor.
FIG. 12 shows an embodiment of the invention with temperature sensitive contacts that allow operation at lower temperature levels.
FIG. 13 shows an embodiment of the invention with multiple contacts for detection of multiple temperature levels.
Repeat use of reference characters throughout the present specification and appended drawings is intended to represent the same or analogous features or elements of the invention
DETAILED DESCRIPTION
One embodiment of the invention is fabricated in a thick device layer of silicon or other conductor material on a silicon-on-insulator (“SOI”) wafer consisting of the device layer, a buried oxide layer, and a handle wafer. FIG. 1 and FIG. 2 illustrate a top and side view of this embodiment of the invention. In this embodiment, the thermal bimorph 1 consists of a micromachined cantilever beam 24 fabricated from the device layer and a sidewall coating 25 of a second, different material with a coefficient of thermal expansion mismatch to the conductor material. Upon application of a temperature load, the thermal bimorph 1 will bend so that its free end 29 moves in a lateral direction (i.e., in a direction substantially perpendicular to the length of the thermal bimorph 1 and substantially parallel to the etched surface 8 of the handle wafer 20 ). The thermal bimorph 1 is anchored to the handle wafer 20 via anchor 6 . The sidewall coating 25 is shown in FIG. 1 and FIG. 2 as partially removed to illustrate dovetail features 27 of the beam 24 beneath. FIG. 3 is a closer perspective view of the end of the thermal bimorph 1 with the sidewall coating 25 partially removed to show the dovetail features 27 of the beam 24 .
FIG. 4A illustrates the high-level process flow 10 for the process used to fabricate one embodiment of the bimorph. While the following discussion focuses on producing a silicon/polyimide thermal bimorph with the process discussed herein, other combinations of materials and other processes can be employed. FIGS. 4B through 4H illustrate the steps in the fabrication process, viewed from the “free” end of the thermal bimorph.
Employing the process illustrated by FIGS. 4A and 4B , the starting material is an SOI wafer 7 with a handle wafer 20 and a 15-micron thick active silicon device layer 22 separated by a 2 micron thick silicon dioxide layer 21 . With attention to FIG. 4C , which illustrates step 12 ( FIG. 4A ) in greater detail, the SOI wafer is first patterned with photoresist 23 using standard lithography to define a silicon cantilever beam with dovetail features.
FIG. 5 illustrates the beam 24 with its dovetail features 27 . The dovetail features 27 of the beam 24 are designed to improve the adhesion of the subsequent second bimorph material to this first material. The dimensions shown in FIG. 5 illustrate one set of possible dimensions for defining the dovetail, although other dimensions and other surface treatments known to one with skill in the art have been and could be employed to improve the adhesion of the second bimorph material to the first material.
As illustrated in FIG. 4D , which shows step 13 of the fabrication process, a deep silicon reactive ion etch exposes the structure of the beam 24 . FIG. 4E (step 14 ) illustrates a temperature sensitive polymer 25 that is applied by spin coating after the deep silicon etch. This layer of polymer 25 is then patterned as shown in FIG. 4F (step 15 ) to allow portions of the polymer 25 to remain in place along the sidewalls of the beam 24 . This polymer 25 forms the temperature sensitive material for the thermal bimorph.
In one embodiment of the invention, the polymer 25 is deposited with dimensions approximating those illustrated in FIG. 6 (dimensions in microns). The 2 micron overlapping of the polymer 25 onto the silicon 24 at the end of the silicon beam 24 is necessary to allow polymer shrinkage during cure and developing.
As is illustrated in FIG. 4G (step 16 ), after the polymer pattern is transferred and the polymer is developed, the silicon dioxide layer 21 in between the device layer 22 and the handle wafer 20 is removed with an isotropic oxide etch that allows portions of the silicon dioxide layer 21 , specifically those underneath anchors and bond pads (not illustrated), to remain and hold the thermal bimorph to the substrate. (Refer to FIG. 1 for a side view of an anchor 6 showing the partially-removed silicon dioxide layer 21 .) After the silicon 24 /polymer 25 structure is released from the handle wafer, the entire device is coated at an angle with a metal deposition system using a process that places metal 26 on the sidewalls of the structure, as illustrated in FIG. 4H (step 17 ). This metal is critical as it forms the contacts that the sensor uses.
FIG. 7 illustrates a schematic diagram of one embodiment of the invention used as a temperature sensor. In this embodiment, the thermal bimorph 1 includes a contact area 2 and a latch 3 . Under a temperature load, T, the bending moment of the bimorph yields a force, F T , that displaces the bimorph sufficiently to force the latch 3 to engage with a similar latch on a thin flexure or pawl 4 attached to the substrate (not illustrated) via anchors 6 . The force also causes the bimorph contact area 2 to connect with a spring-loaded contact 5 . After latching, the contacts remain closed, and the temperature sensor can then be interrogated by external circuitry (not illustrated). A thermal, capacitive, or other actuator (discussed below) can be used to develop a force, F a , and disengage the pawl 4 and return the bimorph 1 to its original position.
FIG. 8 illustrates an embodiment of the invention that provides both a latch signal and a programmable trigger signal depending on the level of external temperature. The thermal bimorph 1 responds to temperature levels by bending and displacing itself in the +y direction. The latch 3 on the bimorph 1 is separated from the pawl 4 by a predetermined distance selected for the temperature level at which the temperature sensor is desired to latch. If that temperature level is achieved, the bimorph 1 and latch 3 will move the distance required to engage the latch 3 with the pawl 4 . A very flexible beam 50 allows the pawl 4 to move easily perpendicular to the motion of the bimorph 1 , and to engage with the latch 3 to prevent the bimorph 1 from returning to its initial state. At this point, the temperature sensor is in its latched state and a closed contact exists between the bimorph 1 and pawl 4 . This closed contact can connect a wake-up signal to a microcontroller or to allow interrogation by an external reader. FIG. 9 illustrates the temperature sensor in a latched state.
In addition, when the bimorph is deflected by a temperature, the contacts 2 on the sidewalls of the latch 3 may connect with the contacts 5 that are anchored to the substrate. The surface of the contact sidewalls ( 2 and 5 ) are designed to provide reliable and low-resistance contact. The contact actuator 51 connected to the contacts 5 allows the distance between the contacts 5 and the latch contacts 2 to be varied, thereby modifying the temperature level required to make contact and providing user programmability. When the contacts 5 connect to the latch contacts 2 , a circuit can be closed that can provide a signal to a microcontroller or be interrogated by an external reader. The temperature level for making a contact between the bimorph and the primary contacts may or may not be the same as that for latching depending on the setting of the contact actuator and the design of the latching mechanism. In other embodiments of the invention, the latching temperature can be adjusted as well.
The temperature sensor is designed to be reset after the sensor (in its latched state) is read or used to provide a signal to an external system. The invention includes a mechanical linkage 52 on the pawl 4 that creates a mechanical connection to a unidirectional reset actuator 53 . When the temperature sensor is unlatched and ready to sense a temperature event, the mechanical linkage 52 is not in contact with the pawl 4 . As the temperature event occurs, the latch 3 on the bimorph 1 makes contact with the pawl 4 and forces it to move perpendicular to the motion of the bimorph 1 . The mechanical linkage 52 decouples the latching motion of the pawl 4 from the reset actuator 53 . Without this mechanical linkage, the reset actuator 53 would apply a stiff resistance to the latching motion, making the sensing of low temperature levels difficult.
After the sensor is in a latched state, the reset actuator 53 can be forced to pull in a direction that will engage the linkage 52 with the pawl 4 . The illustrated embodiment of the invention uses for the reset actuator 53 a thermal actuator that deflects when a specific amount of current is run through the device. Once the actuator 53 is engaged with the pawl 4 , the force from the reset actuator 53 will pull the pawl 4 away from the bimorph 1 . When sufficient force is applied, the latch 3 and pawl 4 disengage, thereby releasing the bimorph 1 and allowing it to return to its initial position. At this point, the sensor is ready to monitor another temperature event.
FIG. 10 defines the primary parameters used to design one embodiment of the sensor to detect specific levels of temperature. For a thermal bimorph, the radius of curvature, R, at temperature, T, is given approximately by:
R = wa + wb 6 ( α a + α b ) ( T - T o )
where wa and wb are the widths of materials A and B respectively in the bimorph, α a and α b are the coefficients of thermal expansion for materials A and B respectively, and T o is the temperature at which the bimorph is not bent.
The amplitude of the deflection of the thermal bimorph is dependent on the radius of curvature and beam length, and is given by:
Δ y = R * ( 1 - cos ( l R ) )
where Δy is the beam displacement, R is the radius of curvature, and l is the length of the beam.
A device will latch if the bimorph deflection is greater than the distance of the latch gap plus the distance across the tip of the pawl, and can be expressed by the following latching condition:
Δ y > lg + lp , or ( T - T o ) > ( wa + wb ) * ( lg + lp ) 3 ( α a - α b ) * l 2
where lg is the latch gap distance and lp is the distance across the tip of the pawl over which the latch structure must traverse to latch. That distance is defined by the geometry of the tip of the pawl.
Table 1 below contains the temperature levels required for latching the sensor in one embodiment of the invention given Material A width of 10 μm, Material B width of 10 μm, and latching gap of 10 μm for a variety of bimorph lengths.
TABLE 1
Table of design parameters versus temperature levels for latching
Temperature Level
Bimorph Beam Length, lb
50° C.
375 μm
75° C.
263 μm
100° C.
215 μm
125° C.
186 μm
In one embodiment of the invention Material A is silicon and Material B is Polyimide. Other metals would be suitable for use as Material A, and other materials would be suitable for use as Material B, provided that the materials have a large enough coefficient of thermal expansion mismatch to yield a deflection large enough to close the latch gap.
Table 2 below contains test results thermal testing of an embodiment of the invention containing a 500 micron-long beam with an eight (8) micron-wide silicon layer and a sixteen (16) micron-wide polyimide layer.
TABLE 2
Results of Thermal Test of Thermal Bimorph
Temperature
Bimorph Movement
(degrees C.)
(microns)
25
0.0
30
0.0
50
1.0
100
3.0
125
5.0
150
7.0
In one embodiment of the invention, the temperature sensor is used to wake up a microcontroller in an embedded sensing application. In other embodiments, the device is used in standalone applications where the sensor is connected to an RFID tag or other transmitter for remote determination of the temperature environment experienced by shipping containers and products. Similar devices for other environmental variables such as shock, humidity, and chemical concentrations can be developed using the principles disclosed herein.
FIG. 11 illustrates a wiring schematic for an embodiment of the invention that is used for waking up an embedded microcontroller from a sleep mode when a certain temperature level is experienced. In this embodiment, a voltage difference is applied across actuators 53 and 51 . In operation a single bias signal is applied to the bimorph 1 of the device. The bias signal could be a voltage or current depending upon the type of readout circuit used. Connections to the external contacts and pawls would be outputs to which the bias signal is connected. These outputs could be connected to microcontroller interrupt lines, to a wireless transceiver, to a large circuit network that performs some function, or a number of other connection and circuits.
Although several embodiments and forms of this invention have been illustrated, it is apparent that those skilled in the art can make other various modifications and embodiments of the invention without departing from the scope and spirit of the present invention. For example, other configurations of the sensor are possible that utilize varying surface features on the contacts, multiple movable contacts, and different actuator types.
One particular embodiment of the invention, shown in FIG. 12 , uses the sidewall 40 of a second thermal bimorph 41 as a moving contact to connect with the sensor's main latching bimorph 1 . When a temperature load is applied, the moving contact 41 will move out of the way of the main latching bimorph 1 during the latching operation, thereby reducing the amount of force required to meet the latching condition. After the latching occurs and the temperature load is removed from the device, the moving contact 41 will return to its original position and make a connection with the device's main latching bimorph 1 . This configuration is useful when designing low temperature trigger devices where the bending force may be insufficient to overcome the retarding force created by the stationary electrical contacts.
Another embodiment, shown in FIG. 13 , includes multiple contacts 70 and multiple latches 71 to allow one sensor device to trigger at and latch at multiple temperature levels that the bimorphs 1 are subjected to.
Another embodiment of the device (not illustrated) uses a capacitive actuator for reset functions instead of a thermal actuator. A capacitive actuator consumes less power but would be suitable for lower force and lower temperature level applications. The configuration would require additional capacitive actuators on the bimorph to move it out of contact with the pawl, thereby eliminating the friction that holds the pawl in contact with the latch. At that point another capacitive actuator could move the pawl out of position, after which the actuator on the bimorph is released, followed by the release of the pawl, at which point the sensor is unlatched and ready for another sensing operation.
Furthermore, other fabrication processes for the device are possible. Any fabrication process that realizes a single thick micromechanical structural layer with 1) conducting sidewalls that can make electrical contact, and 2) sidewall deposition of a material with a different coefficient of thermal expansion from the main micromechanical structural layer can be used to fabricate the device. Examples include bulk micromachining and wafer-bonding fabrication approaches in silicon, silicon dioxide, nickel, titanium and other conductors, as well as LIGA-type fabrication processes using electroplated metals.
Although the embodiments illustrated herein show temperature sensors in which the bimorph responds to temperature increases in order to cause either contact or latching of the sensor, the bimorph also responds to temperature decreases, by bending in the opposite direction. Therefore, other embodiments contemplated that are within the scope of the present invention include devices which sense either temperature decreases or both increases and decreases with the same thermal bimorph. And, for the purposes of this specification, a temperature “load” is defined as either a temperature increase or a temperature decrease.
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The Lateral-Moving Micromachined Thermal Bimorph provides the capability of achieving in-plane thermally-induced motion on a microchip, as opposed to the much more common out-of-plane, or vertical, motion seen in many devices. The present invention employs a novel fabrication process to allow the fabrication of a lateral bimorph in a fundamentally planar set of processes. In addition, the invention incorporates special design features that allow the bimorph to maintain material interfaces.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to cleaning burrs, sticks and trash from harvested cotton mounted upon the same machine which carries the harvester.
(2) Description of the Prior Art
Previously, I have patented a stripper and cleaner combination. See my previous U.S. Pat. Nos. 3,035,312 and 3,423,797.
Also, it is common in the seed cotton cleaning art to snag locks of seed cotton upon a saw cylinder and brush them against knocker bars or grids to knock the burrs, sticks and trash from the locks of seed cotton and to doff seed cotton from the saw cylinders with rotating brush cylinders. Also, to pass the burrs, sticks and trash removed from the seed cotton past a reclamation cylinder to reclaim any cotton contained therein is known to the prior art.
SUMMARY OF THE INVENTION
(1) New and Different Function
I have invented an improved machine and method of operation wherein the air flows through the periphery of the saw cylinder to within the cylinder thereby insuring that all locks of seed cotton are snagged by saws along the periphery.
It will be understood that cotton strippers operate at high rates and often will strip over a ton (2200 lbs) within ten minutes. Therefore, it is necessary that the cleaning mechanisms operate extremely efficiently to handle this amount of cotton within the time period allotted. Also, for the benefit of the physical arrangement of the equipment, as well as better handling of the cotton, I have found it desirable to move the reclaimed cotton into the stream of unclean cotton rather than into the stream of finished cotton as is customary.
Furthermore, I have found that a cylinder with a very large diameter will handle more cotton for a given length of cylinder than a cylinder of a smaller diameter.
OBJECTS OF THIS INVENTION
An object of this invention is to remove burrs, sticks and trash from seed cotton.
Further objects are to achieve the above with a device that is sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, install, adjust, operate and maintain.
Other objects are to achieve the above with a method that is versatile, ecologically compatible, energy conserving, rapid, efficient, and inexpensive, and does not require skilled people to install, adjust, operate, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing, the different views of which are not scale drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cotton stripper and basket mounted upon a tractor with an elevator cleaner according to this invention.
FIG. 2 is a schematic representation mainly in section showing the improved elevator cleaner.
FIG. 3 is a partial perspective of the main saw cylinder showing the spaces and construction of the saw strips thereon.
FIG. 4 is a sectional detail of the spokes on the axle of the main saw cylinder.
FIG. 5 is an end elevational view of the main doffing cylinder.
FIG. 6 is a sectional view of the main saw cylinder and doffing cylinder with parts broken away to show the attachment of the moveable knocker grids thereon.
FIG. 7 is a detail perspective of the connection between the ends of the two knocker segments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, tractor 10 has cotton stripper 12 attached thereto. As is conventional, the cotton is stripped and conveyed back to elevator duct 14. The tractor also carries basket 16 upon it and the seed cotton as stripped by the strippers 12 is moved through elevator duct 14 into basket 16. Fan 18 is at the bottom of the elevator duct 14 and it takes the cotton from the stripper 12 and blows it upward. The cotton is received by the elevator duct and the lower portion of it is herein called inlet section 20.
Those having ordinary skill in the art will understand that the basic arrangements and elements described to this point are old and well known in the art.
According to my invention, the cotton in the air is carried upward to main saw cylinder 22. As may be seen, the elevator cleaner is mounted upon tractor 10 with the elevator cleaner having a longitudinal axis and its longitudinal axis extending upward. The elevator cleaner as a whole has the main saw cylinder 22 near the top and the inlet section 20 at the bottom.
The main saw cylinder 22 has saw strips 24 mounted upon peripheral longitudinal bars or plates 26. The peripheral plates are angled in the direction of rotation of the saw cylinder so that the peripheral plates act similar to fan blades to pull the air from the outside of the cylinder to the inside of the cylinder 22. The saw strips 24 are spaced apart and there is no other peripheral covering over the plates 26. Therefore, there is an open air space between the saw strips 24 so that the air can pass between the saw strips into the interior of the main saw cylinder 22. The air moves from the inside of the saw cylinder 22 out to the ambient air. The cylinder has basically the same width as the main duct 14 at this point, which would also be the width of the elevator cleaner. The ends of the saw cylinder are open to permit the expulsion of the air out the ends of the main saw cylinder which is out into the atmosphere. The drawings show a channel type saw strip, however, those having skill in the art will understand that oftentimes a single saw band is helically wound upon the cylinder and that the peripheral plates 26 could be notched to receive such bands.
Spokes 28 support the rims 30 of the main saw cylinder and are also angled outward so that they act as axial flow fan blades to push the air from the inside of the saw cylinder out into the atmosphere. Although I prefer the spokes to have a propeller like cross section, i.e., to have a rounded nose 32, with a sharpened trailing edge 34, it will be understood by those having ordinary skill in the art, they could be of other configuration. Also, in certain design configurations, it may be decided to make the spokes of no particular "fan" configuration but merely depend upon the fan 18 to move the air up through the duct and through the periphery of the saw cylinder between the saw strips 24 and out the ends of the saw cylinder into the atmosphere. However, I prefer to aid the movement of the air with the axial flow fans built into the spokes of the saw cylinder and also to aid, as much as possible, the flow of the air, by having plates 26 angled toward the direction of rotation so that they too aid in the flow of the air as described. The plates 26 are attached to the rims 30.
The spokes 28 are attached to the main cylinder axle 29 which are rotatably mounted within bearings 31 suitably supported along housing 62 of the elevator cleaning which might also be considered to be the housing of the main duct 14. The main saw cylinder is rotated in the direction as indicated in FIG. 2 by suitable drive means such as a V-belt which would be entirely within the skill of the art. The drive means for this or the other rotating elements has not been shown for clarity of the drawings and conciseness of the specification.
The seed cotton snagged upon the teeth of the saw strips 24 are carried by beater bars and on to the main doffer cylinder 36 which is mounted immediately above or at the top of the main saw cylinder 22. The doffer cylinder 36 has alternate brush strips 38 and flat strips 40, therefore, seed cotton is doffed from the main saw cylinder 22 and also it is doffed with sufficient force and carrying sufficient air with it that it is moved through basket chute 42 into the basket 16. The flat strips 40 are conveniently made of rubber reinforced with canvas and this material is commonly called "belting". However, many flexible or pliable strips of material are suitable for this purpose. The brushes 38 are well known in the art and commercially available on the market.
It will be understood that the cotton strippers will harvest cotton at a rapid rate and, therefore, it is necessary to have a high capacity saw cylinder to carry the cotton at a rapid rate. I have found, by making the diameter of the saw cylinder 22 at least 4 feet (1.2 meter) that it will carry cotton at a rate by which it is stripped from the plant. Also, I have found that passing the air blast through the saw strips aids in fully loading the saw strips and, therefore, in maintaining a high rate of movement of the cotton.
To aid in the holding of the locks of seed cotton that are snagged on the teeth of the saw, cylinder roller 44 is mounted adjacent to the main saw cylinder immediately before the saw cylinder 22 brings the cotton to the knocker bars. If a roller is not used, a brush or flap as is known in the art would be used.
The main grid of knocker bars are mounted so that the grid is easily moveable away from the saws. Two arcuate segments are used. A first segment 46 and second segment 48 are attached together by expansion joint between them so that they can move apart. This is particularly seen in FIGS. 6 and 7. Each segment is about a little over 1/4 of a circle or about 95°. The segments include arcuate rims 50. Stud 52 at each end of the rim is held by loop 54 of eye bolt 56. A pair of lock nuts 58 on the eye bolt limit the inward travel of the segments 46 and 48 against bracket 60. The brackets are conveniently attached to the housing 62 of the elevator cleaner. The first segment 46 includes about six widely spaced cross rods 64. These are widely spaced apart so that sticks and burrs can readily pass between them as the cotton is knocked against them. Following behind these are closely spaced knocker bars 66 for the removal of trash and the like.
The end of the first segment is bifurcated at 68 so that it slides over the stud 52 in the end of the leading edge of the second segment 48. Therefore, it may be seen as the segments may move back and forth from the saws as wads of cotton or stumps or rocks may pass through it is possible for them to expand outward.
As the burrs, sticks and trash are knocked free from the teeth of the saw strips 24, they are caught in burr chute 70 which terminates at the reclamation saw cylinder 72. The reclamation saw cylinder likewise has a brush or flap 74 to aid in getting the material against the reclamation saw 72 so that the teeth of the saw may reclaim any locks of seed cotton found therein. However, burrs and the like which might be therein readily pass through widely spaced reclamation knocker rods 76. These burrs, sticks and trash are expelled directly outside of the elevator cleaner, i.e., back upon the land from which the cotton was harvested. Any cotton reclaimed by the reclamation saw is doffed by reclamation doffer cylinder 78. The doffed seed cotton goes through reclamation chute 80 back into the main duct 14 with the harvested seed cotton going to the main saw cylinder 22.
The embodiment shown and described above is only exemplary. I do not claim to have intended all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of my invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. The restrictive description and drawing of the specific example above do not point out what an infringement of this patent would be, but are to enable the reader to make and use the invention.
As an aid to correlating the terms of the claims to the exemplary drawing, the following catalog of elements is provided:
______________________________________10 tractor 44 roller12 stripper 46 first segment14 duct 48 second segment16 basket 50 rims18 fan 52 stud20 inlet section 54 loop22 main saw cylinder 56 eye bolt24 saw strip 58 lock nut26 plate 60 bracket28 spoke 62 housing29 axle 64 rods30 rims 66 bars31 bearing 68 bifurcated32 nose 70 burr chute34 trailing edge 72 reclamation saw36 doffer cylinder 74 brush38 brush strips 76 reclamation rods40 flap strips 78 reclamation doffer42 basket chute 80 reclamation chute______________________________________
SUBJECT MATTER CLAIMED FOR PROTECTION
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Seed cotton harvested by a stripper is blown upward along a duct to an open saw cylinder. The locks of cotton are snagged on the teeth of the saws of the saw cylinder while the air passes to within the saw cylinders and out the ends of the saw cylinder. The locks of cotton knocked from the saw cylinder are reclaimed by a reclamation saw and doffed into the main duct to again be brought to the main open saw cylinder. The seed cotton is doffed from the open saw cylinder into an overhead basket of the cotton harvester.
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TECHNICAL FIELD
The present invention relates generally to drills and drill bits. More specifically, the present invention relates to carbide drill bits for composite materials.
BACKGROUND
Multi-layer laminates such as carbon fiber-reinforced composites (CFRP) and fiberglass composites (FRP) are widely used in a large number of applications. These laminate materials most often consist of woven layers of strong fibers that are often coated with resins and processed or cured to form a solid structure. Depending on the choice of the fiber and the resin systems used, these materials can be formulated and molded to produce components with excellent mechanical properties and unique geometries that would be difficult or impossible to obtain using other materials.
The properties of high strength CFRP materials may be widely varied by manipulating the characteristics of the matrix formulation, as well as the fiber type, content, orientation, buildup, and the methods used to shape these materials into a finished structure. This variability and the general strength of the CFRP materials make them useful in a wide variety of applications, ranging from bicycle frames to aircraft structures.
The reinforcing fiber most widely used in aircraft structures is a carbon fiber produced by the thermal decomposition of polyacrylonitrile (PAN). Such thermal decomposition coverts the PAN fiber to a pure carbon fiber that is highly abrasive and very strong. In some specific examples, such carbon fibers are reported to have tensile strengths of about 800,000 psi and a modulus of about 40 million psi. Such carbon fiber materials are produced by a number of companies such as Toray, Toho Tenax, Cytec, Hexcel, and Mitsubishi Rayon.
In producing structures such as aircraft components, these high-strength fibers typically are first woven into thin sheets and combined with resins to form flat sheets of composite referred to as “prepregs”. Components such as composite skin sections of aircraft may be produced by placing multiple layers of such prepregs in molds and then using pressure and heat to shape and cure them into a complex wing surface, for example. Alternatively, components may be constructed by chopping carbon fibers into shorter lengths and blending them with resins to produce a compound suitable for use in compression molding or resin-transfer molding.
CFRP laminate parts have been used in the manufacture of aircraft for several years. In one example, the 777 aircraft manufactured by Boeing uses CFRP for the passenger cabin floor beams, for the vertical and horizontal tails, and for aerodynamic fairings. Overall, CFRP-based components make up about 9% of the structural weight of this aircraft.
Composite components such as aircraft parts are often joined together or to other materials by fasteners. Processes used to join such components generally include the steps of drilling and countersinking a precision hole in the structures to be joined and then inserting a close-fitting fastener in a secure manner. Drilling of CFRP components is often difficult as a result of the highly abrasive nature of the material and has a tendency to delaminate and fray when processed using conventional drill bits. One of the more serious problems experienced in drilling CFRP occurs when the exit of the drill bit from the produced hole leaves uncut fibers exposed in the hole. Such fibers then may interfere with the proper fit of the fastener used to join the materials.
While many of the components lend themselves to being manufactured with NC or CNC drilling machines, there remains a portion of the holes in the structure that cannot be manufactured with such equipment and may require a hand held air drill motor to be used. Such drill motors are produced by companies such as Cooper Tools and are often used in conjunction with a hand held guide bushing.
When drilling holes with a hand drill in CFRP, the infeed of the drill bit into the material may be regulated by the operator who forces the drill bit into the material. Unfortunately, the drill bit may often surge at the point it exits the material on the backside, due to a lack of a controlled feed, resulting in uncut fibers. Even with considerable skill and experience, an unacceptable hole is often produced by this method.
The existing practice is to use a four flute straight flute drill bit design. (See FIG. 1 ). Such straight flute drill bits are often difficult to control at exit and in addition may produce a star shape hole as opposed to a round hole in the material. The uncut exit fibers combined with the star shaped hole may result in a less than optimum fit of the fastener in joining the materials.
Hole quality often has a direct bearing on the fatigue properties of the fastened joint. Such properties are documented by fatigue tests. Fatigue results for parts fastened with inferior hole quality. Such inferior hole quality often shows a marked reduction in fatigue life adversely affecting the suitability of the components in advanced aircraft structures.
As a result, it would be desirable to provide drill bits and methods of their use to produce cleaner holes with an improved roundness. Furthermore, it would be desirable to provide drill bits and methods of their use to produce holes using hand drill motors in advanced composite materials such as CFRP that improve the roundness of the hole and eliminate uncut fibers at the exit allowing for an improved fit between the fastener and the hole, thereby resulting in improved fatigue results for these joints.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of a drill bit representative of the current state of the art;
FIG. 2 is a photograph of a series of exit holes produced in a carbon fiber reinforced plastic composite laminate material using a tungsten carbide drill bit of the type shown in FIG. 1 ;
FIG. 3 is a photograph of a series of exit holes produced in a carbon fiber reinforced plastic composite laminate material using an embodiment of a tungsten carbide drill bit according to the present invention;
FIG. 4 is a side plan view of an embodiment of a drill bit according to the present invention;
FIG. 5 is a detailed side plan view of an embodiment of the tip portion of a drill bit according to the present invention;
FIG. 6 is an end view of the tip of an embodiment of a drill bit according to the present invention; and
FIG. 7 is a flow diagram of a method for using an embodiment of a drill bit according to the present invention.
SUMMARY OF THE INVENTION
In an embodiment, a drill bit for producing holes in composite materials is disclosed. The drill bit includes an elongate drill bit body having a drill bit diameter. The drill bit also includes at least two helical flutes. The helical flutes have a reverse helix angle and a primary cutting edge. The primary cutting edge has a positive rake angle. The drill bit further includes a point having a point length. The drill bit also includes a cutting tip with a tip angle and a tip length. The tip length is at least twice the drill bit diameter.
In another embodiment, a drill bit is disclosed. The drill bit has an elongate drill bit body with a drill bit diameter. The drill bit also has at least two helical flutes. The helical flutes have a reverse helix angle. The helical flutes also have a primary cutting edge with a positive rake angle. The drill bit has a point with a point length of approximately half the drill bit diameter. The drill bit also has a cutting tip with a tip angle and a tip length.
In a further embodiment, a drill bit for producing holes in composite materials is disclosed. The drill bit has an elongate drill bit body having a drill bit diameter. The drill bit also has at least two helical flutes. The helical flutes have a reverse helix angle of at least 0.5 degrees. The helical flutes also have a primary cutting edge with a positive rake angle. The drill bit includes a point having a point length of approximately half the drill bit diameter. The drill bit also includes a cutting tip with a tip angle of from approximately 17 degrees. The cutting tip has a tip length of at least twice the drill bit diameter.
The helical flutes, in some embodiments, have different helix angles. For example, in some embodiments, the helical flutes have a helix angle of at least 0.5 degrees. In other embodiments, the helical flutes have a helix angle of 0.5 to 10 degrees. In further embodiments, the helical flutes have a helix angle of 2 to 5 degrees.
In some embodiments, the cutting tip has a tip angle of from about 12 degrees to about 30 degrees, with a preferred angle of about 17 degrees. The point has a point length approximately half the drill bit diameter, in other embodiments.
The primary cutting edge, in some embodiments, has a positive rake angle of at least 6 degrees. In other embodiments, the primary cutting edge has a positive rake angle of at least 10 degrees. In further embodiments, the primary cutting edge has a hook geometry.
In alternative embodiments, the cutting edges may have a positive radial rake. In some embodiments, the radial rake is greater than 6 degrees. In other embodiments, the radial rake is greater than 10 degrees. In still other embodiments, the radial rake uses a hook geometry.
In some embodiments of the drill bit, the flute is a helical flute, which may include a reverse spiral. Some embodiments have a helical flute of at least 0.5 degrees, while other embodiments have a helical flute between 0.5 and 10 degrees. Still other embodiments have a helical flute between 2 and 5 degrees.
A method for using a drill bit is also disclosed. In many embodiments of the method a drill bit is provided that includes a shank with a receiving portion, a point portion, and at least one cutting edge. A material to be drilled is also provided in many embodiments. In one embodiment, a hand drill motor is provided, the drill bit is fixed in the hand drill motor, and the hand drill motor and drill bit are used to drill a hole in the material. In other embodiments, a mill, a lathe, a CNC mill, or a CNC lathe is provided. The drill bit is fixed in the drilling machine, and the drilling machine and drill bit are used to drill a hole in the material.
DETAILED DESCRIPTION
The embodiments of the present invention will be best understood by reference to the drawings. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the drill bits of the present invention, as represented in FIGS. 3 through 7 , is not intended to limit the scope of the invention, as claimed, but is merely representative of present embodiments of the invention. In order to illustrate a practical use of the drill bits of the present invention, the following description will illustrate the use of the drill bits in connection with advanced composite materials, such as CFRP. Of course, the drill bits of the present invention may be configured to drill materials such as wood, masonry, metals, and any other present or future materials.
Referring first to FIG. 1 , a side plan view of a prior art drill bit 10 configuration is shown. The drill bit 10 has an elongated cylindrical shaft 12 with a central longitudinal axis 14 , and an outside diameter 16 . The drill bit 10 has four symmetrical straight flutes 20 a , 20 b , 20 c (the fourth flute is not shown in FIG. 1 , but would be behind flute 20 b ) traveling a portion of the shaft 12 . The flutes 20 a , 20 b , 20 c terminate in a cutting tip 30 . The intersection of the flutes 20 a , 20 b , 20 c with the cutting tip 30 of the drill bit 10 does not create an axial rake face because the flutes 20 a , 20 b , 20 c do not have a helix angle.
The apparatus and method of the present invention have been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available drill bits and related hardware and methods used in drilling advanced composite materials such as CFRP by use of hand drill motors. The drill bit configurations of the invention provide unique drill bits that may produce close tolerance precision holes in advanced composite laminates with minimal delamination and clean exit holes. FIG. 2 shows the exit side of holes 2 a , 2 b , 2 c , 2 d , 2 e , 2 f , 2 g produced by the present state of the art, while FIG. 3 shows the exit side of holes 3 a , 3 b , 3 c , 3 d , 3 e , 3 f , 3 g produced by an embodiment of a drill bit made in accordance with the present invention.
As seen in the embodiment of FIG. 4 , the drill bit 410 may combine four symmetrical left hand helical flutes 420 a , 420 b , 420 c (the fourth flute is not shown in FIG. 4 , but would be behind flute 420 b ) with a helix angle 424 of 0.5 to 10 degrees. The helical flutes 420 a , 420 b , 420 c are blended into a long narrow cutting tip 430 with two of the flutes 420 a , 420 c reaching to the center to provide a faceted point 440 . The drill bit 410 may have an elongated cylindrical shaft 412 with a central longitudinal axis 414 , and an outside diameter 416 . The helical flutes 420 have a helix angle 422 measured from the longitudinal axis 414 .
Helical flutes may create a more stable contact of the drill bit with the hole wall avoiding the star pattern produced by non-helical drill bits. However, a conventional right hand helix may cause the drill bit to grab in the material at the exit and stop rotating. Such grabbing may be very dangerous to the wrist of the operator as the motor continues to apply a torque to rotate the drill bit and drill while at the same time the operator typically must suddenly counterbalance these forces when the drill bit grabs and binds in the material. Although it is often desirable to have a helical drill bit to create a round hole, this tendency to grab makes a drill bit with a right hand helix less desirable for many applications due to the difficulty it may cause the operator.
An embodiment of a drill bit 410 for drilling advanced composite laminates such as CFRP may be used with hand held drill motors without positive feed control. Hand drilling often presents unique challenges as the operator must regulate the advance of the drill bit 410 by the force he or she applies to the drill motor as the drill bit 410 is pressed against the material to be drilled. Although several embodiments of drill bits 410 according to the present invention have been designed for hand operation of a drill motor without feed control, this drill bit 410 may often be used in systems with feed control without any adverse performance. In fact, when some embodiments of the drill bit 410 are used with CNC equipment or positive feed control, the process may be more effective.
In one embodiment of the invention, the helical flutes 420 a , 420 b , 420 c are reverse spiral or left hand flutes in the range of from 0.5 to 10 degrees. In other embodiments, the helical flutes 520 a , 520 b , 520 c are reverse spiral or left hand flutes in the range of 2 to 5 degrees as shown in FIG. 5 . The embodiment of FIG. 5 may counterbalance the thrust forces applied by the operator when drilling the hole thereby allowing the drill bit 510 to slowly exit the CFRP material and avoid the damage that often occurs with drill bits 10 of a straight flute design. Additionally, the drill bits 510 of this embodiment typically do not grab as with the conventional or right hand flute design, thereby eliminating many potential risks to the operator. Further, the holes produced by this embodiment of a drill bit 510 were typically found to be round and of good quality even with inexperienced operators.
The embodiment of a drill bit 510 of FIG. 5 is shown with four helical flutes 520 a , 520 b , 520 c (the fourth flute is not shown in FIG. 4 , but would be behind flute 520 b ) but other embodiments may use multi flute configurations such as two, three, four, five or six or more flutes 520 . The present embodiment is shown with a very long narrow cutting tip 530 with an included tip angle 532 of about 17 degrees. In other embodiments, the included tip angle may range from about 12 to about 30 degrees. The cutting tip 530 has a tip length 534 , which in some embodiments, is approximately two times the diameter 516 of the drill bit 510 . The point 540 of the drill bit 510 may also be truncated with a point length 542 that makes up approximately one-half the diameter 516 of the drill bit 510 . Typically a truncated point 540 may be finished with an approximately 118 degree point, but point angles 544 of larger and smaller angles may also be used. For example, the point 540 may be finished with a point of from about 90 degrees to about 135 degrees.
The embodiment of a drill bit 510 as shown in FIG. 5 with left hand helical flutes 520 a , 520 b , 520 c has the cutting characteristics of a right hand drill bit. This may be accomplished by introducing 10 to 15 degrees of positive radial hook in the face 550 of the flute 520 where it intersects with the primary cutting edge 522 of the drill bit 510 . The unique combination of grinds used to form this drill bit 510 may create a positive axial rake of 0.5 to 5 degrees. These positive rakes typically present a very sharp primary cutting edge 522 to the drill bit 510 to shear the fibers as the drill bit 510 exits the part.
A shorter cutting tip length 534 may delaminate the exit side layer of the composite materials. In order to prevent delamination, the cutting tip length 534 may be varied by changing the included tip angle 532 or the point angle 544 .
The left hand or reverse helix angle 522 is used, in some embodiments, with a very modest angle of about 2 degrees, which may affect the way the drill bit 510 feeds into the material and may prevent the drill bit 510 from surging as the cutting tip 530 exits out the back side. In embodiments with a slight helix angle 522 , the drill bit may create a finished hole that better approaches a true circle than a drill bit 10 without any flute angle.
FIG. 6 illustrates an embodiment of a drill bit 610 with a cutting angle 660 that uses a positive “hook” or radial rake. This feature in the drill bit 610 may allow the cutting edge 622 of the helical flutes 620 at the extreme outer diameter 616 of the drill bit 610 to engage the material with a very positive cutting angle 660 decreasing the cutting forces between the drill bit 610 and the wall of the material. In some embodiments, the cutting angle 660 is a hook that measures in excess of 6 degrees. In other embodiments, the cutting angle 660 is a hook that measures greater than 10 degrees, which may provide the shearing action needed to provide a clean cut to the material. Although other grinds may produce a positive radial rake 660 at this intersection, the use of a “hook” geometry, in some embodiments, may yield a stronger tool design than other geometries. The generation of a highly positive radial rake 660 and the exact geometry used to create that rake may be varied in some embodiments. The point configuration used in the embodiment of FIG. 6 may provide less delamination when drilling composite materials.
FIG. 7 is a flow diagram of an embodiment of a method 700 for using an embodiment of a drill bit of the present invention. A drill bit 410 , 510 , 610 of the present invention may be provided 702 . A drilling machine may also be provided 704 . A drilling machine may be a hand drill motor, a drill press, a mill, a lathe, an NC mill (including a CNC mill), an NC lathe (including a CNC lathe) or any other drilling machine that may be used to drill a hole. The drill bit 410 , 510 , 610 may be fixed 706 in the drilling machine. This may include inserting the drill bit 410 , 510 , 610 into the drilling machine and tightening a chuck or other mechanism for fixing a drill bit in a drilling machine.
A material to be drilled may also be provided 708 . The material may be an advanced composite like those discussed above, or may be any material through which a hole may be desirably drilled, such as wood, metal, masonry, etc.
The drilling machine and drill bit 410 , 510 , 610 may be used 710 to drill a hole in the provided material. This may include fixing the material in a vise or jig in order to prevent the material from moving while drilling. In the case of an NC machine, this may include programming the NC machine to drill in desired locations. In the case of a hand drill motor, the user may hold the material in place by hand.
The methods disclosed herein comprise one or more steps or actions for achieving the described method. The method steps and/or actions may be interchanged with one another without departing from the scope of the present invention. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified without departing from the scope of the present invention.
While specific embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise configuration and components disclosed herein. Various modifications, changes, and variations which will be apparent to those skilled in the art may be made in the arrangement, operation, and details of the methods and systems of the present invention disclosed herein without departing from the spirit and scope of the invention.
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A drill bit for producing holes in composite materials is disclosed. The drill bit includes an elongate drill bit body having a drill bit diameter. The drill bit also includes at least two helical flutes. The helical flutes have a reverse helix angle and a primary cutting edge. The primary cutting edge may have a positive rake angle. The drill bit further includes a point having a point length. The drill bit may also include a cutting tip with a tip angle and a tip length. The tip length is at least twice the drill bit diameter.
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TECHNICAL FIELD
The present invention relates to an improved centrifugal pump.
BACKGROUND
Centrifugal pumps are the most common type of pump. A centrifugal pump has two main components, one moving and one stationary. The moving component consists of an impeller and a shaft and the stationary component consists of a housing.
Dynamic pumps, whether they have a standard impeller or a disc design impeller, have a common problem. The problem is the need to have a seal between the inlet (low pressure) side and the outlet (high pressure side). Many attempts have been made to correct or “seal” this problem. The result has always been the same. When the gasket or material sealing the gap between the high and low pressure sides of the pump are worn, the fluid, or material being pumped, leaks between the two. This is primarily caused by the inability of the internal features of the pump to close the gap when the gasket wears away.
Since all efforts have failed to cure this problem, manufacturers have abandoned sealing efforts and have instead designed pumps with a close tolerance to try to control the amount of “blow-by” or leakage between the inlet and outlet. Engineering their pumps in this fashion has made them inefficient. Most estimates show this efficiency to range from 8% to 20% so that the energy being spent to move fluid or material is also being wasted by 8% to 20%. Applicant's new improved pump is more efficient.
In order for a dynamic pump to maintain good pressure, the tolerance between the impeller and the housing must be very close. This prevents or controls the amount of blow-by or mixture of high and low sides. Because this tolerance or gap is so close, any solids in the material being pumped can clog, foul or build up over time and cause friction between the impeller and housing. A small piece of hard material, such as granite, can lodge itself in this gap and physically stop the impeller. This sudden stop most always ends with damage to the equipment. Motor couplings and keyways are designed to reduce costly pump damage, but more often than not, permanent damage will occur to the impeller or housing.
When pumping fluid with a dynamic pump, it almost always has to be primed. While in service, air pockets in the feed line will cause gas or vapor lock. Applicant's improved pump will act as a fan to pump through the air or gas and pull the fluid to the pump. This eliminates the need to prime.
SUMMARY OF THE INVENTION
The invention is a centrifugal pump comprising a housing, having an inlet, an outlet and a volute. A motor is mounted on the housing. The motor rotatably drives a two piece impeller within the volute, for pumping fluid, or other material, through the housing from the inlet to the outlet. The pump has seals between the inlet, or low pressure, and the outlet, or high pressure, areas of the pump. As the centrifugal force of the two piece impeller forces the fluid outward, it is restricted by the concave shape of the two parts of the impeller. This creates pressure and pushes the two impeller portions outward to force the two halves of the impeller apart. This creates a sealing point between each impeller part and the housing, at a flat surface of contact between the two. A Teflon washer, or other suitable material, is inserted in between the impeller and the housing to reduce wear and friction. The more pressure created between the two parts of the impeller and the housing, the better the seal is between them.
The pump of this invention has a close tolerance only at the output point or perimeter of the impeller. The centrifugal force and speed of fluid or material at this point greatly reduces the chance of any debris being lodged in this area. If solid material occurs, it is easy enough to reduce seal width at the contact point between the impeller and the housing. This will increase the gap between the two sides or halves of the impeller to ensure that the solids pass through unobstructed.
Maintenance on the new pump of this invention is straight forward. The use of Teflon washers and brass bushings will keep rebuilding costs down. The pump disassembles from one end, as do most existing dynamic pumps. Inspection of alignment pins and impeller veins can be done easily and all washers, bushings, seals and bearings can be replaced at once with minimal time and stock.
The above advantages and various other advantages and features may be recognized by those of ordinary skill in the art based on the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a dual intake pump of this invention;
FIG. 2 shows a side view of a pump of this invention;
FIG. 3 shows a flow diagram of the pump;
FIG. 4 shows a chain or belt drive for the pump;
FIG. 5 shows a gear drive for the pump;
FIG. 6 is a top view of the drive side of a dual intake pump;
FIG. 7 is a top view of a dual intake disc pump;
FIG. 8 is a side view of an impeller disc;
FIG. 9 is a side view of a cone spreader;
FIG. 10 is a top view of a single intake disc pump;
FIG. 11 is a front view of an impeller disc;
FIG. 12 is a front view of an impeller disc assembly;
FIG. 13A is a detailed front view of an impeller disc;
FIG. 13B is a top view of the impeller halves and pins;
FIG. 14A is a front view of an impeller disc blade;
FIG. 14B is a side view of an impeller disc blade;
FIG. 15 is one half of the housing and impeller of a single intake pump;
FIG. 16 is the other half of the housing and impeller of a single intake pump;
FIG. 17 is a side view of the inlet side housing with a weep hole;
FIG. 18 shows a seal ridge and weep hole chamfer in the housing;
FIG. 19 is a diagram which depicts the flow of a turbine;
FIG. 20 is a side view of a turbine of this invention; and,
FIG. 21 is an exploded view of a turbine of this invention.
DETAILED DESCRIPTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring to FIG. 1 there is shown an exploded view of dual intake pump 10 of this invention. There are two impeller parts 12 and 14 . The housing is shown in three parts, the drive side housing 16 , the center portion housing 18 and the non-drive housing portion 20 . There are two pipe flanges 22 and 24 . There is also an output pipe flange 26 , part of housing 18 . There are shown three of a plurality of flange mounting studs 28 , 30 and 32 .
On the drive side there is an inner sealing ring 34 and a bearing 36 to hold the impeller inlet tube 43 allowing it to rotate. Seal 34 sits between housing 16 and impeller part 14 at impeller ridge 42 . Seal 40 sits between pipe flange 22 and inlet tube 43 . Seal 38 sits between inlet tube 43 and housing 16 . On the non-drive side, seal 44 seals housing 20 against impeller 12 at impeller ridge 50 . Bearing 48 holds impeller inlet tube 45 . Seal 46 seals pipe flange 24 to inlet tube 45 . Seal 46 and bearing 48 fit between housing 20 and inlet tube 45 . Bolts 52 , 54 , 56 and 58 are four of a plurality of bolts, which connect together the three parts of the housing 16 , 18 and 20 .
Referring to FIG. 2 , there is shown what looks like a standard dynamic pump 60 with an inlet 62 and an outlet 64 . The major difference between the pump of this invention and standard dynamic pumps is the center shaft. Unlike a standard dynamic pump the center 62 is hollow like a pipe and is the intake.
FIG. 3 is a diagram depicting the fluid passage, having a dual input 66 and 68 and output through volute 70 . The cut-away diagram shows four points of the housing 72 , 74 , 76 and 78 , the housing being circular. There are depicted four contact points 80 , 82 , 84 and 86 between the housing and the impeller, also circular. As the centrifugal force of the impeller forces the fluid outward, it forces the two halves of the impeller apart. This creates a sealing point 80 , 82 , 84 and 86 between the impeller and the housing, at a flat surface of contact between the two surfaces. A Teflon washer or other suitable material can be inserted in between to reduce wear and friction. The more pressure created between the two halves of the impeller, the better the seal between the impeller and the housing.
Referring to FIG. 4 , there is shown a basic dynamic pump 60 of the invention where the pump is driven by a chain drive 90 . FIG. 5 shows the same basic dynamic pump 60 where the pump is driven by a gear drive 92 .
Referring to FIG. 6 , there is shown the drive portion of the pump of FIG. 1 , and also shows the pump drive motor 94 with a belt drive 96 . Also shown is pipe supply line 53 with pipe supply line flange 55 . Bolts 57 and 59 are two of a plurality of bolts to connect with flange 22 .
The same principles used in a dynamic pump may also be used in a disc style pump. A standard disc pump has discs that are flat. The disc pump of this invention has concave discs. Referring to FIG. 7 , there is shown multiple concave discs 100 of impeller halves 102 and 104 . The center disc 101 is not concave. The concave shape of the discs will allow pressure between discs 100 to increase as the flow of material moves outward while the pump is in motion. This increase in pressure will ensure a tight seal between the impeller halves 102 , 104 and the housing, not shown here, but shown in FIG. 1 .
Distribution cones or spreaders 106 and 108 help to spread the fluid or material being pumped between the discs equally. In order to maximize the flow from the pump and ensure needed pressure the discs need to be equal distances apart. Each disc will be moving the same amount of material. The length, width and shape of the distribution cones 106 , 108 will change dependent upon the material being pumped, the amount of flow, and the size and number of the discs. FIG. 8 shows the front of a disc 100 with multiple pins 110 and multiple ridges or bumps 112 , which also help to spread the material being pumped. The center disc 101 is not concave and has distribution cones 106 , 108 on both sides. FIG. 9 is a front view of spreader 106 and 108 .
FIG. 10 depicts a single inlet disc pump 114 with the principle set forth above. Disc pump 114 has impeller halves 116 , 118 and multiple concave discs 120 and distribution cone or spreader 122 . The housing is not shown. FIG. 11 shows a disc 120 with pins 126 but without ridges or bumps. FIG. 12 shows a front view of a disc assembly 124 with pins 126 and a front view of spreader 122 .
FIG. 13B shows an impeller disc 128 from a top view of FIG. 13A . 13 B is a top view of two impeller halves 130 and 132 , held together by pins or dowels 134 . The discs, comprised of a plurality of blades or vanes 136 , float on pins 134 . The blades and pins can be manufactured as one piece. However, it is better if the blades float on the pins which hold the two parts together, as shown in FIG. 13B . Optionally, bushings could be installed where the pins insert into the two halves of the impeller 130 , 132 . This would ensure that the two cone-shaped impeller halves should never have to be replaced. All the parts needed to rebuild the entire pump could be sold as a kit.
FIGS. 14A and 14B show an impeller disc blade 136 with pins 134 and pin holders 138 , which are part of the blade 136 . The pins and blades could be made as one unit, as stated above. The pins 134 should be made of hardened steel to resist breakage. The blades 136 could be made of a softer metal to break off and not transfer energy to damage the pins. A brass bushing could be placed around the pins to protect them from wear. These bushings would be inserted around pins 134 .
FIG. 15 shows one side of a single-sided pump with housing 170 and outlet pipe flange 174 . An impeller half 172 has an input shaft 173 . Bearing race 176 is part of housing 170 . Bearing 178 and sealing ring 180 seal input shaft 173 to the housing. Most designs utilize an electric motor to power the pump. In this configuration the half of the impeller that is connected to the motor shaft is stationary. All of the force generated between the two halves of the impellers push to the inlet side and seal between the high and low pressure sides. The inlet or supply line bolts to the housing with the inlet tube of the impeller being inside of the supply line.
FIG. 16 shows the other side of the single-sided pump shown in FIG. 15 . There is impeller 182 , sealing ring 186 , housing 184 , pipe flange 185 , bearing 188 and sealing ring 190 which seal inlet tube 187 to housing 170 , shown in FIG. 15 .
FIG. 17 shows housing 200 with multiple studs 202 for connection, as best shown in FIG. 1 as housing 16 . There is a weep hole 204 in the intake side of housing 200 . FIG. 18 shows a cut through the intake side of housing 200 . There is a shoulder 205 and the weep hole 204 in the intake side of housing 200 . A canal 208 which starts at air gap 212 and ends at the weep hole outlet 210 . If liquid passes through canal 208 , it indicates a leak at seal 206 . The pump then needs to be disassembled and a new seal put in place.
The pump principle of this invention can be applied equally to turbines. When the impeller is configured so that the constriction is in the center and flow is reversed, torque will be applied at the output tubes, or tube and shaft if used in a single-sided configuration.
Referring to FIG. 19 , there is a diagram which depicts the basic flow of a turbine having an input 250 and a dual outlet 254 and 256 . FIG. 20 shows a basic turbine 258 with an input 260 and an output 262 , a dual output using the same principles as the pump.
Referring to FIG. 21 there is shown an exploded view of a turbine. A sprocket, gear or pulley 220 is designed to apply torque to the equipment. There is an output shaft seal 222 , an output shaft bearing 224 , and an output shaft housing 226 . An internal sealing ring 228 on the output shaft side keeps internal pressure from contaminating bearing 224 . One half 230 of the impeller is on the output shaft side. The center section 231 of the housing has an input flange 232 . On the output side is the other impeller half 234 , the two impeller halves facing away from each other. There is an output side internal sealing ring 236 at output tube 235 . The output side housing 238 is complete with a flange 239 for the output pipe or tubing. There is an output tube or pipe bearing 240 and an output tube seal 242 .
Housings 232 and 226 could be combined to reduce production costs, as seen with the pump single side version. Impeller discs or blades and pins are installed between impeller halves 230 and 234 so that the constriction is at the inside of the impeller at the outlet tube or tubes.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. While various embodiments may have been described as providing advantages or being preferred over other embodiments with respect to one or more desired characteristics, as one skilled in the art is aware, one or more characteristics may be compromised to achieve desired system attributes, which depend on the specific application and implementation. These attributes include, but are not limited to: cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments described herein that are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.
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A two piece impeller centrifugal pump comprising two halves of an impeller facing each other within a volute, a housing having two sides, one side adjacent each impeller half and having an inlet and an outlet, a motor mounted on the housing, the motor driving both impeller halves, for pumping fluid or material from the inlet to the outlet, the housing and the impeller halves having a sealing surface where they contact each other, the centrifugal force of the impeller forcing the fluid or material outward, pushing the two impeller halves outward against the housing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to new sialic acid derivatives and more specifically to sialic acid derivatives having active ester groups in the molecules, biochemical half life extenders of biologically active substances, sialic acid derivatives bonding these sialic acid derivatives with amino compounds, and intermediate compounds used for synthesis of the sialic acid derivatives.
2. Related Art Statement
Neuraminic acid derivatives including N-acetylneuraminic acid, that is, sialic acid derivatives, are known to exist widely in the animal world or on the cell surface of several bacteria such as sialo complexes, more specifically, glycoproteins, glycolipids, oligosaccharides, and polysaccharides.
The above-mentioned sialic acid derivatives are compounds which have recently become highly valuable in medical and pharmaceutical fields, in the treatment of nervous functions, cancer, inflammation, immunity, virus infection, differentiation, and hormone receptor, and are attractng keen attention as particularly active molecules located on the cell surface.
Various theories have been set forth about the role played by sialic acid derivatives in the aforementioned sialo complex, but there are many things that have not yet been clarified, and are still a matter of conjecture.
The inventors have studied sialic acid derivatives for many years and succeeded in synthesizing sialic acid derivatives which exhibit conspicuous biological activity (Japanese Patent Application No.62-295641).
Recently, the inventors discovered a new sialic acid derivative that exhibits conspicuous biological activity and in the subject matter of this invention.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a new sialic acid derivative which exhibits high reactivity with various amino compounds.
Another object of the present invention is to provide biological half-life extenders of various biologically active substances using the said sialic acid derivative.
Still another object of the present invention is to provide a new sialic acid derivative which bonds the said sialic acid derivative to various amino compounds including amino acids and amines through amide bonding.
A further object of the present invention is to provide a new sialic acid derivative which is useful as the intermediate for synthesis of the inventive sialic acid derivative.
The above and other objects, features, and advantages of the present invention will become more apparent from the following detailed description and embodiments.
The sialic acid derivative of the present invention has active ester groups expressed by the formula [I]. ##STR2## where R 1 denotes hydrogen or an acetyl group, R 2 denote hydrogen or a lower alkyl group, R 3 C 2 H 4 , C 3 H 6 or C 2 H 2 , R 4 denotes an hydroxyl group, the residue left after removing hydrogen from the alcohol portion of an active ester or alkyloxycarbonyloxy group, Ac denotes an acetyl group, Ph denotes a phenyl group, and X denotes oxygen or sulfur.
In the said sialic acid derivative, the residue R 4 left after removing hydrogen from the alcohol portion of the active ester includes N-hydroxysuccinimide, N-hydroxy-5-norbornene-2, 3-dicarboximide, N-hydroxyphthalimide, N-hydroxybenzotriazole, p-nitrophenol, 2, 4-dinitrophenol, 2, 4, 5trichlorophenol, or pentachlorophenol. r The alkyloxycarbonyloxy group (R 4 ) is introduced by allowing carboxylic acid to react with alkyl or aryl halogenoformates in the presence of bases, wherein the alkyl group includes methyl group, ethyl group, n butyl group, isobutyl group, and the aryl group includes the phenyl group, and benzyl group.
The sialic acid derivative containing the ester group is prepared by the following method using N-acetyl neuraminic acid having the following formula as starting material. ##STR3## where Ac denotes a acetyl group. The same applies to the following.
At first, the methyl ester substance is produced at a high yield by letting N-acetylneuraminic acid react with methanol in the presence of an ion-exchange resin Dowex 50 w (H + ). Then, the methyl-ester compound is allowed to react with excess acetyl chloride (CH 3 COCl), then with ethanol while cooling, to give the chlor substance at a high yield. Then, this chlor substance is allowed to react with anhydrous sodium salt of p nitrophenol in the anhydrous dimethylformamide to give p-nitrophenylglycoside at a high yield. The p-nitrophenylglycoside is a known compound described in "Carbohydrate Research, 162 (1987) 294-297" and details of the synthesis method will be discussed in Embodiment 1 herein.
The chlor substance is allowed to react with anhydrous sodium salt of p-nitrothiophenol in the anhydrous dimethylformamide to give p-nitrophenylthioglycoside (Embodiment 2). Then, to the aforementioned p-nitrophenylglycoside, hydrogen is added in the presence of 5% Pd/C in the methanol to give p-aminophenylglycoside (Embodiment 3). Adding hydrogen to the p-nitrophenylthioglycoside in the presence of 5% Pd/C in methanol expedites the reductive alkylation reaction and N, N'-dimethylaminophenyl-thioglycoside is obtained (Embodiment 4). On the other hand, adding hydrogen to the p-nitrophenylthioglycoside in the acetic acid in the presence of 5% Pd/C give p-aminophenylthioglycoside (Embodiment 5). Next, the said p-aminophenylglycoside is allowed to react with slightly excess succinic anhydride in anhydrous tetrahydrofuran to give an amido-carboxylic acid compound (Embodiment 6). The p-aminophenylthioglycoside is allowed to react with slightly excess succinic anhydride in anhydrous tetrahydrofuran to give an amido carboxylic acid compound (Embodiment 8). Alternatively, the above mentioned p-aminophenylglycoside is allowed to react with maleic anhydride in anhydrous tetrahydrofuran to give an unsaturated amido carboxylic acid compound (Embodiment 7). Next, the amido carboxylic acid compound is allowed to react with sodium methoxide in anhydrous methanol, and is then neutralized by Dowex 50 w (H + ) to give deacetylated substance (Embodiment 9).
Because the sialic acid derivatives of this invention shown by the aforementioned formula [I] contain the active ester group, they exhibit high reactivity to other compounds containing functional groups that can react with ester groups, such as amino compounds. The sialic acid derivative of this invention containing active ester groups is an extremely useful compound as a raw material or intermediate to synthesize various sialic acid derivatives.
Another sialic acid derivative of this invention has the formula [II] as follows: ##STR4## where R 1 is hydrogen or an acetyl group, R 2 hydrogen or a lower alkyl group, R 3 is selected from C 2 H 4 , C 3 H 6 or C 2 H 2 , Ac is a acetyl group, m is 1-60, Ph phenyl group, X is oxygen or sulfur, and Y is the residue left from removing m number of amino groups from amino compounds. The amino compounds include amine of lower class and amino acids.
The sialic acid derivative can be prepared from amino compounds and sialic acid derivatives containing the aforementioned active ester group by the use of the active ester process and the mixed acid anhydride process.
The active ester process produces N-oxysuccinimide ester mixing the amido-carboxylic acid compound with DSC (N, N'-disuccinimidyl carbonate) in anhydrous acetonitrile (Embodiment 10). In this reaction, adding anhydrous pyridine at more than an equivalent mole ratio causes the N-oxysuccinimide ester to transfer to the p-succinimidophenylglycoside of intramolecular ring closure (Embodiment 11). The amido carboxylic acid compound is allowed to react in anhydrous tetrahydrofuran in the presence of WSC (1 ethyl-3-(3-dimethylaminopropyl)-carbodiimide) the condensing agent to give the p-nitrophenyl ester (Embodiment 12). The said ester is not isolated and is allowed to react by adding amino acid methyl ester in the solution to give an amide, the sialic acid derivative of this invention (Embodiment 13-1).
Alternatively, in the mixed acid anhydride process, the amido-carboxylic compound is allowed to react with isobutylchloroformate in anhydrous tetrahydrofuran to give a mixed acid anhydride, Then, the mixed acid anhydride is allowed to react with amino acid methyl ester to give the amide of this invention (Embodiment 13-2). Incidentally, the use of this mixed acid anhydride process can produce the amide from the deacetyl of the amido carboxylic acid compounds under similar reaction conditions (Embodiment 15).
For other processes, there is a method to produce a peracetylated substance by allowing the amide to react with acetic anhydride in anhydrous pyridine (Embodiment 13-3). As reaction species other than the amino acid ester, hydrazine is allowed to react with the N-hydroxysuccinimide ester isolated or in solution in anhydrous acetonitrile to give an acid hydrazide (Embodiment 14).
The sialic acid derivatives of this invention having the aforementioned formula [II] are compounds consisting of sialic acid derivatives represented by the aforementioned formula [I] and amino compounds. For example, when an amino acid is administered to animals or human bodies as nutrient, or when insulin, growth hormone, interferon, and immunogen are administered as medicine, it is predicted that administration of these medicines as the sialic acid derivative of formula [II] will prevent or delay biological reactions of a biologically active substance by the presence of sialic acid. This will produce the beneficial effects of increasing the durability of biologically active substances in the body or displaying desired medicinal effects with a small amount of administration. The sialic acid derivative represented by the said formula [I] is an extremely useful compound as an extender of the biological half-life of various biologically active substances.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the examples, embodiments of the sialic acid derivative according to the present invention will now be described in detail. However, the present invention is not limited by these embodiments.
[Embodiment 1]
Synthesis of methyl (4-nitrophenyl 5-acetamido 4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero D galacto-2-nonulopyranosido)onate
(1) N-acetylneuraminic acid was allowed to react in methanol in the presence of Dowex 50 w (H + ) at the room temperature for six hours to give methyl ester substance (yield=80%). ##STR5##
(2) After the methyl ester was allowed to react with excess acetyl chloride for one day, ethanol was added with cooling (-30 ° C.), and it was allowed to stand for 10 days to give the following chlor substance (yield=83%). ##STR6##
(3) 10.26 g of the anhydrous sodium salt of p-nitrophenol and 6.0 g of the chlor substance obtained in Step 2 (methyl 5-acetamide 4, 7, 8, 9-tetra-O-acetyl-2 chloro-3,5 dideoxy-α-D-glycero-D-galacto-nonulopyranosonate) were dissolved in 120 ml of anhydrous dimethylformamide, and were allowed to react with stirring for 24 hours under moisture-proof conditions.
Then, the solvent was removed from the solution under reduced pressure, xylene was added, and solvent was repeatedly removed. Ethyl acetate was added to the residue obtained and stirred, and the residue was extracted thoroughly with ethyl acetate. The solvent was removed from the extract liquid and the residue was purified with silica gel column chromatography (Wakogel C-300). At first, p-nitrophenol was eluted from the residue with ether, and after removal, it was eluted with ethyl acetate to give a fractional solution containing the object. The solvent was removed from the fractional solution and an oily substance (crude yield point=6.87 g, crude yield=95.4%, melting point=95°-98 ° C.) was obtained.
TLC: Rf=0.41 (Kieselgel 60 F 254 , Merck product, acetate)
Rf=0.44 (Kieselgel 60 F 254 , Merck product, CHCl 3 MeOH=20/1) ##STR7##
Reference
(1) In Volker Eschenfelder and Reinhard Brossmer, Carbohydrate Research 162 (1987) 294-297, the aforementioned synthesis method is described, but the
yield is as poor as 57% (melting point=104°-108° (dec.) (ether/hexane).
Physical Properties of the product
1 H-N (CDCl 3 , TMS)
1 932 (3H, s, --NHCOCH 3 ),
2.055;2.061;2.119;2.193 (all 3H, all s, --OCOCH 3 X 4),
2.304 (1H, t, J=12.8 Hz, H 3ax ),
2.744 (1H, dd, J=13.2 Hz, 4.8 Hz, H 3eq ),
3.663 (3H, s, 2'COOCH 3 ),
4.986 (1H, ddd, J=12.1, 10.3, 4.8 Hz, H-4),
7.153 (2H, d, J=9.2 Hz, phenyl-H)
8.189 (2H, d, J=9.2 Hz, phenyl-H).
IRνKBr/maxcm -1 : 1740, 1660, 1520, 1340, 1220,
Embodiment 2
Synthesis of methyl (4-nitrophenyl 5-acetamido-4, 7, 8, 9 tetra-O-acetyl-2, 3, 5-trideoxy-2-thio-α-D-glycero-D-galacto-2-nonulopyranosido)onate:
The anhydrous sodium salt of p-nitrothiophenol was prepared from 19.6 ml of methanol solution of 1.67 g of p-nitrothiophenol, 0.5 mol of sodium methoxide, and 1.0 g of the chlor substance obtained in Embodiment 1 (2) (methyl 5-acetamide-4, 7, 8, 9 tetra-O-acetyl-2-chloro-3, 5-dideoxy-β-D-glycero-D-galacto-1-nonulopyranosonate) was dissolved in 15 ml of anhydrous dimethylformamide and allowed to react with stirring for 6 hours at room temperature under moisture-proof conditions and a nitrogen atmosphere. Then, after solvent was removed under reduced pressure, xylene was added and solvent was repeatedly removed. The residue obtained was purified with silica gel column chromatography (Wakogel C-300, ethyl acetate) twice and solvent was again removed from the fractional solution, and finally 0.52 g white powder was obtained (yield=42.4%, melting point=94°-96° C.).
TLC: Rf=0.44 (Kieselgel 60 F 254 , Merck product, ethyl acetate) ##STR8##
Physical properties of the product
C 26 H 32 O 14 N 2 S
FAB-MS m/z : 629 (M + +1)
1 H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.891 (3H, s, --NHCOCH 3 ), 2.041;2.061;2.063;2.165 (all 3H, all s,--OCOCH 3 X 4), 2.869 (1H, dd, J=12.8, 4.8 Hz, H 3eq ),
3.611 (3H, s, 2-COOCH 3 ),
4.883 (1H, ddd, J=12.1, 10.3, 4.8 Hz, H-4),
7.655 (2H, d, J=8.8 Hz, phenyl-H),
8.192 (2H, d, J=8.8 Hz, phenyl-H).
IRνKBr/max cm -1 : 3250, 1750, 1650, 1550, 1520, 1350,
Embodiment 3
Synthesis of methyl (4-aminophenyl 5 acetamido 4, 7, 8, 9-tetra-0-acetyl-3, 5-dideoxy-α-D-glycero-D galacto-2-nonulopyranosido)onate: V 6 87 g of methyl (4-nitrophenyl 5-acetamido-4,7,8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosido)onate) obtained in the aforementioned Embodiment 1 (3) were dissolved in 50 ml of methanol. After a slight amount of 5% palladium/carbon was added with a spatula, it was reduced with hydrogen with stirring at room temperature. Then after allowing reaction to proceed for 2 days, the reagents were removed by filtering. Solvent was removed from the filtrate and 4.91 g of an oily substance (yield=71.63%) was obtained. It was further purified by the use of silica gel column chromatography (Wakogel C-300, CHCl 3 /MeOH=40/1) and white powdery crystals (melting point: 95°-99 ° C.) was obtained as TLC one spot purified product as shown below.
TLC: Rf=0.29 (Kieselgel 60 F 254 , Merck product, ethyl acetate)
Rf=0.35 (Kieselgel 60 F 254 , Merck product, CHCl 13 /MeOH=20/1) ##STR9##
Physical properties of the product
C 26 H 34 O 13 N 2
FAB-MS m/z : 583 (M + +1)
1 H-NMR pp/m500 MHz (CDCl 3 , TMS)
1.896 (3H, s, --NHCOCH 3 ),
2.028;2.055;2.115;2.139 (all 3H, all s,--OCOCH 3 X 4),
2.676 (1H, dd, J=12.8, 4.8 Hz, H 3 eq),
3.671 (3H, s, 2-COOCH 3 ),
4.936 (1H, J=12.1, 10.3, 4.8 Hz, H-4),
6.569 (2H, d, J=8.8 Hz, phenyl-H),
6.886 (2H, d, J=8.8 Hz, phenyl-H).
IRνKBr/max cm -1 : 3450, 3370, 1740, 1660, 1540,
Embodiment 4
Synthesis of methyl (4-dimethylaminophenyl 5-acetamido-4, 7, 8, 9-tetra-O-acetyl-2, 3, 5-trideoxy-2-thio-α-D-glycero-D-galacto-2-nonulopyranosido)onate:
0.25 g of [methyl (4-nitrophenyl 5 acetamido-4, 7, 8, 9-tetra-0-acetyl-2, 3, 5-trideoxy-2-thio-α-D glycero-D galacto-2-nonulopyranoside)onate) obtained in the aforementioned Embodiment 2 were dissolved in 10 ml of methanol. After a slight amount of 5% palladium/carbon was added with a spatula, it was reduced with hydrogen with stirring at room temperature for one day. Then reagents were removed by filtering. The solvent was removed from the filtrate and the residue was purified with silica gel column chromatography (Wakogel C-300, CHCl 3 /MeOH=40/1). Solvent was removed from the fractional solution containing the product and 100 mg of white powdery crystals were obtained (yield=40%, melting point=83°-85 ° C.).
TLC: Rf=0.50 (Kieselgel 60 F 254 , Merck product, chloroform/methanol=20/1) ##STR10##
Physical properties of the product
C 28 H 38 O 12 N 2 S
FAB-MS m/z : 627 (M + +1)
1 H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.853 (3H, s, --NHCOCH 3 ),
1.970 (1H, t, J=12.8 Hz, H 3ax ),
2.011;2.054;2.133 (3H;6H;3H, all s, --OCOCH 3 X 4),
2.742 (1H, dd, J=12.8, 4.8 Hz, H 3eq ),
2.987 (6H, s, ##STR11## 3.636 (3H, s, 2 COOCH 3 ),
4.829 (1H, ddd, J=11.7, 10.3, 4.8 Hz, H-4),
6.614 (2H, d, J=8.8 Hz, phenyl-H),
7.330 (2H, d, J=8.8 Hz, phenyl-H).
IRνKBr/max cm -1 : 3360, 1740,
Embodiment 5
Synthesis of methyl (4-aminophenyl 5 acetamido-4, 7, 8, 9-tetra-0-acetyl-2, 3, 5-trideoxy-2-thio-α-D-glycero D galacto-2-nonulopyranosido)onate:
0.10 g of methyl (4-nitrophenyl 5-acetamido-4, 7, 8, 9-tetra-0-acetyl-2, 3, 5-trideoxy-2 thio-α-D-glycero-D galacto-2-nonulopyranosido)onate) obtained in the aforementioned Embodiment 2 were dissolved in 5 ml of acetic acid. After a slight amount of 5% palladium/carbon was added with a spatula, it was reduced with hydrogen with stirring at room temperature. Then reagents were removed by filtering. Solvent was removed from the filtrate and the residue was purified with silica gel column chromatography (Wakogel C-300, CHCl 3/ MeOH=40/1). Therein, the solution of the residue was neutralized with triethylamine, then developed. Solvent was removed from the fractional solvent containing the product and 67 mg of white powdery crystals were obtained (yield=70%, melting point=100°14 102 ° C.).
TLC: Rf=0.29 (Kieselgel 60 F 254 , Merck product, chloroform/methanol=20/1) ##STR12##
Physical properties of the product
C 26 H 34 O 12 N 2 S
FAB-MS m/z : 599 (M + +1)
1H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.858 (3H, s, --NHCOCH 3 ),
1.978 (1H, t, J=12.5 Hz, H 3ax ),
2.016;2.054;2.060 2.138 (all 3H, all s, --OCOCH 3 X 4),
4.144 (1H, dd, J=12.8, 4.8 Hz, H 3eq ),
3.618 (3H, s, 2 COOCH 3 ),
603 (1H, d, J=8.8 Hz, phenyl-H),
266 (1H, d, J=8.8 Hz, phenyl-H),
IRνKBr/max cm -1 3470, 3380, 1740,
Embodiment 6
Synthesis of 4'-[(methyl 5-acetamido 4, 7, 8, 9-tetra-0-acetyl-3, 5-dideoxy-α-D glycero-D-galacto-2-nonylopyranosylonate) oxy] succinanilic acid:
4.91 g of [methyl (4-aminophenyl 5-acetamido-4, 7, 8, 9-tetra-0-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosido)onate] obtained in the aforementioned Embodiment 3 and 1.26 g of succinic anhydride were dissolved in 100 ml of anhydrous tetrahydrofuran and allowed to react for one day with stirring at room tempcrature. After the disappearance of raw materials was confirmed with a TLC, reaction solvent was removed under reduced pressure and the residue was purified with gel filtration chromatography (LH-20, MeOH) and the fractional solution not containing succinic anhydride was obtained. The residue obtained by removing solvent from the fractional solution was recrystallized with acetate, and 4.81 g of the product was obtained (total up to the third crystal, yield=83.7%, melting point=130°-131 ° C.).
TLC Rf=0.13 (Kieselgel 60 F 254 , Merck product, CHCl 3/ MeOH=20/1)
Rf=0.42 (Kieselgel 60 F 254 , Merck product, CHCl 3/ MeOH=10/3) ##STR13##
Physical properties of the product
C 30 H 38 O 16 N 2
FAB-MS m/z : 683 (M + +1)
H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.890 (3H, s, --NHCOCH 3 ),
2.041;2.051;2.121 2.126 (all 3H, all s, --OCOCH 3 X 4),
2.186 (1H, t, J=12.5 Hz, H 3ax ),
2.655-2.710 (3H, m, --CH 2 CH 2 -+H 3eq )),
2.777 (3H, t, J=6.6 Hz, --CH 2 CH 2 --),
3.643 (3H, s, -COOCH 3 ),
4.964 (2H, ddd, J=12.1, 10.3, 4.8 Hz, H-4),
7.011 (2H, d, J=9.2 Hz, phenyl-H),
7.418 (2H, d, J=9.2 Hz, phenyl-H).
IRνKBR/max cm -1 3350, 1740, 1660, 1540,
Embodiment 7
Synthesis of 4'-[(methyl (5-acetamido 4,7,8,9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate)oxy] maleanilic acid
100 g of [methyl (4 aminophenyl 5-acetamido-4, 7, 8, 9-tetra-0-acetyl-3, 5 dideoxy-α-D-glycero-D-galacto-2 nonulopyranosido)onate] obtained in the aforementioned Embodiment 3 and 24 mg of maleic anhydride were dissolved in 3 ml of anhydrous tetrahydrofuran and stirred at room temperature. The reactions took place immediately. After the disappearance of raw materials was confirmed with a TLC, reaction solvent was removed under reduced prsesure. The residue was purified with gel filtration chromatography (LH-20, MeOH) and the fractional solution containing the product was obtained. From this fractional solution, solvent was removed and 74.8 mg of pale yellow powdery crystals were obtained (yield=67.4% melting point=121°-123° C.).
TLC: Rf=0.33 (Kieselgel 60 F 254 , Merck product, CHCl 3/ MeO=10/3) ##STR14##
Physical properties of the product
C 30 H 36 O 16 N 2
FAB-MS m/z: 681 (M + +1)
1 H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.929 (3H, s, NHCOCH 3 ),
2.047;2.095;2.140 2.145 (all 3H, all s, --OCOCH 3 X
2.243 (1H, t, J=12.8 Hz, H 3ax ),
2.715 (1H, dd, J=12.8, 4.4 Hz, H 3eq ),
3.654 (3H, s, 2--COOCH 3 ),
4.955 (1H, ddd, J=12.1, 10.6, 4.4 Hz, H 4),
6.455 (1H, d, J=12.8 Hz, olefin H),
6.499 (1H, d, J=12.8 Hz, olefin H),
7.048 (2H, d, J=8.8 Hz, phenyl-H),
7.543 (2H, d, J=8.8 Hz, phenyl-H),
IRνKBr/max cm -1 3350, 1750, 1770, 1550,
Embodiment 8
Synthesis of 4'-[methyl (5-acetamido 4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate) thio] succinanilic acid
0.1 g of [methyl (4 aminophenyl 5-acetamide-4, 7, 8, -tetra-0-acetyl 3, 5 dideoxy-α-D-glycero D galacto-2 nonulopyranosido)onate] obtained in the aforementioned Embodiment 5 and 20 mg of succinic anhydride were dissolved in 3 ml of anhydrous tetrahydrofuran and were allowed to react with stirring for one day at room temperature. After the disappearance of raw materials was confirmed with a TLC, reaction solvent was removed under reduced pressure conditions. The residue was purified with gel filtration chromatography (LH-20, MeOH) and a fractional solution containing the product was obtained. From this fractional solution, solvent was removed and 9.4 mg of white powdery crystals were obtained (yield=82%, melting point=119°-121 ° C.).
TLC: Rf=0.40 (Kieselgel 60 F 254 , Merck product, CHCl 3/ MeOH=10/3) ##STR15##
Physical properties of the product
C 30 H 38 O 15 N 2 S
FAB-MS m/z : 699 (M + +1)
1H-NMR 500MHz (CDCl 3 , TMS)
1.844 (3H, s, --NHCOCH 3 ),
2 019;2.038;2.059;2.127 (all 3H, all s, --OCOCH 3 X 4),
2.65-2.80(5H, m, --CH 2 CH 2 --+H 3eq ),
3.585 (3H, s, 2 COOCH 3 ),
4.837 (1H, ddd, J=11.4, 10.3, 4.8 Hz, H-4),
7.414 (2H, d, J=8.4 Hz, phenyl-H),
7.534 (2H, d, J=8.4 Hz, phenyl-H),
IRνKBr/max cm -1 3340, 1740, 1220,
Embodiment 9
Synthesis of 4'-[(methyl 5-acetamido-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate)oxy] succinanilic acid and its sodium salts
222 mg of 4'-[(methyl 5-acetamido-4, 7, 8, 9-tetra-0-acetyl 3, 5 dideoxy-α-D-glycero-D-galacto 2-nonulopyranosylonate)oxy]succinanilic acid obtained in the aforementioned Embodiment 6 were dissolved in 20 ml of anhydrous methanol and 386 mg of 28% methanol solution of sodium methoxide were added at room temperature and allowed to react with stirring for two hours. Then, while cooling, 0.8 g of Dowex 50 w (H + ) were added and stirred to be made slightly acidic to pH 4. The ion exchange resin was removed by filtering. Solvent was removed from the filtrate liquid, and a amorphous substance was obtained. The residue obtained was purified with C 18 -column chromatography (YMC.GEL ODS 60Å 60/200 mesh). The residue was eluted first with water, then with methanol, and water was added to the methanol fractional solution containing the object, freeze-dried to give 100 mg of white powdery crystals of free-acid type carboxylic acid (yield=60%, melting point=132 -135° C.). The sodium salts were similarly isolated when the amount of the aforementioned Dowex 50 w (H + ) was less than a half.
TLC: Rf=0.40 (Kieselgel 60 F 254 , Merck product, CHCl 3/ MeOH=6/3/0.5) ##STR16##
Physical properties of the product (COOH substance)
Element analysis C 22 H 30 O 12 N 2
FAB-MS m/z : 515 (M + +1)
1H-NMR ppm/500 MHz (D20, TSP)
2.030 (1H, t, J=12.5 Hz, H 3ax ),
2.039 (3H, s, --NHCOCH 3 ),
2.67-2.69(4H, m, --CH 2 --CH 2 --),
2.880 (1H, dd, J=12.8, 4.8 Hz, H 3eq ),
7.150 (1H, d, J=8.8 Hz, phenyl-H),
7.386 (1H, d, J=8.8 Hz, phenyl-H),
IRνKBr/max cm -1 3400, 1730, 1660, 1550,
Embodiment 10
Synthesis of [4'-(3- (N-succinimidyloxycarbonyl)propionamido) phenyl 5-acetamido-4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-αD-glycero D galacto 2 nonulopyranosido]onate:
100 mg of 4'-[(methyl 5-acetamido-4, 7, 8, 9-tetra-O-acetyl 3, 5-dideoxy-α-D glycero-D-galacto 2 nonulopyranosylonate)oxy]succinanilic acid obtained in the aforementioned Embodiment 6 and 38 mg of N, N'-disuccinimidyl carbonate were dissolved in 10 ml of anhydrous acetonitrile and 11.7 μl of anhydrous pyridine were added and allowed to react with stirring at room temperature.
After disappearance of raw material was confirmed with a TLC, the reaction solvent was removed under reduced pressure condition. The residue obtained was purified with silica gel column chromatography (Wakogel C=300, toluene/acetone=1/1). The residue of the obtained fractional solution was further purified with a gel filtration chromatography (LH-20, toluene/acetone =1/1) and 91 mg of white powdery crystal was obtained (yield=80%, melting point=115°-117 ° C.).
TLC: Rf=0.27 (Kieselgel 60 F 254 , Merck product, toluene/acetone=1/1) ##STR17##
Physical properties of the product
C 34 H 41 O 18 N 3
FAB-MS m/z : 780 (M + +1)
1 H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.902 (3H, s, --NHCOCH 3 ),
2.036;2.051;2.118;2.133 (all 3H, all s, --OCOCH 3 X 4),
2.183 (1H, t, J=12.8 Hz, H 3ax ),
2.699 (1H, dd, J=12.8, 4.8 Hz, H 3eq ),
2.759 (2H, t, J=7.0 Hz, --CH 2 --CH 2 --),
3.056 (2H, t, J=7.0 Hz, --CH 2 CH 2 --),
2.844 (4H, s, H of succinimidyl group),
3.658 (3H, t, 2-COOCH 3 ),
4.944 (1H, ddd, J=12.5, 10.3, 4.8 Hz, H-4),
7.022 (2H, d, J=8 Hz, phenyl-H),
7.413 (1H, d, J=8 Hz, phenyl-H),
IRνKBr/max cm -1 3360, 1740, 1670, 1540,
Embodiment 11
Synthesis of [4 succinimidophenyl 5-acetamido-4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-αD glycero-D-galacto-2-nonulopyranosido]onate
120 mg of 4 -[(methyl 5-acetamido-4, 7, 8, tetra O-acetyl-3, 5 dideoxy-α-D-glycero D galacto-2-nonulopyranosylonate)oxy] succinanilic acid obtained in the aforementioned Embodiment 6 and 247 mg of N, N'-disuccinimidyl carbonate and 340 mg of anhydrous pyridine were dissolved in 20 ml of anhydrous acetonitrile and allowed to react at room temperature for one day. After the reaction solvent was removed, the residue obtained was purified with silica gel column chromatography (C=300, toluene/acetone=1/1). The solvent was removed from the obtained fractional solution containing the product and white powdery crystals were obtained. The residue of the obtained fractional solution was further purified with a gel filtration chromatography (LH-20, ethyl acetate) and 24 mg of white powdery crystal was obtained (yield=20%, melting point=110°-114 ° C.).
TLC: Rf=0.35 (Kieselgel 60 F 254 , Merck product, toluene/acetone=1/1)
Rf=0.26 (Kieselgel 60 F 254 , Merck product, ethyl acetate) ##STR18##
Physical properties of the product
C 30 H 36 O 15 N 2
FAB-MS m/z: 665 (M + +1)
1 H NMR ppm/500 MHz (CDCl 3 , TMS)
1.913 (3H, s, --NHCOCH 3 ),
2.047;2.049;2.121;2.153 (all 3H, all s, --OCOCH 3 X
2.250 (1H, t, J=12.8 Hz, H 3ax ),
2.711 (1H, dd, J=12.8, 4.8 Hz, H 3eq ),
2.875 (4H, s, H of succinimido group),
3.687 (3H, s, 2--COOCH 3 ),
4.971 (1H, ddd, J=12.1, 10.6, 4.8 Hz, H-4),
7.140 (2H, d, J=8.8 Hz, phenyl-H),
7.203 (1H, d, J=8.8 Hz, phenyl-H),
IRνKBr/max cm -1 3460, 3360, 1750, 1710,
Embodiment 12
Synthesis of [4-(3-p-nitrophenyloxycarbonylpropionamide) phenyl 5 acetamido-4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosido]onate:
52 mg of 4'-[(methyl 5-acetamido-4, 7, 8, 9-tetra 0 acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonato)oxy] succinanilic acid obtained in the aforementioned Embodiment 6, 24.1 mg of p-nitrophenol, and 14.5 mg of WSC (1-ethyl-3-(3-dimethylaminopropyl)-carbodiimide hydrochloride] were dissolved in 1 ml of tetrahydrofuran and allowed to react at 0 ° C. with stirring. After disappearance of raw material was confirmed with a TLC, reaction solvent was removed and the residue obtained was purified with silica gel column chromatography (Wakogel C=300, toluene/acetone=1/1) to give the fractional solution containing the object. The solvent was removed from the obtained fractional solution and 20 mg of white powdery crystals were obtained (yield=32.7 melting point=106°-108 ° C.).
TLC: Rf=0.38 (Kieselgel 60 F 254 , Merck product, ethyl acetate)
Rf=0.42 (Kieselgel 60 F 254 , Merck product, toluene/acetone=1/1). ##STR19##
Physical properties of the product
C 36 H 41 O 18 N 3
FAB-MS m/z : 804 (M + +1)
1 H NMR ppm/500 MHz (CDCl 3 , TMS)
1.908 (3H, s, --NHCOCH 3 ),
2.038;2.047;2.126;2.132 (all 3H, all s, --OCOCH 3 X 4),
2.191 (1H, t, J=12.8 Hz, H 3ax ),
2.708 (1H, dd, J=12.8, 4.4 Hz, H 3eq ),
2.779 (2H, t, J=6.6 Hz, --CH 2 --CH 2 --),
3.019 (2H, t, J=6.6 Hz, --CH 2 --CH 2 --),
3.656 (3H, t, 2--COOCH 3 ),
4.947 (1H, ddd, J=12.1, 10.3, 4.4 Hz, H-4),
7.031 (2H, d, J=8.8 Hz, H of nitrophenyl group),
7.313 (2H, d, J=8.8 Hz, aromatic ring H of anilic acid),
7.409 (2H, d, J=8.8 Hz, aromatic ring-H of anilic acid),
8.265 (2H, d, J=8.8 Hz, nitrophenyl group).
IRνKBr/max cm -1 3350, 1740, 1660, 1520, 1340,
Embodiment 13
Synthesis of N-(4'-[(methyl 5-acetamido-4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate)oxy] succinaniloyl)glycine methyl ester [13-1] The first method (active ester process)
100 mg of 4'-[(methyl 5-acetamido-4, 7, 8, 9 tetra-O-acetyl-3, 5 dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate) oxy] succinanilic acid obtained in the aforementioned Embodiment 6, 38 mg of N,N'-disuccinimidyl carbonate, and 11.7 μl of anhydrous pyridine were dissolved in 10 ml of anhydrous acetonitrile and allowed to react at room temperature for 2 hours. After disappearance of raw material was confirmed with a TLC, the acetontrile solution consisting of 18.4 mg of glycine methyl ester hydrochloride and 20.4 μl of triethylamine was added to the mixture of the above-mentioned active ester, and the solution was allowed to react with stirring for one day. After disappearance of the active ester with a TLC, the reaction solvent was removed and the residue obtained was purified with silica gel column chromatography (Wakogel C=300, CHCl 3 /MeOH=20/1), then further with gel filtration chromatography (LH-20, MeOH) to give a fractional solution containing the product. Solvent was removed from the obtained fractional solution and 50 mg of white powdery crystals were obtained (yield=45.5%, melting point =102°-105 ° C.).
TLC: Rf=0.22 (Kieselgel 60 F 254 , Merck product, toluene/acetone=1/1) ##STR20##
Physical properties of the product
C 33 H 43 O 17 N 3
FAB MS m/z : 754 (M + +1)
1 H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.898 (3H, s, --NHCOCH 3 ),
2.034;2.054;2.118;2.133 (all 3H, all s, --OCOCH 3 X 4),
2.175 (1H, t, J=12.5 Hz, H 3ax ),
2.65°-2.71 (5H, m, --CH 2 --CH 2 - +H 3eq ),
3.648 (3H, s, 2 --COOCH 3 ),
3.749 (3H, s, --NHCH 2 COOCH 3 ),
4.946 (1H, ddd, J=12.5, 10.3, 4.8 Hz, H-4),
7.012 (2H, d, J=9.2 Hz, phenyl H),
7.417 (1H, d, J=9.2 Hz, phenyl-H),
IRνKBr/max cm -1 3300, 1750, 1660, 1550,
[13-2] The second method (mixed acid anhydride process) 107.4 mg of 4'[(methyl 5-acetamido 4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate)oxy] succinanilic acid obtained in the aforementioned Embodiment 6, and 20.4 μl of triethylamine were dissolved in 2 ml of anhydrous tetrahydrofuran, and with cooling to -12 ° C. and stirring, 18.9 μl of isobutylchloroformate were added and allowed to react for 10 minutes. Then, 1 ml of anhydrous chloroform solution dissolving 18.3 mg of glycine methyl ester hydrochloride and 20.4 μl of triethylamine was added to the mixture of the above-mentioned mixed acid anhydride solution. After stirring, the solution was allowed to react at 0 ° C. for 1 hour, then at room temperature with stirring for one day. After reaction solvent was removed, the residue obtained was purified with silica gel column chromatography (Wakogel C=300, CHCl 3 /MeOH=20/1) to give a fractional solution containing the product. Solvent was removed from the obtained fractional solution and 36.3 mg of white powdery crystals were obtained (yield=30.6%).
TLC: Rf=0.22 (Kieselgel 60 F 254 , Merck product, toluene/acetone=1/1)
Rf=0.34 (Kieselgel 60 F 254 , Merck product, chloroform/methanol=20/2)
1H-NMR, IR data agreed with that obtained with the aforementioned first method (active ester process). Even when solvents used in the above-mentioned reactions (tetrahydrofuran, chloroform) were replaced with dimethylformamide, a similar product was obtained.
[13-3] The third method
37 4 mg of 4'[(methyl 5 acetamido 3, 5 dideoxy-α-D-glycero-D galacto-2-nonulopyranosylonate) oxy] succinaniloyl) glycine methyl ester and 0.8 ml of acetic anhydride were dissolved in 0.8 ml of anhydrous pyridine and allowed to react at room temperature for one day with stirring. The reaction solvent was removed and the residue obtained was purified with silica gel column chromatography (Wakogel C=300, CHCl 1 /MeOH=20/1) to give fractional solution containing the product. Solvent was removed from the obtained fractional solution and 28.8 mg of white powdery crystals (yield=59.8%) were obtained.
TLC Rf=0.22 (Kieselgel 60 F 254 , Merck product, toluene/acetone=1/1)
Rf=0.34 (Kieselgel 60 F 254 , Merck product, chloroform/methanol=20/1)
1H-NM data completely agreed with that obtained with the aforementioned first method (active ester process).
Embodiment 14
Synthesis of 4'-[(methyl 5-acetamido-4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate)oxy] succinanilohylhydrazide
100 mg of 4'-[(methyl 5-acetamido-4, 7, 8, 9 tetra-O-acetyl-3, 5 dideoxy-α-D-glycero D galacto-2-nonulopyranosylonate)oxy] succinanilic acid obtained in the aforementioned Embodiment 6, 38 mg of N, N'-disuccinimidyl carbonate, and 11.7 μl of anhydrous pyridine were dissolved in 10 ml of anhydrous acetonitrile and allowed to react at room temperature for 8 hours. After disappearance of raw material was confirmed with a TLC, while cooling, 10 μl of anhydrous hydrazine was added and allowed to react for one day. The reaction solvent was removed and the residue obtained was purified with gel filtration chromatography (LH-20, MeOH), then further with silica gel chromatography (Wakogel C-300, CHCl 1 /MeOH=10/1) to give a fractional solution containing the product. Solvent was removed from the obtained fractional solution and 40.5 mg of white powdery crystal (yield=40%, melting point=110°-113 ° C.) were obtained.
Rf=0.52 (Kieselgel 60 F 254 , Merck product, ethyl acetate/methanol=5/3)
Rf=0.20 (Kieselgel 60 F 254 , Merck product, chloroform/methanol=10/1) ##STR21##
Physical properties of the product
Element analysis C 30 H 40 O 15 N 4
FAB-MS m/z: 697 (M + +1)
1 H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.811 (3H, s, --NHCOCH 3 ),
1.972;2.031;2.055 (6H;3H;3H, all s, --OCOCH 3 X 4),
2.108 (1H, t, J=12.5 Hz, H 3ax ),
2.492 (4H, m, --CH 2 --CH 2 --),
2.622 (3H, m, --CH 2 --CH 2 -- +H 3eq ),
3.544 (3H, s, 2 --COOCH 3 ),
4.876 (1H, m, H-4),
6.921 (2H, d, J=8.8 Hz, phenyl-H),
7.355 (2H, d, J=8.8 Hz, phenyl-H),
IVνKBr/max cm -1 3300, 1740, 1660, 1540,
Embodiment 15
Synthesis of N-4'-[methyl (5-acetamido-3,5-dideoxy-α-D-glycero-D-galacto 2 nonulopyranosylonate)oxy] succinaniloyl) glycine methyl ester
98 mg of 4,-[(methyl 5-acetamido 3, 5 dideoxy-α-D glycero-D-galacto-2-nonulopyranosylonate)oxy] succinanilic acid obtained in the aforementioned Embodiment 9 and 27.1 μl of triethylamine were dissolved in 1 ml of anhydrous dimethylformamide and 25 ml of iso-butylchloroformate were added with stirring and cooling (15 ° C.), then allowed to react for 10 minutes. Then, 1 ml of anhydrous dimethylformamide solution dissolving 24.4 mg of glycine methyl ester hydrochloride salt and 27.1 μl of triethylamine was added to the above-mentioned acid anhydride solution. After stirring, the solution was allowed to react at 0 ° C. for 1 hour, then at room temperature with stirring for one day. After the reaction solvent was removed under reduced pressure conditions, the residue obrtained was purified with C 18 -column chromatography (YMC.GEL ODS 60 Å 60/200 mesh). The solution was eluted first with water, then with water/methanol=1/1 solution, and the fractional solution containing the product was freeze-dryed to give 50 mg of white powdery crystals (yield=45%, melting point=111°-113 ° C.).
TLC: Rf=0.46 (Kieselgel 60 F 254 , Merck product, CHCl 3 /MeOH/ACOH=6/3/0.5) ##STR22##
Physical properties of the product
C 25 H 35 O 13 N 3
FAB MS m/z : 586 (M + +1)
1 H-NMR ppm/500 MHz (D20, TSP)
2.040 (1H, t, J=12.5 Hz, H 3ax ),
2.051 (3H, s, --NHCOCH 3 ),
2.68-2.74 (4H m --CH 2 --CH 2 --)
2.890 (1H, dd, J=12.8, 4.4 Hz, H 3eq ),
3.726 (3H, s, 2--COOCH 3 ),
3.763 (3H, s, --NHCH 2 COOCH 3 ),
7.164 H, d, J=8.8 Hz, phenyl-H),
7.397 (2H, d, J=8.8 Hz, phenyl H),
IRνKBr/max cm -1 3350, 1740, 1650, 1550,
Embodiment 16
Synthesis of N 4'-[methyl (5-acetamido-4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate)oxy] succinaniloyl) glycine
100 mg of 4'-[(methyl 5-acetamido-4, 7, 8, 9-tetra-O-acetyl-3, 5-dideoxy-α-D-glycero-D-galacto-2-nonulopyranosylonate) oxy] succinanilic acid obtained in the aforementioned Embodiment 6 and 20.4 μl of triethylamine were dissolved in 2 ml of anhydrous tetrahydrofuran, and 18.9 μl of isobutylchloroformate were added with stirring and cooling (-15 ° C.), then allowed to react for 10 minutes. Then, the above mentioned acid anhydride solution was added to 1 ml of tetrahydrofuran-water (1:1) solution dissolving 11 mg of glycine and 0.4 μl of triethylamine with cooling (0 ° C.) and stirring. The solution was allowed to react at 0 ° C. for hour, then at room temperature with stirring for one day. After the reaction solvent was removed under reduced pressure conditions, the residue obtained was freeze-dried. The methanol solution of the residue obtained was made acidic with Dowex 50 w (H + ), then solvent was removed.
The residue was purified with silica gel column chromatography (Wakogel C 300, acetate/methanol=5/3) to give the fractional solution containing the product. Solvent was removed from the fractional solution and 54 mg of white powdery crystals were obtained (yield=50%, melting point=105°-108 ° C.).
TLC: Rf=0.15 (Kieselgel 60 F 254 , Merck product, acetate/methanol=5/3) ##STR23##
Physical properties of the product
C 32 H 41 O 17 N 3
FAB-MS m/z 740 (M + +1)
1 H-NMR ppm/500 MHz (CDCl 3 , TMS)
1.880 (3H, s, --NHCOCH 3 ),
024;2.085;2.117 (all s, --OCOCH 3 X 4),
3.605 (3H, s, 2--COOCH 3 ),
3.61 (2H, broad s, -NH-CH 2 --COOH),
4.93 (1H, m, H 4),
6.962 (2H, d, J=8.1 Hz, phenyl H),
7.412 (2H, d, J=8.1 Hz, phenyl-H),
IRνKBr/max cm -1 3350, 1740, 1660, 1540,
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Sialic acid derivative with active ester groups expressed with the formula [I] ##STR1## Where R 1 denotes hydrogen or an acetyl group, R 2 denotes hydrogen or a lower alkyl group, R 3 denotes C 2 H 4 , C 3 H 6 or C 2 H 2 , R 4 denotes an hydroxyl group, the residue left after removing hydrogen from the alcohol portion of the active ester or alkyloxycarbonyloxy group, AC denotes an acetyl group, Ph denotes an phenyl group, and X denotes oxygen or sulfur. This sialic acid derivative has high reactivity because it has active ester groups in the molecules and can be used as a raw material or intermediate for synthesis of various sialic acid derivatives.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is broadly concerned with an improved, low cost method for removal of arsenic and other heavy metals from phosphoric acid in order to obtain a greatly purified product. More particularly, it is concerned that such a method which involves, inter alia, a liquid extraction of heavy metal sulfides, preferably through the use of carbon disulfide as an extractant.
2. Description of the Prior Art.
Phosphoric acid is produced on a commercial scale by two methods, namely the furnace process and the wet process. Furnace acid is generally purer than wet process acid (the latter sometimes being referred to as "green acid"), but is significantly more costly to produce. Indeed, furnace grade acid generally is designed for a more specialized market requiring a high degree of purity.
Both types of phosphoric acid generally contain as contaminants heavy metals, and particularly arsenic, lead, copper, and bismuth. Arsenic makes up the very large majority of heavy metal species in most phosphoric acids. These contaminants typically exist in the phosphate ore used as a starting material, and are carried through both commercial processes, thus becoming contaminants in the final acids. The typical concentration of heavy metals in furnace grade acid is from about 50-200 ppm, depending upon the quality of ore employed.
Heavy metal contaminants, and particularly arsenic are very undesirable in phosphoric acid, particularly acids destined for the food grade market. As a consequence, producers of high quality acid take steps to remove the heavy metal contaminants during processing. Almost without exception, such heavy metals are removed by a sulfide treatment of the acid, involving reacting the acid with hydrogen sulfide or a sulfide salt such as sodium sulfide. The resulting heavy metal sulfides tend to form a very fine particulate suspension in the liquid acid, which can be extremely difficult to remove. Accordingly, processors make use of filter aids such as diatomacous earth, perlite, or bentonite clay, which increase filtration retention and/or throughput. Consequently, the filter aids are removed with the heavy metal sulfides as a filter cake.
While the above-described process is capable of lowering the heavy metal content of phosphoric acid to less than 10 ppm (with an arsenic content of less than 3 ppm), the resultant filter cake is considered a hazardous waste, and therefore disposal of the filter cake can be very difficult and expensive. At the same time, the filter cake tends to have considerably greater volume than what would be predicted by the stochiometry of the overall process as it contains phosphoric acid, water, and filter aids in addition to the heavy metal sulfides.
Accordingly, there is a real and heretofore unsatisfied need in the art for an improved process for removing heavy metal contaminants (and especially arsenic) from wet or furnace grade acid which eliminates or at least minimizes the disposal problems inherent in the use of conventional filtering aids.
SUMMARY OF THE INVENTION
The present invention overcomes the problems outlined above and provides a process for removing arsenic and other heavy metals from phosphoric acid through the use of a liquid extractant/gravimetric technique which is capable of removing virtually all offending contaminants while at the same time largely reducing the waste disposal problem inherent in prior processes.
In general, the process of the invention comprises the steps of contacting a heavy metal-containing phosphoric acid with a sulfiding agent (e.g., hydrogen sulfide or sodium sulfide) and a liquid extractant. The sulfiding agent serves to react with the heavy metals and form sulfides thereof, while the extractant serves to sequester the heavy metal sulfides. The final step of the process involves recovery of phosphoric acid, typically through the use of centrifugation and gravimetric separation.
In preferred forms, the sulfiding agent and extractant are added in a stepwise fashion, i.e., the starting acid is initially sulfided with an intermediate settling step, followed by treatement with an extractant, and ultimate separation. Alternately, the sulfiding agent and extractant can be premixed prior to addition to the phosphoric acid, but this procedure is not preferred.
The process of the invention is applicable to all types of phosphoric acid, for example furnace grade and wet process phosphoric acids. In addition, although the process can be used with acids having a wide variety of P 2 O 5 contents, it is preferred that the acid have from about 50 to 65% P 2 O 5 . At lower P 2 O 5 contents, the specific gravities of the acid and preferred extractant (carbon disulfide) are similar, thus presenting difficulties in separation; with extremely high P 2 O 5 content acid, the viscosity of the acid presents handling problems.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The initial step of the preferred process of the invention involves sulfiding heavy metal-containing phosphoric acid in order to produce heavy metal sulfides, particularly arsenic sulfide. Advantageously, the sulfiding step is carried out at an elevated temperature of from about 50° to 90° C. and can involve sparging gaseous hydrogen sulfide into the liquid acid (typically carried out with moderate mechanical agitation over a period of from about 1-4 hours) or addition of a sulfiding salt. The preferred sulfiding agents are selected from the group consisting of hydrogen sulfide, the alkali metal sulfides, and phosphorous pentasulfide.
After the sulfiding agent has been added to the acid, and the intial reaction complete, it is desirable to allow the initially sulfided acid to set for a period of up to about 16 hours, more preferably from about 15 minutes to about 3 hours. During this time, it is also desirable to permit the acid to drop in temperature to approximately ambient or more broadly from about 20° to 40° C. Such lowered temperatures eliminate the possibility of boil-off of the extractant when subsequently added to the acid.
The extraction step involves addition of a minor amount of liquid extractant to the initially sulfided acid, with sufficient agitation to assure an even dispersion. The preferred extractant is liquid carbon disulfide, and this agent should be added to the acid at a level sufficient to effect (upon setting) separation into a phosphoric acid fraction and an arsenic compound-bearing fraction. The carbon disulfide may be added at a level of up to about 10% by weight of the initially sulfided phosphoric acid, although this would typically be greatly in excess of the requirements. This presents no difficulty, however, inasmuch as the excess carbon disulfide can readily be recovered by distillation.
After the extractant is added with sufficient agitation, the mixture is allowed to settle. During this process, the extractant tends to agglomerate or sequester the heavy metal sulfides in the acid, and distinct layers form in the reaction vessel. The lower fraction is primarily phosphoric acid, followed by a heavy metal sulfide layer and a layer primarily comprising carbon disulfide. In the preferred form of the invention, the specific gravity differences between the materials leads to rather prompt separation of the materials. If desired though, steps can be made to enhance the separation time, e.g., centrifugation. In any event, the setting time required is variable depending upon reaction conditions but generally varies from between about 15 minutes and 16 hours.
The final separation step is of course conventional and involves merely decanting the upper layers or draining of the lower layer in order to effect the necessary separation of the acid. It may occur that the decontaminated acid contains a small fraction of carbon disulfide therein. This can be readily removed by oxidation, which may involve passing air into the acid or the addition of a minor amount of hydrogen peroxide followed by heating to a level of about 70°-100° C. This treatment serves to render the acid clear and odor free. Actual experiments using the process of the invention demonstrate that the arsenic level in the treated acid is very low, usually under 1 ppm.
In order forms of the invention, the extraction process may be enhanced by the addition of 1 part diatomaeous earth to 1 part heavy metal sulfide content in the acid subsequently to the initial sufiding step. The diatomaceous earth may be added during the sulfiding step to good advantage. This modification renders the overall process more rapid, since extraction can proceed as soon as the proper temperature levels are reached.
In another alternative, very good results can be obtained by the addition of a strongly acid cationic surfactant or flocculating agent to the initially sulfided acid. Here again, this permits the processor to begin the extraction step as soon as the acid reaches the desired temperature.
The followin examples illustrate the principles of the invention.
EXAMPLE 1
The starting material for this example was a 84% P 2 O 5 polyphosphoric furnace grade acid solution. the acid solution had a reported analysis of 120 ppm arsenic content. Subsequent analysis (colorimetric analysis by reduction of the arsenic species in the acid and recovery of the resulting AsH 3 in pyridine) revealed a minimum arsenic content of 100 ppm. The 84% P 2 O 5 polyphosphoric acid was diluted down to 54% strength phosphoric acid and verified by hydrometer.
20 mililiters of the 54% P 2 O 5 phosphoric acid was placed into a test tube, and several pellets of sodium sulfide were then added. By vigorously shaking the test tube of acid and at the same time relieving the buildup of gas pressure (hydrogen sulfide), the acid was crudely sulfided at room temperature in a matter of several minutes. The sulfided acid was then split into two 10 mililiter samples in separate test tubes. The acid samples were allowed to set overnight undisturbed (16 hours).
After setting, one of the initially sulfided acid samples was filtered through a 10 micron retention fretted glass filter. The resulting cake was of a yellowish-green color. The 54% P 2 O 5 acid filtrate was perfectly clear. Subsequent analysis of the acid filtrate revealed a 20 ppm arsenic content.
2 mililiters of carbon disulfide was added to the second acid sample. This was vigorously shaken for 15 seconds and then allowed to settle for 30 minutes. The upper yellowish-green layer of carbon disulfide was decanted off to leave a slightly yellowish 54% P 2 O 5 acid raffinate. Subsequent analysis of the acid revealed a 22 ppm arsenic content.
EXAMPLE 2
In this example an improved sulfiding technique was employed. The procedure of Example 1 was repeated with the exception of the sulfiding operation. In this case, a hydrogen sulfide generator was constructed (dropwise addition of sulfuric acid into a flask of sodium sulfide solution). The evolved hydrogen sulfide gas was routed into the test tube of 54% P 2 O 5 acid and allowed to sparge through it for 2 hours, while maintaining the acid solution at 70° C. (in a hot water bath). Filtered and carbon disulfide extracted samples yielded 1.0 ppm and 1.0 ppm arsenic contents in their respective acids.
EXAMPLE 3
This test repeats the procedure of Example 2, but shortens the time the acid is allowed to set after sulfiding from 16 hours to 15 minutes. Arsenic contents of both the filtered and carbon disulfide extracted acid rose to 4 ppm and 5 ppm arsenic respectively. The initially sulfided sample of 54% P 2 O 5 strength acid that was to be extracted had to be cooled to room temperature (by running cold water over the outside of the test tube) before the carbon disulfide could be added, in order to prevent boil off of the carbon disulfide.
EXAMPLE 4
The following illustrates a preferred method in accordance with the invention. 100 mililiters of 54% P 2 O 5 strength phosphoric acid with a known 80 ppm arsenic content was placed in a 250 mililiter Erlenmeyer flask, kept at 70° C. in a hot water bath. The acid was sparged with hydrogen sulfide gas for 2 hours under moderate mechanical agitation. The flask was then removed from the bath and allowed to cool to room temperature over a period of 3 hours. The initially sulfided acid was poured into a 250 mililiter separatory funnel, and 5 mililiters of carbon disulfide added. The separatory funnel was then vigorously shaken for 1 minute and allowed to set for 15 minutes. After 15 minutes the bottom yellowish tinted acid layer was removed by opening the stopcock at the bottom of the funnel. The tinted 54% P 2 O 5 strength phosphoric acid was then treated with 1 mililiter of 30% hydrogen peroxide and heated to 90° C. to oxidize out traces of carbon disulfide, colloidal sulfur, hydrogen sulfide, etc. Within 10 minutes, the acid solution became clear and odor free. The arsenic content of this treated acid was 0.5 ppm.
EXAMPLE 5
In this test, the procedure of Example 4 was followed, but the sensitivity of the extraction method with surfactant addition was tested.
The addition of 5 ppm by weight of Nacconal 40DB, an anionic linear alkylate sulfonate surfactant, was found to inhibit the extraction method. However, the addition of 5 ppm Amerfloc 490, a cationic polymer sold by Drew Chemical Corporation, 1 Drew Chemical Plaza, Boonton, N.J., 07005, enhanced the separation of the carbon disulfide suspension with arsenic sulfide from the phosphoric acid. The cationic polymeric surfactant was added to the sulfided acid before adding the carbon disulfide.
Using this method, it was possible to reduce the separation time from 15 minutes (Example 4) to 10 minutes and still maintain the same low arsenic content (0.5 ppm) of the final product sold.
EXAMPLE 6
In another test using the procedure of Example 4, the addition of a small amount of diatomaceous earth filter aid (Eagle Pitcher FW-12) was found to enhance the separation of the carbon disulfide/arsenic sulfide layers from the phosphoric acid. Again, it was possible to reduce the separation time from 15 minutes (Example 4) to 10 minutes by the addition of 80 ppm of filter aid to the sulfided acid prior to the addition of carbon disulfide. The same low arsenic content (0.5 ppm) in the final product acid was the result.
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An improved, low cost, liquid extraction method for significantly reducing the arsenic and other heavy metal content of phosphoric acid is disclosed which can routinely achieve essential elimination of arsenic compounds while producing relatively small amounts of usable heavy metal by-product. Preferably, the impure acid (wet process or furnace grade having a P 2 O 5 content of about 50-65%) is initially sulfided at elevated temperatures to form arsenic and other heavy metal sulfides, whereupon the sulfided acid is allowed to set and cool; a liquid extractant, preferably carbon disulfide, is then added with agitation and subsequent setting, to form easily separable phosphoric acid and heavy metal-bearing fractions. Residual extractant can be removed from the separated acid by oxidation, leaving phosphoric acid having a very low arsenic content.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the invention generally relate to optical fiber technology, and more specifically, to optical interconnection devices used to connect an optical fiber to an optical device or component.
2. Description of the Related Art
Optical fibers have generally replaced copper wire as the preferred medium for carrying telecommunications signals. As with copper wire, it is necessary to provide for the interconnection of optical fibers, during installation, repair, or replacement of the fibers, and to terminate the fibers onto active optical devices. Optical devices include, for example, optical switches, optical sensors, and transceivers. The termination of an optical fiber may be indirect, i.e., the fiber may be connected to some other (passive) optical device, such as a beam splitter or polarizer, before the optical signal is directed to the active optical device. The present invention is generally directed to an optical interconnection sub-assembly for a termination of an optical fiber.
Optical interconnection sub-assemblies are generally manufactured over a significant period of time as a result of the amount of time it takes to cure the components epoxied inside the sub-assembly. An optical interconnection subassembly generally includes a housing having one or more components therein, such as a fiber stop, ferule-receiving sleeve, or securing bushing. Each component is generally secured to the housing using an epoxy. The securing epoxy takes some time to cure, and consequently, this curing time hinders the manufacturing process of optical interconnection sub-assemblies and reduces the manufacturing throughput.
Therefore, a need exists for an easily manufactured, efficient, and cost effective optical interconnection sub-assembly that overcomes the disadvantages of conventional optical interconnection sub-assemblies.
SUMMARY OF THE INVENTION
Embodiments of the invention are generally directed to an optical interconnection sub-assembly. In one aspect, the optical interconnection sub-assembly includes a housing having a longitudinal bore formed therethrough, a tapered ring secured to a first end of the longitudinal bore, a split sleeve ring secured to the tapered ring, a fiber stop secured to the split sleeve ring, and one or more bushings secured to a second end of the longitudinal bore. Each of the components is generally press-fitted into the housing, and therefore, no epoxy or curing time is required to manufacture the optical interconnection sub-assembly of the invention.
Embodiments of the invention further provide an optical interconnection sub-assembly having a first end and a second end. The first end of the optical interconnection sub-assembly is configured for coupling the optical interconnection sub-assembly to an optical device, while the second end of the optical interconnection sub-assembly is configured for receiving a terminal end of an optical fiber. The sub-assembly includes one or more bushings positioned at the second end of the sub-assembly. The bushings are configured for receiving and holding the terminal end of the optical fiber in the sub-assembly. The sub-assembly further includes a split sleeve ring positioned at the first end of the sub-assembly. The split sleeve ring is configured for holding the terminal end of the optical fiber. The split sleeve ring may include a fiber stop secured inside the split sleeve ring. The fiber stop is configured for abutting against the terminal end of the optical fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the invention may be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof, which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of the invention, and are therefore, not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments without departing from the true scope thereof.
FIG. 1 illustrates a side cross sectional view of an optical interconnection sub-assembly in accordance with an embodiment of the present invention; and
FIG. 2 illustrates a perspective view of the split sleeve ring in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments of the invention are generally directed to an optical interconnection sub-assembly. The optical interconnection sub-assembly may be used to connect a terminal end of an optical fiber to an optical device, such as a transceiver or an optical switch, for example. At a front end of the optical interconnection sub-assembly, the optical interconnection sub-assembly is configured to receive the terminal end of the optical fiber. At a back end, the optical interconnection sub-assembly is configured to be connected to an optical device. The optical interconnection sub-assembly generally includes a housing with a longitudinal bore formed through the housing. One or more bushings are placed inside a front end of the longitudinal bore, and a tapered ring is press-fitted inside a back end of the longitudinal bore. A split sleeve ring is press-fitted into the tapered ring, and a fiber stop is press-fitted inside the split sleeve ring. The bushings and the split sleeve ring are generally configured to receive and hold a terminal end of the optical fiber. The split sleeve is configured to hold the fiber stop in addition to the terminal end of the optical fiber. In operation, the bushings and the split sleeve ring hold the terminal end of the optical fiber while the fiber stop abuts against the terminal end of the optical fiber. Generally, the fiber stop is aligned with the terminal end of the optical fiber such that an optical signal transmitted from the terminal end of the optical fiber passes through the fiber stop with minimal connection loss.
FIG. 1 illustrates a side cross sectional view of an exemplary optical interconnection sub-assembly 100 of the invention. The optical interconnection subassembly 100 is generally configured to receive a terminal portion of an optical fiber 200 at a front end 110 of the sub-assembly 100 . The back end 120 of optical interconnection sub-assembly 100 is configured to couple to an optical device, such as, an optical switch, a transceiver, and the like. The optical interconnection subassembly 100 generally includes an elongated housing 130 having a longitudinal bore 140 formed therethrough. The longitudinal bore 140 has a front end that coincides with the front end 110 of the sub-assembly 100 and a back end that coincides with the back end 120 of the sub-assembly 100 . The longitudinal bore 140 is generally shaped to hold one or more optical components. For example, the longitudinal bore 140 may be threaded at the front end, cylindrical at the middle, and tapered at the back end. Generally, the longitudinal bore 140 has a diameter of about 1 mm to about 1.25 mm. The housing 130 may be made from a stainless steel material or a heat treated alloy, such as, stainless steel with a condition H 1150 or 430, or Carpenter® custom 718 or 630. In this manner, the housing 130 is generally manufactured from a material that has lesser ductility than the components contained therein.
The optical interconnection sub-assembly 100 further includes a first bushing 150 and a second bushing 160 positioned proximate the front end 110 . The first bushing 150 and the second bushing 160 may be positioned inside the optical interconnection sub-assembly 100 by being pressed into the front end of the longitudinal bore 140 . Alternatively, a unitary bushing may be implemented in lieu of the first bushing 150 and the second bushing 160 . Regardless of the number of bushings implemented, the bushings may be double or single threaded, and may be configured to receive and hold the optical fiber 200 therein. More specifically, the inside surface portion 155 of the bushings is generally configured to hold the outer diameter surface 210 of the optical fiber 200 . Additionally, the inner diameter of the bushings may be configured to receive and secure an optical ferrule (not shown) encasing an optical fiber therein. The bushings are generally manufactured from a material that matches the thermal expansion of the housing 130 , such as, materials with a coefficient of thermal expansion (CTE) of 416, 303 or 302 and beryllium copper. However, if two bushings are implemented, embodiments of the invention contemplate that the first bushing 150 may be manufactured from a different material than the second bushing 160 .
Furthermore, in order for the respective bushings to be properly secured into the end of housing 130 , the perimeter of exterior surfaces of the respective bushings may have finger members, i.e., members resembling threads without the spiraling pattern associated with threads, extending therefrom. The extending finger members may be used to gauge and regulate the securing force applied to the respective bushings, as the fingers are generally configured to crush or deform at specific forces. These specific crush forces may be correlated with specific securing forces, and therefore, used to regulate the securing force applied to the respective bushings. Factors that may be determinative of the crush force of a particular finger include the physical structure/shape of the finger and the composition thereof, i.e., softer metals may be used to generate lower securing forces, while harder less deformable metals may be used to generate higher securing forces.
The optical interconnection sub-assembly 100 further includes a tapered ring 170 , a split sleeve ring 180 , and a fiber stop 190 positioned near the back end 120 of the sub assembly 100 . The tapered ring 170 has an inner surface 172 and an outer surface 174 that is tapered. The inner surface 172 generally defines a cylindrical bore having a uniform diameter. The outer surface 174 generally defines a cylindrical solid having an increasing diameter going from the middle portion of the sub-assembly 100 to the back end 120 of the sub-assembly 100 . The tapered ring 170 is generally press-fitted into the longitudinal bore 140 at the outer surface 174 such that the tapered outer surface 174 slidably engages the longitudinal bore 140 to secure the tapered ring 170 inside the longitudinal bore 140 . That is, the tapered ring 170 is held or secured against the inside portion of the housing 130 primarily by friction. In this manner, no epoxy is required to hold the tapered ring 170 against the inside portion of the housing 130 . In order to facilitate press fitting the tapered ring 170 into the longitudinal bore 140 , the longitudinal bore 140 is generally shaped to receive the tapered ring 170 . For example, the longitudinal bore 140 may be angled so as to facilitate press-fitting the tapered ring 170 into the longitudinal bore 140 . The longitudinal bore 140 may also include an inner ledge 142 and an outer ledge 144 . The inner ledge 142 and the outer ledge 144 are configured to stop the tapered ring 170 from going too far into the longitudinal bore 140 . The tapered ring 170 may be made from a non-heat treated material that is more ductile than the housing 130 , such as copper or steel, for example. As will be made clear in the following paragraphs, the tapered ring 170 is configured to hold the split sleeve ring 180 and the fiber stop 190 .
Press-fitted against the inner surface 172 of the tapered ring 170 is the split sleeve ring 180 , which has an inner diameter surface 182 and an outer diameter surface 184 . The split sleeve ring 180 includes a slit, along its length, extending from one end to the other end. In other words, the split sleeve ring 180 includes a longitudinal section that has been removed so as to enable the split sleeve ring 180 to expand and contract according to the size of the component (e.g., fiber stop 190 ) contained inside the split sleeve ring 180 . More particularly, a longitudinal strip is removed from the sleeve ring 180 , which generates a C-shaped solid, as illustrated in FIG. 2 . Once assembled into the sub-assembly 100 , the outer diameter surface 184 is pressed against the inner surface 172 of the tapered ring 170 . This configuration operates to hold the split sleeve ring 180 inside the tapered ring 170 primarily by friction. In this manner, no epoxy is required to hold the split sleeve ring 180 against the inner surface 172 of the tapered ring 170 . The split sleeve ring 180 may also be separated from the second bushing 160 by a distance. In this manner, the split sleeve ring 180 is placed proximate the second bushing 160 . The split sleeve ring 180 may be made from stainless steel, ceramic, beryllium copper, or any material with a proper elastic deformation characteristics, i.e., materials configured to expand to receive the optical fiber 200 therein and then contract to secure the optical fiber 200 inside the split sleeve 180 . The split sleeve ring 180 is configured to hold the fiber stop 190 and the terminal end of the optical fiber 200 . The inside diameter of the split sleeve ring 180 may be slightly less than the outside diameter of the optical fiber 200 to be received therein, so as to accommodate the optical fiber 200 and firmly secure the optical fiber 200 inside the split sleeve ring 180 .
A fiber stop 190 is generally press-fitted against the inner diameter surface 182 of the split sleeve ring 180 . The fiber stop 190 has an inner diameter surface 192 and an outer diameter surface 194 , which is press-fitted against the inner diameter surface 182 of the split sleeve ring 180 . The fiber stop 190 is, therefore, held inside the split sleeve ring 180 primarily by friction. In this manner, no epoxy is required to hold or secure the fiber stop 190 against the inner diameter surface 182 of the split sleeve ring 180 . The outer diameter of the fiber stop 190 is generally slightly greater than the inner diameter of the split sleeve ring 180 so as to enable the split sleeve ring 180 to firmly secure the fiber stop 190 therein. The fiber stop 190 (at its front end 196 ) is configured to stop a terminal end of the optical fiber 200 , such that the fiber stop 190 abuts against the terminal end of the optical fiber 200 . The fiber stop 190 further includes a tunnel cavity 220 configured for passing an optical signal transmitted from the terminal end of the optical fiber 200 . The tunnel cavity 220 has a first diameter 197 at the front end 196 of the fiber stop 190 and a second diameter 198 at the back end 199 of the fiber stop 190 , which is significantly larger than the first diameter 197 . The first diameter 197 at the front end 196 is designed to be smaller than the outside diameter of the optical fiber 200 so as to prevent the terminal end of the optical fiber 200 from passing through the fiber stop 190 . The diameter of the tunnel cavity 220 gradually increases from the front end 196 of the fiber stop 190 to the back end 199 of the fiber stop 180 so as to provide an optical clearance for the optical signal transmitted from the optical fiber 200 . The fiber stop 190 is generally aligned with the terminal end of the optical fiber 200 , such that the optical signal from the terminal end of the optical fiber 200 passes through the tunnel cavity 220 with minimal connection loss, thus forming a low loss optical path. The fiber stop 190 may be longitudinally positioned anywhere inside the split sleeve ring 180 . The back end 199 of the fiber stop 190 , however, is generally parallel with the back end of the split sleeve ring 180 , and the length of the fiber stop 190 is generally about half the length of the split sleeve ring 180 . The fiber stop 190 may be manufactured from a material with a low coefficient of thermal expansion, e.g., 416.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention generally is directed to an optical interconnection sub-assembly, which includes a housing, a longitudinal bore formed through the housing, a tapered ring press-fitted into a first end of the longitudinal bore, a split sleeve ring press-fitted into the tapered ring, a fiber stop press-fitted into the split sleeve ring, and one or more bushings threaded into a second end of the longitudinal bore. The interconnection generally operates to secure a fiber in one end and communicate a signal received from the fiber to a device attached thereto. Further, the interconnection generally does not require any epoxy or other chemical affixation methods, as press fitting and shrink fitting methods are employed, which substantially reduces the assembly time.
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TECHNICAL FIELD
[0001] The present invention relates to a method and a system for controlling a combustion engine for propelling a motor vehicle. In particular the present invention relates to a method and apparatus for controlling a motor vehicle equipped with an engine employing Variable Turbine Geometry (VTG) Technology.
BACKGROUND
[0002] An engine used in trucks can be provided with a Variable Turbine Geometry (VTG) also termed Variable Geometry Turbocharger or Variable Geometry Turbine (VGT). One reason for employing VTG technology is that it facilitates fulfillment of emission requirements for i.a. diesel engines.
[0003] As is the case for all gear shifting there is a desire to minimize the time required to carry out the gear shift. This is because during gear shift there should not be any torque on the drive line. Gear shifting is also described in the international patent application having the international publication number WO 03/018974. Furthermore, in the U.S. Pat. No. 6,089,018 a method of controlling a VTG during gear shift is described.
[0004] Hence, there exist a need for a method and a system that is capable of providing a quick gear shift.
SUMMARY
[0005] It is an object of the present invention to provide a method and a system that is capable providing a quick gear shift.
[0006] It is another object of the present invention to provide a method and a system that is capable of providing a quick retardation of the engine speed during gear shift.
[0007] These objects and others are obtained by the method, system and computer program product as set out in the appended claims. Thus, closing the VTG to a maximally acceptable closed position and keeping the VTG in such a position during the gear shift will allow a quick retardation of the engine speed.
[0008] In order to obtain a quick deceleration of the engine speed when up-shifting, the VTG can be set to act as an engine braking device. Hence, by creating a high exhaust gas pressure upstream the VTG turbine that pressure will increase the pumping losses of the engine hence striving to decelerate the engine speed. In such an operation the more closed the VTG, the more pump losses will have to be overcome by the engine and as a result the engine speed will decelerate quicker. However, the VTG can only sustain a certain pressure drop. Hence, the pressure difference over the VTG can not be allowed to exceed an inherent value particular to each type of VTG.
[0009] Knowing the maximally allowed pressure difference over the VTG and controlling the VTG to be as closed as possible without exceeding the maximally allowed pressure, the VTG will act to decelerate the engine speed as quickly as possible without endangering the VTG. The result of such a control strategy is a very fast deceleration of the engine speed and as a consequence the gear shift can be made quicker.
[0010] In one embodiment, the control system is adapted to determining the effective flow area for the Variable Turbine Geometry, and to determining the maximally allowed closed position for the Variable Turbine Geometry from the determined effective flow area of the Variable Turbine Geometry. Hereby a fast calculation of the optimal VTG position can be obtained whereby the control method can be made fast and accurate.
[0011] In one embodiment the control system has access to a stored map of Variable Turbine Geometry positions for different effective flow areas whereby the maximally closed Variable Turbine Geometry position directly can be determined to be the position corresponding to the effective flow area of the map, which even further speeds up the time required for finding the optimal VTG position.
[0012] In one embodiment the control system is adapted to repeatedly update the maximally allowed closed position for the Variable Turbine Geometry during the gear shift. Hereby it is assured that the optimal closed position is applied for the entire time period when gear shift is in progress. Also it is ensured that the VTG is closed to a position where the VTG is not endangered.
[0013] In one embodiment the VTG is closed some time period before a gear shift is performed. This is advantageous because when the gear shift begins the engine breaking is already maximized and full engine brake can be obtained during the entire gear shift operation.
[0014] In another embodiment the engine breaking properties of a VTG are combined with a conventional exhaust gas engine breaking device, such as an exhaust break.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will now be described in more detail by way of non-limiting examples and with reference to the accompanying drawings, in which:
[0016] FIG. 1 a is a general partial view of a drive line comprising an engine including a turbo charger with VTG,
[0017] FIG. 1 b is a view illustrating the exhaust gas flow of the engine in FIG. 1 a in more detail,
[0018] FIG. 2 is a flowchart illustrating steps performed when controlling an engine with VTG used for propelling a motor vehicle in accordance with a first embodiment, and
[0019] FIG. 3 is a flowchart illustrating steps performed when controlling an engine VTG used for propelling a motor vehicle in accordance with a second embodiment.
DETAILED DESCRIPTION
[0020] In FIG. 1 a selected parts of a drive line 100 of a motor vehicle 10 are schematically depicted. The drive line depicted in FIG. 1 can for example be designed to be part of a truck or any other heavy vehicle such as a bus or the like. The drive line 100 comprises an engine 101 , e.g. in the form of diesel engine. The engine 101 comprises a turbocharger driven by a turbine having a Variable Turbine Geometry VTG 103 . The engine is further connected to a gear box 105 , for example a gear box adapted for automatic gear shift. The vehicle 10 can also be provided with an exhaust break, as is shown in FIG. 1 b.
[0021] The engine 101 and the gearbox 105 are controlled by at least one control unit 107 , such as an electronic control unit (ECU). The control unit is adapted to receive sensor signals from different parts of the vehicle, including, but not limited to, signals used for controlling the gearbox and the engine. The control unit 107 is also adapted to provide control signals to different parts and components of the vehicle such as for example the engine and the gear box.
[0022] The control of the different parts and components of the vehicle is governed by pre-programmed instructions stored in the control unit. The pre-programmed instructions typically are in the form of a computer program executed by the control unit. By changing the instructions the vehicle can be made to behave differently in a particular situation. Typically, the programmed computer instructions are provided in the form of a computer program product 110 stored on a readable digital storage medium 108 , such as memory card, a Read Only Memory (ROM) a Random Access Memory (RAM), an EPROM, an EEPROM or a flash memory.
[0023] In FIG. 1 b the exhaust gas flow of the engine depicted in FIG. 1 a is shown in more detail, where the arrows indicate the exhaust gas flow direction. Thus, downstream the engine the VTG 103 is located. Upstream the VTG, e.g. at the beginning of the exhaust gas system, a first pressure sensor 115 is located. A second pressure sensor 116 is located downstream the VTG 103 . In addition there may be an exhaust gas break 117 provided further downstream the second pressure sensor 116 .
[0024] In FIG. 2 , a flowchart illustrating some procedural steps performed when controlling an engine with VTG of a motor vehicle in accordance with one embodiment of the present invention is shown. Thus, in a first step 201 , the control unit calculates the maximally allowed closed position for the VTG using the current readings from the pressure sensors before and after the VTG.
[0025] The pressure downstream the turbine can also be approximated with the outside pressure or, for example, using the model below for the pressure drop in the exhaust system.
[0000]
p
at
=
p
atm
2
+
p
atm
2
4
+
K
res
RT
em
m
.
t
2
[0026] The closed VTG position can for example be calculated using the following prediction calculations:
[0000]
m
.
t
=
A
t
p
bt
T
em
R
Ψ
(
p
at
p
bt
,
γ
e
)
where
A
t
=
A
r
*
C
d
γ
e
=
c
p
/
c
v
(
1
)
Ψ
(
p
at
p
bt
,
γ
e
)
=
{
2
γ
e
γ
e
(
(
p
at
p
bt
)
2
γ
e
-
(
p
at
p
bt
)
γ
e
+
1
γ
e
)
if
p
at
p
bt
≥
(
2
γ
e
+
1
)
γ
e
γ
e
+
1
γ
e
(
2
γ
e
+
1
)
γ
e
+
1
γ
e
-
1
else
(
2
)
[0027] Solving equation (1) for A t gives A t as a function of the following variables.
[0000] A t =f ( {dot over (m)} t ,T em ,p be ,p at ) (3)
[0028] Using reference values for the pressure values, and measured values for mass flow and exhaust gas temperature, equation (3) gives the effective flow area for the VTG that corresponds to the desired pressure drop over the turbine. Since the effective flow area is a function of VTG position, VTG positions that correspond to a certain effective flow area are stored in a map (f 2 ) in the ECU.
[0000] VTG Position= f 2 ( A t )
DESCRIPTION OF VARIABLES
[0000]
{dot over (m)} t =massflow through turbine
A t =effective flow area turbine
A r =Cross sectional area of flow path
C d =Flow coefficient
K res =Tunable model parameter
T em =temperature of exhaust gas
p atm =atmospheric pressure
p at =pressure after turbine
p bt =pressure before turbine
c p =Specific heat capacity at const. pressure
c v =Specific heat capacity at const. volume
R=Ideal gas const
[0041] The calculations performed in step 201 are continuously renewed so that the control unit at all times has access to an updated prediction value for the closed VTG position. When a gear shift is to be performed and the present gear is disengaged it is desired to quickly reduce the engine speed to a speed synchronized with the next gear after which the next gear can be engaged. A high exhaust gas pressure will contribute to reduce the engine speed quicker and hence reduce the time necessary to wait before the next gear can be engaged. Therefore it is beneficial to apply a high exhaust gas pressure when a gear shift is to take place.
[0042] Thus, when a gear shift is initiated in a second step 203 this event is signaled to the control unit. The signal can for example be a trigger signal from another control unit controlling the gear box, which upon initiating a gear shift also signals to the control unit controlling the VTG position. The control unit has access to data relating to the currently maximum closed VTG position and can emit a control signal setting the VTG to the corresponding position thereby maximizing the exhaust gas pressure in a third step 205 . Thereupon, the procedure checks if the gear shift has been completed in a fourth step 207 . If the gear shift has been completed the procedure ends in a fifth step 209 and the control of the VTG is performed according to whatever control strategy the control unit is programmed to execute.
[0043] If, on the other hand, the gear shift has not been completed in step 207 , the procedure continues to a sixth step 211 , where the VTG calculations as described above are updated so that the VTG can continue to be controlled to the maximum closed position. The procedure then returns to step 205 where the VTG is again set to a position corresponding to the result of the VTG calculations.
[0044] In FIG. 3 a flowchart illustrating some procedural steps performed when controlling the VTG of a vehicle in accordance with another embodiment of the present invention is shown.
[0045] Because it is desired that the exhaust gas pressure is as high as possible during the gear shift phase and building a high exhaust gas pressure takes time, it can be advantageous to start building a high exhaust gas pressure before the actual gear shift is initiated. Such a control procedure is shown in FIG. 3 .
[0046] Thus, in a first step 301 , the control unit calculates the maximally allowed closed position for the VTG using the current readings from the pressure sensors upstream and downstream the VTG. The pressure after the turbine can also be approximated with the outside pressure or some other approximation.
[0047] The closed VTG position can for example be calculated using the calculations as set out above in conjunction with FIG. 2 . The calculations performed in step 301 are continuously renewed so that the control unit at all times has access to an updated prediction value for the closed VTG position. When a gear shift is to be performed and the present gear is disengaged it is desired to quickly reduce the engine speed to a speed synchronized with the next gear after which the next gear can be engaged. A high exhaust gas pressure will contribute to reduce the engine speed quicker and hence reduce the time necessary to wait before the next gear can be engaged. Therefore it is beneficial to apply a high exhaust gas pressure just before a gear shift is to take place so that a high exhaust gas pressure can be generated and applied immediately when a gear shift begins.
[0048] Thus, when an event making it likely that a gear shift will take place in the near future occurs in a second step 303 , the control unit has access to data relating to the currently maximum closed VTG position and can emit a control signal setting the VTG to the corresponding position thereby maximizing the exhaust gas pressure in a third step 305 . In another embodiment instead of open control of the VTG position, a closed loop control of the exhaust gas pressure can be employed. Hence, instead of closing the VTG to the predicted position, the exhaust gas pressure is controlled to a maximum pressure that the VTG is estimated to sustain without suffering any damage in order to ensure that the VTG is not damaged.
[0049] The event triggering closing of the VTG can for example be a reduced torque demand or any other event signaling that a gear shift is likely to occur in the near future.
[0050] Thereupon, the procedure checks if the gear shift has been completed in a fourth step 307 . Also if the closing of the VTG was triggered and no gear shift was performed step 307 also times the time between the trigger event and actual gear shift initiation. If there is no gear shift for some predetermined period of time a timer in step 307 times out. If the gear shift has been completed or the timer in step 307 times out, the procedure ends in a fifth step 309 and the control of the VTG is performed according to whatever control strategy the control unit is programmed to execute.
[0051] If, on the other hand, the gear shift has not been completed and the timer has not timed out in step 307 , the procedure continues to a sixth step 311 , where the VTG calculations as described above are updated so that the VTG can continue to be controlled to the maximum closed position. The procedure then returns to step 305 where the VTG is again set to a position corresponding to the result of the VTG calculations.
[0052] Furthermore, because it is likely that the power demand from the engine will be high after completing a gear shift, keeping the exhaust gas pressure high for some time period after completion of a gear shift can be advantageous. Thus, by keeping the VTG closed for some time after completing a gear shift will maintain a high exhaust gas pressure before the turbine which can be used to power the turbo charger and thereby increase the power generated by the engine immediately after a gear shift.
[0053] The methods of providing quick engine retardation in conjunction with a gear shift as described herein can also be combined with a conventional exhaust break if this turns out to be advantageous in some applications.
[0054] Using the VTG to obtain a quick retardation of the engine speed is advantageous for a number of different reasons. There is for example little noise associated with building a high exhaust gas pressure. The VTG is further relatively easy to control. In addition a high exhaust gas pressure before the turbine enables a high power to the turbo compressor.
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When controlling an engine provided with Variable Turbine Geometry (VTG), the VTG is closed to a maximally acceptable closed position without endangering the VTG when performing an up-shift. The VTG is kept in such a position during the gear shift which, allows for a quick retardation of the engine speed.
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