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FIELD OF THE INVENTION
The present invention generally relates to a foot garment and, more particularly, is concerned with providing the human foot with the individual gripping action of the toes and barefoot when contacting the ground and at the same time providing the protection of a shoe. A stretchable tubular shaped material or fabric that is tight and snug fits around a human foot. An adhesive is applied to the bottom of the material or fabric with the adhesive hardening into a gripping or non-skid type of element, thus forming the bottom of the foot garment.
DESCRIPTION OF THE PRIOR ART
Running speed is important in many athletic events particularly track and field. It has been discovered that wearing track shoes slows a runner down, particularly on the synthetic track surfaces currently being utilized. This is because the runner must pull the spikes out of the synthetic surface when running and thus must overcome the friction and suction of the spikes when it contacts the surface. Many times runners in their bare feet tend to be able to run faster than those runners wearing shoes with the traditional spikes.
There have been many inventions to improve the foot stocking or shoe. For example, U.S. Pat. No. 1,308,483 to Craighead discloses an improved foot stocking which incorporates separate stalls for each toe.
A foot correcting inner slipper to correct deformities of the large toe or toes is disclosed by Levey in U.S. Pat. No. 3,013,564. The inner slipper is also comfortable to the wearer, easy to put on and take off. The inner slipper also provides an arch support with a sock or stocking disposed within the slipper to provide an inner lining for the slipper. The sock, inner slipper combination also providing a separate toe encasing portion for the large toe and a separate toe encasing portion for the rest of the toes.
U.S. Pat. No. 3,128,763 to Lengenfeld discloses a stocking with separate stalls for each toe and in addition thereto a pad or tubular strip around each of the stalls to prevent a number of foot ills or discomforts such as chafing, fungus growth, irritation or excessive perspiration. The pad also permitting the application of medication to points between the toes or around the toes.
An improved version for a shoe with individual compartments for the toes is disclosed in U.S. Pat. No. 3,967,390 to Anfruns. Each toe compartment has a separate sole portion, a separate upper portion, and a flexible strip disposed around and between the toe compartments. An indentation is extended into the sole to provide flexing of the separate tool compartments. The sole is usually made of a strong, natural leather or synthetic plastic, and the upper portions are usually made of leather. As a result of the toe compartments flexible construction the toe compartments are free to be independent therefore improving the toe compartments contact with the ground.
The above inventions provide better protection for the individual toes and foot, are more comfortable and provide better foot and toe contact with the ground. However, they are for casual wear and not for athletic events which require much more from a foot garment. Therefore, there is still a current need for a foot garment that is lightweight, which protects the feet, allows the individual toes and feet to engage and grip the ground, and to prevent the toes and feet from sliding within the foot garment when it is being used.
SUMMARY OF THE INVENTION
A lightweight foot garment which is tight and snug around the foot and providing the individual toes and feet to grip the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the present invention.
FIG. 2 is a bottom view of one embodiment of the present invention.
FIG. 3 is a bottom view of one embodiment of the present invention.
FIG. 4 is a cross sectional view taken along lines 4--4 in FIG. 2.
FIG. 5 is a cross sectional view of an individual toe compartment with one form of a spike.
FIG. 6 is a cross sectional view of an individual toe compartment with another form of a spike.
FIG. 7 is a cross sectional view of an individual toe compartment with another form of a spike.
FIG. 8 is a cross sectional view of an individual toe compartment with another form of a spike.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is an improvement of a garment to be worn on the human foot. The present invention will provide a wearer the gripping and control of barefoot while at the same time providing protection as if wearing a shoe. The present invention also would prevent the foot from sliding within the garment which would result in discomfort and a number of foot ills such as blisters and chafing. A particular application for the present invention is track and field events, particularly running. For example, a runner usually likes to carry as little weight as possible to run faster but yet not be inconvenienced or discomforted by the savings in weight. When a runner wears track shoes he must work against the force of the weight of the shoes and he must overcome the gripping force of the spikes or sole of the shoe on the track surface. Additionally, the foot within the shoe tends to slide back and forth therefore causing, without proper protection, a number of foot ills such as blisters and chafing. If a runner does not wear shoes and runs barefoot, he has less weight and less frictional forces to overcome and gains more control but loses the protection of wearing a shoe.
The present invention provides the benefits of running barefoot and at the same time provides the protection of wearing a shoe. A lightweight stretchable sock is worn by the runner instead of a shoe. A plurality of gripping type of material is disposed at key areas on the bottom of the sock or across the entire bottom of the sock to provide the gripping and control of runners in their barefeet. An adhesive is used to secure the pads to the sock or can be used alone to provide the gripping pads.
FIG. 1 shows the present invention from a side view. The sock 10 is made of a stretchable fabric but yet fits tight on the foot. The lower leg portion of the sock 11 may be as low as the ankle or as high as the knee. A plurality of pads 30, 32, 34 and 36 are disposed on the bottom portion of the sock at key locations where the foot contacts the ground. These pads are secured to the sock by an adhesive 20 such as hot melt glue. The pads are made of any gripping or non-skid type of material such as ground rubber particles.
Alternatively, the hot melt glue could be allowed to dry and harden without applying the ground rubber particles to it. Therefore, the hot melt glue would form the gripping pads. If additional support is required to prevent the foot from sliding within the sock, a bandage or any wrapping material may be wrapped around the ankle and foot to provide such support. If wrapping is desired, a sports medicine specialist should be consulted first.
Referring to FIG. 2, the sock is constructed such that there are individual stalls or compartments 12 for each toe. To provide the gripping and control of the bare foot, pads are disposed directly under each toe 30, at the base of each toe 32, on the side opposite the arch of the foot 34 and at the heel 36. Constructing the sock with individual stalls or toe compartments would allow independent and free movement of each toe therefore maximizing the gripping and control of the foot.
FIG. 3 shows the sock 10 constructed such that there is an individual compartment for the large toe 14 and an individual compartment for the rest of the toes 16. The pads are disposed similar to that in FIG. 2. However, the pads 32, 34 and 36 may be disposed to cover the entire bottom of the foot (not shown) or a unitary one piece pad may be disposed to cover the entire bottom of the sock (not shown).
The actual placement of the pads will vary from individual to individual and a pair of socks can be custom made for each person if it is desired. However, for mass production purposes, the pads may be placed at the positions where the average persons foot contacts the ground. Many methods can be used to locate the critical points on the bottom of the foot which makes contact with the ground. For example, a person may stand barefoot on a section of glass with a mirror placed at an angle to the glass such that the bottom of the foot may be observed through the glass. While standing on the glass, certain portions on the bottom of the foot will be more pale than other portions foot. This would indicate the areas which the weight of the body is distributed across the bottom of the foot. These areas could be sufficient to determine the placement of the pads. However, if a scope is used in conjunction with the glass and mirrors, the specific areas which the foot makes contact with the glass is indicated and could then be recorded and transfered to the bottom portion of the sock where the pads will be appropriately placed. Alternatively, a mold can be made for an individual foot to indicate the critical points. The thickness of the pads may also vary depending on the individual and the particular use of the sock.
The stretchable fabric 18 as shown in FIG. 4 can also vary in thickness depending on the protection desired by the wearer and the type of activity engaged by the wearer. Additionally, a soft pad or arch support may be placed within the sock for comfort. The bottom portion of each individual toe compartment 12 is sprayed or manually applied such as by spatula with the adhesive 20. In addition to hot melt glue, a variety of adhesives may be applied. For example, hot melt plastic or vinyls, or a wax-like substance may be used. The ground rubber particles 30 are then applied to the adhesive 20 before the adhesive hardens. In addition to ground rubber a variety of other materials may be used such as cork, many plastics, and polyethylene. In the event the ground rubber particles or other material are not positioned correctly, the adhesive may be reheated and the ground rubber particles or material may be moved to the proper position.
Depending on the activity engaged by the person, it may be desired to incorporate spikes on the bottom of the sock. This can be accomplished a variety of ways. The ground rubber particles 30 may be built up on the hot melt glue 20 such that the ground rubber particles forms a spike-shaped element as shown in FIG. 5. Alternatively, the hot melt glue itself 20 may be built up to form a spike-shaped element as shown in FIG. 6. Alternatively, a metal or nylon spike 40 may be applied to the hot melt glue 20 before it hardens, and an additional coat of hot melt glue 20 applied over the metal or nylon spike 40. The hot melt glue 20 could then be allowed to harden or the ground rubber paticles 30 may be applied to the hot melt glue 20 before it hardens. This is shown in FIG. 7. Also, the metal or nylon spike 40 may be embedded within the stretchable material 18. The hot melt glue 20 is then applied to the sock and either allowed to harden or ground rubber particles 30 may be applied to the hot melt glue 20 before it hardens. This is shown in FIG. 8.
Although the particular activity used as an example was running, and track and field events, there are many other uses for the present invention. For example, in sports the present invention may be used in gymnastics especially the balance beam, tennis, softball, baseball, and football, especially for a wide receiver. Additionally, the present invention may be used by rock climbers. However, if such is desired, it will be necessary to dispose gripping pads on the medial or lateral side or both sides of the sock. These additional pads provides a rock climber with more protection and more gripping surfaces when climbing. The present invention may also be used in aerobics and in industry. For example, roofers may use the present invention because it is essential for their feet to have a proper grip on the surface (the roof).
The present invention may also be modified such that a smooth or slippery material is substituted for the non-skid material. A particular application for this substitution is bowling where balance is important and a slippery or sliding surface on the bottom of the foot is required. Additionally, the present invention may be worn within a normal shoe, if such is desired.
The present invention provides the gripping action of a barefoot, enhances the foot contact surface compared to the barefoot, is lighter than wearing a shoe, and yet provides the protection of wearing a shoe.
The form described is merely a preferred or exemplary embodiment and it is apparent that various changes may be made by those skilled in the art without departing from the spirit and scope of the invention. | A lightweight foot garment which is made from a tubular shaped material to cover a human foot. The tubular shaped material being stretchably tight and snug fitting around the foot. An adhesive is applied to the bottom portion of the tubular shaped material such that the adhesive is soft and sticky-like when first applied then hardening into a gripping or non-skid type of material, thus forming the bottom of the foot garment. Alternatively, a smooth pad or non-skid type of material such as ground rubber or plastic may be applied to the bottom portion of the tubular shaped material, with the adhesive applied to secure the smooth pad or non-skid type of material to the tubular shaped material. | 0 |
BACKGROUND AND SUMMARY
The present invention relates to commercial vehicles; and more particularly to drivetrain control strategies for such vehicles as heavy trucks, buses and the like.
In the course of driving heavy vehicles such as overland trucks and buses (which should be considered interchangeable for purposes of the description contained herein), it is common to be required to drive at relatively slow speeds, often for extended periods of time. Exemplary situations are driving in slow, backed up traffic and maneuvering about loading yards where high-speed travel is not possible. In modern heavy vehicles, it is common to find that such vehicles are equipped with a semi-automatic transmission or an automatic mechanical transmission (AMT) or a power-shifting automatic transmission. In any of the above cases, computer control strategies are utilized in the selection of gear engagements, as well as transition strategies between the different gear choices of the transmission. Furthermore, in a stepped transmission some gearwheels and shafts that are used for torque transfer in different gears are rotationally fixed to each other by means of connecting devices, for instance clutches, hi a positive connecting device, such as a dog clutch, the torque is transferred substantially by normal forces, as opposed to a frictional connecting device, such as a plate clutch, where the torque is transferred substantially by friction forces. The difference between the different types of available stepped transmissions can be described as the operation of clutch, gear selection, and carrying out the gear selection, hi an automatic mechanical transmission the operation of the clutch, gear selection and the carrying out of the gear selection is performed automatically without driver intervention. A manual transmission requires the driver to perform the operation of the clutch, gear selection and the carrying out of the gear selection. Manual transmissions are typically of the mechanically engaged type in general. A semi-automatic transmission is one in which one or more of the operation of the clutch, gear selection, or carrying out gear selection is performed by the driver of the truck. The semi-automatic transmission may also be of the mechanical type transmission. In a transmission of the mechanically engaged type, there are positive connecting devices. During a gear shift, there will normally be an interruption of the torque transfer in a transmission of the mechanically engaged type. Frictional connecting devices are mainly found in power-shifting transmission, where torque is also transferred during a gear shift. Power-shifting transmissions are usually automatic or semi-automatic. Automatic transmissions of the mechanically engaged type are referred to as automatic mechanical transmissions. Such a transmission may use a manual transmission with controllers to automate the operation of the transmission. It may also be specifically designed to be automatic and not based on a manual transmission. Hereinafter, the automatic mechanical transmission and power-shifting automatic transmission are referred to as an automatic transmission.
Referring to the situations in which it is desired that the heavy vehicle moves slowly but substantially constantly on course, operators have developed habits for engaging an appropriate low gear which carries the vehicle forward or backward under the power of the idling engine. Thus, the driver of the vehicle is idle driving, i.e. without pressing an accelerator pedal, or any other drive torque controlling device, arranged in the vehicle. Depending upon the desired speed and the heavy vehicle load, among other factors, different low gears are selectable.
The low gears available for selection, however, are limited by the torque that can be developed in each gear by the engine operating at the preset idle speed, and the range of gears available for use at any particular time will be determined by conditions of the vehicle, as well as conditions of the environment within which the vehicle is operating. The two primary conditions upon which the range of available gears is dependent is the mass of the vehicle (including any load) and ground inclination. Dependent at least in part on each of these two characteristics, the highest gear of the transmission can be determined at which the idling engine can maintain a substantially constant speed of the vehicle without losing speed because of insufficient torque capability. Heretofore, drivers have been left to draw on their experience for selecting an initial gear for such idle travel, with adjustments being made up or down in order to engage the gear which produces the desired travel speed, and which is also capable of maintaining that speed using the torque developed at the preset idle speed of the engine, for example, 650 revolutions per minute.
It is appreciated that if presently existing conditions are known which bear upon the highest gear selection at which the idling engine can maintain a constant vehicle speed, that gear can be determined, engaged and utilized for powering travel of the vehicle. Often times, however, the gear ratio carries the vehicle at a groundspeed slower than desired. For instance, the traffic speed within which the heavy truck is operating maybe faster than this speed which the idling engine can maintain under existing conditions. Heretofore, as described above, selection of the proper gear which permits the engine to operate at idle and produce the desired higher speed of the vehicle was performed by the driver himself based on past experience and trial-and-error with respect to selection within a typical low range of gears and the selection of accelerator pedal position to achieve the right vehicle acceleration and finally the right vehicle speed.
This type of trial-and-error, hunt-and-peck of gear selection and accelerator pedal position by the driver obviously has drawbacks; among others, if the truck is operating under slow speed conditions, the driver can become unnecessarily fatigued by the selection process. Still further, operating economy can suffer not only because of inefficiencies associated with constant gear changing and adjustments of the accelerator pedal position, but also if the optimal gear is not selected which can use the preset idle speed of the engine for maintaining the desired vehicle speed. Therefore, the need has been recognized for a drivetrain control system in which such gear selections and selection of accelerator pedal position are made on at least a semi-automated basis with only minimal or no direct selection input from the driver.
In at least one embodiment, the present invention takes the form of a method for operating a semi-automatic or automatic transmission of a heavy vehicle when driving at idle speed. The method according to the invention comprises (includes, but is not necessarily limited to) supplying fuel to the engine of the heavy truck at a rate that facilitates engine-idle operation. In another step, the method engages the semi-automatic or automatic transmission in a gear higher than the starting gear of the transmission and permits the vehicle to operate at a first substantially uniform driving velocity under engine-idle power. Depending upon traffic and environmental requirements which require a faster speed, the driver upshifts the semi-automatic or automatic transmission by manually controlling a control device for manual gear selection and then drives the vehicle at a second substantially uniform driving velocity under engine-idle power. Necessarily, the second substantially uniform driving velocity is higher than the first substantially uniform driving velocity. The method according to the invention gives an increased driving comfort and fuel savings. The method also decreases unnecessary clutch slip.
In another embodiment of the invention by controlling the engine speed of the vehicle the engine speed is automatically increased up to a predetermined vehicle speed before the upshift is performed. In still another embodiment the speed of the vehicle is automatically increased after the upshift by reengaging the clutch. Thus synchronization of engine idling speed to the new gear is performed by the clutch, m another embodiment the speed of the vehicle is increased by performing a combination of engine control and clutch control, hi still another embodiment the vehicle speed increase is dependent of and adapted to current vehicle travel resistance. The upshift function according to the invention could also only be available when travel resistance of said vehicle is below a predetermined value. This could also include predicted future travel resistance. In another embodiment of the invention the manual driver control of the control device causes the transmission to upshift one gear, and in still another embodiment a longer manual control (such as e.g. depression) of the control device can cause the transmission to upshift at least two gears. In still another embodiment of the invention a certain number of manual control actions of the control device cause the transmission to upshift corresponding number of gear steps.
Further advantageous embodiments of the invention emerge from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be more fully described, by way of example, with reference to the accompanying drawing in which:
FIG. 1 is a diagram showing the connection of the control device on a gear shift lever to the engine and transmission.
FIG. 2 illustrates a flow diagram of one method of upshifting a semi-automatic or automatic transmission in idle drive mode according to the invention.
FIG. 3 illustrates a flow diagram of one method of upshifting a semi-automatic or automatic transmission in idle drive mode according to a second embodiment of the invention.
FIG. 4 illustrates a flow diagram of one method of upshifting a semi-automatic or automatic transmission in idle drive mode according to a third embodiment of the invention.
DETAILED DESCRIPTION
In such commercial vehicles as heavy trucks and buses, it is common to have computer-controlled subsystems. Among others, those subsystems typically include at least the engine 300 , and now transmission 310 , to greater or lesser extents as shown in FIG. 1 . With the introduction of computer-based control systems for the engine 300 and transmission 310 , and the capability for the exchange of information therebetween, it is now possible to automate coordination between the two subsystems for such benefits as fuel economy and acceleration, as well as driver comfort and drivability. Using such computer-based control systems, driver fatigue can be substantially reduced, as well as facilitate a less experienced operator's near expert control of the vehicle. In below shown embodiments of the invention said transmission 310 comprises a clutch 360 and a gearbox 370 . A gear shift lever 340 enables the driver to select an appropriate drive mode including but not limited to automatic, manual, and low. The manual mode enables the driver to make a manual gear selection through a control device 350 for manual gear selection arranged on the gear shift lever 340 . This control device 350 is in FIG. 1 shown as a toggle switch with a plus and minus end for selecting upshifts and downshifts respectively. The control device 350 could also be in the form of separated plus/minus buttons or a scroll. The control device 350 could also be a lever or joystick arranged somewhere near the driver, e.g. by the steering wheel, by the gear shift lever or by a driver's seat.
As described hereinabove, driving conditions often exist in which it is desirable that the vehicle be driven at a substantially constant speed, albeit, a relatively slow speed in such conditions as heavy traffic or load yard maneuvering. The need for such slow speed travel can be either forward or reverse, though the need for a greater selection of forward speeds is appreciated.
In a heavy vehicle, such as an overland truck powered by a prime mover 300 , a preset idle speed is typically programmed in the engine control strategy. The prime mover preferably is a diesel engine, but can include other devices designed to propel the vehicle such as an electric motor, gasoline engine or hybrid engine combining two or more of the above mentioned devices. As those persons skilled in the art will appreciate regarding a standard torque curve, the engine, at this idle speed will have a maximum torque capability. Variable characteristics of the vehicle bear upon its resistance to travel, as do varying road conditions. While there are several variables within each category (vehicle versus environment) that can influence vehicle travel resistance, the two primary variables are vehicle mass and ground inclination. Both of these characteristics are presently able to be quantified in suitably equipped vehicles, and therefore these variables become known inputs for calculations and gear selections made according to the present invention.
A typical and exemplary situation in which a driver desires to increase the speed of an idle engine speed travel condition is when the high traffic driving pattern around the vehicle is increasing its speed. When such a situation is foreseen by a driver, the initial reaction is to press an accelerator pedal 330 (put their foot on the gas) and begin to accelerate in order to trying to match the faster traffic pattern or zone. According to the current invention the driver will not need to accelerate the vehicle by pressing the accelerator pedal. With the current invention the driver would only have to press the plus end of the control device 350 for manual selection of a higher gear. The pressing of the control device 350 and the vehicle being in an idle driving condition initiates a control unit in the vehicle to select (if possible) a higher idle driving gear and see to that the vehicle is automatically accelerated to a new higher idle driving speed and that the new higher gear is engaged so that the vehicle can continue travel with the new idle driving speed.
FIG. 2 discloses a preferred embodiment according to the invention where the control unit in a first step 20 is controlling the vehicle to drive in a first vehicle idle speed 51 . Thus, the vehicle is driven forward without the driver depressing the accelerator pedal 330 nor a brake pedal 320 in the vehicle. In step 21 the control unit is programmed to sense if the driver of the vehicle is demanding an upshift by depressing the plus end of said control device 350 for manual gear selection. If “No”, the control unit continues to drive with current gear engaged and idle speed 51 , according to step 10 in FIG. 2 . If “Yes”, i.e. if the driver demands an idle speed increase by depressing said control device 350 , the control unit is then programmed to increase output torque from the engine 300 in order to accelerate the vehicle speed to a new speed S 2 correspondent to a rotational speed in the gearbox 370 for the next higher gear selected to be engaged and which would be substantially synchronous with the engine idle speed when engaged. This is indicated by step 22 in FIG. 2 . The acceleration of the vehicle to the higher speed S 2 can be controlled in a very optimized way, compared to if the driver would control the vehicle acceleration manually by pressing the accelerator pedal. An optimized acceleration saves fuel. When the new speed S 2 has been reached the control unit is programmed to disengage the clutch 360 arranged between the engine 300 and gearbox 370 . The clutch 360 is for transmitting engine torque from the engine to the gearbox and driven wheels of the vehicle rotatably fixed connected thereto. When the new higher gear has been engaged, the clutch is reengaged so that driving torque can be transmitted and driving can be performed with the new speed S 2 . In step 23 the new gear is engaged, the clutch is reengaged and torque output from the engine is controlled so that the new speed S 2 will is maintained.
FIG. 3 shows another embodiment of the invention. Steps 30 , 31 and 33 are identical to the corresponding steps of the embodiment in FIG. 2 . In step 32 the control unit is programmed to disengage the clutch and the currently engaged gear in the gearbox without accelerating the vehicle with the engine. The control unit engages the new higher gear in the gearbox and then accelerates the vehicle to speed S 2 by reengaging the clutch. The difference in rotational speed between engine idle speed and the rotational speed of the new gear is synchronized through the engagement of the clutch. The control of engine output torque during the clutch engagement is optimized and matched to prevailing vehicle travel resistance so the engine at least holds idle driving rotational speed. Also the control of the clutch engagement as such is matched to the prevailing vehicle travel resistance. The clutch engagement according to the embodiment in FIG. 3 tends to be slower, i.e. takes more time, compared to the clutch engagement according to the embodiment in FIG. 2 . A slower or softer clutch engagement gives better comfort for the embodiment in FIG. 3 .
FIG. 4 shows another embodiment of the invention. Steps 40 , 41 and 43 are identical to the corresponding steps of the embodiment in FIG. 2 . In step 42 the control unit is programmed to first increase output torque from the engine 300 in order to accelerate the vehicle speed to a speed intermediate of S 1 and S 2 and closer to target speed S 2 (idle driving speed for the new higher gear). When the intermediate speed is reached the control unit initiates a clutch disengagement and gear disengagement. The control unit then engages the new higher gear and accelerates the vehicle to speed S 2 by reengaging the clutch. Thus, the last difference in rotational speed between engine idle speed and the rotational speed of the new higher gear is synchronized through the reengagement of the clutch.
In a preferred embodiment of the invention the control unit is also programmed to first check if the vehicle will be able to travel at a new higher idle driving speed. Preferably this is done by checking at least current vehicle travel resistance. In a preferred embodiment the control unit could be programmed to predict future vehicle travel resistance. This can be done by known technique, such as GPS-device combined with electronic maps or different interpolation methods. The control unit can also be programmed to use current or current and future predicted vehicle travel resistance to optimize the increase in rotational engine speed before upshift to the new higher gear. This is especially applicable to the embodiments shown in FIGS. 2 and 4 .
Another preferred embodiment is a method to cause the transmission to engage in multiple upshifts. The depression or control of the control device 350 to cause upshifts can be performed through several different methods, and two embodiments are described below. If the control device 350 is continually depressed it will trigger an upshift command to be issued to the transmission, and upshifts with corresponding vehicle acceleration will continue to occur until the point in which the transmission has upshifted to the highest gear at which idle drive is possible. Another embodiment is where the control device 350 is bump-pressed and then released and bump-pressed again. For each of these bump-press procedures the transmission will be upshifted and the vehicle accelerated to a higher idle driving speed. This procedure can be repeated until it reaches the highest gear at which idle drive is possible. Thus, the bump-press on the control device 350 effectively works to interrupt the normal automation of the transmission and to provide for driver control of the upshift. This allowed when the vehicle is operating in the idle-driving mode.
A natural and frequent occurrence is that the need for relatively slow idle driving travel eventually ceases and the operator desires to accelerate the vehicle up to a higher travel speed. In order to do so, the accelerator pedal 330 is depressed, and depending upon the degree to which the pedal is depressed, normal transmission programming would cause a downshift for increased torque production at a higher engine speed. For certain reasons such as driver comfort and economy, it is desired that such downshifting be prohibited as the vehicle pulls out of the idle speed travel mode and the same gear engagement at which idle travel was taking place be maintained. As the vehicle gains speed, the regular driving transmission control strategies resume operation.
If the driver needs to stop or slow down the vehicle when idle driving the idle driving condition will cease when the brake pedal 320 is depressed. As the vehicle speed slows down, the regular driving transmission control strategies resume operation.
In the manner described hereinabove, computer-based transmission control facilitates easier and more efficient idle speed driving of a heavy commercial vehicle, as well as gives the operator an easy-to-use procedure for incrementally increasing idle speed travel once established, and accommodating a smooth economical return to normal road speed travel.
The invention should not be deemed to be limited to the embodiments described above, but rather a number of further variants and modifications are conceivable within the scope of the following patent claims. | A method for operating a semi-automatic or automatic mechanical transmission of a heavy truck when driving at idle speed is provided. The method includes supplying fuel to the engine of the heavy truck at a rate that facilitates engine-idle operation. In another step, the method engages the automatic or semi-automatic transmission in a gear higher than the starting gear of the transmission and permits the truck to operate at a first substantially uniform driving velocity under engine-idle power. Depending upon traffic and environmental requirements which require a higher speed, the driver upshifts the semi-automatic or automatic transmission by depressing a control device for manual gear selection arranged on a gear shift lever of the truck and then drives the truck at a second substantially uniform driving velocity under engine-idle power. The second substantially uniform driving velocity is greater than the first substantially uniform driving velocity. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims priority to U.S. Provisional Patent Application Ser. No. 61/484,449, filed May 10, 2011, entitled “Reduction of Decoder Line Buffers for SAO and ALF”, U.S. Provisional Patent Application Ser. No. 61/498,265, filed Jun. 17, 2011, entitled “Reduction of SAO and ALF Line Buffers for LCU-based Decoding”, U.S. Provisional Patent Application Ser. No. 61/521,500, filed Aug. 9, 2011, entitled “Reduction of Decoder Line Buffers for SAO and ALF”, U.S. Provisional Patent Application Ser. No. 61/525,442, filed Aug. 19, 2011, entitled “Boundary Processing for Sample Adaptive Offset or Loop Filter”, U.S. Provisional Patent Application Ser. No. 61/532,958, filed Sep. 9, 2011, entitled “Virtual Boundary Processing for Sample Adaptive Offset”, and U.S. Provisional Patent Application Ser. No. 61/543,199, filed Oct. 4, 2011, entitled “Reduction of Decoder Line Buffers for SAO and ALF”. The U.S. Provisional patent applications are hereby incorporated by reference in their entireties.
FIELD OF INVENTION
[0002] The present invention relates to video coding system. In particular, the present invention relates to method and apparatus for reduction of SAO and ALF line buffers associated with a video encoder or decoder.
BACKGROUND OF THE INVENTION
[0003] Motion estimation is an effective inter-frame coding technique to exploit temporal redundancy in video sequences. Motion-compensated inter-frame coding has been widely used in various international video coding standards The motion estimation adopted in various coding standards is often a block-based technique, where motion information such as coding mode and motion vector is determined for each macroblock or similar block configuration. In addition, intra-coding is also adaptively applied, where the picture is processed without reference to any other picture. The inter-predicted or intra-predicted residues are usually further processed by transformation, quantization, and entropy coding to generate a compressed video bitstream. During the encoding process, coding artifacts are introduced, particularly in the quantization process. In order to alleviate the coding artifacts, additional processing has been applied to reconstructed video to enhance picture quality in newer coding systems. The additional processing is often configured in an in-loop operation so that the encoder and decoder may derive the same reference pictures to achieve improved system performance.
[0004] FIG. 1A illustrates an exemplary adaptive inter/intra video coding system incorporating in-loop processing. For inter-prediction, Motion Estimation (ME)/Motion Compensation (MC) 112 is used to provide prediction data based on video data from other picture or pictures. Switch 114 selects Intra Prediction 110 or inter-prediction data and the selected prediction data is supplied to Adder 116 to form prediction errors, also called residues. The prediction error is then processed by Transformation (T) 118 followed by Quantization (Q) 120 . The transformed and quantized residues are then coded by Entropy Encoder 122 to form a video bitstream corresponding to the compressed video data. The bitstream associated with the transform coefficients is then packed with side information such as motion, mode, and other information associated with the image area. The side information may also be subject to entropy coding to reduce required bandwidth. Accordingly, the data associated with the side information are provided to Entropy Encoder 122 as shown in FIG. 1A . When an inter-prediction mode is used, a reference picture or pictures have to be reconstructed at the encoder end as well. Consequently, the transformed and quantized residues are processed by Inverse Quantization (IQ) 124 and Inverse Transformation (IT) 126 to recover the residues. The residues are then added back to prediction data 136 at Reconstruction (REC) 128 to reconstruct video data. The reconstructed video data may be stored in Reference Picture Buffer 134 and used for prediction of other frames.
[0005] As shown in FIG. 1A , incoming video data undergoes a series of processing in the encoding system. The reconstructed video data from REC 128 may be subject to various impairments due to a series of processing. Accordingly, various in-loop processing is applied to the reconstructed video data before the reconstructed video data are stored in the Reference Picture Buffer 134 in order to improve video quality. In the High Efficiency Video Coding (HEVC) standard being developed, Deblocking Filter (DF) 130 , Sample Adaptive Offset (SAO) 131 and Adaptive Loop Filter (ALF) 132 have been developed to enhance picture quality. The in-loop filter information may have to be incorporated in the bitstream so that a decoder can properly recover the required information. Therefore, in-loop filter information from SAO and ALF is provided to Entropy Encoder 122 for incorporation into the bitstream. In FIG. 1A , DF 130 is applied to the reconstructed video first; SAO 131 is then applied to DF-processed video; and ALF 132 is applied to SAO-processed video. However, the processing order among DF, SAO and ALF can be re-arranged.
[0006] A corresponding decoder for the encoder of FIG. 1A is shown in FIG. 1B . The video bitstream is decoded by Video Decoder 142 to recover the transformed and quantized residues, SAO/ALF information and other system information. At the decoder side, only Motion Compensation (MC) 113 is performed instead of ME/MC. The decoding process is similar to the reconstruction loop at the encoder side. The recovered transformed and quantized residues, SAO/ALF information and other system information are used to reconstruct the video data. The reconstructed video is further processed by DF 130 , SAO 131 and ALF 132 to produce the final enhanced decoded video.
[0007] The coding process in HEVC is applied according to Largest Coding Unit (LCU). The LCU is adaptively partitioned into coding units using quadtree. In each leaf CU, DF is performed for each 8×8 block and in HEVC Test Model Version 4.0 (HM-4.0), the DF is applies to 8×8 block boundaries. For each 8×8 block, horizontal filtering across vertical block boundaries is first applied, and then vertical filtering across horizontal block boundaries is applied. During processing of a luma block boundary, four pixels of each side are involved in filter parameter derivation, and up to three pixels on each side can be changed after filtering. For horizontal filtering across vertical block boundaries, unfiltered reconstructed pixels (i.e., pre-DF pixels) are used for filter parameter derivation and also used as source pixels for filtering. For vertical filtering across horizontal block boundaries, unfiltered reconstructed pixels (i.e., pre-DF pixels) are used for filter parameter derivation, and DF intermediate pixels (i.e. pixels after horizontal filtering) are used for filtering. For DF processing of a chroma block boundary, two pixels of each side are involved in filter parameter derivation, and at most one pixel on each side is changed after filtering. For horizontal filtering across vertical block boundaries, unfiltered reconstructed pixels are used for filter parameter derivation and are used as source pixels for filtering. For vertical filtering across horizontal block boundaries, DF processed intermediate pixels (i.e. pixels after horizontal filtering) are used for filter parameter derivation and also used as source pixel for filtering.
[0008] Sample Adaptive Offset (SAO) 131 is also adopted in HM-4.0, as shown in FIG. 1A . SAO can be regarded as a special case of filtering where the processing only applies to one pixel. In SAO, pixel classification is first done to classify pixels into different groups (also called categories or classes). The pixel classification for each pixel is based on a 3×3 window. Upon the classification of all pixels in a picture or a region, one offset is derived and transmitted for each group of pixels. In HM-4.0, SAO is applied to luma and chroma components, and each of the luma components is independently processed. SAO can divide one picture into multiple LCU-aligned regions, and each region can select one SAO type among two Band Offset (BO) types, four Edge Offset (EO) types, and no processing (OFF). For each to-be-processed (also called to-be-filtered) pixel, BO uses the pixel intensity to classify the pixel into a band. The pixel intensity range is equally divided into 32 bands. After pixel classification, one offset is derived for all pixels of each band, and the offsets of center 16 bands or outer 16 bands are selected and coded. As for EO, it uses two neighboring pixels of a to-be-processed pixel to classify the pixel into a category. The four EO types correspond to 0°, 90°, 135°, and 45° as shown in FIG. 2A . Similar to BO, one offset is derived for all pixels of each category except for category 0, where Category 0 is forced to use zero offset. Table 1 shows the EO pixel classification, where “C” denotes the pixel to be classified.
[0000]
TABLE 1
Category
Condition
1
C < two neighbors
2
C < one neighbor && C == one neighbor
3
C > one neighbor && C == one neighbor
4
C > two neighbors
0
None of the above
[0009] Adaptive Loop Filtering (ALF) 132 is a video coding tool in HM-4.0 to enhance picture quality, as shown in FIG. 1A . Multiple types of luma filter footprints and chroma filter footprints are used. For example, a 9×7 cross shaped filter is shown in FIG. 2B and a 5×5 snowflake shaped filter is shown in FIG. 2C . Each picture can select one filter shape for the luma signal and one filter shape for the chroma signal. In HM-4.0, up to sixteen luma ALF filters and at most one chroma ALF filter can be applied for each picture. In order to allow localization of ALF, there are two modes for luma pixels to select filters. One is a Region-based Adaptation (RA) mode, and the other is a Block-based Adaptation (BA) mode. In addition to the RA and BA for adaptation mode selection at picture level, Coding Units (CUs) larger than a threshold can be further controlled by filter usage flags to enable or disable ALF operations locally. As for the chroma components, since they are relatively flat, no local adaptation is used in HM-4.0, and the two chroma components of a picture share a same filter.
[0010] The RA mode simply divides one luma picture into sixteen regions. Once the picture size is known, the sixteen regions are determined and fixed. The regions can be merged, and one filter is used for each region after merging. Therefore, up to sixteen filters per picture are transmitted for the RA mode. On the other hand, the BA mode uses edge activity and direction as a property for each 4×4 block. Calculating the property of a 4×4 block may require neighboring pixels. For example, 8×8 window 210 is used in HM-3.0 and 5×5 window 220 is used in HM-4.0 as shown in FIG. 2D . After properties of 4×4 blocks are calculated, the blocks are classified into fifteen categories. The categories can be merged, and one filter is used for each category after merging. Therefore, up to fifteen filters are transmitted for the BA mode.
[0011] FIG. 1A and FIG. 1B illustrate exemplary encoder and decoder implementation according to HM-4.0. The encoding process is divided into two parts. One is LCU-based processing including Intra Prediction (IP) 110 , Motion Estimation/Motion Compensation (ME/MC) 112 , Transformation (T) 118 , Quantization (Q) 120 , Inverse Quantization (IQ) 124 , Inverse Transform (IT) 126 , and Reconstruction (REC) 128 . The other is picture-based processing including Deblocking Filter (DF) 130 , Sample Adaptive Offset (SAO) 131 , and Adaptive Loop Filter (ALF) 132 . Entropy Encoder 122 may use picture-based processing and indicate the selection using sequence parameter set (SPS), picture parameter set (PPS), or slice-level syntax elements. Entropy Encoder 122 may also use the LCU-based processing and indicate the selection using LCU-level syntax elements. Similarly, the decoding process is also divided into two parts. One is LCU-based processing including Intra Prediction (IP) 110 , Motion Compensation (MC) 113 , Inverse Quantization (IQ) 124 , Inverse Transform (IT) 126 , and Reconstruction (REC) 128 . The other is picture-based processing including Deblocking Filter (DF) 130 , Sample Adaptive Offset (SAO) 131 , and Adaptive Loop Filter (ALF) 132 . Entropy Decoder 142 may belong to the picture-based processing as indicated by SPS, PPS, or slice-level syntax elements. Entropy Decoder 142 may also belong to the LCU-based processing as indicated by LCU-level syntax elements. In software-based implementation, picture-based processing is easier to implement than LCU-based processing for DF, SAO, and ALF. However, for hardware-based or embedded software-based implementation, picture-based processing is practically unacceptable due to requirement of large picture buffer. On-chip picture buffers may alleviate the high system bandwidth requirement. However, on-chip picture buffers may significantly increase chip cost. On the other hand, off-chip picture buffers will significantly increase external memory access, power consumption, and data access latency. Therefore, it is very desirable to use LCU-based DF, SAO, and ALF for cost-effective encoder and decoder products.
[0012] When LCU-based processing is used for DF, SAO, and ALF, the encoding and decoding process can be done LCU by LCU in a raster scan order with an LCU-pipelining fashion for parallel processing of multiple LCUs. In this case, line buffers are required for DF, SAO, and ALF because processing one LCU row requires pixels from the above LCU row. If off-chip line buffers (e.g. DRAM) are used, it will result in substantial increase in external memory bandwidth and power consumption. On the other hand, if on-chip line buffers (e.g. SRAM) are used, the chip area will be increased and accordingly the chip cost will be increased. Therefore, although line buffers are already much smaller than picture buffers, it is still desirable to further reduce line buffers to reduce line buffer cost.
[0013] FIG. 3A illustrates an example of line buffer requirement for processing luma component associated with DF, SAO, and ALF in an LCU-based encoding or decoding system. Lines 310 and 312 indicate horizontal and vertical LCU boundaries respectively, where the current LCU is located on the upper side of the horizontal LCU boundary and the right side of the vertical LCU boundary. Lines A through J are first processed by horizontal DF and then by vertical DF. Horizontal DF processing for Lines K through N around the horizontal LCU boundary usually has to wait until the lines below the horizontal LCU boundary becomes available. Otherwise, line buffers to temporarily store horizontally processed DF (H-DF) pixels corresponding to lines K through N for the vertical DF have to be used, which will require four pre-DF pixels and four H-DF pixels on each side of the horizontal LCU boundary to be stored for deriving filter parameters and filtering respectively, as indicated by the 4-pixel stripe 320 in FIG. 3A . The pre-DF pixel refers to reconstructed pixels that are not yet processed by DF at all. Accordingly, in a typical system, four lines (K-N) are used to store pre-DF pixels for subsequent DF processing. Based on the system configuration shown in FIG. 1A and FIG. 1B , SAO is then applied to DF output pixels. Since the vertical DF for lines K-N will not change line K (according to HM-4.0, only three luma pixels at the block boundary may be modified), horizontal DF can be applied to line K in order to allow SAO process on line J, as illustrated by the 3×3 square 330 . The H-DF pixels of line K will not be stored in the line buffer and have to be generated from pre-DF pixels again when the lower LCU is processed. However, this will not be an issue for a hardware-based system since the power consumption involved with the operation is very minimal.
[0014] After lines A through J are SAO processed, the 4×4 block property, as illustrated by box 340 , can be calculated for block-based adaptation processing. According to HM-4.0, the derivation of block property for the 4×4 block requires a 5×5 window as indicated by box 342 . Upon the derivation of block properties for 4×4 blocks, ALF can be applied to lines A through H if the snowflake shaped ALF filter is selected. The ALF cannot be applied to line I since it will require SAO-processed data from line K as illustrated by the ALF filter 350 for pixel location 352 . After ALF is completed for lines A through H, no further process can be done for the current LCU until the lower LCU becomes available. When the lower LCU becomes available, lines K through P will be first processed by DF and then processed by SAO. Line J will be required when SAO processes line K. However, only EO partial results associated with comparing pixels on line K and line J have to be stored instead of the actual pixel values. The partial results need two bits per pixel, which requires only 20% and 25% of the pixel line buffer for high efficiency (HE) coding system configuration using 10-bit pixels and low complexity (LC) coding system configuration using 8-bit pixels, respectively. Therefore, one line (J) of SAO partial results has to be stored for SAO. The 4×4 block properties for lines I through P can then be calculated and ALF can be applied accordingly.
[0015] When line I is filtered, it requires lines G through K, as illustrated by the 5×5 snowflake shaped filter 350 in FIG. 3A . However, derivation of block properties of lines I and J still needs lines F through J. Therefore, five lines (F to J) of SAO output pixels have to be stored for ALF processing. If a filter index line buffer can be used to store BA mode filter selections for lines G through J, it is not necessary to compute the block properties again during ALF processing of lines I and J. Accordingly, the line buffer for one line (F) of SAO output pixels can be eliminated for ALF. The filter index line buffer (4 bits per block) requires only about 10% size of a pixel line buffer. Therefore, four lines (G to J) of SAO output pixels and one line of filter indices (4×4 blocks on lines G to K) have to be stored for ALF. In summary, the entire in-loop filtering requires about 8.3 luma line buffers. When the entire decoding system is considered, since the intra luma prediction already stores one line (N) of pre-DF pixels, this luma line buffer can be shared.
[0016] The line buffer requirement for DF, SAO and ALF processing of the chroma components can be derived similarly. The DF processing for the chroma components uses only two pixels at a block boundary to determine DF selection. DF is applied to one pixel at the block boundary. Accordingly, the entire in-loop filtering requires about 6.2 chroma line buffers.
[0017] In the above analysis of an exemplary coding system, it has been shown that the line buffer requirements of DF, SAO and ALF processing for the luma and chroma components are 8.3 and 6.2 lines respectively. For HDTV signals, each line may have nearly two thousand pixels. The total line buffer required for the system becomes sizeable. It is desirable to reduce the required line buffers for DF, SAO and ALF processing.
SUMMARY OF THE INVENTION
[0018] A method and apparatus for in-loop processing of reconstructed video are disclosed. The method configures in-loop processing so that it requires no or reduced source pixels from other side of a virtual boundary. According to one embodiment of the present invention, the method comprises receiving reconstructed video data, processed reconstructed video data, or a combination of both; determining a virtual boundary related to a video data boundary; determining to-be-processed pixels; and applying in-loop processing to the to-be-processed pixel on one side of the virtual boundary, wherein the in-loop processing is configured to require no source pixel or reduced source pixels from other side of the virtual boundary. The in-loop processing may correspond to SAO (Sample Adaptive Offset) processing or ALF (Adaptive Loop Filter) processing. The method can be applied to luma component as well as chroma components. When the in-loop processing requires a source pixel from the other side of the virtual boundary, one embodiment according to the present invention uses a replacement pixel. The replacement pixel may use a predefined value or an adaptive value. Furthermore, the replacement pixel may be derived from source pixels on said one side of the virtual boundary, source pixels on the other side of the virtual boundary, or a linear combination or a nonlinear combination of replacement pixels hereinabove. The in-loop processing can also be configured to skip the to-be-processed pixel when the in-loop processing for the to-be-processed pixel requires one or more source pixels from other side of the virtual boundary. The in-loop processing can also be configured to change ALF filter shape or filter size when the in-loop processing for the to-be-processed pixel requires one or more source pixels from other side of the virtual boundary. A filtered output can be combined linearly or nonlinearly with the to-be-processed pixel to generate a final filter output, wherein the filtered output is generated by said applying in-loop processing to the to-be-processed pixel. The virtual boundary can correspond to N pixels above a horizontal LCU (Largest Coding Unit) boundary, wherein N is an integer from 1 to 4.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A illustrates an exemplary adaptive inter/intra video encoding system incorporating DF, SAO and ALF in-loop processing.
[0020] FIG. 1B illustrates an exemplary adaptive inter/intra video decoding system incorporating DF, SAO and ALF in-loop processing.
[0021] FIG. 2A illustrates Edge Offset (EO) windows corresponding to 0°, 90°, 135°, and 45° being used in HM-4.0 to determine the category for a current pixel to apply SAO (Sample Adaptive Offset).
[0022] FIG. 2B illustrates an example of a 9×9 cross shaped filter for ALF.
[0023] FIG. 2C illustrates an example of a 5×5 snowflake shaped filter for ALF.
[0024] FIG. 2D illustrates an example of a 8×8 window and a 5×5 window for determining 4×4 block property in block-based adaptive processing.
[0025] FIG. 3A illustrates an example of line buffer requirement for DF, SAO and ALF processing near a virtual boundary for the luma component.
[0026] FIG. 3B illustrates an example of line buffer requirement for DF, SAO and ALF processing near a virtual boundary for the chroma components.
[0027] FIG. 4 illustrates an example of horizontal virtual boundaries.
[0028] FIG. 5 illustrates an example of vertical virtual boundaries.
[0029] FIGS. 6-14 illustrate an example of various steps during in-loop processing according to an embodiment of the present invention for pixels above a virtual boundary.
[0030] FIGS. 15-24 illustrate an example of various steps during in-loop processing according to an embodiment of the present invention for pixels below a virtual boundary.
DETAILED DESCRIPTION
[0031] The line buffer analysis shown above indicates that the DF processing requires four line buffers for the luma component and two line buffers for the chroma component. Additional line buffers are required to support SAO and ALF processing. In order to eliminate or reduce the line buffer requirements for SAO and ALF, Virtual Boundary (VB) is disclosed herein. FIG. 4 illustrates an example of VB for horizontal LCU boundaries where the VBs are upward shifted from the horizontal LCU boundaries by N pixels. For each LCU, SAO and ALF can process pixels above the VB before the lower LCU becomes available. However, SAO and ALF cannot process pixels below the VB until the lower LCU becomes available since these pixels are not yet processed by DF yet. As mentioned before, four line buffers are used for the luma component and two line buffers are used for the chroma components to store pre-DF pixels at the bottom of the current LCU. Accordingly, N is equal to 4 for the luma component and N is equal to 2 for each of the chroma components. After the pixels above the VB are processed by DF, the SAO processing is modified for every to-be-processed pixel on one side of a VB to reduce or eliminate data access from the other side of the VB. Accordingly, SAO can be performed for all pixels above the VB without the dependency or with reduced dependency on the lower LCU. Finally, ALF is modified for every to-be-processed pixel on one side of a VB to reduce or eliminate any data access from the other side of the VB.
[0032] FIG. 3A can be used to illustrate the use of VB for the luma component to reduce or eliminate line buffer requirement for SAO and ALF, where line 312 indicates the horizontal VB. When the current LCU is processed, lines A through J can be processed by DF (horizontal and vertical). However, lines K through N cannot be processed by vertical DF because the lower LCU is not yet available. If the SAO and ALF processing for lines A through J does not require any pixel below the VB, lines A through J can be processed by SAO and ALF without the lower LCU. When the lower LCU becomes available, lines K through P can be processed by DF. At this time, if the SAO and ALF processing for lines K through P can be modified to reduced or eliminate the dependency on pixels above the VB, line buffers for storing lines F through J can be reduced or eliminated.
[0033] While FIG. 4 illustrates an example of horizontal VB processing, the VB processing can also be applied to vertical VB boundaries as shown in FIG. 5 , where the vertical VB boundaries are shifted right from the vertical LCU boundaries by N pixels. For the luma component, N is equal to 4; and for the chroma components, N is equal to 2 if MH-4.0 is used.
[0034] A detailed example of horizontal VB processing is disclosed below. The luma VB processing can be divided into two parts. The first part corresponds to processing of pixels above the VB, while the second part corresponds to processing of pixels below the VB. FIGS. 6-14 illustrate the luma VB processing associated with DF, SAO and ALF for to-be-processed pixels above the VB according to an embodiment of the present invention. In FIG. 6 , line 610 indicates a horizontal LCU boundary and line 620 indicates a horizontal VB. All pixels of the current LCU have been processed by REC, and four lines (p 0 -p 3 ) of pre-DF pixels are stored in DF line buffers. In FIG. 7 , pixels above the VB and one line (p 3 ) below the VB are processed by horizontal DF as indicated by shaded areas 710 . As mentioned previously, luma DF reads four pixels to evaluate the boundary strength and overwrites up to three pixels on each side of the 8×8 block boundary. In FIG. 8 , pixels above the VB are processed by vertical DF to generate DF outputs as indicated by shaded area 810 . In FIG. 9 , pixels above the VB are processed by SAO. At this moment, line p 3 has been processed by horizontal DF in FIG. 7 and will not be changed by vertical DF. Therefore, DF output pixels of line p 3 are available for SAO to process line p 4 . During SAO processing for line p 4 , each to-be-processed pixel on line p 4 (denoted as C) needs to be compared with a neighboring pixel on line p 3 (denoted as N) if non-zero degree EO is selected. These SAO partial results can be stored in SAO line buffer instead of the actual pixel data. Each to-be-processed pixel requires two bits to indicate whether the corresponding pixel is greater than, equal to, or smaller than the corresponding neighboring pixel. Other method may also be used to store the partial results efficiently. For example, the partial results of two to-be-processed pixels (C1, C2) and two neighboring pixels (N1, N2) can be compressed from four bits to two bits to represent C1>N1 && C2>N2, C1<N1 && C2<N2, and none of the above. Therefore, the number of SAO pixel line buffers is equivalent to 0.1 and 0.125 in the High Efficiency (HE) mode and Low Complexity (LC) mode, respectively. In FIG. 10 , all pixels above the VB have been processed by SAO as indicated shaded area 1010 .
[0035] FIGS. 11-14 illustrate an example that pixels above the VB are further processed by ALF. During filtering, SAO output pixels below the VB may be needed according to a conventional approach. In these cases, filtering has to be modified according to the present invention. FIG. 11 illustrates an example of ALF using a 5×5 snowflake-shaped filter 1110 . The ALF filtering on line p 5 would have to use data below the VB in a conventional approach. However, an embodiment according to the present invention will use padding, averaging, or other means to generate the needed data without reference to any data below the VB. ALF filtering for line p 4 is skipped according to one embodiment of the present invention since the corresponding ALF 1120 will need two lines below the VB (p 3 and p 2 ). Padding means a pixel on the other side of the VB is replaced by its nearest pixel on the same side of the VB as shown by these arrows in FIG. 11 . Examples of data padding include repetitive padding, mirror-based padding with odd symmetry, or mirror-based padding with even symmetry. Averaging means the filtered output pixel is averaged with the filter input pixel as the final ALF output pixel. In other words, the filtered output at pixel C is averaged with pixel C to obtain the final output. Accordingly, FIG. 11 illustrates an example of eliminating the need for pixels from the other side of the VB by using padding and averaging. While averaging serves as an example of linear combination of the filtered output and the to-be-filtered pixel to generate a final ALF output, other linear combination may also be used. For example a weighted sum may be used to combine the filtered output with the to-be-filtered pixel. Furthermore, nonlinear combination may also be used to combine the filtered output with the to-be-filtered pixel. For example, the absolute value of the difference between the filtered output and the to-be-filtered pixel is used to determine how the final filter output should be formed. If the absolute value is very small, the filtered output may be accepted as the final filter output. If the absolute value is very large, the filtered output is disregarded and the to-be-processed pixel is used as the final output. Otherwise, the average between the filtered output and the to-be-filtered pixel is used. FIG. 12 illustrates an example of a 9×9 cross shaped filter selected for ALF. The filter size is reduced to 9×7 as indicated by 1210 and 9×5 as indicated by 1220 for filtering line p 7 and line p 6 , respectively. In order to maintain proper filter output level, the discarded coefficients are added to the center pixel to normalize the filter coefficients. FIG. 13 illustrates the 9×9 cross shaped filter is further reduced to 9×3 as indicated by 1310 and 9×1 as indicated by 1320 for filtering line p 5 and line p 4 , respectively. Again, the discarded coefficients are added to the center pixel. By adding the discarded coefficients to the center pixel will remove the need to change ALF syntax and also serve the purpose of normalization of coefficients without the need of multiplications and divisions. FIG. 14 illustrates the case that all pixels above the VB have been processed by ALF. At this moment, pixels above the VB can be written to a decoded picture buffer. The system is ready to process pixels below the VB when the lower LCU arrives.
[0036] FIGS. 15-24 illustrate an example of luma VB processing for pixels below the VB according to an embodiment of the present invention. FIG. 15 illustrates the state that four lines (p 0 -p 3 ) of pre-DF pixels are read from the DF line buffers. FIG. 16 illustrates the case that pixels below the VB are first processed by horizontal DF as indicated by shaded areas 1610 . As mentioned before, calculating horizontal DF decisions for lines p 0 -p 3 requires pre-DF pixels of lines p 0 -p 7 . In order to reduce line buffer requirement for storing lines p 4 -p 7 , these horizontal DF decisions are computed and stored in a decision line buffer during the horizontal DF for lines p 3 -p 7 in FIG. 7 . The decision buffer only requires one bit per 8×8 block and can be simply implemented as on-chip registers or SRAMs. FIG. 17 illustrates the state that pixels below the VB are processed by vertical DF. At this time, the DF processing is completed for lines p 0 -p 3 and lines q 0 -q 3 . It is noted that vertical DF decisions use pre-DF pixels. Therefore the vertical DF decisions at the horizontal LCU boundary have to be calculated before the horizontal DF is performed as shown in FIG. 16 .
[0037] FIG. 18 illustrates that SAO is performed after DF processing is completed for pixels below the VB, where SAO 1810 is being applied to pixel C of line p 3 . During SAO processing for line p 4 in FIG. 9 , each pixel on line p 4 (regarded as a current pixel C) was compared with a neighboring pixel on line p 3 (denoted as N) for non-zero degree EO. These SAO partial results were stored in SAO line buffer according to one embodiment of the present invention. Now, the partial results can be read from SAO line buffer for SAO processing of line p 3 . When line p 3 is processed, for each to-be-processed pixel (pixel C in FIG. 18 ) of line p 3 , the partial result associated with the relationship between the current pixel C and a neighboring pixel in line p 4 was stored during SAO processing of pixels above the VB according to an embodiment of the present invention. However, the pixel in line p 4 was regarded as a current pixel C while the pixel in line p 3 was regarded as a neighboring pixel N. Two bits are needed to indicate the relationship as one of C>N, C<N, and C==N. In another embodiment of the present invention, partial results corresponding to relationship between two to-be-processed pixels on line p 3 (N1, N2) and two corresponding pixels on line p 4 (C1, C2) are represented in two bits from SAO line buffer to indicate C1>N1 && C2>N2, C1<N1 && C2<N2, or none of the above. If none of the above is selected, C1==N1 && C2==N2 will be used in the EO process. FIG. 19 illustrates that all pixels below the current VB (and above the next VB) have been processed by SAO.
[0038] FIGS. 20-23 illustrate exemplary steps of ALF processing on pixels below the VB. According to a conventional approach, calculating ALF block properties of lines p 0 -p 3 requires SAO output pixels of lines p 0 -p 4 . However, SAO output pixels of line p 4 are not available any more. Therefore, an embodiment according to the present invention is shown in FIG. 20 to remove the dependency of ALF processing on pixels across the VB. FIG. 20 illustrates an example of repetitive padding in the vertical direction, as indicated by these arrows, to generate pixels of line p 4 from SAO output pixels of line p 3 in order to determine block property of 4×4 block 2010 based on 5×5 window 2020 . During filtering, SAO output pixels above the VB may also be needed according to a conventional approach. In these cases, filtering has to be modified so that the dependency of ALF processing on pixels across the VB can be removed. FIG. 21 illustrates an example where a 5×5 snowflake shaped filter is selected for ALF. ALF filtering 2110 for line p 3 (ALF filter for pixel C of line p 3 is indicated by 2110 ) is skipped, and ALF filtering for line p 2 (ALF filter for pixel C of line p 2 is indicated by 2120 ) uses padding and averaging. The meaning of padding and averaging has been described in the specification associated with FIG. 11 .
[0039] FIG. 22 illustrates the case where a 9×9 cross shaped filter is selected for ALF. According to one embodiment of the present invention, the filter size is reduced to 9×1(as indicated by 2210 ) and 9×3 (as indicated by 2220 ) for filtering line p 3 and line p 2 , respectively to eliminate the dependency of ALF processing on SAO processed data above the VB. For the purpose of filter coefficient normalization, the discarded coefficients will be added to the center pixel. FIG. 23 illustrates an embodiment according to the present invention where the filter size is reduced to 9×5 (as indicated by 2310 ) and 9×7(as indicated by 2320 ) for filtering line p 1 and line p 0 , respectively. Again, for the purpose of filter coefficient normalization, the discarded coefficients will be added to the center pixel. FIG. 24 illustrates the case that all pixels below the VB (and above the next VB) have been processed by ALF. At this moment, pixels below the VB (and above the next VB) can be written to a decoded picture buffer.
[0040] The luma VB processing shown in FIGS. 6-24 illustrates one embodiment according to the present invention. The specific exemplary techniques used in various steps of the SAO/ALF processing to remove the dependency across the VB are summarized in Table 2. In FIG. 7 and FIG. 16 , it can be seen that line p 3 is processed by horizontal DF twice. This only happens in LCU-based processing, not in picture-based processing. The redundant computation causes very minor impact on hardware because the DF hardware has been already allocated and the DF is not the throughput bottleneck of the system. The redundant computation can be avoided by optionally adding one line buffer to store H-DF pixels of line p 3 .
[0000]
TABLE 2
Operation
To-Be-Processed Line
Design Principle
SAO pixel classification
1st line above the VB
Unchanged
ALF snowflake filtering
1st line above the VB
Skip filtering
ALF snowflake filtering
2nd line above the VB
Use padding and
averaging
ALF cross filtering
1st line above the VB
Reduce filter size
ALF cross filtering
2nd line above the VB
Reduce filter size
ALF cross filtering
3rd line above the VB
Reduce filter size
ALF cross filtering
4th line above the VB
Reduce filter size
SAO pixel classification
1st line below the VB
Use SAO partial
results of 1st
line above the VB
ALF block property
1st line below the VB
Use padding
calculation
ALF snowflake filtering
1st line below the VB
Skip filtering
ALF snowflake filtering
2nd line below the VB
Use padding and
averaging
ALF cross filtering
1st line below the VB
Reduce filter size
ALF cross filtering
2nd line below the VB
Reduce filter size
ALF cross filtering
3rd line below the VB
Reduce filter size
ALF cross filtering
4th line below the VB
Reduce filter size
[0041] As shown in the above detailed example, if the VB processing technique is applied to ALF to remove dependency of ALF processing on pixels of the other side of the VB, the line buffers for the entire in-loop filtering are reduced from 8.3 lines to 4.2 lines for the luma component and from 6.2 lines to 2.2 lines for the chroma components. If the VB processing is applied to both SAO and ALF, the line buffers for the entire in-loop filtering become 4.1 lines for the luma component and 2.1 lines for the chroma components. In the above example, the ALF or SAO are modified to remove the dependency on pixels of the other side of the VB. It is also possible to practice the present invention to modify ALF and/or SAO so that the dependency on pixels on the other side of the VB is reduced.
[0042] The example of VB processing for SAO and ALF according to the present invention shown in FIGS. 6-24 fully removes the need for any additional line buffers, beyond the line buffers allocated for DF processing, except for small buffer for some SAO partial results and DF decisions. However, another embodiment according to the present invention may also reduce the dependency of data for SAO and ALF across the VB so that the additional line buffers beyond what has been allocated for DF can be reduced. While a 3×3 window for SAO classification is used in the above example, other window shapes and/or sizes may also be used for deriving the classification for adaptive SAO processing. While a 9×9 cross shaped filter or a 5×5 snowflake shaped filter is used as an example for ALF processing, other filter shapes or filter sizes may also be used to practice the present invention. Furthermore, SAO and ALF are illustrated as two in-loop processing in addition to DF, the present invention may also be practiced for an encoding or decoding system using other types of in-loop processing to reduce or eliminate the associated line buffers.
[0043] While the steps in FIGS. 6-24 are used to illustrate an example of luma VB processing according to the present invention, steps for practicing the present invention on chroma components can be derived similarly.
[0044] The system performance associated with the above example is compared against a conventional system without luma VB processing. Test results indicate that the system with the luma and chroma VB processing results in about the same performance as a convention system in termed of BD-rate. BD-rate is a well-known performance measurement in the video coding field. While resulting in above the same performance, the exemplary system according to the present invention substantially reduces the line buffer requirement. The advantage of the VB processing according to the present invention is apparent.
[0045] In the above exemplary VB processing, SAO and ALF are used as examples of adaptive in-loop processing. An adaptive in-loop processing usually involves two steps, where the first step is related to determination of a category using neighboring pixels around a to-be-processed pixel and the second step is to apply the in-loop processing adaptively according to the determined category. The process of determination of a category may involve pixels across the VB. An embodiment according to the present invention reduces or removes the dependency on pixels across the VB. Another embodiment according to the present invention may skip the process of determination of a category if the process relies on pixels across the VB. When the process of category determination is skipped, the corresponding in-loop processing may be skipped as well. Alternatively, the in-loop processing can be performed based on the classification derived for one or more neighboring pixels on the same side of the VB.
[0046] Embodiment of video coding systems incorporating Virtual Buffer (VB) processing according to the present invention as described above may be implemented in various hardware, software codes, or a combination of both. For example, an embodiment of the present invention can be a circuit integrated into a video compression chip or program codes integrated into video compression software to perform the processing described herein. An embodiment of the present invention may also be program codes to be executed on a Digital Signal Processor (DSP) to perform the processing described herein. The invention may also involve a number of functions to be performed by a computer processor, a digital signal processor, a microprocessor, or field programmable gate array (FPGA). These processors can be configured to perform particular tasks according to the invention, by executing machine-readable software code or firmware code that defines the particular methods embodied by the invention. The software code or firmware codes may be developed in different programming languages and different format or style. The software code may also be compiled for different target platform. However, different code formats, styles and languages of software codes and other means of configuring code to perform the tasks in accordance with the invention will not depart from the spirit and scope of the invention.
[0047] The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described examples are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A method and apparatus for in-loop processing of reconstructed video are disclosed. The method and apparatus configure the in-loop processing so that the processing requires no pixel or reduced pixels from other side of a virtual boundary. When the in-loop processing of the to-be-processed pixel requires a pixel from the other side of the virtual boundary, the pixel from the other side of the virtual boundary is replaced by a replacement pixel. The in-loop processing can also be configured to skip the pixel when the processing requires a pixel from other side of the virtual boundary. The in-loop processing can also be configured to change ALF filter shape or filter size when the in-loop processing requires a pixel from other side of the virtual boundary. A filtered output can be combined linearly or nonlinearly with the to-be-processed pixel to generate a final filter output. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to saws, and in particular to circular saws of the type comprising a table, a pivot member on the table and a saw assembly pivoted about a pivot axis with respect to the pivot member, whereby said saw assembly carrying a motor driven blade can be plunged into a workpiece supported on the table.
Such saws are known and described in published patent documents such as EP-0133666 and EP-0450400. These saws are useful and have numerous possibilities for enhancement to improve the capacity, capability and efficiency not to mention cleanliness and safety of their arrangements. On the other hand, all these features add complexity and cost, and may render the saw user unfriendly.
The present invention particularly, although not exclusively, relates to saws of the type described above but which in addition have the table mounted in a frame such that the table may be inverted, as by pivoting about an axis, so that the saw assembly is then beneath the table. The table is in addition provided with a slot so that the blade can protrude through the slot to render the saw a bench or table saw. Such saws are known and described in DE-1628992, EP-0502350 and EP-0586172.
Both EP-0133666 and EP-0450400 mentioned above describe saws in which the saw assembly comprises an upper guard and a lower guard for the blade. The upper guard is formed from the housing of the assembly and permanently covers a top part of the blade. A bottom part of the blade is covered by the lower guard but this must be withdrawn in use so that the blade is exposed when required to perform cutting operations.
A handle is disposed on the upper guard by means of which a user can pivot the saw assembly up and down to perform cutting operations on a workpiece supported on the table. Further, if the table has a rotational portion carrying the saw assembly, mitre cuts can also be made in a workpiece on the table.
The lower guard may be opened entirely by an actuating lever disposed on the handle. Alternatively the guard may be opened automatically by pivoting of the saw assembly, there being provided a connection between the guard and the pivot member for this purpose. A further alternative is that the guard may be opened partly by either of these arrangements and only further opened by direct contact with a workpiece.
Means must be provided to bias the saw assembly to a raised upright position when it is at rest so that the user is not required to lift the not-insignificant weight of the saw assembly after completing a plunge cut. Such means is normally in the form of a powerful spring.
Although the upper and lower guards mentioned above provide satisfactory protection for the saw blade when the saw assembly is acting as a plunge or mitre saw, when the table is flipped-over to convert the saw into a bench saw the saw blade is once again exposed. In this configuration, a separate guard must be provided which, in the past, has been mounted on a riving knife of the bench saw each time the saw is used as a bench saw.
It is also known from U.S. Pat. No. 5,060,548 to mount the saw assembly on a rod which can slide through a support mounted on the table. The pivot which carries the motor and saw blade is positioned at one end of the rod and the pivot bracket limits the motion of the rod through the support. Furthermore, all the weight of the motor and saw blade acts on one side of the support, thereby requiring the support to have significant strength.
SUMMARY OF THE INVENTION
In the light of the prior art mentioned above, the applicant has invented an improved saw which has advantages over the prior art.
According to the present invention, there is provided a saw comprising a table, a support mounted on the table, a saw assembly, the saw assembly including a blade journalled in the assembly and a motor to drive the blade, and a slot in the table through which the blade can be plunged, wherein the support defines a channel which receives a shaft carried by the saw assembly such that the saw assembly can slide relative to and over the support to extend the reach of the saw blade along the slot. By allowing the saw assembly to travel above the support, the weight of the saw assembly is transferred to the table more vertically through the support so that twisting forces on the support are reduced. Further, the space taken up by the saw assembly and support is reduced.
Preferably the support defines two parallel channels and two corresponding shafts are carried below the saw assembly for sliding along the channels. Improved support for the saw assembly is thereby provided.
Each channel is preferably C-shaped in cross-section. The shafts are preferably shaped to conform to the cross-section of the channels. It will, of course, be appreciated that the shafts (or rods) need only to be shaped to be retained within the channels and do not have to be shaped to conform to the cross-sections of the channels.
Each channel preferably includes a bearing between the support and the shaft. A low friction material, such as PTFE, may be used to reduce the friction between the shafts and the channels.
In a preferred embodiment, the saw assembly includes a detent for holding the assembly in a retracted position on the support until the saw blade is plunged towards the slot. This detent preferably automatically re-engages when the saw assembly returns to its start position.
Preferably the support includes a pivot block fixed to the table and a pivot member which defines the or each channel, the pivot member being pivotable relative to the pivot block to adjust the angle of cut of the saw blade so that bevel cuts can be made.
A retraction mechanism may act between the pivot block and the pivot member to urge the saw blade into a preferred position, which may be substantially perpendicular to the slot.
The saw assembly may include a quadrilateral linkage which, as the saw blade is plunged towards the slot, opens a blade guard to expose the saw blade.
The saw assembly preferably further comprises a motor plate which carries each shaft, and spring means between the motor plate and the motor which act to raise the blade away from the slot. By including such spring means, a user of the saw does not have to raise the not-insignificant weight of the saw assembly at the end of a cut.
The spring means preferably comprise a spring and a lever which, when rotated, releases the tension in the spring to lower the saw blade. This is important if the saw is to be used as a table saw rather than as a plunge (or chop) saw.
Preferably the motor plate carries a locking device for locking the lever to prevent movement of the saw blade.
The spring means may further comprise a worm drive which, when the lever is rotated, is brought into engagement with a rack mounted on the motor, such that the worm drive can be used to control the position of the saw blade relative to the slot.
If the saw assembly includes a quadrilateral linkage, the rack is preferably formed on an extension of the linkage.
Preferably means are provided for locking the saw assembly at any position relative to the support. A toggle lever carried by the saw assembly may be used to lock the saw assembly position.
As will be appreciated, although the present invention is particularly applicable to chop saws, it may also be applied to saws which can act as both a chop saw and a table saw. In such a case, the table is preferably mounted in a frame and adapted to adopt two positions. In the first of said two positions of the table the saw assembly is above the table, the saw thereby forming a chop saw for performing plunge cuts on workpieces supported on a first side of the table. In the second of said two positions of the table, the saw assembly is below the table and the saw thereby forms a bench saw for performing cuts on workpieces passing through the blade on a second opposite side of the table.
DESCRIPTION OF THE DRAWINGS
Specific embodiments of the present invention are now described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective sketch of a saw according to the present invention;
FIG. 2 is a more detailed front view of a saw according to the present invention;
FIG. 3 is a top plan view;
FIG. 4 is a side view;
FIG. 5 is another side view showing different details;
FIG. 6 is another plan view showing different details;
FIG. 7 is yet another plan view showing different details;
FIG. 8 is a rear view (the mirror of FIG. 2);
FIG. 9 is a side view from the other side with respect to FIGS. 4 and 5; and
FIG. 10 is a view like FIG. 1, but with the guards and levers shown in schematic.
DETAILED DESCRIPTION
A saw 10 comprises a table 12 having a slot 14 and a pivot block 16 rigidly fixed to the table. A pivot member 18 is pivotably attached to the pivot block 16 about an axis 20 lying in the plane of the table 12 and passing along the slot 14. A bolt 22 received in the pivot block 16 passes through an arcuate slot 24 in the pivot member 18 and terminates with a lever 26 by means of which the bolt 22 may be tightened to secure the pivot member 18 in any angular position between two limits.
The pivot member 18 also comprises a bearing cage 30 having two parallel C-shaped bearing channels 32, 34 including C-shaped bearings 32B, 34B (shown in FIG. 2). A motor plate 40 has two bars 42, 44 rigidly fixed thereto. The bars 42, 44 are received in the channels 32, 34 respectively. The plate 40 can therefore slide back and forth relative to the pivot member 18. The bars 42, 44 and channels 32, 34 are arranged so that the direction of slide is always parallel to the axis 20 (and slot 14).
Since the channels 32, 34 are open in section and the connection to the bars 42, 44 is through the open channel, the length of the bars 42, 44 can be minimised for the given travel of the saw assembly 400 (which includes motor 48 and saw blade 54) and the mechanical support requirements of the saw assembly 400 through the bearings 32B, 34B. This is further enhanced by the weight distribution of the saw assembly 400 and motor plate 40 through the bearings 32B, 34B. Despite not having a full circumference, bearings 32B, 34B can be small because there are less torsional stresses on them about an axis parallel axis 50. This is important given the desire to minimise the bulk of the final saw and the working room required for its satisfactory operation. This is particularly the case where the saw is a pivoting saw where the table 12 is arranged to pivot within a frame 300. The frame 300 should be kept to a minimum in size for easier transportation and reduced working room requirements. The present arrangement facilitates that end by minimising the intrusion of the slide system within the overall volume envelope of the saw.
Hinge parts 46 are formed at the front of the plate 40. A motor 48 has another hinge part 47 which is joined to hinge parts 46 through an axle which enables pivoting of the motor 48 relative to the plate 40 about an axis 50. The motor 48 is fixed to a blade assembly 52 which includes a saw blade 54 driven by the motor 48.
The axis 56 of the blade 54 is parallel to the axis (not shown) of the motor 48 and axis 50. The blade 54 is arranged above the slot 14 so that pivoting of the motor 48 about axis 50 plunges the blade 54 into the slot 14, at whatever angle the pivot member 18 is with respect to the pivot block 16. Moreover the slot 14 is long enough to accommodate full movement of the plate 40 back and forth with respect to the pivot member 18, even with the blade 54 plunged fully downwards.
Turning to FIG. 2, the plate 40 is carried by the bearing cage 30. The bearings 32B, 34B are retained by set screws 33. The bars 42, 44 are secured to the plate 40 by screws 43, staggered with respect to one another along the length of the bars 42, 44.
FIG. 3 shows the extent of the plate 40 and the cage 30. Also, at the back of plate 40 is mounted spring release lever 60, which is mounted for rotation about axis 62 in the plate 40. An eccentric catch element 64 retains one end of a tension spring 66. The lever 60 is received firstly in a large aperture 68 in an arm 70 upstanding from the plate 40, and secondly in a bracket 72 fixed to the plate 40 by screws 73.
Turning to FIG. 4, the spring 66 acts between the element 64 on the lever 60 and a catch 74 on the side of the motor 48 at its front end (see also FIG. 7). Thus, pivoting of the motor 48 about axis 50 (to plunge the blade 54 into slot 14) extends and tensions the spring 66, which is of course strong enough to lift the motor 48 and saw assembly 400 when released by the user from a plunged position.
Blade assembly 52 includes a parallelogram lever 80 which at the top end is pivoted to an upper blade guard 82 which is also pivoted about the blade axis 56. The lever 80 is pivoted At its lower end to the upstanding arm 70 about axis 84. An extension 200 at the top end of the lever 80 prevents the blade assembly 52 from being plunged down unless switch lever 202 is pulled. Switch 202 is mounted on handle 204 fixed to the upper blade guard 82. Lever 202, when first pulled, rotates lower blade guard 206 a small amount so that a cam 208 on the lower blade guard 206 is released from blocking engagement with extension 200. Thereafter, further opening of the lower blade guard 206 is accomplished by action of the extension 200 on the front face of cam 208. A spring (not shown) biasses the lower blade guard 206 to its covering position with respect to the blade 54. When the assembly 52 is permitted to pivot down, however, the parallelogram lever 80 maintains the disposition of the upper guard 82 with respect to the table 12.
Pivoting down of the motor 48 and blade assembly 52 releases a detent 86 connected to the back of the motor 48 and which otherwise catches, at its lower end 88, against the back of the bearing cage 30 and prevents the plate 40 from sliding along the cage 30. The lower end 88 is pivoted to the detent 86 at 90 so that, when the blade assembly 52, motor 48 and plate 40 are slid forwardly to a front position (not shown) and the blade assembly 52 is permitted to rise under the action of the spring 66, the detent 86 does not prevent such raising. On such raising of the blade assembly 52, the catch 88 is merely deflected by contact with the top of the cage 30 about axis 90 until the plate 40 is slid back to the position shown in FIG. 4, whereupon catch 88 snaps off the cage 30 under the action of a spring 92.
An extension 94 at the lower end of the lever 80 has a rack 96 formed thereon. Also, a worm assembly 98 is pivoted about axis 100 to the upstanding arm 70 (see also inset to FIG. 2). When the spring release lever 60 is in the position shown in the drawings, a flat surface 102 between its ends (see also FIGS. 3 and 7) faces the back of worm assembly 98 so that the worm assembly 98 lies with its back at the position shown at 98'. Here, the worm assembly 98 is not contacted by the rack 96 when the assembly 52 is pivoted down, and the rack 96 and worm assembly 98 have no function. However, when the table 12 is inverted (by means not shown) to convert the saw 10 to a bench saw and where the blade 54' protrudes right through the slot 14, the rack 96 and worm assembly 98 come into operation. The spring release lever 60 is turned, anti-clockwise in FIG. 4. This first releases the tension in the spring 66. Secondly, curved surface 103 of the lever 60 presses the back of the worm assembly 98 so that it eventually adopts the position shown in FIG. 4, and this brings worm 104 (see inset to FIG. 2) in the assembly 98 into engagement with the rack 96. A knob 106 enables a user to rotate worm 104 which then alters the position of parallelogram lever 80 and hence the degree of protrusion of the blade 54 through the slot 14.
Turning to FIG. 5, a key 61 on the end of the spring release lever 60 limits the rotation of the lever 60 between two positions, and, at least in the position shown in FIG. 4, locks lever 60 in that position, in the sense that the spring 66 pressure presses the key 61 against its stop.
Also in FIG. 5 is a lock 108, which can be employed to lock the plate 40 in position at one end of the cage 30. The lock 108 has a toggle lever 110 by means of which the lock 108 may be permanently disengaged (see also FIG. 8).
FIG. 6 shows a retraction mechanism 112 fixed to the plate 40 which has a spring loaded cable 114, one end 116 of which is connected to the cage 30. This serves to bias the blade assembly 52 and plate 40 back to the position shown in FIG. 4.
It will of course be understood that the present invention has been described above purely by way of example, and that modifications of detail can be made within the scope of the invention. | A saw comprising a table, a support mounted on the table, a saw assembly including a blade journalled in the assembly and a motor to drive the blade, and a slot in the table through which the blade can be plunged, wherein the support defines a channel which receives a shaft carried by the saw assembly such that the saw assembly can slide relative to and over the support to extend the reach of the saw blade along the slot. By allowing the saw assembly to lie above the support, the weight of the saw assembly is transferred to the table through the support and the space occupied by the saw assembly and support can be reduced. | 8 |
RELATED APPLICATIONS
This application is a divisional application of application Ser. No. 12/386,553, filed Apr. 20, 2009. This application is hereby incorporated inthis application by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention is directed toward improvements in roll-up closures. This invention is more particularly directed toward a tensioning unit for tensioning the spring in a roll-up closure. The invention is also more particularly directed toward the drum for carrying the hinged door on the closure.
2. Background Art
Roll-up closures are mounted over the opening to be closed by the hinged door of the closure. The closure has an axle which is normally fixedly mounted between end plates fastened to the wall of a building framing the opening. A drum is rotatably mounted on the axle. A hinged door is attached at its top end to the drum and wound up on the drum when the drum is rotated to open the opening. A motor is normally mounted on the axle within the drum to rotate the drum. However the motor could be mounted outside the drum at one end or the drum could also be rotated manually. A tension coil spring is mounted on the axle within the drum with one end of the spring connected to the axle and the other end connected to the drum. The spring is normally initially tensioned when the closure is installed and is further tensioned when the opening is closed by the hinged door, the door unwinding off the drum. The tensioned spring makes it easier for the door to move up when opening the opening. The tension in the spring can be adjusted externally by various known tensioning means.
The known closures have several disadvantages however. The tensioning means employed to adjust the tension in the spring is often mounted outside the end plates making it difficult to employ the closure in tight places. The tensioning means also are quite complicated to use, some requiring two people, some requiring a precarious perch on a ladder. The drum normally employed is cylindrical making it difficult to smoothly roll the hinged door onto the drum. It is also difficult to position and mount elements, such as the drive motor, within the drum.
SUMMARY OF THE INVENTION
It is the purpose of the present invention to provide a roll-up closure having an improved tensioning unit. The tensioning unit is simple in construction and quite compact and can be mounted within the end plates allowing the closure to be installed in tight places. The unit is also quite easy to assemble and can be easily and safely used by one person on the ground. It is another purpose of the present invention to provide a drum for a roll-up closure which easily and securely allows the hinged door of the closure to be connected to it; which more evenly wraps the hinged door thereon; and which makes it easier to mount elements within the drum.
In accordance with the present invention there is provided a tensioning unit comprising a ratchet wheel fixedly mounted on the axle, the axle normally rotatable on the end plates. The ratchet wheel is adjacent one of the end plates and a stop member, slidably mounted on the one end plate, cooperates with the ratchet wheel to lock it, and thus the axle, against rotation in a direction that reduces tension in the spring. A lever is movably mounted on the axle between the ratchet wheel and the end plate. The lever is movable radially to allow it to selectively connect with the ratchet wheel and is also rotatable on the axle to allow it to rotate the wheel in one direction when connected to it. Rotation of the ratchet wheel in the one direction will rotate the axle and thus the one end of the spring to tighten it. The stop allows the wheel to rotate in the tightening direction but prevents the wheel and axle from rotating in the opposite direction to loosen the spring and reduce tension when the lever is disconnected from the wheel.
Also in accordance with the present invention there is provided a drum for the closure comprising an extruded tube with a mounting for the one end of the hinged door on its surface. The mounting comprises a shallow depression in the wall, formed from the outside of the drum, the depression extending across the width of the drum parallel to its longitudinal axis. The depression has a hook-shaped end to snugly receive the male hinge element on the free side of the first slat in the hinged door. The mounting includes a support surface for part of the first slat adjacent the male hinge element, the surface extending tangentially from the depression. The tube, seen in cross-section, has the wall generally follow a spiral curve from the support surface on one side of the depression to the other side of the depression, the radial distance of the wall from the center of the tube gradually increasing the farther away from the support surface that you go. The shape makes it easier to wind the door thereon. The tube also has extruded channels on its inner surface, extending across the tube parallel to the longitudinal axis of the tube, to help slidingly mount elements within the tube. The channels make it easier to longitudinally position the elements within the tube while preventing them from rotating within the tube.
The invention is particularly directed toward a spring tensioning unit for a roll-up closure. The closure has a pair of end plates; an axle rotatably mounted between and on the end plates; a drum for carrying a closure, the drum rotatably mounted on the axle; and a tensioning coil spring mounted on the axle and connected between the axle and the drum. The tensioning unit has a ratchet wheel fixedly mounted on the axle adjacent one end plate, the wheel having spaced-apart teeth on its periphery. A stop member is slidably mounted on the one end plate with a stop tab cooperating with the teeth on the wheel to stop movement of the wheel in a direction reducing tension on the spring. A lever is mounted between the wheel and the end plate, the lever having a lever tab for cooperating with the wheel. The lever is movable on the axle both radially and rotationaly to position the lever tab against a tooth and to then rotate the tooth, and the axle, in a direction to increase tension on the spring.
The invention is also directed toward a hollow drum for a roll-up closure that is extruded and which has at least two apart channels on the inner surface of its wall opening radially inwardly, the channels slidably receivng elements to be mounted within the drum while preventing their rotation.
The invention is further directed toward a hollow, extruded, drum for a roll-up closure. The drum has a shallow depression formed in the wall, the depression extending inwardly and extending across the width of the drum. There is an overhang extending partway over the depression from one side of the depression, the one side of the depression being curved to match the curve of one side of a male hinge member on one side of a slat of a door to be wound on the drum. The overhang and the curved side imitate the curved open side of the female hinge member on the other side of the slat.
DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a partial front view, in partial section, of a roll-up closure;
FIG. 2 is a perspective view of an end plate;
FIG. 3 is a detail front view of the tensioning unit;
FIG. 4 is a perspective view of the tensioning unit;
FIG. 5 is a detail front view of the ratchet wheel;
FIG. 6 is a perspective view of the stop;
FIG. 7 is a front view of the lever;
FIG. 8 is a cross-section view of the tube.
DETAILED DESCRIPTION OF THE INVENTION
The rolling closure 1 , as shown in FIGS. 1 and 2 , includes a hinged door 3 made from a plurality of hinged slats 5 wound on a drum 7 rotatably mounted an axle 9 . The closure 1 is mounted at the top of an opening 11 in a wall 13 . Side frames 15 are mounted on each side of the opening 11 on the wall 13 and an end plate 17 is mounted on top of each frame 15 . The end plate 17 is offset, as shown at 18 in FIG. 2 , to have a portion 19 spaced a short distance from the side of the opening. The axle 9 is rotatably mounted in slots 20 in the off set portion 19 of the end plates 17 to extend between the plates. A guide 21 on top of each frame 15 guides the side 23 of the hinged door 3 into an inside groove 25 running the length of the frame 15 .
To control the movement of the door 3 a tension coil spring 27 is normally mounted over the axle 9 within the drum 7 with one end 29 of the spring mounted on the axle 9 and the other end 31 mounted to the drum 7 . The tension of the spring 27 is adjusted during installation so that the spring winds up during movement of the hinged door 3 off the drum 7 to close the opening making it easier to raise the door during opening of the opening 11 .
A tensioning unit 37 is employed to be able to adjust the tension of the spring 27 . The tensioning unit 37 , as shown in FIG. 3 , has a ratchet wheel 39 fixedly mounted on the axle 9 adjacent the inside of the end plate 17 . The ratchet wheel 39 has uniformly spaced-apart teeth 41 about its periphery as shown in FIGS. 4 and 5 . Each tooth 41 has an initial straight surface portion 43 leading from the previous tooth to a curved surface portion 45 moving radially away from the center of the wheel 39 and terminating in a stop edge 47 that extends radially inwardly to the start of the straight surface portion 43 of the next adjacent tooth. There is slot 49 extending into the tooth from the bottom of the stop edge 43 , the bottom of the slot 49 aligned with the straight surface portion 43 of the next tooth.
The tensioning unit 37 includes a stop member 51 . The end plate 17 mounts a stop member 51 in a vertical, T-shaped, slot 53 , the stop freely movable vertically in the slot 53 . The stop 51 , as shown in FIG. 6 , has a laterally projecting tab 54 that normally interferes with a stop edge 47 on a tooth 41 on the ratchet wheel 39 when the stop 51 is at the bottom of the slot 53 . The stop tab 54 enters the slot 49 on the tooth 41 . The stop tab 54 prevents the wheel 39 , and thus the axle 9 , from rotating counter clockwise, when viewing the wheel from the drum side, and thus unwinding the spring 27 while it is tensioned. The stop 51 has an upper tab 55 above the stop tab 54 , both tabs joined by a back plate 56 . The tab 55 is shorter than the stop tab 54 . The tabs 54 , 55 are wider than the stem 57 of the slot 53 , almost as wide as the cross-bar 58 of the slot 53 . Both tabs 54 , 55 have groves 59 , 60 in their sides intermediate their ends for receiving the end plate 17 to retain the stop slidably on the end wall. The stop 51 is mounted in the slot 53 by inserting the stop tab 54 through the cross-bar portion 58 of the slot 53 until its grooves 59 are aligned with the end plate 17 and then dropping onto the end plate to slide down the stem 57 of the slot 53 . There is a little play between the grooves 59 and the end plate 17 allowing the stop to be slid down the stem with the upper tab 55 adjacent the outside surface of the end plate 17 . Once the upper tab 55 reaches the cross-bar portion 58 , it is passed through it to align its grooves 60 with the end plate 17 and then the stop 51 is further dropped down to have the end plate 17 running through both tabs 54 , 55 to retain the stop slidably within the slot 53 .
The tensioning unit 37 further includes an elongated lever 61 , as shown in FIG. 7 , mounted loosely on the axle 9 between the ratchet wheel 38 and end plate 17 . The lever 61 is in the form of a narrow plate and has an elongated slot 63 adjacent one end 65 through which the axle 9 passes. The slot 63 allows the lever 61 to rotate about the axle 9 and also to move radially with respect to the axle 9 . The other end 67 of the lever 61 carries a tubular receiver 68 . The lever 61 has a laterally projecting tab 69 bent out from about the middle of the lever intermediate its ends 65 , 67 . The lever tab 69 is located so it can be abutted against the stop edge 45 of one of the teeth 41 on the ratchet wheel 39 when the lever 61 is manipulated by an operator, and more particularly, so it can enter the slot 49 at the bottom of the stop edge 45 .
In use, when the spring 27 is to be tensioned, an elongated rod 71 , or the like, is inserted by an operator into the receiver 68 on the lever 61 , the lever normally hanging down from the axle 9 . The rod 71 is used to manipulate the lever 61 on the axle 9 by rotating it and moving it radially so the lever tab 69 carried by it rests in the slot 49 in the stop edge 47 of a selected tooth 41 on the ratchet wheel 39 . The operator then rotates the lever 61 clockwise, as shown by the arrow ‘A’ in FIG. 4 , about the axle 9 while keeping the tab 69 abutted against the stop edge 47 , and in the slot 49 , to rotate the ratchet wheel clockwise to tighten the spring 27 . As the ratchet wheel 39 rotates, so does the axle 9 , tightening the spring against the inertia of the drum 7 and the hinged door 3 on it. The rotation of the ratchet wheel 39 also causes the stop member 51 to ride up the curved part 45 of the next tooth adjacent to it, as shown by the arrow ‘B’, until the stop 51 reaches and passes the stop edge 47 of the tooth to drop down and locate its stop tab 54 in slot 49 in the stop edge 47 of the tooth. The stem 57 of the slot 53 is high enough to prevent the top tab 55 from normally reaching the cross-bar 58 as the stop 51 rises. Having the stop tab 54 in the slot 49 prevents the spring 27 from unwinding and allows the operator to disengage the lever 61 from the tooth it initially engaged with and move it back to the next adjacent tooth to repeat the process if needed.
If the tension in the spring 27 needs to be reduced, the operator can slightly rotate the ratchet wheel 39 with the lever 61 to withdraw the stop tab 54 from the slot 49 in the tooth and then merely push the stop 51 upwardly with another bar to have it clear the stop edge 45 . The operator then releases the lever 61 allowing the ratchet wheel 39 to rotate counter clockwise one tooth while simultaneously releasing the stop 51 to drop to engage the next tooth, to reduce tension in the spring.
The tensioning unit is compact allowing it to be mounted inside the end plate and still clear of the hinged door. With the unit between the end plates, the closure can be mounted in tight places with at least one of the end plates tight in a wall corner if needed. The unit is easy to use. Only one person is required to tension the spring and the tensioning can be done from the ground. Having the lever 61 located between the end plate and the ratchet wheel causes it to act as a washer reducing wear between the ratchet wheel 39 and the end plate 17 .
The drum 7 for supporting the closure can be constructed to mount elements such as the motor in if more easily. To this end the drum 7 is extruded with the inner surface 75 of the wall 77 of the drum provided with mounting channels 79 at spaced-apart locations along the length of the drum as shown in FIG. 8 . Three channels are shown but two or four could be provided. The elements to be mounted within the drum, such as a motor 81 , have projecting tabs 83 about their circumference allowing the element to be slid into the drum with the tabs 83 entering the channels 79 to keep the element from rotating within the drum. The element can be slid into the drum the required distance guided by the channels and then locked in place by one or more screws 85 passed through the wall 77 of the drum into one of the channels 79 and the tab 83 in the channel.
The drum 7 also has mounting means 91 on the outer surface 93 of the wall 77 for mounting the hinged door thereon more easily. The mounting means 91 has a shallow depression 95 formed in the wall 77 of the drum to receive the male hinge end 97 of the end slat 5 A of the door 3 . The depression 95 extends across the width of the drum. The depression has an overhang 99 on one side 101 to help retain the end 97 of the slat within the depression. The overhang 99 and the side 101 of the depression are shaped to form part of the female hinge end 103 of a slat so as to snugly receive part of the male hinge end 97 . The overhang 99 forms part of a flat section 105 of the wall 77 of the drum that extends generally tangentially away from the depression 95 . The flat section 105 is wide enough to receive about half of the width of the panel portion 107 of the end slat 5 A. The weight of the door hanging down the one side of the drum pulls the male end 97 of the end slat 5 A tight into the depression 95 , the male end 97 held in place by the overhang 99 . The end slat 5 A extends generally tangentially away from the depression 95 with the female hinge end 103 positioned relatively close to the wall 77 of the drum. The door is easily mounted on the drum by merely sliding the male hinge end 97 into the depression under the overhang 99 .
The wall 77 of the drum leaving the flat section 105 follows a spiral curve moving gradually radially away from the center of the drum as it returns to the other side of the depression 95 . The gradual enlarging of the drum around its periphery allows the hinged door 3 to be smoothly wound about the drum. | A drum for a roll-up closure, the closure having a door of hinged together slats, one end of the door adapted to be mounted on the drum, the door adapted to be wound on the drum as the drum is rotated. The drum has a wall defining its shape with a depression in the wall extending both inwardly and across the width of the drum. The cross-section of the wall defines an increasing spiral from one side of the depression to the other side of the depression. An extension of the wall extends from the one side of the depression towards the other side to partially close the depression. The partially closed depression is shaped to receive the one end of the door to mount the door on the drum. | 4 |
This is a continuation of application Ser. No. 07/386,578, filed July 28, 1989, which was abandoned upon the filing hereof.
FIELD OF THE INVENTION
This invention relates generally to a reusable writing device for tools and more particularly, to a reusable writing device used in conjunction with a tape measure to allow the user to record data while using the tool.
BACKGROUND OF THE INVENTION
Tool users, such as carpenters and others skilled in the art, have long been hampered by the unavailability of a convenient writing surface that is readily available, easy to use, and inexpensive for recording measurements or making diagrams and the like. This need has been particularly acute for those using tape measures, where it is necessary to record measurements so that materials may be cut and used as efficiently and cost effectively as possible.
While a number of various items or articles are available in the work place to record important information, they have generally been unacceptable for a number of different reasons. For example, a worker may record writings and drawings on paper carried to the work site. This poses a problem because it is not practical for a tool user to carry paper. Further, the use of disposable materials entails additional work because it must be disposed of. At present, workers may record data on construction materials. This method has met with limited success as it is often very difficult, if not impossible, to move such materials to the proper place for cutting or fitting. Further, the above-described means for recording data are generally not reusable and therefore are unmanageable for a worker who must carry the means for recording data throughout the work day.
The present invention offers a reusable writing surface that fills a need in the art for a simple, effective, inexpensive and easy to use device, the use of which is not limited by the needs and limitations of a carpenter or other tool user.
SUMMARY OF THE INVENTION
The present invention comprises a reusable writing surface of the type particularly suitable for use with tools and the like. The device includes a reusable writing member having a front surface and a back surface. A pressure sensitive adhesive is connected to the writing member whereby the device may be adhered to a tool.
In a preferred embodiment of the device, the reusable writing member comprises a transparent plastic for receiving markings which may be removed. Further, the preferred embodiment of the invention includes a design connected to the back surface of the writing member which may be seen through the transparent front surface. A layer of adhesive is bonded to the back of the design. A backing may be connected to the adhesive so that the device is protected until a user adheres it to the preferred tool or article.
While the present invention will be described with respect to a preferred configuration of the device, and with respect to preferred materials and shapes of construction, it will be understood that other configurations, materials, and shapes could be used for constructing the device, without departing from the sphere and scope of this invention. Various advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and which form a part hereof. However, for a better understanding of the invention and its advantages obtained by its use, reference should be made to the drawings which form a further part hereof and to the accompanying descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings, wherein like numerals represent like parts throughout the several views:
FIG. 1 is an exploded perspective view of the device constructed according to the principles of this invention and illustrating its position on a tool, such as a tape measure;
FIG. 2 is a perspective view of an example of usage of the device disclosed in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the Figures, there is generally illustrated at 10 a reusable writing device or notation area insert of a configuration and shape particularly suitable for use with tools and the like, wherein the device is used to record data. The data is easily removed from the surface by eraser, rubbing, or wiping with water or another liquid. In the preferred embodiment, the device 10 includes a reusable writing member 12 made of a plastic material. The writing member 12 may comprise any appropriate plastic material suitable for receiving markings by a pencil, and is preferably of a polycarbonate material or polyvinyl chloride material. In the preferred embodiment of the invention, LEXAN® has been found to perform satisfactorily. LEXAN® is a polycarbonate material manufactured by General Electric. Any appropriate material which could be cleaned by a conventional eraser or using a small amount of water or liquid to moisten the surface and wipe it clean would be adequate. In the preferred embodiment, it has been found that use of a material which does not absorb dirt or other extraneous matter and does not scratch easily is preferable. Scratches and/or absorption would hinder use of the device. Use of a pencil has been found to be a preferable writing implement although other implements may be used.
The writing member 12 is a generally circular disk, as illustrated in FIGS. 1 and 2 in the preferred embodiment. This shape is particularly useful for applying the device to tape measures such as illustrated in FIG. 2. While it will be understood that many configurations, sizes and shapes of the device can be envisioned within the sphere and scope of the invention, dimensions of the generally circular writing member 12 as illustrated in FIGS. 1 and 2 of the preferred embodiment are 23/8 inches in diameter and 1/32 inch thick. Dimensions and configurations may be modified and changed within the scope of the invention to suit varying applications.
The writing member 12 includes a front surface 14 and a back surface 16 where the front surface 14 receives the markings of the user. A design layer 18 is connected to the back surface 16 of the writing member 12 in the preferred embodiment. It should be understood that the design layer 18 may be of any suitable material and configuration and may be connected to the writing member 12 by any suitable means. However, in the preferred embodiment the design is silk screened onto the back surface 16 of the writing member 12. For purposes of clarity, the design layer 18 is shown as a separate layer in FIG. 1 although the design is silk screened to writing member 12 in the preferred embodiment. By means of example, the design layer 18 could incorporate a grid to aid in drawing diagrams, as shown in the preferred embodiment. A 1/8 inch grid is utilized in the preferred embodiment to aid in drawing diagrams.
An alternative embodiment may include a design layer 18 including a layer of vinyl or other suitable material. The layer of vinyl may provide a background with or without a design. The layer of vinyl may be combined with the silk screening of a design to the back surface 16 of the writing member. An adhesive cooperatively connects the vinyl layer or material to the writing member 12. It should be understood that any other means to connect the design layer 18 to the writing member 12 may be utilized.
The design layer 18 could consist of almost anything, including a logo for advertisement or other information desired by the worker or the advertiser. The placement of the design on the back surface 16 of the writing member 12 ensures that the design layer 18 will not wear. The design layer 18 is sized and configured to fit the configuration of the writing member 12 in the preferred embodiment. It should be understood that the configuration and size of the design may be of any desired specification which falls within the scope of this invention.
A pressure sensitive adhesive 20 is applied to the back surface 16 of the writing member 12 or if a design is incorporated, the adhesive is applied to the back of the design layer 18. The adhesive utilized in the preferred embodiment is 467 High Performance adhesive manufactured by 3M of Minnesota. The adhesive 20 is used to adhere the device of the present invention to a tool or other appropriate surface.
A backing or adhesive protectant 22 may be connected to the adhesive layer 20 to protect the adhesive during shipping and handling. In the preferred embodiment, a waxed paper backing sheet is used to cover the adhesive. This backing 22 may be removed by the user in order to use the present invention. The paper backing 22 is optional and serves only to protect the adhesive during shipment and storage. The paper backing 22 is shown curled away from the adhesive layer 20 in FIG. 1 to demonstrate that the backing 22 in the preferred embodiment is removed in this manner.
In use, the adhesive protectant or backing 22 is removed by the user and the device is preferrably placed within a depression on a tool, such as in the depression on the side of a tape measure 24, as shown in FIG. 2. The user may take measurements for example, and then record this data on the front surface 14 of writing member 12 with a pencil, as shown in FIG. 2. The writing member 12 may also be used for recording a list of materials needed by the worker or may be used to leave notes to others in the work area.
To remove the markings, the user merely rubs the front surface 14 thereby eliminating the writing. Another means of removal of the marking is to moisten the front surface 14 and wipe it clean. Also, a pencil eraser may be used to erase the data from the device 10. Therefore, the present invention provides a reusable writing surface or note pad for users of tools and the like, and more particularly tape measures. The invention provides the advantage of an easily available writing surface in conjunction with the standard measuring tool used in the industry. The present invention fulfills the need for a handy, inexpensive method of keeping track of measurements and other information useful to workers. In the preferred embodiment, the device combines a reusable writing surface with a necessary tool of the trade. In this way, there is no need to carry an additional piece of equipment to perform this function. The present invention provides a means for recording measurements, performing calculations and recording reminders. In this manner, the present invention leads to a saving of materials and time for workers and users. Mistakes which result from error in memory or recording of measurements are eliminated. Time spent in rechecking measurements is also eliminated.
As discussed above, the particular configuration and shape of the device 10 can be varied to suit the particular conditions and requirements of its usage. An example of how the device 10 may be varied is with tools of different size and shape. The device 10 may be modified to cover a larger or smaller area depending on the size of tool used.
It is believed that the invention, its mode of operation, construction and assembly and many of its advantages should be readily understood from the foregoing without further description. While a particular embodiment of the invention has been described, other modifications of the invention will be apparent to those skilled in the art in light of the foregoing description. This description is intended to provide a specific example of an embodiment which clearly discloses the present invention. Accordingly, the invention is not limited to the described embodiment or the use of specific elements therein. All alternative modifications and variations of the present invention which fall within the sphere and broad scope of the appended claims are covered. | An improved tape measure having a writing member is disclosed. The writing member has a front surface for receiving markings and a back surface with an adhesive connected to the back surface for attaching the writing member to the tape measure device. | 6 |
FIELD OF THE INVENTION
[0001] The present application relates to an LDMOS transistor structure.
BACKGROUND OF THE INVENTION
[0002] LDMOS transistor structures are widely used in semiconductor devices for many types of transistor applications such as high voltage MOS field effect transistors. An LDMOS transistor comprises a lightly doped drain region to enhance the breakdown voltage. FIG. 1 shows a top view of a combined transistor structure including two MOSFET transistors. Both transistors are arranged within an active, for example, p doped area 1 that is isolated from the surroundings, by a so-called field region 11 . The transistors share a common drain region consisting of a n + doped region 9 surrounded by a n − doped region 8 . Two source regions 6 , 7 are arranged on the left and the right side of this drain region 8 , 9 . Thus, two channels are defined by the drain region 8 , 9 and the two source regions 6 and 7 , respectively. The broken lines indicate the gates 4 and 5 which are arranged above these channels. To the left and the right of the source regions 6 and 7 , there are arranged p + sinker structures 2 and 3 which extend from the surface of epitaxial layer to the bottom of the substrate to provide for a source connection on the backside of the substrate.
[0003] The active region 1 can be enclosed by a single step, the LOCal Oxidation of Silicon (LOCOS) as known in the art. This process creates a so called high stress field oxide bird's beak region which in combination with the p + sinker structure implants 2 and 3 can result in a leakage path between the n + drain and the p + sinker structure along the interface stress and implant damage induced defect centers as indicated by arrows 10 .
[0004] The conventional solution to prevent such a leakage is to increase the spacing between p + and n + implants to the bird's beak to suppress the leakage current. The disadvantages of such a measurement is, however, the increase of the non-functional part of the transistor fingers and the reduction of the isolation region.
SUMMARY OF THE INVENTION
[0005] According to the present application, a new transistor structure is introduced which avoids such a leakage.
[0006] A semiconductor device comprises an active region of a first conducting type including a transistor structure, and a ring shaped region of the first conducting type extending from a surface of the active region into the active region and substantially surrounding the transistor structure.
[0007] The transistor structure may comprise, a drain region, a source region, wherein the drain and the source define a channel, a gate being arranged above said channel, and a sinker structure of said first conducting type arranged substantially along said source region reaching from the surface of the active area next to the source region to the bottom of the active area. The p ring can be less doped than the sinker structure. The device may further comprise a metal layer on the backside of the semiconductor device. The transistor structure can be a two transistor structure comprising, a common drain region, a first source region arranged on one side of the common drain region, a second source region arranged on the respective opposite side of the drain region, wherein the drain region and the source regions each define a channel, a first and second gate being arranged above said channels, and a first and second sinker structure of said first conducting type arranged substantially along said source regions reaching from the surface of the active area next to the respective source regions to the bottom of the active area. The drain region may comprise a lightly doped drain region. The ring can be doped in the range of 10 14 -10 5 /cm 2 . The active area can be created and enclosed by a LOCOS process. The active area may comprise a substrate and an epitaxial layer on top of said substrate. The first conducting type can be the p type or n type. The ring can be created by masked ion implant. Boron can be used as a dopant. The ring may have a rectangular, circular, oval, or polygon shape. The ring may comprise at least one gap that does not substantially influence an insulating function of the ring.
[0008] According to another embodiment, a semiconductor device comprises an active region of a first conducting type including a transistor structure, wherein the transistor structure comprises, a drain region of a second type, a channel, and a gate being arranged above said channel, and a ring shaped region of the first conducting type extending from a surface of the active region into the active region and surrounding the transistor structure.
[0009] The device may further comprise a source region of the second type arranged along one side of the drain region, and a sinker structure of said first conducting type arranged substantially along said source region reaching from the surface of the active area next to the source region to the bottom of the active area. The device can also further comprise a second source region arranged on the respective opposite side of the drain region, wherein the drain region and the source regions each define a channel, a first and second gate being arranged above said channels, and a first and second sinker structure of said first conducting type arranged substantially along said source regions reaching from the surface of the active area next to the respective source regions to the bottom of the active area. Again, the drain region may comprise a lightly doped drain region and the device may further comprise a metal layer on the backside of the semiconductor device. The ring may be less doped than the sinker structure and can be doped in the range of 10 14 -10 15 /cm 2 . The active area can be created and enclosed by a LOCOS process. The active area may comprise a substrate and an epitaxial layer on top of said substrate. The first conducting type can be the p type or n-type. The ring can be created by masked ion implant. Boron can be used as a dopant. The ring may have a rectangular, circular, oval, polygon, or partially open shape. The ring may further comprise at least one gap that does not substantially influence an insulating function of the ring.
[0010] A method of manufacturing a semiconductor device comprises the steps of:
forming an active region of a first conducting type within a semiconductor material; forming a transistor structure, and forming a ring shaped region of the first conducting type extending from a surface of the active region into the active region and surrounding the transistor structure.
[0014] The step of forming a transistor structure may comprise the steps of forming a drain region of a second type, a source region of the second type arranged along one side of the drain region, and a sinker structure of said first conducting type arranged substantially along said source region reaching from the surface of the active area next to the source region to the bottom of the active area. The method may further comprise the step of forming a second source region arranged on the respective opposite side of the drain region, and a first and second sinker structure of said first conducting type arranged substantially along said source regions reaching from the surface of the active area next to the respective source regions to the bottom of the active area. The drain region can be formed in such a way that it comprises a lightly doped drain region. The method may further comprise the step of arranging a metal layer on the backside of the semiconductor device. The step of forming the ring may include the step of doping the ring less than the sinker structure. The ring can be doped in the range of 10 14 -10 15 /cm 2 . The active area can be created and enclosed by a LOCOS process. The ring can be created by masked ion implant. Boron may be used as a dopant. The ring can have a rectangular, circular, oval, polygon, or partially open shape.
[0015] Other technical advantages of the present disclosure will be readily apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A more complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
[0017] FIG. 1 is a top view of a combined transistor structure enclosed by a LOCOS area according to the prior art;
[0018] FIG. 2 is a top view of a combined transistor structure enclosed by a LOCOS area according to an embodiment of the present invention;
[0019] FIG. 3 is a sectional view along the line 3 - 3 in FIG. 2 .; and
[0020] FIG. 4 shows different possible shapes of the inter unit cell ring.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Turning to the drawings, an exemplary embodiment of the present application will now be described. FIG. 2 depicts a similar transistor structure as shown in FIG. 1 . This figure only shows the drain region and indicates the, sinker, the source region, and the gates by broken lines. Similar structures and elements carry similar numerals. Within the active area 1 , an additional p doped ring structure 20 is implanted that extends from the surface of the active area 1 into the epitaxial layer to additionally isolate transistor structures as will be shown in more detail in FIG. 3 . FIG. 2 shows the p doped ring as rectangular ring structure with two parallel “vertical” areas 22 and two parallel “horizontal” areas 21 . However, other forms, such as a circle, oval, hexagonal, or any other polygon shape can be used. The such formed inter-unit cell p ring 20 completely surrounds both transistors. The p ring profile can be generated by masked ion implant, for example, with a boron dose in the range of 10 14 -10 15 /cm 2 . The inter-unit cells p ring, thus, is created with a lower dose than the p + sinker and is used to terminate the electrical field (depletion region) at the end of the unit cells to prevent the electrical field to come in contact with the defect centers, thus limiting the leakage current and providing the leakage current insulating function. The lower dose p ring design reduces the implant damage, improves the source resistance, and suppresses the snapback behavior
[0022] For a conventional device, the depletion edge extends along the end of the drain fingers 8 , 9 with increasing drain bias. A drain to source leakage path can be formed when the depletion region, in case of an electrical field>0, starts covering the stress and implant damage induced defect centers. As stated above, the inter-unit cells p ring terminates the electrical field (depletion region) at the end of unit cells and effectively prevents the electrical field to come in contact with the defect centers and, thus, suppress the leakage current.
[0023] FIG. 3 shows the P ring profile within the transistor structure in a sectional view along the line 3 - 3 of FIG. 2 . However, only a partial view is presented and, thus, only the left transistor is shown in this figure. A wafer comprises for example an active p-area created by the LOCOS process which includes n-type areas 8 , 9 and 34 implanted on the surface to provide a drain and source region, respectively. The backside of the substrate comprises a wafer backside metal layer 30 which can be made of gold or aluminum and is used for contact purposes. The area 1 is usually covered with an insulator layer 31 such as silicon oxide in which a polysilicium gate 4 is arranged to cover the channel between the drain region 8 and source region 34 . On top of this layer is usually a passivation layer (not indicated in FIG. 3 ). The source 34 in this exemplary LDMOS transistor can be additionally surrounded by a p doped well 35 depending on what type of technology is used. Electrodes 33 and 32 made of gold or aluminum or any other suitable metal reach through the insulating layer 31 to provide respective couplings between runners for the drain and the source regions, respectively. Runners can also be contacted with the respective drain, source and gate regions by other suitable means, such as, vias or similar coupling structures. To generally reduce a feedback capacitance, the source runner 33 is here extended to cover the gate 4 as shown in FIG. 3 . Such a so called field plate over the gate 4 effectively decouples the gate drain capacitance C gd between the gate and the drain. However, other embodiments for the runners are possible. A p + sinker implant 36 similar as used in the prior art embodiment of FIG. 1 is shown on the left side of the source 34 of the left transistor. Such a p + sinker 36 can be created by ion implantation. Effectively, this p + sinker merges with the p well area 35 and, thus, reaches from the source runner contact 33 to the backside metal layer 30 . Contrary to the p + sinker 36 , the p ring 20 surrounds or encloses the transistor structure. As shown in FIG. 3 , the p ring structure extends from the surface of the active area 1 downwards. Furthermore, the p ring 20 partially overlaps with the p + sinker and the source region 34 in areas 22 (see FIG. 2 ) where the source 34 and the p + sinker 36 are located. As indicated in FIG. 2 , these areas 22 extend along the left and the right side of the drain regions 8 , 9 . Thus, the p ring 20 in FIG. 3 reaches from the surface into the active area in the areas 21 and 22 (as shown in FIG. 2 ) and encloses the combined transistor. Again, the p+sinker 36 can reach over the boundaries of the active area 1 . However, the p ring 20 is completely located within the active area 1 . As also indicated in FIG. 2 , the p ring 20 can reach the right and left sides of the field oxide. (LOCOS edge). If no sinker structure is present, this can be done by designing the ring to extend from the left and right side into the active area. However, as shown in FIG. 2 , if a p + sinker is used it will merge with the p ring 20 and thus, p ring 20 can extend to the edge of the field oxide.
[0024] Although particular embodiments of the invention have been shown and described, the invention is not limited to the preferred embodiments and it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention, which is defined only by the appended claims and their equivalents. For example, the embodiment shown describes a combined dual transistor arrangement. However, the principle of an insulating ring according to the present application can also be applied to structures with more than two transistors or to a single transistor structure. Furthermore, the substrate/epitaxial layer can be a p-type or an n-type substrate. Thus, source, drain region, the p ring, and other doped areas would be according to their function either of the n-type or the p-type.
[0025] Furthermore, the ring structure does not have to be in a rectangular form as shown in FIG. 2 . Depending on the form of the transistor structure other suitable surrounding shapes can be used, such as a circle, oval, hexagonal, or any other polygon shape. FIG. 4 A-F shows an exemplary variety of different ring shapes. For example, FIG. 4 A depicts a circle shape, FIG. 4B a polygon shape, and FIG. 4D an oval shape. The main function is to insulate the electrical field. Therefore, depending on the structure of the transistor the ring might have some openings as long as they do not influence the substantially the shielding function. FIG. 4C , thus, shows another rectangular or square shape formed by four elements 40 . These elements 40 can merge at their respective ends to form a continuous rectangular ring structure but also could have small gaps as long as the insulating function is kept. FIG. 4F shows another example, of a four element structure 42 with gaps at less critical areas of the ring. In FIG. 4E only two elements 41 are provided in the “horizontal” areas. These elements 41 merge with the p + sinker structures and, thus, form the insulating ring. Any other ring structure or combination of elements is possible to reach a similar result. | A semiconductor device comprises an active region of a first conducting type including a transistor structure, and a ring shaped region of the first conducting type extending from a surface of the active region into the active region and substantially surrounding the transistor structure. | 7 |
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates primarily to three-sided, totally enclosed containers which, by hand, may be rapidly collapsed to conserve time and space during storage; and, which may be rapidly expanded by hand to form a lid-covered, structurally strong, liquid tight, space insulated container. Industrial material handling boxes, equipment carrying cases, insulated food and beverage containers, trash containers, and tote pails are product examples in this field.
(b) Description of the Prior Art
Totally enclosed collapsible and expandable containers are known in the art. However, the tendency is for time consuming modes of expansion, collapsing, and gaining interior access. Due to the requirement for collapsibility, liquid tightness and insulation tend to be ineffective, while structural rigidity is a common problem.
SUMMARY OF THE INVENTION
The present invention stems from the requirement to improve upon prior art in the field of invention. The invention includes two blanks arranged for high rate production. The blanks being a plurality of surfaces interconnected through a plurality of hinge lines. From one blank a double-walled, folding bottom, three-sided, collapsible container is formed by two interior and two exterior attachments. The container features several stiffeners, an insert frame retainer clip; a self-acting hinge, a three-position lid which serves to retain container in the expanded configuration and a flexible bail which also provides retention of the collapsed container configuration. The container is transformed from collapsed to expanded configuration by inward movement of the two exterior attachments. After pushing the bottom inward, container transformation from expanded to collapsed configuration is accomplished by inward movement of container sides adjacent to an exterior attachment. From the other of the blanks is formed a triangular insert frame around which double flexible liners are tightly placed, thus forming an air pocket therebetween, with said air pocket acting as an insulator. The insert frame containing the two flexible liners may be temporarily or permanently positioned in the insert frame retainer clip of subject container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a blank from which a container may be made embodying the principles of the invention.
FIG. 2 is a plan view of the blank with stiffener flaps folded into position.
FIG. 3 is an elevation view of the constructed blank.
FIG. 4 is a horizontal section of the constructed blank taken on line 4--4 of FIG. 3.
FIG. 5 is a vertical section of the constructed blank taken on line 5--5 of FIG. 4.
FIG. 6 is a vertical section of the constructed blank taken on line 6--6 of FIG. 4.
FIG. 7 is a plan view of the expanded blank construction.
FIG. 8 is a vertical section of the expanded blank construction taken on line 8--8 of FIG. 7.
FIG. 9 is a view of the expanded blank construction showing the lid positions.
FIG. 10 is a side elevation of the blank configuration with a bail installed through both side and lid.
FIG. 11 is an elevation view of the blank construction in a collapsed state with band retainer.
FIG. 12 is an elevation view of the blank construction in a collapsed state with the flexible bail retainer arrangement of FIG. 10.
FIG. 13 is a plan view of the blank configuration with lid rims partially formed.
FIG. 14 is a plan view of the blank configuration with lid rims completely formed.
FIG. 15 is a perspective view of the expanded blank construction with flexible bail attached through sides.
FIG. 16 is an elevation view of the blank construction in a collapsed state with the flexible bail retainer arrangement of FIG. 15.
FIG. 17 is a plan view of a blank from which a liner frame may be made embodying the principles of the invention.
FIG. 18 is an exploded perspective view showing a liner, liner frame and frame installation.
FIG. 19 is a vertical section of a liner, liner frame and frame retainer clip taken on line 19--19 of FIG. 18.
FIG. 20 is a vertical section detail of a liner, liner frame and frame retainer clip.
FIG. 21 is a vertical section detail of a liner, liner frame and frame retainer clip.
FIG. 22 is a vertical section detail of the expanded blank construction enclosed in flexible cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows blank 1 suitable for making a three-sided collapsible container embodying a collapsible bottom, double-walled sides, a self-acting hinge, handles, a three-position lid, bail and hang holes. The blank 1 materials may be of any combination which provides sufficient structural rigidity when scored, creased, hinged or connected by any suitable flexure material. The blank 1 surface attachment may be by any suitable fastening means. Referring specifically to FIG. 1 and generally to blanks within the detailed description of this patent, solid lines represent blank cut lines; alternately long and short dashed lines represent blank fold lines with adjacent surfaces bending up to construct, expand or operate subject blank embodiment; and, alternately long and double short dashed lines represent blank fold lines with adjacent surfaces bending down to construct, expand or operate subject blank embodiment.
In blank of FIG. 1 a triangular bottom 2 formed by fold lines 3, 4, 5 is intersected from vertex by hinge line 6. Through fold line 3, bottom 2 is attached to a quadrilateral exterior side 7 bounded by fold lines 8, 9, 10, 3. Enclosed within the exterior side 7 are a handle ellipse formed by cut line 11 and fold line 12, two bail holes 13, and an adhesive strip 14. Through generally parallel double fold lines 15, 8 forming a narrow strip 16, exterior side 7 is attached to a quadrilateral front attachment tab 17 extending from fold line 10 to fold line 3 with said tab 17 including adhesive strip 18. Through fold line 10 exterior side 7 is attached to a quadrilateral rim stiffener 19 extending from notch 20 at fold line 9 to bevel 21 at hinge line 8 with said rim stiffener 19 including adhesive strip 22. Through fold line 9, exterior side 7 is attached to a quadrilateral back tension member 23 bound by fold lines 24, 9, 25 and a cut line which is the general extension of hinge line 3 from fold line 9 to fold line 24. Said back tension member 23 contains hang hole 26. Through fold line 25 back tensor 23 is attached to a quadrilateral rim stiffener 27 extending from notch 20 at fold line 9 to fold line 28 with said rim stiffener 27 including adhesive strip 29, a portion of fold line 24, and hang hole 26. Through generally parallel double fold line 24, 28, forming a narrow strip 30, back tension member 23 is attached to a quadrilateral back attachment tab 31 bound by a fold line 28 and three cut lines. Two of the cut lines are the general extension of fold lines 25, 3. The tab 31 includes adhesive strip 32. Through fold line 5 is attached to bottom 2 a quadrilateral exterior side 33 bounded by fold lines 5, 34, 35 and cut line 36. Enclosed within the exterior side 33 is a handle elipse formed by cut line 37 and fold line 38, two bail holes 39; and an adhesive strip 40. Through fold line 34 exterior side 33 is attached to a quadrilateral rim stiffener 41 extending from notch 42 at fold line 35 to bevel 43 at cut line 36 with said rim stiffener 41 including adhesive strip 44. Through fold line 35 exterior side 33 is attached to a quadrilateral back tension member 45 bound by fold lines 35 and 46, a cut line which is the general extension of fold line 5; and cut line 47. The back tension member 45 contains hang hole 48. Through fold line 46 back tensor 45 is attached to a quadrilateral rim stiffener 49 extending from notch 42 at fold line 35 to cut line 47 with the stiffener 49 including adhesive strip 50 and hang hole 48. The remaining third side of triangular bottom 2 is a straight line consisting of fold line 4 and two substantially equal length off-set cut lines 51, 52 extending to fold lines 3, 5 respectively. Attached to the triangular bottom 2 through fold line 4 is a quadrilateral interior back 53 bound by fold lines 54, 55, 4, 56. Enclosed within said interior back 53 is a plurality of fold lines forming three fold line triangles 57, 58, 59. Relief fold line triangle 57 is formed by fold lines 60, 61, 4 and is intersected from vertex by fold line 62. Fold line triangle 58 is formed by fold lines 63, 64, 4; contains within its area relief fold line triangle 57; and is intersected by fold lines 62, 65 through vertex. Fold lines 6, 62, 65 form a straight line fold hereafter referred to as the lower straight line fold. Lid fold line triangle 59 is formed by fold lines 55, 66, 67. Fold line 68 intersects lid fold triangle 59 from vertex. Through fold line 54 interior side 69 is attached. Included on the boundaries of said interior side 69 is a corner bevel cut line 70, notch 71 with one side a portion of fold line 54, and relief cut line 51. Through fold line 56 interior side 72 is attached. Included on the boundaries of said interior side 72 is a corner bevel cut line 73, notch 74 with one side a portion of fold line 56, and relief cut 52. Through generally parallel double fold lines 75, 55 forming a narrow strip 76, interior back 53 is attached to triangular lid 77 formed by fold lines 78, 75, 79. Fold line 80 intersects said lid 77 from vertex. Fold lines 120, 68, 80 form a straight line fold hereafter referred to as the upper straight line fold. Note that the combination of fold lines 120, 80, 68 forming upper straight line fold do not necessarily form a straight line with the combination of fold lines 6, 62, 65 forming lower straight line fold. Through fold line 78, lid 77 is attached to quadrilateral lid stiffener 81. The stiffener 81 is bounded by a cut line and fold lines 78, 82, 83 with the stiffener containing bail hole 84. Attached to stiffener 81 through fold line 82 is quadrilateral stiffener 85 which includes bail hole 84 and is bounded by fold line 82 and three cut lines which form a mirror image of stiffener 81. Through fold line 79, lid 77 is attached to quadrilateral stiffener 86 with the stiffener 86 bounded by a cut line and fold lines 79, 87, 88. Stiffener 86 contains bail hole 84. Attached to stiffener 86 through generally parallel double fold lines 87, 89 forming narrow strip 90, is attached quadrilateral stiffener 91 which includes bail hole 84 and is bounded by fold line 89 and three cut lines which form a mirror image of stiffener 86. Through fold line 83, is attached tip triangle 92 bounded by fold lines 83, 93 and a cut line generally the extension of fold line 82. Through fold line 88, is attached tip triangle 94 bounded by fold lines 88, 93 and a cut line generally the extension of fold line 87.
FIG. 2 is a plan view of blank 1, showing one embodiment with stiffeners 19, 27, 81, 86, 85, 91, 92, 94, 49, 41 in place after rotating around their respective fold lines as indicated by the blank 1 in FIG. 1. Only slight rotation has been given to stiffeners 81, 92, 94, 86.
Shown in FIG. 3 through FIG. 6 the construction of this invention from blank 1 may be accomplished by making all bends as indicated by fold lines in FIG. 1 except those represented by fold lines 75, 55, 66, 67, 60, 61, 4; attaching interior side 69 to exterior side 7; attaching interior side 72 to exterior side 33; attaching tab 17 to exterior side 33; and attaching tab 31 to back tension member 45. During construction fold line 8 is placed on or near cut line 36 thus necessitating narrow strip 16 to allow wrap-around of blank 1 material thickness. Likewise, during construction, fold line 28 is placed on or near cut line 47 thus necessitating narrow strip 30 to allow wrap-around of blank 1 material thickness. Due to blank 1 material thickness, offset cut lines 51, 52 are necessary to allow positioning of interior sides 69, 72 against exterior sides 7, 33 respectively. Liquid tight construction results below adhesive strips 14, 40 when said strips 14, 40 are placed near cut line pattern of interior side quadrilaterals 69, 72. The constructed embodiment of blank 1 is displayed in FIG. 3 through FIG. 6. FIG. 6 shows the internal attachment of interior sides 69, 72 to exterior sides 7, 33 by adhesive strips 14, 40. FIG. 4 shows the exterior attachment of tab 17 to exterior side 33 through adhesive strip 18. FIG. 4 also shows the exterior attachment of tab 31 to back tension member 45 through adhesive strip 32. FIG. 4 and FIG. 5 displays the necessary condition that upon construction the combined length of fold lines 6, 62, 65 in combination with the relative positioning of interior sides 69, 72 with respect to exterior sides 7, 33 must be such that interior back 53 is in contact with stiffeners 27, 49 of back tension member 23, 45 near fold line 120 with said fold line 120 generally parallel with narrow strip 30. The expanded position shown in FIG. 7 can be made to be full or flat by controlling the combined lengths of back tension member 23, 45 relative to the length of interior back 53; relative positioning of the interior sides 69, 72 with respect to exterior sides 7, 33 respectively; and the procedure for attaching tab 31 to back tension member 45 establishes the expanded configuration of the embodiment shown in FIG. 7 and the characteristics of lid 77 operation shown in FIG. 9. In the expanded configuration it is important to assure built-in residual compression in interior back 53 and, in turn, built-in residual tension in back tension member 23, 45. Both expanded position and lid characteristics will be described later. Bail holes 13, 39 and handle ellipses 11, 37 are positioned in blank 1 so as to be centered over the centroid of the expanded container volume.
From FIG. 4 through FIG. 6, following construction, the embodiment is placed in a working configuration by pressing down on fold line 6 of triangular bottom 2 near relief triangle 57 and simultaneously pushing up on bottom edges of exterior side quadrilaterals 7, 33 as shown by arrows in FIG. 6. This results in the bending of fold lines 60, 61, 4 as indicated in blank 1 of FIG. 1 and also results in the working configuration of the embodiment shown in FIG. 7, FIG. 8, and FIG. 11. Two working configurations exist. The expanded configuration is shown in FIG. 7 which is attained by forcing the working embodiment into a self-standing position by momentarily pressing inward near external attachment tabs 31, 17 as shown by arrows in FIG. 7. The collapsed position is attained as shown in FIG. 7 by pushing inward near center of triangular bottom 2 while pushing inward near fold lines 9, 35 which is to say pushing inward on exterior side 7, 33 adjacent to exterior attachment 17, as shown by arrows in FIG. 7. From FIG. 9, when lid 77 is placed in back position 96, prior to forcing into collapsed position, the retained collapsed configuration shown in FIG. 11 can be achieved by the use of retainer band 97.
While in the expanded configuration of FIG. 7, through a self-acting fold action, the lid 77 will snap to three definite positions 98, 99, 96 as shown in FIG. 9. As seen in the natural position 98, created during construction and following placement into the expanded position of FIG. 7, lid 77 is bent inward around fold line 80. As lid 77 is forced backward it gradually becomes flat until dead center position 100 is reached. At this position further backward movement will cause lid 77 to snap by embodiment self-action to back position 96 as lid 77 rotates around fold lines 75, 55 the spacing of which defines narrow strip 76 shown in blank 1 of FIG. 1. The width of narrow strip 76 in relation to the thickness of blank 1 material determines to some degree the location at which back position 96 will occur through a stopping action. As lid 77 moves toward back position 96, the lid 77 bends outward around fold line 80. Similar embodiment self-action will snap lid 77 to natural position 98 if lid 77 is forced forward slightly past dead center position 100. When lid 77 is forced forward from position 98 it gradually becomes flat until dead center position 100 is reached, at which position further forward movement will cause lid 77 to snap by embodiment self-action to position 99 as it rotates around fold lines 66, 67 and bends outward around fold line 80. Similar embodiment self-action will snap lid 77 to natural position 98 if forced backward slightly past dead center position 100. Position 96 is required to allow collapsing of embodiment as shown in FIG. 11. Position 98 may be utilized to retain lid 77 in open position and position 99 may be utilized to keep lid closed as well as lock embodiment into expanded position. The embodiment action of FIG. 9; the exact locations at which the lid 77 positions 98, 99, 100, 96 occur; and the force required or developed to move lid to positions 98, 99, 100, 96 depend on the resistance of the expanded embodiment to configuration change. Many factors may cause such resistance including relative positioning of interior sides 69, 72 with respect to exterior sides 7, 33 respectively; the residual compression in interior back 53 shown in FIG. 4; the width of narrow strip 76 shown in FIG. 1 and FIG. 9; fold line length 68 shown in FIG. 1 and FIG. 9; the blank 1 material; and internal pressure applied by container contents. FIG. 10 shows the expanded configuration with flexible loop bail 101 through bail holes 39, 13 in exterior sides 33, 7 respectively, and through lid 77 bail holes 84 in a figure eight fashion. Force on said bail 101 tends to close lid 77 by said arrangement. FIG. 12 shows the collapsed position of FIG. 10 embodiment with bail 101 acting as holding band. It is to be noted that the length of bail 101 is exactly that required to hold embodiment of FIG. 10 in tightly collapsed position by one loop around bottom and one loop crossed over top, then seated and held in place by corner notch formed by tab 31.
Another embodiment of present invention is shown in FIG. 13 in which blank 1 has lid stiffeners 81, 85, 92, 94, 91, 86 partially positioned to form a rim. FIG. 14 is the completed lid rim of blank 1 showing quadrilaterals 81, 85, 86, 91 and triangles 92, 94 in finished position. FIG. 15 is the blank 1 embodiment of the subject invention with lid rim and flexible bail 102 installed therein. FIG. 16 shows the collapsed position of FIG. 15 embodiment with bail 102 acting as holding band. It is to be noted that the length of bail 102 is exactly that required to hold embodiment of FIG. 15 in tightly collapsed position by one loop 102 around bottom and one loop 102 crossed over top, then seated and held in place in notch formed by 91, 85, 92, 94.
FIG. 22 shows another embodiment of blank 1 in which a flexible liner 121 encloses all surfaces visually exposed in both collapsed and expanded configuration.
Shown in FIG. 17 through FIG. 21, an embodiment of this invention is the attachment of a flexible insert 103 consisting of two flexible liners 104, 105 stretched tightly over a frame 106 forming a trapped air pocket insulator 107. The embodiments of this invention provides for the attachment of a flexible liner such as that of FIG. 18. FIG. 17 shows the plan view of frame blank 106 which is utilized to form the flexible insert 103 of FIG. 18. Frame blank 106 of FIG. 17 is further defined through utilizing the line convention previously established for blanks of this invention. Said frame 106 materials may be of any combination which provides sufficient rigidity when scored, creased hinged or connected by any suitable flexure material. Blank 106 consists of four quadrilaterals 108, 109, 110, 111 attached at fold lines 112, 113. Attached to quadrilaterals 108, 109 through fold lines 114, 115, are quadrilaterals 116, 117 respectively. Adhesive strip 118 is attached to quadrilaterals 109, 108. Formation of the blank 106 into the frame embodiment is accomplished by bending on the fold lines as shown in FIG. 17. FIG. 18 shows the frame embodiment in which quadrilaterals 110, 111 are fixed to quadrilaterals 109, 108 respectively through adhesive strip 118. Quadrilaterals 117, 116 are fixed by tab 119 at edge opposite fold lines 115, 114 respectively thus forming a triangular embodiment from blank 106. In FIG. 17 blank 106, all quadrilaterals and crease lines are proportioned through coordination with the embodiment of blank 1 shown in FIG. 1 such that insert 103 fits tightly flush inside container embodiment of blank 1 of FIG. 1. Referring to blank 1 of FIG. 1 and blank 106 of FIG. 17, frame quadrilaterals 108, 109 match interior back 53 with fold line 112 overlaying hinge line 120 thus allowing frame embodiment 106 to conform to the configuration of blank 1 embodiment. As shown in FIG. 18, exterior sides 33, 7 and interior sides 72, 69 including respective notches 74, 71 and bevels 73, 70 provide for position guidance of insert 103 into retainer clip formed thereby. FIG. 19 shows one arrangement in which clip spring action between exterior sides 33, 7 and interior sides 72, 69 respectively, retain insert 103. FIG. 20 is another retainer clip arrangement in which insert 103 is retained against upward movement. FIG. 21 displays a retainer clip of the present invention in which insert 103 is retained against downward movement with flush fitting action providing further clamping. FIG. 19 insert 103 is wrapped from air pocket counterclockwise around frame 106. FIG. 20 shows insert 103 wrapped from air pocket clockwise around frame 106.
Thus, it will be appreciated that, as a result of the present invention, a blank and collapsible container are provided by which objectives of the invention are fulfilled. Also, it will be understood from the preceding description that modifications may be made in the illustrated embodiments without departure from the invention. Accordingly, it is expressly intended that the foregoing description and accompanying drawings are illustrative only, not limiting, and that the true spirit and scope of the present invention is to be determined by reference to the appended claims. | An insulated collapsible container suitable for a material handling box, equipment carrying case, food insulator, beverage insulator, trash receptacle, tote pail and the like, which is constructed from two flat blanks of structural material arranged for a high production rate. One blank forms a three sided collapsible structure including double walls, an inwardly folding bottom, a three position snap action lid hinge, an insert frame retaining clip, rim stiffeners, bail holes and hand holes. The remaining blank forms the mating insert frame around which two flexible liners are tightly placed, thus forming an insulating air entrapment therebetween. After pushing inward the bottom, container transformation from expanded to collapsed configuration is by inward movement of container sides. A flexible bail serves the dual purpose of container transport and retention of the collapsed state. The container is transformed from collapsed to expanded configuration by inward movement of front and back edges. | 1 |
This application claims priority to U.S. Provisional Patent Application Serial No. 60/207,238, which was filed on May 26, 2000. That Provisional Application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to watercraft and more particularly to features for personal watercraft.
2. Description of the Related Art
Various types of watercraft exist, each being suited for different types of activities. The term personal watercraft generally refers to a sporty, jet-propelled watercraft capable of accommodating a driver and, in some instances, two or three passengers. One advantage of a personal watercraft is its maneuverability. A typical watercraft, for example, is capable of making relatively tight turns on the water, and is capable of achieving relatively high speeds.
A characteristic that makes a personal watercraft capable of achieving this kind of maneuverability and speed is its small size and shape which permit it to be ridden like a motorcycle.
A typical personal watercraft provides a small hull defining an engine compartment below a seating area. Because they are usually small and compact, personal watercraft generally are limited in storage space and in the number of passengers they can accommodate.
Larger sport boats, on the other hand, can provide significant storage space and accommodate greater numbers of passengers. However, larger sport boats do so at the expense of sportiness and maneuverability.
Therefore, personal watercraft and larger sport boats satisfy different goals. Personal watercraft are designed for speed, nimbleness, and maneuverability. Large sport boats do not focus on these attributes. Instead, they excel at storage and passenger space. These two attributes have not, heretofore, been combined into a single boat, especially of the type described herein.
SUMMARY OF THE INVENTION
Thus, it is an object of the present invention to provide a watercraft, which combines the speed, maneuverability, and personal convenience of a personal watercraft with the roominess, storage capability, and size of a larger sport boat.
A watercraft, according to the present invention, includes a powered hull and at least one compartment integrally formed within the hull, the compartment being adapted for storage and having an opening thereinto defined by a planar surface.
The watercraft includes a powered hull, a deck attached to the hull defining a central area on which a straddle-type seat is disposed and at least one storage compartment disposed at a stern of the watercraft and being accessible through an opening in the deck. The watercraft also includes at least one deck section mounted to the deck and being moveable between a closed position where the compartment is covered and an open position where the compartment is accessible, wherein, when in the closed position, a top surface of the at least one deck section defines a sun deck area.
Finally, according to the present invention, the planar seal resiliently engages the planar surface when the compartment is closed to prevent the ingress of water into the compartment.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a top view of the watercraft of the present invention from a rear perspective;
FIG. 2 is a side perspective view of the of the watercraft of the present invention, illustrating grab handles provided at the rear thereof;
FIG. 3 is a partial rear perspective view of the watercraft of the present invention, showing one storage compartment therein;
FIG. 4 is a partial side view of the layout of the sundeck of the watercraft of the present invention, illustrating the location of the resilient seal thereunder;
FIG. 5 is a perspective top view of a the watercraft of the present invention;
FIG. 6 is a schematic side view of the watercraft of the present invention, illustrating the relationship between the position of the center of gravity and the position of the center of buoyancy;
FIG. 7 is a schematic front view of the watercraft of the present invention, showing the relationship between the position of the center of gravity and the position of the center of buoyancy; and
FIG. 8 is a drawing defining a standard person.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Incorporated herein by reference is the Sea-Doo® Watercraft parts catalog 2000 for the 5688 LRV Watercraft.
FIG. 1 is a top view of the improved personal watercraft ( 2 ) of the present invention. The watercraft ( 2 ) includes at least a stern ( 22 ), a port side ( 24 ), and a starboard side ( 26 ). The basic structure for the watercraft ( 2 ) is divided into the hull ( 4 ), or lower portion, and the deck ( 3 ), or upper portion, that are connected to one another. The hull ( 4 ) and deck ( 3 ) define a housing for an engine and propulsion system (not shown). Integrally formed within the watercraft ( 2 ) are storage compartments ( 6 a ) and ( 6 b ), which are positioned respectively on the starboard side ( 26 ) and port side ( 24 ) of watercraft ( 2 ). In addition, the deck ( 3 ) forms a substantially vertical rear wall surface ( 28 ) at the stern ( 22 ), which includes a top portion ( 28 a ) and a bottom portion ( 28 b ).
FIG. 2 illustrates an entirely new feature for this class of watercraft, a sun deck ( 12 ). In an exemplary embodiment, the sun deck ( 12 ) is a padded area for lounging and relaxing. The sun deck ( 12 ) provides riders with alternative seating and an area on which to sun bathe, or remain seated, but not necessarily in a straddle-type position at the rear of the watercraft ( 2 ) while the engine is stopped and the watercraft is not moving. In addition, sun deck ( 12 ) provides a platform from which a rider may participate in a wide variety of aquatic activities. The sun deck ( 12 ) may have a number of different sections such as section ( 12 a ), positioned on the starboard side of the watercraft ( 2 ), and section ( 12 b ) positioned on the port side of the watercraft ( 2 ). Each section ( 12 a ) and ( 12 b ) is mounted onto the hull ( 4 ) by hinges ( 14 ). The hinges ( 14 ) permit the sections ( 12 a ) and ( 12 b ) to be selectively moved between a first open position ( 16 ), shown in FIG. 1, and a second closed position ( 18 ), shown in FIG. 2 . Alternatively, the sun deck ( 12 ) could be mounted on the deck ( 3 ) without storage compartments ( 6 a ) and ( 6 b ). Also, the sun deck ( 12 ) could be positioned any where on the watercraft ( 2 ).
Each section ( 12 a ) and ( 12 b ) also acts as a cover for respective storage compartments ( 6 a ) and ( 6 b ), which may be used to store a variety of items and accessories such as food, clothes, first aid materials, skis, wake boards, emergency paddles, and/or a tent for weekend activities, for example. The storage compartments ( 6 a ) and ( 6 b ) respectively include openings ( 8 a ) and ( 8 b ), which provide access to the compartments ( 6 a ) and ( 6 b ). In prior art sport boats, the area around any access opening into the hull is provided with a lip to prevent the ingress of water. However, such an arrangement is not necessary on the improved personal watercraft ( 2 ) of the present invention, as discussed in detail below.
A lower grab handle ( 30 ), which is attached to the rear wall surface ( 28 ) of the watercraft ( 2 ) is provided. Additionally, an upper grab handle ( 32 ), attached to the deck ( 3 ), is positioned above the lower grab handle ( 30 ). By holding on to the lower and upper grab handles ( 30 ) and ( 32 ), and using rear deck ( 31 ) as a boarding platform, a person may board the watercraft ( 2 ) from the water at the stern ( 22 ) position. The lower and upper grab handles ( 30 ) and ( 32 ) provide a graduated access onto the watercraft ( 2 ).
FIG. 2 further illustrates that when the sun deck ( 12 ) is in the closed position ( 18 ), the lower grab handle ( 30 ) is positioned below rear sections ( 12 a ′) and ( 12 b ′) of the sun deck ( 12 ). The upper grab handle ( 32 ) is positioned between a seat ( 34 ) and the sun deck ( 12 ). The seat ( 34 ), which is disposed longitudinally along a central area ( 35 ) of the deck ( 3 ) and which provides a straddle-type configuration, provides seating for a driver of the watercraft ( 2 ) and three or more passengers. The sun deck ( 12 ) is disposed rearwardly ( 36 ) of the seat ( 34 ) in order to optimize passenger space on the watercraft ( 2 ). Additionally, when the sun deck sections ( 12 a ) and ( 12 b ) are in the closed position ( 18 ), respective top portions ( 12 a ″) and ( 12 b ″) form a substantially flat surface ( 12 c ), also shown in FIG. 4 . The flat surface ( 12 c ) permits the driver and passenger to comfortably sit or sun bathe while the watercraft ( 2 ) is stationary.
As illustrated more clearly in FIG. 3, each compartment opening, for example opening ( 8 a ) of compartment ( 6 a ), has a planar surface ( 10 ) therearound. The planar surface ( 10 ) provides a tight seal with for the corresponding sun deck section ( 12 a ), which acts as a storage cover for the storage compartment ( 6 a ). As shown, sun deck section ( 12 a ) includes a bottom portion ( 13 ) which includes a seal ( 20 ), formed and shaped to match the shape of the planar surface ( 10 ). When the sun deck section ( 12 a ) is switched from the open position ( 16 ) to the closed position ( 18 ), the seal ( 20 ) resiliently engages the planar surface ( 10 ), thus forming a tight seal ( 11 ), illustrated in FIG. 4 . This tight seal ( 11 ) prevents the ingress of water into the storage compartment ( 6 a ). In the prior art, the ingress of water is prevented by providing the storage compartment opening with a lip, with which the compartment cover may mate. The planar seal approach of the present application, however, can operate with or without a lip, thus providing for a less complicated construction.
FIG. 5 illustrates respective port side ( 24 ) and starboard side ( 26 ) gunwales, ( 40 ) and ( 42 ), which permit a person to board the watercraft ( 2 ) from each of the respective sides.
Watercraft in the prior art have been prone to tip over when a relatively large amount of weight is placed on only one of the gunwales. Such a situation could occur, for example, when more than one person tries to board the watercraft ( 2 ) from the same side at the same time. In the exemplary embodiment of the present invention, however, the lateral static stability of the watercraft has been greatly improved.
As shown in FIG. 6, and as generally understood by one skilled in the art of watercraft buoyancy, in order for any body or system, immersed in water, to float so that it is level with the water, its center of gravity must be aligned with its center of buoyancy. The center of gravity is the point in a body or system, around which its mass or weight is evenly distributed and through which a line of force, exerted by the earth's gravitational force, will pass. When an immersed body floats, it displaces a corresponding volume of water. The center of gravity of this displaced volume of water is defined as the center of buoyancy of the immersed body. In order for the immersed body to float on a level plane, its center of buoyancy must be aligned with its center of gravity.
Thus, as illustrated in FIG. 6, in order for the watercraft ( 2 ) to remain afloat in water ( 38 ) when being boarded by passengers, its center of gravity ( 46 ) must remain substantially aligned ( 48 ) with its center of buoyancy ( 44 ), which is positioned vertically lower than the center of gravity ( 46 ). If substantial misalignment of the metacentric stability occurs due to an inordinate amount of weight, the watercraft ( 2 ) will simply tip over ( 50 ), toward the side from which it is being boarded, as illustrated in FIG. 7 .
However, in the present invention, Applicant's have found through experimentation that by decreasing the distance (x) between the center of gravity ( 46 ) and the center of buoyancy ( 44 ), lateral stability is greatly enhanced. That is, as the distance (x) decreases, the amount of weight, applied to either one of the gunwales ( 40 ) or ( 42 ), required to tip-over the watercraft ( 2 ), increases. Designed in accordance with this principle, a watercraft will be less likely to tip over, even when the rated number of people for that watercraft attempt to simultaneously board the watercraft from the same gunwale.
It should be noted that each watercraft is “rated” for (or approved for use with) a specific number of persons. The watercraft ( 2 ) of the present invention is rated for up to four passengers. With the lateral stability designed into this vehicle as described above, three or four adults of average size simultaneously may attempt to board the watercraft ( 2 ) from the same gunwale without the vehicle tipping over. An adult of average size is defined as an adult having a weight of at least 175 pounds. Appended herein as FIG. 8 is a drawing defining the dimensions of such a standard person. The stability features described herein conform to the standards for vessel stability, as defined in the American Society for Testing and Materials publication F1321-92, which is incorporated herein by reference.
The lateral stability of the watercraft ( 2 ) is also enhanced by the hour-glass shape thereof. As shown in FIG. 1, outwardly extending sections ( 102 , 104 , 106 , 108 ) of the hull ( 4 ) and deck ( 3 ) provide additional areas that extend from a longitudinal line of the watercraft ( 2 ). These outwardly extending sections ( 102 , 104 , 106 , 108 ) provide additional buoyant areas at positions outwardly further from the longitudinal centerline of the watercraft ( 2 ) than prior art watercraft of this type. The additional lateral buoyancy that these sections ( 102 , 104 , 106 , 108 ) provide further enhances the lateral stability of the watercraft ( 2 ).
From the invention thus described, it will be obvious that the invention may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended for inclusion within the scope of the following claims. | The benefits of a sporty and maneuverable personal watercraft and those of a larger sport boat, having the ability to accommodate a large number of riders, are combined into a single watercraft. The watercraft is equipped with a rear sundeck large enough for passengers to sun bathe while the watercraft is stationary. Disposed beneath the sundeck are storage compartments, each having a lip-less seal for preventing the ingress of water into the compartments. Additionally, the storage compartments are large enough to store a variety of items and accessories such as food, clothes, and first-aid materials. The watercraft is designed such that a relationship between the position of its center of gravity and the position of its center of buoyancy, prevents the watercraft from tipping over even when three of four adults of average size simultaneously board the watercraft from the same side. | 1 |
FIELD OF THE INVENTION
The invention relates to a pouch-like container, in particular in the form of a billfold, pocketbook and the like, having insertion compartments which are arranged in a staggered, shingled or graduated manner one above the other and each have at least one insertion opening adapted, in particular, to credit cards and the like.
BACKGROUND INFORMATION
Wallets, billfolds and pocketbooks of the type mentioned are known in various forms and basically also fulfill their purpose to a satisfactory extent. In particular for credit cards and/or plastic cards, these pouch-like containers have insertion compartments which are arranged in a flat state one upon the other and in a staggered manner. The object of the invention is to improve the functions of these insertion compartments.
SUMMARY OF THE INVENTION
In order to achieve the above mentioned object, the invention provides that the direction for pushing the cards into the insertion compartments and the direction of the main axis of the staggering are arranged transversely to one another.
In the case of the known containers or pouches of the type in question here, the insertion direction and the staggering direction coincide with one another. This means, in practice, that the insertion compartments are open in the direction of a free border of the pouch-like container, with the result that, in principle, there is a risk of cards being able to drop out of the insertion compartments. This applies, in particular, when the insertion compartments have a relatively large amount of clearance. In order that the cards do not drop out of the insertion compartments, the latter are usually very narrow and adapted directly to the format of the cards. This means that only a single card in each case fits into an insertion compartment. Nowadays, however, it is frequently the case that users of credit cards and other plastic cards require not just one or two cards, but often a dozen cards, with the result that it is correspondingly necessary for a number of cards to be accommodated in a pouch-like container of the type in question here. This is also possible in a space-saving manner if not just a single card, but two or three cards, can be arranged in an insertion compartment, it nevertheless being ensured that a card cannot be lost even when only a single card is located in the insertion compartment intended for more than one card. This safety aspect is achieved if, according to the invention, the staggering direction and the insertion direction are not the same, as has been the case hitherto, with the result that the insertion openings are open, for example, toward the pouch interior or toward a folding axis of a pouch comprising, for example, two halves. The position of the insertion opening provides an additional safeguard against loss of the article located in the insertion compartment, it being possible for said article to be a credit card and/or plastic card or also, in the broadest sense, some other document or paper.
The invention, however, is not restricted to this particularly expedient method of arranging the insertion openings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail hereinbelow with reference to exemplary embodiments which are illustrated in the drawing, in which:
FIG. 1 shows a view of a conventional wallet with a bill compartment and with insertion compartments for credit cards or other plastic cards;
FIG. 2 shows a view as in FIG. 1, but of a wallet according to the invention with insertion compartments open transversely to the direction of graduation or staggering thereof;
FIG. 3 shows, on an enlarged scale, a view as in FIG. 2 of a modified wallet with a bill compartment and with an insertion-compartment graduation or staggering arranged transversely to the insertion direction;
FIG. 4 shows a view of a pocketbook with the insertion direction for credit cards and/or plastic cards arranged transversely to the graduation or staggering of the compartments and with the insertion direction for an identity card, driver's license and the like arranged transversely to the graduation or staggering of the compartments, and with a bill compartment;
FIG. 5 shows a view of a coin holder as a handling unit, additionally for use with a pocketbook according to FIG. 4;
FIG. 6 shows, on a different scale, a view of the inside of another pocketbook comprising two halves;
FIG. 7 shows, on an enlarged scale, an illustration of essential parts during the production of an insertion compartment for the pocketbook of FIG. 6; and
FIG. 8 shows a schematic diagram as in FIG. 7 once the insertion compartment has been produced.
DETAILED DESCRIPTION OF THE INVENTION
According to the prior art, a pouch-like container 1 in the form of a basically known wallet according to FIG. 1 comprises two container halves 2 and 3 which are connected to one another along a common folding axis 4 . This container 1 has a coin compartment 5 with a cover 6 and a bill compartment 7 which extends over both container halves 2 and 3 . Moreover, a plurality of insertion compartments 9 , each having an insertion opening 8 , are provided for credit cards 10 and/or for plastic cards or the like. These insertion compartments 9 are arranged in a staggered manner one above the other, with the insertion direction (double arrow E) for pushing the credit cards 10 and/or plastic cards into the insertion openings 8 corresponding to the staggering direction of the main axis 11 for the staggering (arrow S).
As FIG. 1 also shows, all the insertion compartments 9 are open toward a border 12 of the container 1 . This means that, in principle, a credit card 10 and/or plastic card can drop out of an insertion compartment 9 if the insertion opening 8 is of generous dimensions.
FIG. 2 shows basically the same type of container 1 , likewise in the form of a wallet with a coin compartment 5 , bill compartment 7 and insertion compartments or pockets 9 for credit cards 10 and/or for plastic cards, but arranged according to the invention. Here too, the insertion compartments 9 are arranged in a graduated or staggered manner one above the other, the main axis 11 of the staggering (arrow S) being in the same direction as in the case of the conventional wallet illustrated in FIG. 1 . However, the insertion openings 8 of the insertion compartments 9 , rather than being opened toward the border 12 of the container 1 as in conventional FIG. 1, are opened in the insertion direction E toward the interior 13 or the folding axis 4 of the container 1 , and thus perpendicularly to the staggering direction S in the inventive arrangement shown in FIG. 2 .
All the insertion compartments 9 in the container 1 are closed toward the respectively adjacent borders 12 , 14 and 15 . It is thus not possible for credit cards 10 and/or plastic cards to drop out of a container 1 or out of a wallet when the two container halves 2 and 3 are located one upon the other, as is usually the case in the closed state.
Finally, it is particularly advantageous for it also to be possible for more than one credit card 10 to be arranged in an insertion compartment 9 in each case. This is illustrated by way of example in FIG. 2 .
The essential difference between the two containers 1 according to FIGS. 1 and 2 resides in the fact that the push-in and removal direction E for the credit cards and the direction of the staggering S are the same in the case of the known container 1 , whereas they are arranged transversely to one another in the case of the container 1 according to the invention. The push-in and removal direction E is thus located perpendicularly to the main axis 11 of the staggering S.
A further container 1 a —to be precise likewise in the form of a wallet—is illustrated, on a somewhat larger scale, in FIG. 3 . Basically the same parts have the same designations and, in addition, the letter index a.
The container 1 a comprises, in turn, two container halves 2 a and 3 a with a coin compartment 5 a, a bill compartment 7 a and a plurality of insertion compartments 9 a for cards equal in size to a credit card 10 a. It is possible for one or more credit cards 10 a to be arranged in each insertion compartment 9 a.
The insertion openings 8 a of the insertion compartments 9 a are each located, just as with the first-described container 1 according to FIG. 2, on a narrow border 16 or 16 a of each insertion compartment 9 or 9 a, respectively. In accordance with the exemplary embodiment illustrated in FIG. 3, the insertion compartments 9 a are opened toward the border 12 a of the container 1 a, as can also be gathered from FIG. 3 with reference to the double arrow for the insertion and removal direction E. The insertion and removal direction E is located, in turn, perpendicularly or transversely to the staggering S of the insertion compartments 9 a.
In the exemplary embodiment illustrated in FIG. 3, the main axis 11 a of the staggering S of the insertion compartments 9 a is arranged perpendicularly to the folding axis 4 a, about which the two container halves 2 a and 3 a can be folded one upon the other.
The insertion openings 8 a of the insertion compartments 9 a are arranged such that they are directed neither toward the folding axis 4 a nor toward the pouch interior 13 a, whereas the staggering S in accordance with the main axis 11 a for the insertion compartments 9 a arranged in a staggered manner is directed toward the folding axis 4 a and pocket interior 13 a.
It may also be gathered from the exemplary embodiment illustrated in FIG. 3 that the border 16 a of at least one insertion opening 8 a is angled at at least one end 17 a.
With both containers 1 and 1 a, the insertion compartments 9 , 9 a are staggered via the long sides 18 and 18 a, respectively. Correspondingly, the insertion openings 8 , 8 a are located on the narrow sides 16 , 16 a. Even if not illustrated in the figures, it nevertheless goes without saying that it is also possible for the insertion compartments to be graduated via the narrow sides and to have the insertion openings on their long sides.
A further exemplary embodiment of a container 1 b, which may be a pocketbook, is illustrated in FIG. 4 . Basically the same parts, again, have the same designations and, in addition, the letter index b.
The container 1 b is provided with a billfold 7 b and has a container half 2 b with insertion compartments 19 b for identity papers and the like on its inside. These insertion compartments 19 b may be intended, in particular, for small-format identity papers. Insertion compartments 9 b for cards 10 b of credit card format are provided on the inside of the other container half 3 b. These insertion compartments 9 b are arranged in a staggered manner in the direction S, whereas the openings 8 b for the insertion compartments 9 b, corresponding to the push-in and removal direction E in FIG. 4, are arranged transversely thereto. The short or narrow borders 16 b of the insertion compartments 9 b are located parallel to the folding axis 4 b of the container 1 b, it being possible for the two container halves 2 b and 3 b to be folded one upon the other about this folding axis 4 b. The insertion and removal openings 8 b ′ of the insertion compartments 19 b are likewise located parallel to the folding axis 4 b. The removal openings 8 b ′ are each located in long sides 20 b of the insertion compartments 19 b. The insertion compartments 19 b are staggered via the respectively short or narrow sides 21 b in accordance with the arrow S in FIG. 4 .
In the state in which the two container halves 2 b and 3 b have been folded one upon the other, that is to say in the closed state of the same, the contents of all the insertion compartments 9 b and 19 b are secured against dropping out in each case.
Finally it is expedient if a pocketbook in accordance with the container 1 b contains an additional holder 22 b as a separate handling unit exclusively for coins according to FIG. 5 .
A further container 1 c can be gathered from FIG. 6, and details relating to the production of the container 1 c are illustrated in FIGS. 7 and 8.
The container 1 c, in turn, has two container halves 2 c and 3 c which can be folded one upon the other about a folding axis 4 c and which each bear insertion compartments 9 c and 19 c on the inside. The insertion compartments 9 c and 19 c are staggered in a direction S parallel to the folding axis 4 c. The insertion openings 8 c for credit cards 10 c, on the one hand, and the insertion openings 8 c ′ of the large insertion compartments 19 c on the other hand, are respectively opened in different directions in accordance with the double arrows E. The insertion openings 8 c for the credit cards 10 c are thus located parallel to the folding axis 4 c and therefore transversely to the staggering S, whereas the insertion openings 8 c ′ are opened in the direction of the staggering S. The insertion compartments 9 c for the credit cards 10 c, in turn, are closed on both long sides and on one short or narrow side, and are open in each case only on one short or narrow side, which is directed toward the folding axis 4 c of the container 1 c. The steps illustrated in FIGS. 7 and 8 may be used in order to produce such a staggered arrangement of the compartments.
As shown in FIG. 7 in a first step, a respectively top compartment wall 23 c is sewn along its top border 24 c to a base 25 c and has a flap 26 c which is to be inserted into a slit 27 c and adhesively bonded there. In the sewn-on and adhesively bonded state in the following step as shown in FIG. 8, the compartment wall 23 c, also connected to the border 28 c of the base 25 c, forms an insertion compartment 9 c with an insertion opening 8 c.
It goes without saying, however, that the production of the containers 1 according to FIG. 2 to 1 c according to FIG. 6 is not restricted to the measures described above.
Finally, it is expedient if a container 1 b in the form of a pocketbook has a small pocketbook format or is adapted to the size of a back pocket of men's trousers. | A billfold, pocketbook, wallet or the like, has insertion compartments that are arranged in a staggered partially overlapping manner one above the other, and that are intended for receiving credit cards and the like through an insertion and removal opening of the respective compartment. The direction for pushing cards into and removing cards from the insertion compartments is transverse to the main axis of the staggering of the compartments and preferably is oriented inwardly perpendicular to a folding axis of the wallet. The credit cards are thereby prevented from inadvertently falling out of the compartments. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a liquid sealed type vibration isolator used to support a vibration generating member including mainly an automobile engine.
[0003] 2. Description of the Related Art
[0004] The known liquid sealed type vibration isolators, such as an engine mount for supporting a vibration generating member, such as an automobile engine so that the vibration of the vibration generating member is not transmitted to a body include, for example, a liquid sealed type vibration isolator shown in FIG. 26, or a liquid sealed type vibration isolator shown in FIG. 27 or 28 .
[0005] All of these related art liquid sealed type vibration isolators 100 include a metal fixing member 102 to be secured to one of vibration generating member, such as an engine and a support member, such as a body, a metal fixing member 103 to be secured to the other thereof, a vibration isolating base member 104 connecting these two metal fixing members 102 , 103 together and formed of an elastic body of a rubber-like material, a diaphragm 106 provided on the side of the metal fixing member 103 so as to be opposed to the vibration isolating base member 104 , a liquid chamber 105 formed between the vibration isolating base member 104 and diaphragm 106 , and a partition 107 dividing the liquid chamber 105 into two, i.e. a main liquid chamber 105 a and an auxiliary liquid chamber 105 b , an orifice 118 communicating the main and auxiliary liquid chambers with each other being formed on an outer circumferential side of the partition 107 to fulfil a vibration damping function of the vibration isolator by an effect of flows of a liquid, which occur owing to the provision of the orifice 118 , in the two liquid chambers, and also a vibration insulating function of the vibration isolator by the vibration isolating base member 104 .
[0006] In the case of the liquid sealed type vibration isolator shown in FIG. 27 or 28 , an elastic film of a rubber-like material 180 is provided in addition to the above-described structure, in a central region of the partition 107 by a vulcanization bonding device or a sandwiching device so as to reduce a dynamic spring constant of a high-frequency region (especially, an engine noise region).
[0007] In order to obtain stable product characteristics of such a liquid sealed type vibration isolator, it becomes an important factor that the volume, especially, a cross-sectional area of the orifice having a vibration damping function be set to a desired level.
[0008] However, all of the liquid sealed type vibration isolators of FIGS. 26, 27 and 28 employ a mode in which an outer circumferential portion of the partition 107 constitutes upper and inner circumferential surfaces and a bottom surface of the orifice, i.e. three sides of a cross section of the orifice, and in which a cylindrical liquid chamber-forming rubber portion 122 , which guides the partition 107 for the press fitting of the same thereinto, and which is on the inner circumferential side of a cylindrical trunk portion 114 of the metal fixing member 103 , constitutes the remaining one side (outer circumferential surface) of the cross section of the orifice.
[0009] Therefore, when, especially, the partition 107 is formed by bending one piece of metal plate by pressure molding or deep drawing, a molding process for forming the three sides of a cross section of the orifice becomes complicated.
[0010] When the construction of the partition 107 is simplified so that the pressing or deep drawing thereof can be carried out easily, for the purpose of overcoming the difficulties, there is the possibility that problems arise concerning the radial and vertical positioning of the partition. Especially, when a structure like those of the related art vibration isolators of FIGS. 26, 27 and 28 is employed in which a lower end portion of the partition 107 is bent radially outward with the resultant outer end portion 171 caulked to a caulking portion of the metal fixing member 103 , i.e. a fastened section 116 formed by a caulking device and formed of the cylindrical trunk portion 114 and a bottom member 113 of the metal fixing member 103 , there is the possibility that the partition 107 slips in the radial and vertical directions due to a tightening force of the caulking device.
[0011] When the partition is thus displaced in the radial and vertical directions, the orifice formed by utilizing the partition cannot be set to a desired cross-sectional area, so that stable product characteristics cannot be obtained.
[0012] According to an aspect of the present invention, the liquid sealed type vibration isolator is capable of solving these problems, and obtaining stable characteristics.
[0013] In the case of the liquid sealed type vibration isolator provided with the elastic film 180 in a central region of the partition 107 which divides the liquid chamber 105 into two, i.e. main and auxiliary chambers, the elastic film setting system has problems different from those encountered in the above-described vibration isolator.
[0014] Namely, in the case of the liquid sealed type vibration isolator of FIG. 27, the lower end portion of the partition 107 is caulked to the fastened section 116 of one metal fixing member 103 with an upper end portion of a cylindrical side wall 172 expanded and press fitted into an inner circumference of the liquid chamber-forming rubber portion 122 , whereby the orifice 118 is formed between the cylindrical side wall and liquid chamber-forming rubber portion 122 . The elastic film of a rubber-like material 180 is vulcanization bonded to a central opening of a top plate portion 123 of the partition 107 .
[0015] In the case of the liquid sealed type vibration isolator of FIG. 28, the partition 107 is formed of two partition members 107 a , 107 b . The upper partition member 107 a is of a disc type shape, provided with an opening 173 in a central portion thereof and press fitted in the liquid chamber-forming rubber portion 122 . The lower partition member 107 b is formed to a shape of an inverted cup, bent radially outward at a lower end portion thereof and caulked at the same portion to the fastened section 116 of the metal fixing member 103 , provided with an opening 175 in a top plate portion 174 thereof, and has the elastic film of a rubber-like material 180 held between the top plate portion 174 and upper partition member 107 a . A space surrounded by an outer circumferential portion of the upper partition member 107 a cylindrical side wall 172 of the lower partition member 107 b , and liquid chamber-forming rubber portion 122 forms the orifice 118 which communicates the main and auxiliary liquid chambers 105 a , 105 b with each other.
[0016] Regarding a method of setting the elastic film 180 , the partition 107 of the type in which the elastic film 180 is held between two pressing metal members (partition members) shown in the related art example of FIG. 28, the shapes of the two partition members are simplified but two metal press dies for the manufacturing of the partition members become necessary. In the case of the partition in the related art example of FIG. 27 of the type which is formed by bending one piece of metal plate, and vulcanization bonding the elastic film 180 to the bent plate, the molding of the partition itself becomes complicated, and a bonding agent application step has to be carried out before the elastic film has been formed. In all of these cases, the cost increases.
[0017] According to another aspect of the present invention, the liquid sealed type vibration isolator capable of solving the above-mentioned problems, facilitating the manufacturing of the partition provided with an elastic film thereon, and reducing the manufacturing cost.
SUMMARY OF THE INVENTION
[0018] In order to achieve the first-mentioned vibration isolator, the inventors of the present invention earnestly discussed the members by which the orifice should be formed and how to position these members for obtaining a desired cross-sectional area of the orifice, with the simplification of the partition taken into consideration as a premise.
[0019] As a result, the inventors discovered that, when the orifice was formed by defining two or one side of a cross section thereof out of three sides thereof by the partition, and the remaining sides thereof by, for example, the liquid chamber-forming rubber portion, vibration isolating base member or an outer circumferential reinforcing metal member of the diaphragm, and not by defining the three sides of such a cross section by the partition as in the related art examples, the shape of the partition was simplified correspondingly.
[0020] Namely, the first-mentioned invention is a liquid sealed type vibration isolator the construction of which is basically identical with those of the above-described related art examples, i.e., includes two metal fixing members for a vibration generating member and a support member, a vibration isolating base member interposed between the two metal fixing members and formed of an elastic body of a rubber-like material, a diaphragm provided so as to be opposed to the vibration isolating base member, a liquid chamber formed between the vibration isolating base member and diaphragm, and a partition dividing the liquid chamber into two, i.e. a main liquid chamber and an auxiliary liquid chamber, an orifice being formed between the partition and a liquid chamber-forming rubber portion on an outer circumferential side thereof, an outer circumferential portion of the partition being formed so as to define at least a part of one or two sides of a cross section of the orifice, either one of the partition and the other orifice-forming member being press fitted or inserted or engaged at a part thereof in a connecting section between the partition and the remaining orifice-forming member into or with the other thereof, whereby the partition and the other orifice-forming member are positioned.
[0021] According to this liquid sealed vibration isolator, the partition forms at least only a part of one or two of the wall surfaces of the orifice, the shape of the partition is simplified and variation of the shape thereof decreases. Moreover, the partition and the other orifice-forming member are positioned at the connecting section therebetween by a press fitting or inserting or engaging structure. Therefore, even when a flange portion at a lower section of the partition is caulked to the relative metal fixing member, the partition is retained without being displaced. This enables the partition molding work to be carried out easily, a highly accurate desired cross section of the orifice to be obtained, and stable characteristics to be secured.
[0022] In this structure, the partition defines at least a part of two or one side of the cross section of the orifice, so that the positioning of the partition in the liquid chamber becomes an important factor. Therefore, it is specially preferable in view of the accuracy of this positioning operation that a positioning device be formed by providing an annular positioning groove in either one of the partition and the other orifice-forming member, and a free end portion, which is to be press fitted or inserted into the groove, on the other thereof.
[0023] In this liquid sealed type vibration isolator, it is possible that the outer circumferential portion of the partition has a mode in which this outer circumferential portion is bent to an L-shaped cross section so as to define the inner circumferential surface and bottom surface of the orifice, and a mode in which the mentioned outer circumferential portion is formed as a substantially vertical wall so as to define the inner circumferential surface of the orifice with the outer circumferential reinforcing metal member of the diaphragm, which is positioned on the lower side of the vertical wall, utilized as a bottom wall of the orifice. All of these modes enable the shape of the partition to be simplified, and variation of the shape thereof and that of the shape of the outer circumferential reinforcing metal member of the diaphragm to be minimized.
[0024] A device for positioning the partition of the above-described construction employs the following structure.
[0025] When the outer circumferential portion of the partition is formed to an L-shaped cross section so as to define the inner circumferential and bottom surfaces of the orifice, an upper end section of the outer circumferential portion, which defines the inner circumferential surface of the orifice, is extended upward, i.e., in the partition inserting direction, and an annular positioning groove is formed in the liquid chamber-forming edge portion, which is opposed to this upwardly extended portion, of the vibration isolating base member, the partition being positioned by press fitting or inserting the upwardly extended portion into the groove.
[0026] Owing to this arrangement, the upper end portion of the partition is engaged with the liquid chamber-side circumferential portion of the vibration isolating base member by the press fitting of the former into the groove of the latter. Therefore, even when a lower portion of the partition is bent and extended radially outward so as to form a bottom wall of the orifice with an outer circumferential end section of the resultant lower extended portion caulked to the relative metal fixing member, the radial and vertical positioning accuracy can be kept high, and a desired cross section of the orifice can be obtained.
[0027] Even in the case where the outer circumferential portion of the partition is formed as a substantially vertical wall with the outer circumferential metal member of the diaphragm defining a bottom surface of the orifice, the upper end section of the outer circumferential portion of the partition is extended upward, and an annular positioning groove is formed in the liquid chamber-side circumferential edge portion, which is opposed to this upwardly extended portion, of the vibration isolating base member in the same manner as in the above-described case, the partition being positioned by press fitting or inserting the upwardly extended portion into the groove.
[0028] In this case, the partition is also positioned by engaging the upper end portion thereof with the liquid chamber-side circumferential edge portion of the vibration isolating member by press fitting the former into the groove of the latter, while the bottom surface of the orifice is positioned by caulking the outer circumferential reinforcing metal member of the diaphragm to the relative metal fixing member. Accordingly, a desired cross section of the orifice can be retained with a high accuracy.
[0029] When the outer circumferential reinforcing metal member of the diaphragm defines the bottom surface of the orifice as mentioned above, it is preferable that the connecting surfaces of the bottom wall of the orifice and the lower end of the partition be sealed, with a rubber member interposed therebetween. When a structure in which an annular groove is formed in this rubber member between the two connecting surfaces with the lower end portion of the partition press fitted or inserted in the groove is employed, the positioning of the two parts can also be done excellently.
[0030] The liquid sealed type vibration isolator according to the present invention can also employ a mode in which the lower surface of the outer circumferential portion of the partition constitutes the upper surface of the orifice, the outer circumferential reinforcing metal member, which is positioned on the lower side of the same lower surface, of the diaphragm being formed to an L-shaped cross section so as to define the inner circumferential and bottom surfaces of the orifice, the upper end portion of the reinforcing metal member being brought into pressure contact with the lower surface of the partition via a seal rubber member, whereby this arrangement is utilized for the formation of the orifice. In this case, the simplification of the shape of the partition, facilitation of the molding process and minimization of the variation of the shape of the partition are also attained.
[0031] When this structure is employed, it is recommended to bend the outer circumferential end portion of the partition in the upward direction, bring the resultant outer circumferential wall into pressure contact with the inner circumferential surface of the cylindrical liquid chamber-forming rubber portion, and engage the upper end portion of the partition with a flat portion formed on the liquid chamber-side circumferential edge portion, which is positioned above the liquid chamber-forming rubber portion, of the vibration isolating base member, whereby the partition is positioned. This enables the positioning of the partition as well as the outer circumferential metal member of the diaphragm to be done with a high accuracy.
[0032] Especially, since the circumferential wall is formed by upwardly bending the outer circumferential end portion the partition, an operation of a rib for heightening the rigidity of the partition is performed thereby. The circumferential wall also plays the role of a guide when the partition is press fitted into the vibration isolating base member along the cylindrical liquid chamber-forming rubber portion.
[0033] The partition can also be positioned by bringing the circumferential wall thereof into pressure contact with the inner circumferential surface of the liquid chamber-forming rubber portion, and press fitting or inserting the upper end section of the circumferential wall of the partition into the annular positioning groove formed in the liquid chamber-side edge portion of the vibration isolating base member. This enables the above-mentioned positioning operation to be carried out in a more desirable manner.
[0034] The liquid sealed type vibration isolator according to the present invention can also be constructed by forming the outer circumferential portion of the partition as a substantially vertical wall defining an upper half of the inner circumferential surface of the orifice, bending the outer circumferential reinforcing metal member of the diaphragm to an L-shaped cross section so as to define the bottom surface and a lower half of the inner circumferential surface of the orifice, and elastically engaging the upper end of the reinforcing metal member with the lower surface of the partition via the seal rubber member. In this case, the simplification of the shape of the partition, facilitation of the molding process and minimization of the variation of the shape of the partition are also attained.
[0035] When a structure is employed which is obtained by extending the outer circumferential end portion of the partition in the upward direction, forming an annular positioning groove in the liquid chamber-side edge portion, which is opposed to the upwardly extended portion, of the vibration isolating base member, and positioning the partition by press fitting or inserting the upwardly extended portion of the partition into the groove, the partition is positioned by the groove provided in the vibration isolating base member as well as the outer circumferential reinforcing metal member of the diaphragm caulked to the relativemetal fixing member. When a structure is further employed which is obtained by forming an annular groove in the rubber member, and press fitting or inserting the upper end portion of the reinforcing metal member into the groove, the combining of the partition and the outer circumferential reinforcing metal member of the diaphragm with each other is done excellently, and the positioning accuracy and sealability of these parts are more improved.
[0036] In all of the above-mentioned modes, the cross-sectional shape of the orifice formed on the inner side of the outer circumferential surface of the partition is not specially limited but it is preferable, in view of the necessity of simplification of the construction of the partition, that the portion defining the inner circumferential surface of the orifice has a shape close to that of a vertical wall. As long as this condition is satisfied, the orifice may have any of a triangular cross section and a rectangular cross section.
[0037] For example, any of a structure in which a cross-sectionally triangular orifice is formed by expanding the lower part of the liquid chamber-forming rubber portion which defines the outer circumferential surface of the orifice, and a structure in which a cross-sectionally rectangular orifice is formed by providing a horizontal flat portion on the part of the liquid chamber-side circumferential edge portion of the vibration isolating base member which is above the liquid chamber-forming rubber portion defining the outer circumferential surface of the orifice, to thereby form the upper surface of the orifice; and having these parts and the partition alone or the outer circumferential metal member of the diaphragm cooperate with each other.
[0038] The partition may be obtained by any of the method of molding one piece of metal plate into a bent product, and the method of molding a cast product of aluminum into such a product. Especially, the former method enables the pressing work or deep drawing work to be simplified.
[0039] In any of these modes, varying the radial and vertical sizes of the portion to be press fitted of the partition, and the radial and vertical sizes of the groove formed in the vibration isolating base member, into which the partition is to be press fitted, in such a manner that the groove extends in the direction of the whole circumference of the same base member enable the degree of freedom of a characteristic tuning operation to be increased. Therefore, when the liquid chamber-side circumferential edge portion of the vibration isolating base member is formed as the upper surface of the orifice, a structure is preferably employed which is formed by bending the upper end portion of the relative metal fixing member in the inward direction, and burying the resultant bent portion in the vibration isolating base member to thereby secure an increased rigidity of the portion of the vibration isolating base member which defines the upper surface of the orifice.
[0040] The shape of the central region of the partition is not specially limited. For example, when it is necessary in the vibration isolator to reduce a dynamic spring constant in a high-frequency region (especially, an engine noise region), a structure having an elastic film provided in the central region of the partition can also be employed.
[0041] In order to achieve the second-mentioned invention, the inventors of the present invention earnestly discussed the method of setting the elastic film with respect to the partition, to discover that, when one cylindrical partition and an elastic film covering the opening thereof were molded separately with the resultant products positioned firmly, it became possible to reduce the dimensions of a metal vulcanization mold for the elastic film, omit the bonding agent application process, and manufacture the partition at a low cost.
[0042] Namely, according to a second aspect of the present invention, the liquid sealed type vibration isolator includes in the same manner as the above-described invention two metal fixing members, a vibration isolating base member interposed between the two metal fixing members and formed of an elastic body of a rubber-like material, a diaphragm disposed so as to be opposed to the vibration isolating base member, a liquid chamber formed between the vibration isolating base member and diaphragm, and a partition dividing the liquid chamber into two, i.e. main and auxiliary liquid chambers, an orifice being formed between the partition and a liquid chamber-forming rubber portion extending around the partition, the partition being formed of one cylindrical partition plate, and a disc type elastic film formed to a diameter larger than that of an opening of an upper cylindrical portion of the partition plate and closing the central opening of the partition plate, the elastic film and partition plate being formed separately, the elastic film being provided with a positioning bore in a lower surface of a circumferential portion thereof, the upper cylindrical portion of the partition plate being press fitted or inserted in the positioning bore.
[0043] This structure enables the dimensions of the metal vulcanization mold for the elastic film to be reduced, and the bonding agent application process to be rendered unnecessary. Moreover, the positioning (centering) of the elastic film and partition plate can be done easily.
[0044] In order to position the partition vertically, a system for engaging the upper end of the outer circumferential portion of the elastic film with a circumferential wall of the liquid chamber, for example, a liquid chamber-side circumferential edge portion of the vibration isolating base member formed of an elastic body of a rubber-like material; forming a flange portion by bending a lower end portion of the partition in the radially outward direction; and caulking this flange portion to the relative metal fixing member can be employed. Regarding a lower end portion of the partition, a system for supporting a lower end portion of the partition plate by engaging the same lower end portion with the outer circumferential reinforcing metal member of the diaphragm can also be employed.
[0045] In all of these cases, an orifice having a desired cross-sectional area can be formed between the partition and the liquid chamber-forming rubber portion on the outer circumferential side thereof, and stable characteristics can be secured.
[0046] Concerning the positioning bore formed in the lower surface of the elastic film, the depth thereof is not specially limited. A groove formed in the lower surface of the circumferential portion of the elastic film, or a slit type through hole extending from at least a part of the lower surface of the circumferential portion of the elastic film to an upper surface can also be substituted for the positioning bore. When the through hole is employed, it is recommended that the upper end section, which is press fitted or inserted through the through hole, of the upper cylindrical portion of the partition plate be bent and caulked. This can prevent the elastic film from coming off, and enables the combining of the partition plate with the elastic film to be done reliably. The upper end section of the upper cylindrical portion may be bent either radially inward or radially outward.
[0047] The positioning bore is provided preferably so as to extend in the direction of the whole circumference of the elastic film for the purpose of preventing the leakage of a liquid from a clearance between the elastic film and partition plate. In the case of the through hole, forming a connecting portion between the central portion and outer circumferential portion of the elastic film is necessary, so that the through hole has to be formed discontinuously in the circumferential portion thereof.
[0048] When the cross-sectional area of the orifice is large, the part of the vertically intermediate portion of the cylindrical partition plate which is lower than the lower surface of the elastic film is expanded to form a stepped section on the same intermediate portion, and this stepped section can be used as a bottom wall of the orifice. This enables an orifice of a desired cross-sectional area to be obtained.
[0049] When the positioning bore is formed of a through hole, it is recommended that the upper end portion, which extends through the through hole, of the partition plate be bent radially outward and caulked, and that the elastic film be held in the direction of the height thereof (vertically) between the resultant bent end portion and the stepped section or the lower flange portion of the partition plate. Owing to this arrangement, the fixing of the partition plate and elastic film to each other can be done more easily and reliably.
[0050] The elastic film and the upper cylindrical portion of the partition plate which define the inner circumferential surface of the orifice are provided with a first opening communicating the main liquid chamber and orifice with each other, and a second opening communicating the auxiliary liquid chamber and orifice with each other. In order to prevent these two openings from being short-circuited, it is recommended that a partition wall for shutting off an orifice passage be formed on a circumferential portion of the elastic film so as to be integral with the elastic film. Even when this partition wall is provided on any of the vibration isolating base member and the elastic film, the invention can be practiced. However, providing the partition wall on the elastic film is advantageous because it enables the relation between the opening of the orifice passage and partition wall to be determined independently.
[0051] The thickness of the elastic film and the diameter of the partition plate are not specially limited but can be selected suitably in accordance with the damping characteristics thereof. Varying the thickness and diameter mentioned above enables a characteristics tuning operation to be carried out easily.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] Preferred embodiments of the present invention will be described in detail with reference to the following figures, wherein:
[0053] [0053]FIG. 1 is a longitudinal sectional view showing a first mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0054] [0054]FIG. 2 is a longitudinal sectional view of the same embodiment taken along a different plane;
[0055] [0055]FIG. 3 is a sectional view showing a partition constituting a principal portion of the embodiment and separated from a vibration isolating base member;
[0056] [0056]FIG. 4 is a longitudinal sectional view showing a second mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0057] [0057]FIG. 5 is a longitudinal sectional view showing a third mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0058] [0058]FIG. 6 is a longitudinal view of the same embodiment taken along a different plane;
[0059] [0059]FIG. 7 is a longitudinal sectional view showing a fourth mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0060] [0060]FIG. 8 is a longitudinal sectional view showing a fifth mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0061] [0061]FIG. 9 is a longitudinal sectional view showing a sixth mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0062] [0062]FIG. 10 is a longitudinal sectional view of the same embodiment taken along a different plane;
[0063] [0063]FIG. 11 is a longitudinal sectional view of a seventh mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0064] [0064]FIG. 12 is a longitudinal sectional view of an eighth mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0065] [0065]FIG. 13 is a longitudinal sectional view of the same embodiment taken along a different plane;
[0066] [0066]FIG. 14 is a longitudinal sectional view of a ninth mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0067] [0067]FIG. 15 is a longitudinal sectional view of a tenth mode of embodiment of the liquid sealed type vibration isolator according to the first-mentioned invention;
[0068] [0068]FIG. 16 is a longitudinal sectional view showing a first mode of embodiment of the liquid sealed type vibration isolator according to the second-mentioned invention;
[0069] [0069]FIG. 17 is a longitudinal sectional view of the same vibration isolator taken along a different plane;
[0070] [0070]FIG. 18 is a plan view of a partition of the same vibration isolator;
[0071] [0071]FIG. 19 is a plan view of a partition plate of the same vibration isolator;
[0072] [0072]FIG. 20 is a plan view of an elastic film of the same vibration isolator;
[0073] [0073]FIG. 21 is a longitudinal sectional view showing a second mode of embodiment of the liquid sealed type vibration isolator according to the second-mentioned invention;
[0074] [0074]FIG. 22 is a longitudinal sectional view of the same vibration isolator taken along a different plane;
[0075] [0075]FIG. 23 is a plan view of a partition of the same vibration isolator;
[0076] [0076]FIG. 24 is a plan view of a partition plate of the same vibration isolator;
[0077] [0077]FIG. 25 is a plan view of an elastic film of the same vibration isolator;
[0078] [0078]FIG. 26 is a sectional view showing an example of a liquid sealed type vibration isolator of the related art;
[0079] [0079]FIG. 27 is a sectional view showing another example of a liquid sealed type vibration isolator of the related art; and
[0080] [0080]FIG. 28 is a sectional view showing still another example of a liquid sealed type vibration isolator of the related art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0081] The preferred embodiments of the liquid sealed type vibration isolator according to the present invention will now be described with reference to the drawings. The present invention is not limited to these embodiments.
[0082] [0082]FIG. 1 shows a first mode of embodiment of the liquid sealed type vibration isolator according to a first invention, and FIG. 2 is a longitudinal sectional view of the same vibration isolator taken along a different line, FIG. 3 being a sectional view of a principal portion of the same vibration isolator.
[0083] As shown in the drawings, a liquid sealed type vibration isolator 1 according to the present invention includes an upper metal fixing member 2 secured to a vibration generating member, such as an engine, a lower metal fixing member 3 secured to a body, a vibration isolating base member 4 interposed between and connecting together these two metal fixing members 2 , 3 and formed of an elastic body of a rubber-like material, a diaphragm 6 provided on the side of the lower metal fixing member 3 so as to be opposed to the vibration isolating base member 4 , forming a liquid chamber 5 , in which a liquid is sealed, between the diaphragm 6 and vibration isolating base member 4 and formed of a rubber film, and a partition 7 dividing the liquid chamber 5 into a main liquid chamber 5 a on the side of the vibration isolating base member 4 and an auxiliary liquid chamber 5 b on the side of the diaphragm 6 .
[0084] The upper metal fixing member 2 is formed flat, to a central portion of which a fixing bolt 9 , by which the metal fixing member 2 is secured to a vibration generating member, such as an engine, is fixed in an upwardly projecting state. A pin 11 for positioning a base end portion of a metal stopper (not shown), which is adapted to prevent and absorb a large vertical displacement of the upper metal fixing member 2 , is also fixed to an upper surface of the same metal fixing member 2 .
[0085] The lower metal fixing member 3 includes a bottomed cylindrical bottom member 13 having an expanded outer flange 13 a at an upper end thereof, and a cylindrical trunk portion 14 fastened at a lower end section thereof to the outer flange 13 a from the outer side thereof.
[0086] A fixing bolt 15 for securing the lower metal fixing member 3 to the body is fixed to a bottom portion of the bottom member 13 . The cylindrical trunk portion 14 has a lower end flange 14 a at its lower end portion, and the lower end flange 14 a and the outer flange 13 a of the bottomed cylindrical member 13 are adapted to sandwich outer circumferential portions of the diaphragm 6 and partition 7 therebetween. The lower end flange 14 a is provided at a free end thereof with a fastened portion 16 extended downward, and the outer flange 13 a of the bottomed cylindrical member 13 is inserted into the inner side of the fastened portion 16 , the fastened portion 16 being caulked to the outer flange 13 a so as to enclose the latter, whereby the fastened portion 16 is in a cross-sectionally C-shaped condition. An upper end section of the cylindrical trunk portion 14 is bent inward, and an inner end of a resultant bent section 17 is extended to a position beyond a radially inner end of an orifice 18 , which will be described later, and buried in the vibration isolating base member 4 .
[0087] In the vibration isolating base member 4 , an elastic body of a rubber-like material is formed in the shape of an umbrella to constitute a rubber body portion the upper and lower end sections of which are vulcanization bonded to the upper metal fixing member 2 and the cylindrical trunk portion 14 of the lower metal fixing member 3 respectively, the lower end section of the base member 4 also enclosing the bent portion 17 at the upper end section of the cylindrical trunk portion 14 . A lower surface of the part of the vibration isolating base member 4 which is below the bent portion 17 , i.e. a liquid chamber-side circumferential portion of the vibration isolating base member 4 is provided with a flat surface section 19 , in which an annulalr groove 20 for press fitting or inserting thereinto an upper end portion of the partition 7 which will be described later is formed. The part of the mentioned portion of the lower surface of the vibration isolating base member which is on the radially outer side of this groove 20 defines an upper surface of the orifice which communicates the main and auxiliary liquid chambers 5 a , 5 b with each other. The elastic body of a rubber-like material constituting the vibration isolating base member 4 is extended in a thin film state continuously from an outer circumferential edge part of the flat surface section 19 to a lower end of an inner circumferential surface of the cylindrical trunk portion 14 to thereby form a cylindrical liquid chamber-forming rubber portion 22 defining an outer circumferential surface of the orifice.
[0088] The partition 7 is formed by deep drawing or pressure molding one piece of disc type metal plate into a bent product, and has a disc type central flat portion 23 dividing the liquid chamber 5 into main and auxiliary liquid chambers 5 a , 5 b . An outer circumferential section of the central flat portion 23 includes a circumferential wall 24 bent upward and stood up, and folded back and extended downward to form a cylindrical inner circumferential surface, which is formed of a vertical wall surface, of the orifice, and a flange 26 extending radially outward from a lower end of the circumferential wall 24 to form a bottom surface of the orifice.
[0089] An outer end portion of the flange 26 of the partition 7 is caulked to a fastened portion 16 of the lower metal fixing member 3 . A folded portion 27 at an upper end section of the circumferential wall 24 is extended to a position higher than the upper surface of the orifice 18 , and this extended end portion is positioned by being press fitted or inserted into the groove 20 of the vibration isolating base member 4 .
[0090] The outer circumferential wall 24 defining the inner circumferential surface of the orifice is provided with openings 28 , 29 opened into the main and auxiliary liquid chambers 5 a , 5 b . In order to prevent these openings 28 , 29 from being short-circuited, a part of a circumferential portion of the liquid chamber-forming rubber portion 22 joined to the vibration isolating base member 4 is provided with a partition wall 30 , which is adapted to shut off the two openings 28 , 29 from each other, in such a manner that the partition wall 30 is integral with the vibration isolating base member 4 .
[0091] Owing to this arrangement, the flange 26 , circumferential wall 24 , liquid chamber-forming rubber portion 22 , and flat surface section 19 of the liquid chamber-forming inner circumferential edge portion of the vibration isolating base member 4 form the bottom surface, inner circumferential surface, outer circumferential surface and upper surface respectively of the orifice, and these surfaces are joined together in a liquid-tight condition to form the cross-sectionally rectangular orifice 18 which communicates the main and auxiliary liquid chambers 5 a , 5 b with each other.
[0092] The diaphragm 6 has an elastic film 6 a of a flexible rubber-like material, and an annular outer circumferential reinforcing metal member 25 an inner end portion of which is buried firmly in an outer circumferential portion of the elastic film 6 a , an outer end portion of the outer circumferential reinforcing metal member 25 being placed on the outer flange 13 of the bottom member 13 . The inner end portion of the outer circumferential reinforcing metal 25 is bent and extended upward, and the resultant bent extended portion 32 is enclosed with the rubber member 33 integral with the diaphragm. This bent extended portion 32 is engaged with the inner side of a lower portion of the circumferential wall 24 of the partition 7 . An air chamber 38 is formed between the diaphragm 6 and bottom member 13 .
[0093] In order to assemble this vibration isolator 1 , the cylindrical trunk portion 14 is set in a liquid tank with the lower end opened portion thereof directed upward, and the partition 7 is inserted into this opened portion, the folded portion 27 at the inserting free end section of the circumferential wall 24 being press fitted or elastically inserted into the groove 20 of the vibration isolating base member 4 . The diaphragm 6 is then fixed to the resultant product, and a combination of these parts is taken out into the atmosphere. After the residual liquid on this product has been removed, the fastened portion 16 is caulked to complete the assembling operation.
[0094] In this assembling operation, the upper end portion of the circumferential wall 24 of the partition 7 is put in an engaged state with respect to the groove 20 of the vibration isolating base member 4 by pressure fitting or inserting the former into the latter, so that the radial and vertical positioning of the partition 7 can be done with a high accuracy. Consequently, the cross-sectional area of the orifice 18 enclosed with the partition 7 , vibration isolating base member 4 and liquid chamber-forming rubber portion 22 can be set to a desired level, and excellent vibration damping characteristics can be obtained.
[0095] [0095]FIG. 4 shows a second mode of embodiment of the first-mentioned invention, in which main parts of the construction identical with that of the corresponding parts of the above-described first mode of embodiment are designated by the same reference numerals.
[0096] In this mode of embodiment, an opening 34 is formed when a dynamic spring constant in a high-frequency region (especially, an engine noise region) requires to be reduced, in a central flat portion 23 of a partition 7 , and an elastic film 8 of a rubber-like material is vulcanization bonded to the partition 7 so as to cover the opening. Owing to the effect of this elastic film 8 , the dynamic spring constant in the high-frequency region (especially, an engine noise frequency) can be reduced. The construction and effects of the parts other than those referred to above are identical with those of the corresponding parts of the first-mentioned embodiment.
[0097] [0097]FIG. 5 shows a third mode of embodiment of the first-mentioned invention, and FIG. 6 a longitudinal sectional view of the same embodiment.taken along a different plane, the main parts of this embodiment the construction of which is identical with that of the corresponding parts of the above-described embodiment being designated by the same reference numerals.
[0098] The vibration isolator i of this mode of embodiment is formed by utilizing as orifice-forming members a flat surface portion 19 and liquid chamber-forming rubber portion 22 of the vibration isolating base member, partition 7 and an outer circumferential reinforcing metal member 25 of a diaphragm.
[0099] The partition 7 is obtained by pressing or deep drawing one piece of disc type metal plate into a bent product, which has a shape of a tray and includes a disc type central flat portion 23 , and a circumferential wall 24 formed in a bent state so as to extend upward from an outer circumferential part of the flat portion 23 and define an upper half of an inner circumferential surface of the orifice. An upper end portion of the circumferential wall 24 extends to a position higher than the flat surface portion 19 of a liquid chamber-side circumferential edge section of the vibration isolating base member 4 , and a resultant upwardly extended portion 24 a is press fitted or inserted into an annular groove 20 formed in the vibration isolating base member 4 , whereby the partition is positioned. The circumferential wall 24 is provided with an opening 28 therethrough which communicates the main liquid chamber 5 a and orifice 18 with each other.
[0100] An inner end portion of the outer circumferential reinforcing metal member 25 of the diaphragm 6 is bent and extended upward, and a resultant bent and extended portion 32 is covered at its circumferential part with a rubber member 33 , via which an upper end of the bent and extended portion 32 is elastically engaged with a lower surface (on the side of the diaphragm) of the central flat portion 23 of the partition 7 . The bent extended portion 32 is provided with an opening 29 therethrough which communicates the orifice 18 and auxiliary chamber 5 b with each other. The outer circumfential reinforcing metal member 25 of the diaphragm 6 constitutes a bottom surface of the orifice, and an outer end portion of the reinforcing metal member is caulked to a fastened portion 16 of the lower metal fixing member 3 . The construction of the other parts is substantially identical with that of the corresponding parts of the first embodiment.
[0101] In order to assemble this vibration isolator, a cylindrical trunk portion 14 is set in a liquid tank with a lower end opened portion thereof directed upward in the same manner as in the first mode of embodiment, and the partition 7 is inserted into the opened end portion. A free end portion (extended portion 24 a ), with respect to the direction of the insertion of the partition, of the circumferential wall 24 is then press fitted or inserted into the groove 20 of the vibration isolating base member 4 , and the diaphragm 6 is fixed. The resultant product is then taken out into the atmosphere, and the residual liquid is regulated, the fastened portion 16 being then caulked to complete the assembling work.
[0102] In this case, the partition 7 is formed to a simple tray-like shape in which the circumferential wall 24 stands up on an outer circumferential part of the central flat portion 23 . Therefore, the partition 7 has various advantages, i.e., it has a simple construction, and is molded easily. Moreover, the partition can be positioned by merely press fitting or inserting the upper end extended portion 24 a of the circumferential wall 24 thereof into the groove 20 of the vibration isolating base member 4 , and can easily set the orifice 18 having a desired cross section.
[0103] [0103]FIG. 7 shows a fourth mode of embodiment of the first-mentioned invention, and the main parts thereof the construction of which is identical with that of the corresponding parts of the above-described modes of embodiments are designated by the same reference numerals.
[0104] In the vibration isolator 1 of the fourth embodiment, an opening 34 is formed in a central flat portion 23 of the partition 7 , and an elastic film 8 is vulcanization bonded to the partition so as to cover the opening 34 , the vibration isolator being made capable of effectively reducing a dynamic spring constant in a high-frequency region (especially, an engine noise region) by an operation of the elastic film 8 . The construction and effects of the other parts are identical with those of the corresponding parts of the above-described third mode of embodiment.
[0105] [0105]FIG. 8 is a longitudinal sectional view showing a fifth embodiment of the first-mentioned invention, the main parts the construction of which is identical with that of the corresponding parts of the above-described modes of embodiments are designated by the same reference numerals.
[0106] In the vibration isolator 1 of the fifth embodiment, an opening 34 is formed in a central flat portion 23 of a partition 7 , and an upper end of a bent portion 32 of an outer circumferential reinforcing metal member 25 of the diaphragm 6 and the partition 7 sandwich an elastic film 8 so as to cover the opening, to thereby enable a dynamic spring constant in a high-frequency region (especially, an engine noise region) to be reduced effectively. The construction and effects of the other parts are identical with those of the corresponding parts of the third mode of embodiment.
[0107] [0107]FIG. 9 is a longitudinal sectional view showing a sixth embodiment of the first-mentioned invention, and FIG. 10 a longitudinal sectional view of the same embodiment taken along a different plane. In this embodiment, the structural parts identical with those of the above-described embodiments are also designated by the same reference numerals.
[0108] In the sixth embodiment, a cross-sectionally rectangular orifice 18 is formed by a liquid chamber-forming rubber portion 22 defining an outer circumferential surface of the orifice, a partition 7 defining an upper surface thereof, and an outer circumferential reinforcing metal member 25 of a diaphragm 6 which defines an inner circumferential and bottom surfaces thereof.
[0109] The partition 7 is formed by pressing or deep drawing one piece of metal plate into tray-like structure including a disc type central flat portion 23 , and a circumferential annular wall 24 standing up from an outer circumferential section of the central flat portion 23 . The outer circumferential section 24 of this partition 7 is press fitted into an inner circumferential section of the liquid chamber-forming rubber portion 22 , and an upper end thereof is engaged with the flat surface portion 19 of a liquid chamber-side circumferential edge section of a vibration isolating base member 4 .
[0110] An outer circumferential reinforcing metal member 25 of the diaphragm 6 includes a ring-shaped bottom portion 25 a caulked at an outer end section thereof to a fastened portion of a lower metal fixing member 3 , and a cylindrical portion 32 extended in a bent state and standing up from an inner end of the bottom portion and forming an inner circumferential surface of the orifice, an upper end section of the bent extended portion 32 being press fitted or inserted in an annular groove 41 of a rubber member 40 annularly vulcanization bonded to a lower surface of the central flat portion 23 of the partition 7 . owing to this arrangement, joint surfaces of the partition 7 and the outer circumferential reinforcing metal member 25 of the diaphragm are sealed, and a space enclosed with these parts and liquid chamber-forming rubber portion 22 functions as the orifice 18 .
[0111] The central flat portion 23 of the partition 7 is provided at an outer circumferential section thereof with an opening 28 communicating with a main liquid chamber 5 a , while the outer circumferential reinforcing metal member 25 of the diaphragm 6 is provided at an inner circumferential portion 32 thereof with an opening 29 communicating with an auxiliary liquid chamber 5 b . A partition wall 43 for preventing these openings 28 , 29 from being short-circuited is molded so as to become integral with a part of a circumferential portion of the rubber member 40 vulcanization bonded to a lower surface of the partition 7 . The construction of the remaining parts is identical with the corresponding parts of the first mode of embodiment.
[0112] In order to assemble this vibration isolator 1 , a cylindrical trunk portion 14 is set in a liquid tank with a lower end opened part thereof directed upward, and an inserting free end section of the partition 7 is engaged with the flat surface portion 19 of the vibration isolating base member 4 as the partition 7 is press fitted into the base member along the liquid chamber-forming rubber member 22 . The diaphragm 6 is then fixed, and an upper end section of the bent extended portion 32 of an inner end part of the outer circumferential reinforcing metal member 25 is press fitted or inserted into the groove 41 of the annular rubber member 40 on the lower surface of the partition 7 . A combination of these parts is then taken out, and the residual liquid is regulated, the fastened portion 16 being thereafter caulked.
[0113] Although, in this case, the partition 7 is formed by merely standing up the outer circumferential part of the central flat portion 23 and has a simple shape, the circumferential wall 24 thereof is in pressure contact with the liquid chamber-forming rubber portion 22 with the upper end thereof engaged with the flat surface portion 19 of the vibration isolating base member 4 , whereby the radial and vertical positioning of the partition 7 is done. Moreover, the circumferential wall 24 of the partition 7 functions as a rib, and the rigidity of the partition 7 can thereby be secured, so that variation of the cross-sectional area of the orifice due to vibration can also be prevented. Since the outer circumferential reinforcing metal member 25 of the diaphragm 6 includes the bottom portion 25 a , and cylindrical bent extended portion 32 standing up from the inner end of the bottom portion, and has also a simple shape, a molding operation therefor by deep drawing work or pressing work can be carried out easily.
[0114] [0114]FIG. 11 is a longitudinal sectional view showing a seventh mode of embodiment of the first-mentioned invention, in which the main parts the construction of which is identical with that of the corresponding parts in the above-described modes of embodiments are designated by the same reference numerals.
[0115] In the vibration isolator in the seventh embodiment, an opening 34 is formed in a central flat portion 23 of a partition 7 , and an elastic film 8 is vulcanization bonded to the central flat portion so as to cover the opening, whereby a dynamic spring constant in a high-frequency region (especially, an engine noise region) can be effectively reduced. This elastic film 8 is vulcanization molded so that it becomes integral with a rubber member 40 and a partition wall 43 which are formed on a lower surface of the partition 7 . The construction and effects of the other parts are identical with those of the corresponding parts of the sixth embodiment.
[0116] [0116]FIG. 12 is a longitudinal sectional view showing an eighth mode of embodiment of the first-mentioned invention, and FIG. 13 a longitudinal sectional view of the same embodiment taken along a different plane. The main parts the construction of which is identical with that of the corresponding parts of the above-described modes of embodiments are designated by the same reference numerals.
[0117] A vibration isolator 1 of the eighth mode of embodiment is basically substantially identical with the vibration isolator of the sixth mode of embodiment, i.e., in the eighth embodiment, a cross-sectionally rectangular orifice 18 is formed of a liquid chamber-forming rubber portion 22 defining an outer circumferential surface of the orifice, a partition 7 defining an upper surface thereof, and an outer circumferential reinforcing metal member 25 of a diapharm which defines an inner circumferential and bottom surfaces thereof. However, the construction of a device for positioning the partition 7 , and that of joint portions of the partition 7 and outer circumferential reinforcing metal member 25 are different from those of the corresponding parts of the sixth mode of embodiment.
[0118] Concretely speaking, the partition 7 is formed to a tray-like shape in the same manner as in the sixth mode of embodiment. Acircumferential wall 24 of the partition is press fitted in an inner curcumferential section of the liquid chamber-forming rubber portion 22 , and an upper end extended part 24 a thereof is press fitted or inserted into an annular groove 20 formed in a boundary section between a flat surface portion 19 of a liquid chamber-side circumferential part of a vibration isolating base member 4 and the liquid chamber-forming rubber portion 22 , whereby the partition is positioned. An annular groove 45 is further provided in a lower surface of an outer circumferential section of a central flat portion 23 of the partition 7 , and a thin film type rubber member 40 is vulcanization bonded to the partition along the annular groove 45 , the rubber member having a cross-sectionally groove-shaped portion in conformity with the groove 45 of the partition 7 .
[0119] The construction of an outer circumferential reinforcing metal member 25 of a diaphragm 6 is also identical with that of the same member in the sixth mode of embodiment, and an upper end section of an upwardly bent extended portion 32 of an inner end part thereof is press fitted into an annular groove 40 a of the rubber member 40 on the lower surface of the partition 7 . Owing to this arrangement, joint surfaces of the partition 7 and outer circumferential reinforcing metal member 25 are sealed, and a space enclosed with these parts and liquid chamber-forming rubber portion 22 functions as an orifice 18 . The construction of the other parts is identical with that of the corresponding parts of the sixth mode of embodiment.
[0120] In order to assemble this vibration isolator 1 , a cylindrical trunk portion 14 is set in a liquid tank with a lower end opened section directed upward, and an inserting free end extended part thereof is press fitted or inserted into the groove 20 of the flat surface portion 19 of the vibration isolating base member 4 as the partition 7 is press fitted into the vibration isolating base member 4 along the liquid chamber-forming rubber portion 22 . A diaphragm 6 is then fixed, and an upper end section of the bent extended portion 32 at an inner end part of the outer circumferential reinforcing metal member 25 is engaged with the groove 40 a of the rubber member 40 of the partition 7 . The resultant product is taken out into the atmosphere, and the residual liquid is regulated, a fastener portion 16 being caulked to complete the assembling work.
[0121] Although, in this case, the partition 7 is formed by merely standing up the outer circumferential edge section of the central flat portion and has a simple shape, the outer circumferential wall 24 is in pressure contact with the liquid chamber-forming rubber portion 22 with the upper end part thereof engaged with the groove 20 of the vibration isolating base member 4 in a press fitted or inserted state. Therefore, the radial and vertical positioning of the partition 7 can be done in more desirable manner than in the sixth mode of embodiment. The operation and effects of the other parts are identical with those of the corresponding parts of the sixth mode of embodiment.
[0122] [0122]FIG. 14 is a longitudinal sectional view showing a ninth mode of embodiment of the first-mentioned invention, in which the main parts the construction of which is identical with that of the corresponding parts of the above-described modes of embodiments are designated by the same reference numerals.
[0123] In the ninth mode of embodiment, an opening 34 is formed in a central flat portion 23 of the partition 7 with an elastic film 8 vulcanization bonded to the partition so as to cover the opening 34 in the same manner as in the seventh mode of embodiment. Accordingly, a dynamic spring constant in a high-frequency region (especially, an engine noise region) can be effectively reduced. This elastic film 8 is vulcanization molded so that the film becomes integral with a rubber member 40 and a partition wall 43 which are on a lower surface of the partition 7 . The construction and effects of the other parts are identical with those of the corresponding parts of the eighth mode of embodiment.
[0124] [0124]FIG. 15 is a longitudinal sectional view showing a tenth mode of embodiment of the first-mentioned invention, in which the constituent parts the construction of which is identical with that of the corresponding parts of the above-described modes of embodiment are also designated by the same reference numerals.
[0125] In the vibration isolator of the tenth mode of embodiment, an orifice 18 is formed of a liquid chamber-forming rubber portion 22 defining an outer circumferential surface of the orifice, a liquid chamber-side flat surface portion 19 of a vibration isolating base member 4 which defines an upper surface thereof, a partition 7 defining an inner circumferential surface there of, and an outer circumferential reinforcing metal member 25 of a diaphragm 6 which defines a bottom surface thereof. This mode of embodiment differs from the first mode of embodiment in the following points only. The outer circumferential reinforcing metal member 25 defines the bottom surface of the orifice. The partition 7 does not have a lower end flange. A lower end of a vertical circumferential wall 24 is engaged with an upper surface of the outer circumferential reinforcing metal member 25 . The construction of the other portions is identical with the corresponding portions of the first mode of embodiment.
[0126] Concretely speaking, the partition 7 is formed by bending one piece of disc type metal plate by deep drawing or pressure molding, and includes a central flat portion 23 , and a cylindrical circumferential wall 24 constituting a vertical wall surface and formed by bending an outer circumferential part of the central flat portion 23 upward, and then folding back the upwardly extending part downward, a lower end of this circumferential wall 24 being elastically engaged with a rubber member 33 in which the outer circumferential reinforcing metal member 25 is buried.
[0127] The partition 7 in this case is press fitted or inserted in a groove of a vibration isolating base member 4 , and a lower end of the partition is elastically engaged with the outer circumferential reinforcing metal member 25 of the diaphragm, so that the radial and vertical positioning of the partition can be done with a high accuracy.
[0128] As described above, the first-mentioned invention has the following advantages. Since a partition press fitting or inserting structure with respect to a groove, or a surface engaging structure therefor is utilized in a joint portion between the partition 7 and the other orifice-forming member with the simplification of the construction of the orifice-forming partition and the facilitation of a partition molding process achieved, the positioning of the partition and the other orifice-forming member can be done easily.
[0129] Next, the modes of embodiments of the liquid sealed type vibration isolator of the second-mentioned invention will be described with reference to the drawings.
[0130] [0130]FIG. 16 is a longitudinal sectional view showing a first mode of embodiment of the liquid sealed type vibration isolator of the second-mentioned invention, FIG. 17 a longitudinal sectional view of the same vibration isolator taken along a different plane, FIG. 19 a plan view of a partition, and FIG. 20 a plan view of an elastic film.
[0131] As shown in the drawings, the basic construction of the liquid sealed type vibration isolator of this invention is identical with that of the above-described first-mentioned invention. The parts the construction of which is identical with that of the corresponding parts of the first-mentioned invention are designated by the same reference numerals, and the detailed descriptions thereof are omitted. The vibration isolator of the second-mentioned invention generally has the following construction.
[0132] This vibration isolator includes an upper metal fixing member 2 secured to a vibration generating member, such as an engine, a lower metal fixing member secured to a body, a vibration isolating base member 4 formed of an elastic member of a rubber-like material connecting these two metal fixing members 2 , 3 together, a diaphragm 6 provided on the lower metal fixing member 3 so as to be opposed to the vibration isolating base member 4 , and forming a liquid chamber 5 between the diaphragm and vibration isolating base member 4 , and a partition 7 dividing the liquid chamber 5 into main and auxiliary liquid chambers 5 a , 5 b.
[0133] A fixing bolt 9 , and a pin 11 for positioning a large displacement preventing metal stopper are fixed to the upper metal fixing member 2 . The lower metal fixing member 3 includes a bottom member 13 having an outer flange 13 a at an upper end section thereof and a fixing bolt 15 at a bottom section thereof, and a cylindrical trunk portion 14 . A lower end flange 14 a of the cylindrical trunk portion 14 and the outer flange 13 a of the bottom member 13 are fastened together by caulking. An outer circumferential portion of the diaphragm 6 is caulked to this fastened portion 16 .
[0134] The vibration isolating base member 4 is formed of an elastic body of a rubber-like material having an umbrella-like shape, and vulcanization bonded at an upper portion thereof to the upper metal fixing member 2 , and at a lower circumferential portion thereof to the cylindrical trunk portion of the lower metal fixing member 3 . An inner end section of an upper end bent part 17 of the cylindrical trunk portion 14 is extended inward to a position beyond an inner circumferential surface of an orifice 18 and buried in the vibration isolating base member 4 . A lower surface, i.e. a liquid chamber-side circumferential edge section of the vibration isolating base member 4 is formed as a flat surface portion 19 , with which an elastic film of the partition 7 which will be described later is engaged. The elastic body of a rubber-like material of the vibration isolating base member 4 is extended in a thin film state from an outer circumferential edge section of the flat portion 19 thereof to a lower end of an inner surface of the cylindrical trunk portion 14 to form a cylindrical liquid chamber-forming rubber portion 22 .
[0135] In the case of this invention, the partition 7 is formed of a cylindrical partition plate 70 , and an elastic film 80 formed to a diameter larger than that of an upper cylindrical portion 71 of the partition plate 70 and formed of a disc type elastic body of rubber closing a central opening 72 of the partition plate.
[0136] As shown in the drawings, a lower end portion of the partition plate 70 is bent radially outward to form a flange 73 , which is caulked to a fastened portion 16 of the lower metal fixing member 3 . The part of the partition plate 70 which is lower than a vertically intermediate section thereof is expanded to form a stepped portion 74 , which defines a bottom surface of the orifice, and a larger-diameter portion 75 lower than the stepped portion 74 is engaged under pressure with a liquid chamber-forming rubber portion 22 . The partition plate 70 is provided at two portions of a circumferential section thereof with a recess 51 and a through hole 52 for communicating the orifice 18 with the main and auxiliary chambers 5 a , 5 b respectively.
[0137] The elastic film 80 is adapted to reduce a dynamic spring constant in a high-frequency region (especially, an engine noise region), and formed in the shape of a disc and engaged at an upper edge part of an outer circumferential portion thereof with a flat surface portion 19 of the vibration isolating base member 4 . The elastic film 80 is provided in its lower surface with a positioning groove 81 extending in the direction of the whole circumference thereof as shown in FIG. 20, and the upper cylindrical portion 71 of the partition plate 70 is press fitted or inserted in the groove 81 .
[0138] The elastic film 80 is provided at a part of an outer circumferential edge portion thereof with a recess 37 correspondingly to the recess 51 of the partition plate 70 , and this recess 37 constitutes an opening communicating the main liquid chamber 5 a and orifice 18 with each other. The elastic film 80 is also provided in an outer circumferential surface thereof with a lateral hole 39 correspondingly to the through hole 52 of the partition plate 70 , and this lateral hole 39 and the through hole 52 of the partition plate 70 constitute an opening communicating the auxiliary liquid chamber 5 b and orifice 18 with each other.
[0139] Between the recess 37 and lateral hole 39 of the elastic film 80 , a partition wall 43 of a rubber-like material for preventing the short-circuiting of an orifice-communicating opening is molded so that the partition wall 43 is integral with the elastic film 80 and projects outward from a circumference thereof.
[0140] The diaphragm 6 has an elastic film 6 a of a flexible rubber-like material, and an inner end portion of an annular outer circumferential reinforcing metal member 25 is buried firmly in an outer circumferential portion of the elastic film 6 a , an outer end portion of this outer circumferential reinforcing metal member 25 being placed on the outer flange 13 a of the bottom member 13 . An air chamber 38 is formed between the diaphragm 6 and bottom member 13 .
[0141] In order to assemble this vibration isolator 1 , the partition is first assembled by press fitting or inserting the upper cylindrical portion 71 of the partition plate 70 into the groove 81 in the lower surface of the elastic film 80 , and the lower end opened section of the cylindrical trunk portion 14 of the metal fixing member 3 is then set in an upwardly directed state in a liquid tank, the partition 7 being inserted therein with the elastic film 80 brought into contact with the flat surface portion 19 of the vibration isolating base member 4 . The diaphragm 6 is then fixed, and the resultant product is taken out into the atmosphere, the residual liquid being regulated. The fastened portion 16 is then caulked to complete the assembling work.
[0142] In this assembled product, a space enclosed with the outer circumferential surface 80 a of the elastic film 80 , stepped portion 74 of the partition plate 70 , liquid chamber-forming rubber portion 22 and the flat surface portion 19 of the liquid chamber-side circumferential surface of the vibration isolating base member 4 functions as the orifice 18 . In this case, the elastic film 80 is engaged at the groove 81 in the lower surface thereof with the partition plate 70 , whereby the elastic film 80 is radially positioned. Since the elastic film 80 is engaged at the upper end thereof with the flat surface portion 19 of the vibration isolating base member 4 , and at the lower surface thereof with the stepped portion 74 of the partition plate 70 , it is also positioned vertically. Consequently, the cross-sectional area of the orifice 18 formed by these members is set to a desired level, and excellent vibration damping characteristics are obtained.
[0143] [0143]FIG. 21 is a longitudinal sectional view of a liquid sealed type vibration isolator showing a second mode of embodiment of the second-mentioned invention, FIG. 22 a longitudinal sectional view of the same vibration isolator taken along adifferent plane, FIG. 23 aplanviewof apartition, FIG. 24 a plan view of a partition plate, and FIG. 25 a plan view of an elastic film. The main parts the construction of which is identical with that of the corresponding parts of the above-described modes of embodiments are designated by the same reference numerals.
[0144] As shown in FIG. 23, a partition 7 in this mode of embodiment is identical with that in the first mode of embodiment in that it is formed of a cylindrical partition plate 70 and a disc type elastic film 80 but the shape of a hole for positioning the elastic film 80 and that of an upper portion, which is inserted into this hole, of the partition plate 70 are different from those of the corresponding parts of the first embodiment.
[0145] Namely, as shown in FIG. 24, an upper cylindrical portion 71 of the partition plate 70 is provided at an upper end thereof with an upwardly extended portion 71 a , while the elastic film 80 is provided correspondingly to the extended portion 71 a with a slit type through hole 83 extending from a lower surface of an outer circumferential edge portion of the elastic film 80 to an upper surface thereof. After the upper cylindrical portion 71 of the partition plate 70 has been press fitted or inserted into this through hole 83 , the extended portion 71 a at the upper end of the upper cylindrical portion 71 is bent, and the bent extended portion 71 a and an intermediate stepped portion 74 of the partition plate 70 sandwich the elastic film 80 therebetween, the resultant product being caulked, whereby the elastic film 80 is fixed to the partition plate 70 .
[0146] The diameter of an outer end of the bent extended portion 71 a is set equal to the outer diameter of a lower large-diameter portion 75 of the partition plate 70 , and an outer end section of the bent extended portion is formed so that it is press fitted into an inner circumferential surface of a liquid chamber-forming rubber portion 22 . An upper surface of the bent extended portion 71 a is adapted to be engaged with a liquid chamber-side flat surface portion 19 of a vibration isolating base member 4 .
[0147] In this mode of embodiment, a recess 54 is formed in a liquid chamber-side portion of the vibration isolating base member 4 , and used as an opening communicating a main liquid chamber 5 a and an orifice 18 with each other. A through hole 55 is formed in an elastic film-passing portion of the partition plate 70 which is higher than the stepped portion 74 thereof, and a recess 56 is formed correspondingly to this through hole so as to extend from an outer circumferential side of the elastic film to a lower surface thereof. The recess 56 and the through hole 55 of the partition plate 70 form an opening communicating an auxiliary liquid chamber 5 b and orifice 18 with each other.
[0148] Since the construction of the remaining portions of the partition plate 70 and elastic film 80 and that of the parts other than these are identical with that of the corresponding portions and parts of the first mode of embodiment, the descriptions thereof will be omitted.
[0149] In the structure of the second embodiment, a positioning operation is carried out by passing the upper end portion of the partition plate 70 through the through hole 83 provided in an outer circumferential portion of the elastic film 80 , the radial positioning (centering) of the elastic film 80 can be done easily. Since the elastic film 80 is sandwiched in the direction of height (vertically) between the bent extended portion 51 and stepped portion 74 of the partition plate 70 and caulked, the combining of the partition plate 70 and elastic film 80 together can be done easily.
[0150] A few more sentences will be added. In any of the above modes of embodiments, the thickness of the rubber of the elastic film 80 may be set suitably in accordance with the required damping characteristics, and the invention is not limited to the illustrated modes of embodiments in this regard.
[0151] As is clear from the above description, the providing of an elastic film on a partition for the purpose of reducing a dynamic spring constant in a high-frequency region is done according to the second-mentioned invention by forming one cylindrical partition plate and a disc type elastic film separately, forming a positioning bore in a circumferential portion of a lower surface of the elastic film, and press fitting or inserting an upper portion of the partition plate into this bore. Therefore, a step, such as a bonding agent application step becomes unnecessary, and the dimensions of a metal vulcanization mold for the elastic film are reduced. This enables the partition plate and elastic film to be manufactured advantageously at a low cost. | The present invention aims at providing a liquid sealed type vibration isolator capable of positioning a partition excellently with the construction of the partition simplified, and maintaining stable damping characteristics of an orifice. To meet the requirements, an outer circumferential portion of the partition forming the orifice is made so that the outer circumferential portion defines at least a part of one or two sides of a cross section of the orifice, and a positioning device formed of a partition press fitting or inserting structure with respect to a groove, or a partition engaging structure is provided in a joint portion between the partition and the other orifice forming member with the construction of the partition simplified, whereby it is rendered possible to improve the accuracy of the partition and obtain a desired cross section of the orifice. When an elastic film is provided on the partition so as to reduce a dynamic spring constant in a high-frequency region, the steps of forming one cylindrical partition and a disc type elastic film separately, forming a positioning bore in a lower surface of a circumferential portion of the elastic film, and positioning the partition radially by press fitting or inserting an upper cylindrical portion thereof into the bore are employed, whereby the manufacturing cost is reduced. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to an improved process for preparation of Bicalutamide, which is simple, convenient, safe and cost effective.
BACKGROUND OF THE INVENTION
[0002] Bicalutamide, which is chemically known as N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) sulfonyl]-2-hydroxy-2-methyl propanamide and represented by formula (I),
[0000]
[0000] is a non-steroidal anti-androgen used in combination therapy with a Luteinizing Hormone Releasing Hormone (LHRH) analogue for treatment of advanced prostate cancer.
[0003] The first synthesis of Bicalutamide was disclosed by Tucker in U.S. Pat. No. 4,636,505, the key step essentially comprising oxidation of N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide of formula (II),
[0000]
[0000] to give Bicalutamide of formula (I). The sulfide compound is in turn prepared through reaction of 4-cyano-3-trifluoromethyl N-(2,3-epoxy-2methyl propionyl) aniline of formula (III)
[0000]
[0000] with p-fluorothio phenol.
[0004] The synthesis of Bicalutamide as disclosed in U.S. Pat. No. 4,636,505 is summarized in Scheme-I
[0000]
[0000] U.S. Pat. No. 4,636,505 mentions that the oxidizing agent and conditions used will determine whether a sulfinyl (S→O) or a sulfonyl (O═S═O) compound is obtained. Thus, oxidation with sodium metaperiodate in methanol solution at or below laboratory temperature was considered to convert a thio compound into the corresponding sulfinyl compound; and oxidation with a peroxy acid, for example m-chloroperbenzoic acid, in methylene chloride solution at or above laboratory temperature was considered to convert a thio compound into the corresponding sulfonyl compound. From the above as well as the description given in Example 6 of U.S. Pat. No. 4,636,505 it would be abundantly evident that the most preferred oxidizing agent is a peroxy acid, especially m-chloroperbenzoic acid.
[0005] A similar synthesis of Bicalutamide comprising oxidation of the sulfide (II) with m-chloroperbenzoic acid is disclosed by Tucker et al in Journal of Medicinal Chemistry, 1988, Vol. 31, No. 5 page 954-959.
[0006] Many variants/improvements of Bicalutamide synthesis have been subsequently reported, all of which in particular relate to certain improvements in the step of oxidation of sulfide (II) to Bicalutamide. These are:
i). Soros et al in WO 01/00608 A1, while stating that the method disclosed in U.S. Pat. No. 4,636,505 and Journal of Medicinal Chemistry, 1988, Vol. 31, No. 5 page 954-959 is not industrially and environmentally safe provide an improved method comprising oxidation of the sulfide (II)
a) with an inorganic peroxy salt in a mixture of water and a solvent miscible or immiscible with water, in the latter case in the presence of a phase transfer catalyst, or b) with aqueous hydrogen peroxide in presence of a C 1 -C 4 aliphatic carboxylic acid, or under aqueous basic conditions, in presence of an organic solvent miscible with water, or in an organic solvent immiscible with water in the presence of a phase transfer catalyst and a salt of a metal belonging to the vanadium or chromium group.
ii). Chen, Bang-Chi et al in WO 02/24638 A1 also disclose oxidation of sulfide (II) using conventional oxidizing agents known in the art, specifically a peroxy acid, such as peracetic acid, trifluoroperacetic acid, 3-chloroperbenzoic acid, and the like; dioxiranes such as dimethyldioxirane, methyltrifluoromethyldioxirane, and the like; hydrogen peroxide; sodium periodate; N-methylmorpholine; N-oxide and Oxone, with peroxy acids in particular trifluoroacetic acid being more preferable. The specification further states that trifluoroperacetic acid is preferably formed in situ from hydrogen peroxide and trifluoroacetic anhydride. Typically the oxidation is carried out by treating a solution of sulfide (II) in dichloromethane with 30% aqueous hydrogen peroxide solution and cooling the mixture to −55° C., followed by addition of trifluoroacetic anhydride and allowing the oxidation to proceed at a temperature of between −15° C. to 0° C. iii). Tetsuya et al in U.S. Pat. No. 6,740,770 have criticized the method disclosed by Tucker et al in Journal of Medicinal Chemistry, 1988, Vol. 31, No. 5 page 954-959 as well as U.S. Pat. No. 4,636,505 in that they utilize dichloromethane as a solvent in the oxidation step, which is harmful, potentially carcinogenic, expensive and creates a burden in waste treatment. U.S. Pat. No. 6,740,770 further criticizes the method disclosed by Tucker et al in Journal of Medicinal Chemistry, 1988, Vol. 31, No. 5 page 954-959 as using m-chloroperbenzoic acid as an oxidizing agent, which is not only highly explosive but also expensive and possess an economic problem. Furthermore, U.S. Pat. No. 6,740,770 criticizes the methods disclosed by WO 01/00608 A1 and WO 02/24638 A1 as also not industrially and environmentally benign as well as not safe and expensive in that the said methods are found to utilize again dichloromethane in one of the steps, utilize cryogenic temperature of −55° C., utilize expensive trifluoroacetic anhydride as a reactant. Accordingly, U.S. Pat. No. 6,740,770 provides an alternate method, which is reportedly an economically and industrially viable method for production of Bicalutamide, the key feature of which comprises oxidation of sulfide (II) with:
a) Aqueous hydrogen peroxide (H 2 O 2 ) in ethyl acetate as solvent and in presence of sodium tungstate or a solvate there of, phenylphosphonic acid and a phase transfer catalyst; or b) Monoperpthalic acid prepared from pthalic anhydride and hydrogen peroxide.
When aqueous hydrogen peroxide is employed as oxidizing agent, the oxidation reaction requires that it be carried out in the presence of sodium tungstate, phenyl phosphonic acid and phase transfer catalyst with at least up to 20 fold excess of hydrogen peroxide employed. Use of such large excess of hydrogen peroxide makes the process not particularly safe. Furthermore, use of sodium tungstate, its hydrates and its solvates as well as expensive phase transfer catalysts such as tetrabutylammonium bromide, benzyl trimethylammonium chloride, tetrabutylammonium hydroxide and the like make the method specially not economical. In the case of oxidation using Monoperpthalic acid apart from the hazards associated with its use, low temperatures of between 0 to −30° C. are recommended, thereby increasing the cost of manufacture. iv). Shintaku, Tetsuya et al in WO2005/037777 disclose an oxidation reaction with per carboxylic acid, which again is associated with the shortcomings mentioned hereinbefore.
From the foregoing, it would be apparent that the reported methods for synthesis of Bicalutamide suffer from one or more of the following limitations, viz.
[0000]
a) Use of halogenated solvents specially dichloromethane, which is harmful, potentially carcinogenic, expensive and creates a burden in waste treatment;
b) Use of peroxy acids such as m-chloroperbenzoic acid, hydrogen peroxide, trifluoroperacetic acid Monoperpthalic acid as oxidizing agents, which are highly explosive in nature thereby causing safety and environment concerns;
c) Use of cryogenic temperature as low as −50° C. or higher temperatures of about 80° C., which requires energy and thereby increasing the cost of manufacturing;
d) Use of expensive tungsten, vanadium or chromium compounds which are not only expensive but also create problem in waste disposal; and
e) Use of corrosive chemicals like trifluoroacetic anhydride, which calls for extreme precautions not only in handling as well as create problems in waste disposal.
[0024] Further, the by-products of such oxidation reactions e.g. benzoic acid obtained on oxidation when m-chloroperbenzoic acid are also in many instances difficult to remove calling for tedious separation and purification techniques.
[0025] Considering the therapeutic and commercial importance of Bicalutamide there exists a need for a method which is free of the limitations of the prior art methods and which, more over is safe, simple convenient and economical.
[0026] The present invention is a step forward in this direction and provides a simple convenient and economical method for manufacture of Bicalutamide, which is both industrially and environmentally safe.
OBJECTS OF THE INVENTION
[0027] An object of the present invention is to provide a method for preparation of Bicalutamide, which avoids use of peroxy acids.
[0028] Another object of the present invention is to provide a method for preparation of Bicalutamide, which avoids use of halogenated solvents.
[0029] Yet another object of the present invention is to provide a method for preparation of Bicalutamide, which does not require cryogenic or high temperatures.
[0030] Further object of the present invention is to provide a method for preparation of Bicalutamide, which avoids use of expensive tungsten, vanadium and chromium compounds as well as expensive phase transfer catalysts.
[0031] Yet further object of the present invention is to provide a method for preparation of Bicalutamide, which avoids use of corrosive chemicals.
[0032] Another object process for preparation of Bicalutamide, which is safe, simple, convenient and economical.
[0033] From the prior art, reporting various methods utilized for preparation of Bicalutamide it is quite evident all methods invariably utilize a peroxy acid
[0000]
[0000] for oxidation of the sulfide (II) compound to give Bicalutamide.
[0034] Further, from the teachings of U.S. Pat. No. 4,636,505, it is again evident that only use of a peroxy acid as an oxidizing agent can lead to the formation of a sulfonyl compound i.e., Bicalutamide, whereas use of other oxidizing agents like sodium metaperiodate would result in the formation of a sulfinyl compound i.e., a sulfoxide and not sulfone.
[0035] Against this background, the present inventors have found that the sulfide compound (II) can be oxidized completely to the corresponding sulfone (O═S═O) derivative i.e., Bicalutamide (I) using a “Non peroxy acid” agent, which apart from being free of the shortcomings associated in general with use of a peroxy acid or similar agents provides the desired end product i.e., Bicalutamide not only in good yields, but also of quality conforming to pharmacopeial specifications world over.
[0036] In particular, the present inventors have found that the sulfide compound (II) can be oxidized to Bicalutamide (I) using potassium permanganate (KMnO 4 ) which:
i) Unlike many of the peroxy acid compounds is highly stable at room temperature; ii) Unlike many of the peroxy acid compounds is non-hygroscopic and not sensitive to air and moisture; iii) Unlike many of the peroxy acid compounds is not explosive in nature and therefore easy and safe to handle on an industrial scale; iv) Unlike many of the peroxy acid compounds is inexpensive and readily available; v) Forms manganese dioxide (MnO 2 ) as by-product, which can not only be easily removed but also recycled back to potassium permanganate (KMnO 4 ); vi) The oxidation can be carried out under neutral conditions unlike acidic or basic conditions required for oxidation using a peroxy acid; vii) Can be carried out in water or a mixture of water and a water miscible environmentally benign solvent, which unlike halogenated solvents are non-carcinogenic, safe and do not cause concern in waste disposal; and
Can be carried out at ambient temperatures and does not require cryogenic or very high temperatures.
SUMMARY OF THE INVENTION
[0044] Thus the present invention relates to a process for preparation of Bicalutamide of formula (I),
[0000]
comprising oxidation of compound of formula (II),
[0000]
[0000] with potassium permanganate in presence of water or a mixture of water and water miscible solvent and isolating Bicalutamide of formula (I) thereof.
[0046] The present invention also relates to Bicalutamide prepared by the aforesaid process which exhibits
[0047] i) X-ray diffraction pattern as given in FIG. 1 .
[0048] ii) DSC thermogram as given in FIG. 2 .
[0049] iii) IR spectrum as given in FIG. 3 .
[0050] iv) solid state 13 C NMR spectrum as given in FIG. 4 .
[0051] X-ray diffraction pattern as given in FIG. 1 .
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0052] FIG. 1 represents a characteristic X-ray diffraction pattern of Bicalutamide obtained by the method of the present invention.
[0053] FIG. 2 represents a characteristic DSC thermogram of Bicalutamide obtained by the method of the present invention.
[0054] FIG. 3 represents a characteristic IR spectrum of Bicalutamide obtained by the method of the present invention.
[0055] FIG. 4 represents a characteristic solid-state 13 C NMR spectrum of Bicalutamide obtained by the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0056] The process of the present invention is further detailed as hereunder.
[0057] As mentioned hereinearlier, the oxidation of the sulfide compound of formula (II) is carried out using potassium permanganate in presence of water or water miscible organic solvents such as nitrites, ketones, aliphatic acids etc in admixture with water at ambient temperature or under slight warming.
[0058] The oxidation of sulfide (II) compound can be carried out with potassium permanganate:
a) under near neutral conditions; b) using equivmolar to slight molar excess of potassium permanganate; and
In presence of water or a mixture of water and a water miscible environmentally benign solvent selected form nitrites, ketones, aliphatic acids etc in admixture with water, which are not only safe in handling, environmentally benign and do not pose any problem in health and waste disposal.
[0061] Potassium permanganate can be employed in equimolar to molar excess of up to three molar equivalents to the sulfide compound (II). Preferably potassium permanganate is employed in the range 2 to 3 molar equivalents per mole of sulfide compound (II).
[0062] Water miscible organic solvents that can be employed include nitrites selected from acetonitrile, propionitrile and benzonitrile; ketones such as acetone, methyl isobutyl ketone, methyl ethyl ketone, and cyclohexanone; and aliphatic acids such as acetic acid, propionic acid, and butyric acid.
[0063] Amongst nitrites, acetonitrile is more preferred; amongst ketones, acetone is more preferred; and amongst aliphatic acids, acetic acid is more preferred.
[0064] Amongst the water miscible solvents, nitrites are more preferred and the most preferred solvent is acetonitrile.
[0065] Typically the water or mixture of water and the water miscible organic solvent employed as solvent or reaction medium is 5 to 30 times by volume of the sulfide compound (II) and preferably they are employed in the range of 10 to 15 times by volume of the sulfide compound (II).
[0066] The ratio of the water miscible organic organic solvent and water employed can be in a ratio of between 1:1 and 1:4 and preferably the ratio is of between 1:1 and 1:2.
[0067] The temperature employed can be between ambient to slightly higher than ambient and is in the range of between 25-60° C. Preferably the temperature employed is in the range of between 25-45° C.
[0068] In a typical embodiment, to a solution of the sulfide compound (II) in water or mixture of water and the water miscible organic solvent, kept at a temperature of between 25-35° C. is added potassium permanganate in lots over a period of 30-60 minutes, followed by agitation of the reaction mixture at a temperature of 35-60° C. till completion of the reaction (5-8 hours).
[0069] At the end of the reaction, an aqueous solution of sodium bisulfite is added to the reaction mixture and the precipitated solids filtered and washed with water till all permanganate is washed away as indicated by the colourlessness of the filtrate.
[0070] The advantage of the method is that at the end of the oxidation the oxidized product i.e., Bicalutamide is generally thrown out from the reaction mixture and can be collected by filtration. Furthermore, the product isolated is generally of very high purity and most importantly is relatively free of manganese dioxide. The product is further crystallized from acetonitrile and, if required can be further purified to match any specific pharmacopoeial requirement through simple techniques.
[0071] The solid residue thus obtained is further dissolved in acetonitrile, optionally charcoalised, and filtered through micron filters etc and from which Bicalutamide is crystallized in highly pure form.
[0072] Alternatively, the reaction mixture after treatment with sodium bisulfite can be extracted with a water immiscible organic solvent such as ethyl acetate, dichloromethane, dichloroethane etc. The organic layer that contains Bicalutamide is evaporated and the residue is crystallized from acetonitrile as mentioned hereinabove.
[0073] The product i.e., Bicalutamide obtained has X-ray diffraction pattern, DSC thermo gram, IR spectrum and solid-state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
[0074] Alternatively the product can be further crystallized from a mixture of ethyl acetate and petroleum ether as per method disclosed in Journal of Medicinal Chemistry, 1988, Vol. 31, No. 5 page 954-959. The product thus obtained is also found to exhibit X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
[0075] The present inventors have carried out oxidation of the sulfide compound (II) using various prior art methods e.g. using hydrogen peroxide and trifluoroacetic anhydride as per the method disclosed in WO 02/24638 A1; using m-chloroperbenzoic acid as per the method disclosed in WO 2004/074350 A2; using peracetic acid as per the method disclosed in WO 02/24638 A1; and using monoperpthalic acid as per the method disclosed in U.S. Pat. No. 6,740,770. The yield of Bicalutamide (41-67%) in all such methods was found to be lower than the yield of Bicalutamide (74%) obtained through oxidation with potassium permanganate as per method of present invention. A comparison of the yield of Bicalutamide obtained by the method of the present invention with that obtained utilizing prior art methods is summarized in Table-1 Bicalutamide obtained by the process of the present invention is found to exhibit an X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
[0076] Alternatively, the Bicalutamide prepared by the present invention can be converted to the known polymorphic forms reported e.g. Form-I and Form-II as disclosed in US 2004/0063782 A1 through utilization of the methods disclosed therein.
[0000]
TABLE 1
Comparison of yields of Bicalutamide (I) obtained by
the method of the present invention vs. that obtained
through utilization of prior art methods.
Sr.
Yield
No.
Oxidizing Agent
(%)
1.
H 2 O 2 & Trifluoroacetic anhydride
67
(WO 02/24638 A1)
2.
m-CPBA
41
(WO 2004/074350 A2)
3.
PeraceticAcid.
41
(WO 0224638)
4.
Monoperpthalic acid
58
(US 2004013303-A1)
5.
Potassium Permanganate
74
(Method of the Present Invention)
[0077] The present invention is further illustrated by the following examples, which should not be construed as limiting the scope of the invention.
EXAMPLE 1
[0078] To a mixture of acetonitrile (150 ml) and water (100 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [II, 10.0 gm, 0.025 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (7.94 gm, 0.050 mol, 2.0 eq) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C., and to which was added a solution of sodium bisulfite (12 gm) in water (600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate became colorless.
[0079] The solid was dried and dissolved in acetonitrile (50 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (6.0 gm, 55%) of Bicalutamide having a purity 99.07% and exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 2
[0080] To a mixture of acetonitrile (150 ml) and water (100 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II), 10.0 gm, 0.025 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (9.93 gm, 0.062 mol, 2.5 eq) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C. and to which was added a solution of sodium bisulfite (14 gm) in water (600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate becomes colorless.
[0081] The solid was dried and dissolved in acetonitrile (50 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (6.8 gm, 63%) of Bicalutamide having a purity 99.77% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 3
[0082] To a mixture of acetonitrile (900 ml) and water (600 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II), 60 gm, 0.15 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (72 gm, 0.45 mol, 3.0 eq) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C. and to which was added a solution of sodium bisulfite (100 gm) in water (3600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate becomes colorless.
[0083] The solid was dried and dissolved in acetonitrile (300 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (45 gm, 70%) of Bicalutamide having a purity 99.68% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 4
[0084] To a mixture of acetonitrile (150 ml) and water (100 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II), 10.0 gm, 0.025 mol] at 25-30° C. The temperature of reaction mixture was raised to 30-35° C. and to the solution was added potassium permanganate (12 gm, 0.076 mol, 3 eq) in lots over a period of 30 minutes maintaining the temperature between 30-35° C. during addition. The reaction mixture was agitated at 30-35° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C., and to which was added a solution of sodium bisulfite (12 gm) in water (600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate become colorless.
[0085] The solid was dried and dissolved in acetonitrile (50 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (7.30 gm, 67%) of Bicalutamide having a purity 99.8% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 5
[0086] To a mixture of acetonitrile (150 ml) and water (100 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II) 10.0 gm 0.025 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (12 gm, 0.076 mol, 3 eq) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C., to which was added a solution of sodium bisulfite (12 gm) in water (600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate become colorless.
[0087] The solid was dried and dissolved in acetonitrile (50 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (6.0 gm, 55%) of Bicalutamide having a purity 99.07% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 6
[0088] To a mixture of acetonitrile (150 ml) and water (100 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II) 10.0 gm, 0.025 mol] at 25-30° C. The temperature of reaction mixture was raised to 50-60° C. and to the solution was added potassium permanganate (12 gm, 0.076 mol, 3 eq) in lots over a period of 30 minutes maintaining the temperature between 50-60° C. during addition. The reaction mixture was agitated at 50-60° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C., to which was added a solution of sodium bisulfite (12 gm) in water (600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate become colorless.
[0089] The solid was dried and dissolved in acetonitrile (50 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (6.0 gm, 55%) of Bicalutamide having a purity 99.07% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 7
[0090] To a mixture of acetonitrile (100 ml) and water (100 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II) 10.0 gm, 0.025 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (12 gm, 0.076 mol, 3 eq) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C., to which was added a solution of sodium bisulfite (12 gm) in water (600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate becomes colorless.
[0091] The solid was dried and dissolved in acetonitrile (50 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (6.0 gm, 55%) of Bicalutamide having a purity 99.07% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 8
[0092] To a mixture of acetone (150 ml) and water (100 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II) 10.0 gm, 0.025 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (12 gm, 0.076 mol, 3 eq) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C. to which was added a solution of sodium bisulfite (24 gm) in water (600 ml). The reaction mixture is agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate become colorless.
[0093] The solid was dried and dissolved in acetonitrile (50 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (4.5 gm, 41.66%) of Bicalutamide having a purity 99.34% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 9
[0094] To a mixture of acetonitrile (900 ml) and water (600 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II), 60 gm, 0.15 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (72 gm, 0.45 mol, 3 eq.) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C. to which was added a solution of sodium bisulfite (100 gm) in water (3600 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate become colorless.
[0095] The solid was dried and dissolved in acetonitrile (300 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through fine microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (45 gm, 70%) of Bicalutamide having a purity 99.67% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 10
[0096] To water (500 ml) was added N-[4-cyano-3-(trifluoromethyl) phenyl]-3-[(4-fluorophenyl) thio]-2-hydroxy-2-methyl propanamide [(II), 50.0 gm, 0.1256 mol] at 25-30° C. The temperature of reaction mixture was raised to 40-45° C. and to the solution was added potassium permanganate (60 gm, 0.3797 mol, 3 eq) in lots over a period of 30 minutes maintaining the temperature between 40-45° C. during addition. The reaction mixture was agitated at 40-45° C. for further time till the completion of reaction. The reaction mixture was cooled to 25-35° C., to which was added a solution of sodium bisulfite (120 gm) in water (2000 ml). The reaction mixture was agitated at 25-35° C. for 6-7 hours and the solid precipitated was filtered and washed with water till the filtrate become colorless.
[0097] The solid was dried and dissolved in acetonitrile (250 ml) under heating. To the hot solution was added activated charcoal and the mixture heated to reflux for 1-2 hours. The hot mixture was filtered to remove charcoal and optionally passed through five microfilters. The filtrate was concentrated, cooled to 25-35° C. and the precipitated solid filtered and dried to give (7.0 gm, 64.8%) of Bicalutamide having a purity 99.4% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively.
EXAMPLE 11
[0098] To a hot ethyl acetate kept at temperature between 80-90° C. was added Bicalutamide (756.5 gm) obtained by any of the methods described in examples 1-10 to get a clear solution. To the hot solution was added petroleum ether (60-80° C.; 3.4 ltrs), wherein the solution starts becoming turbid. More ethyl acetate (94.5 ltrs) was added to get a clear solution. The solution was cooled to 25-30° C. and further 0-5° C. and maintained at this temperature for 3 hrs. The crystallized solid was filtered and dried at 60-70° C. to give pure Bicalutamide (600 gm) having a purity 99.91% exhibiting the X-ray diffraction pattern, DSC thermogram, IR spectrum and solid state 13 C NMR spectrum as depicted in FIGS. ( 1 ), ( 2 ), ( 3 ) and ( 4 ) respectively. | A process for preparation of Bicalutamide of formula (I),
comprising oxidation of compound of formula (II),
with potassium permanganate in presence of water or a mixture of water and water miscible solvent and isolating Bicalutamide of formula (I) thereof. | 2 |
BACKGROUND OF THE INVENTION
The importance of regular exercise is widely appreciated for reasons ranging from the need to control weight to programs for those recovering from heart ailments.
While the type and extent of the exercise individuals practice often depends on a physician's recommendations, it is recognized that exercise should not only be regular but also sufficiently strenuous to cause the heart beat to be accelerated for a reasonable but substantial interval.
For many, exercise outdoors is preferred with jogging popular while others enjoy brisk walks. For others, however, weather conditions and the character of the neighborhood make exercise indoors preferable although it is then usually necessary to use a captive bicycle or a treadmill exerciser.
Such devices, however, are monotonous to use as a consequence of which, interest in an exercise program is often lost so that what is needed is a way to make the use of such devices a pleasurable interval with the exercise automatically taking place.
It is, therefore, an object of the present invention to provide an exerciser which may obviate and mitigate the above-mentioned drawbacks.
SUMMARY
This invention relates to a multi-purpose exerciser.
It is the primary object of the present invention to provide a multi-purpose exerciser which utilizes a throttling valve for presenting a selectable number of operable speeds to the user.
It is another object of the present invention to provide a multi-purpose exerciser which can be operated by a wide range of users of various strength capabilities.
It is still another object of the present invention to provide a multi-purpose exerciser which is easy to operate.
It is still another object of the present invention to provide a multi-purpose exerciser which is economic to produce.
It is a further object of the present invention to provide a multi-purpose exerciser which is facile to manufacture.
Other objects and merits and a fuller understanding of the present invention will be obtained by those having ordinary skill in the art when the following detailed description of the preferred embodiment contemplated for practicing the best mode of the invention has been read in conjunction with the accompanying drawings wherein like numerals refer to like or similar parts and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a multi-purpose exerciser according to the present invention;
FIG. 2 is a fragmentary view showing structure of the rack of the multi-purpose exerciser;
FIG. 3 is a cross-sectional view taken along line A--A of FIG. 2;
FIG. 4 shows the oil passage of the multi-purpose exerciser;
FIG. 5 shows the motion of the sliding block of the multi-purpose exerciser;
FIG. 6 is a rear view taken from arrow B of FIG. 1;
FIG. 7 is an enlarged fragmentary view showing the connection of the cross bar and the adjusting bracket;
FIG. 8 shows the structure of the adjusting bracket;
FIG. 9 shows a first application of the multi-purpose exerciser;
FIG. 10 shows a second application of the multi-purpose exerciser;
FIG. 11 shows a third application of the multi-purpose exerciser;
FIG. 12 shows a fourth application of the multi-purpose exerciser;
FIG. 13 shows a fifth application of the multi-purpose exerciser; and
FIG. 14 shows how to connect the contractible rod to the sliding rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the present invention in detail, it is to be understood that the 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. Also it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
With reference to the drawings and in particular to FIG. 1 thereof, the multi-purpose exerciser according to the present invention mainly comprises two racks 10 and 20, a controlling button 30, a cross rod 40, an upright stand 50, a base 60, two contractible rods 70 and 75, two frames 80 and 85, and a supporting rod 90. The front ends of the racks 10 and 20 are fixed on the cross rod 40 which is provided with a dashboard 41 at the middle for showing the rate of energy consumption. The cross rod 40 is fixed on the upright stand 50 by an adjusting bracket 45. The upright stand 50 is rigidly mounted on the lower stand 60. The lower stand 60 is connected to the lower rod 90 via two contractible rods 70 and 75 on which are respectively mounted two frames 80. The lower ends of the racks 10 and 20 are rotatably connected with the supporting rod 90. As a result, the angle of inclination of the racks 10 and 20 will change when the adjusting bracket 45 is moved along the upright stand 50. The front ends of the two contractible rods 70 and 75 are respectively rigidly joined to two sleeves 71 and 76 enclosing a rear rod 61. The two contractible rods 70 and 75 are merely inserted into the supporting rod 90 and can be taken up as shown in FIG. 10. The contractible rods 70 and 75 are composed of two rods respectively united together by two screws 72 and 77 (not shown).
Referring to FIG. 2, there is shown the structure of the rack 10. The racks 10 and 20 are the same in structure and so only one of them is shown for illustration. As illustrated the rack 10 is formed with a slot 101 covered with two rubber pads 102 and 103 for keeping away dust. Mounted on the rack 10 is a pedal 15 which has a base plate 151, a riding plate pivoted thereon, a stopper 154 formed on the base plate 151 and a holding means 153 attached to the bottom surface of the riding plate. The pedal 15 is slidably mounted on the rack 10 by means of four rollers 104, 105, 106, and 107 (see FIG. 3). The inner side of the base plate 151 is rigidly attached to the front end of a sliding rod 31. Two rollers 312 and 313 are respectively mounted at two sides of the sliding rod 31. The sliding rod 31 is fixedly connected to piston 321 of a cylinder 32. An extension rod 311 is welded or otherwise joined to the sliding rod 31. Consequently, the pedal 15 can be moved along a distance equal to the throw of the sliding rods as the piston 321 is traversed by pedal 15 within the cylinder 32.
As shown in FIGS. 4 and 5, the housing 301 of the controlling button 30 is fixed on the lower rod 90. Inside the housing 301 there is a throttling valve 302 having two rubber tubes 303 and 304 respectively connected to two sides thereof. Two contractible enveloping means 305 and 306 are respectively mounted between the racks 10 and 20 and the housing 301. The rubber tubes 303 and 304 are connected to two cylinders 32 and 36 respectively having two sliding rod 31 and 35. Since the two cylinders 32 and 36 are connected by rubber tubes 303 and 304 and the throttling valve 302, the sliding rod 35 will be lifted upward when the sliding rod 31 is moved downward. Thus, the pedals 15 and 25 can be moved with respect to each other. The throttling valve 302 is designed to control the rate of oil passing therethrough thereby presenting a selectable number operable speeds to the user.
With reference now to FIG. 6, the cross rod 40 is formed with a plurality of holes 401 on the rear side thereof. The front ends of the racks 10 and 20 is respectively provided with a bolt 16 for regulating the distance between the two racks 10 and 20. The cross rod 40 is pivoted to the adjusting bracket 45 by a pin 402. The adjusting bracket 45 is provided with four rollers 451, 452, 453 and 454 so that it can be easily moved along the upright stand 50. The upright stand 50 has a plurality of holes 501 whereby the adjusting bracket 45 can be fixed in position by engaging a bolt 455 therewith. A spring 456 is disposed with the adjusting bracket 45 and the upright stand 50 so as to enable the bolt 455 to return to its original position.
As illustrated in FIG. 9, the upright stand 50 is rigidly mounted on the lower stand 60. The lower stand 60 is formed with an extension base 601 joined to a supporting rod 61. Two ends of the rear rod 61 are provided with two rollers 611 and 612, respectively.
As may be seen in FIGS. 1 and 5, the multi-purpose exerciser can enable the user to practice climbing.
Furthermore, the present invention can be used to practice skating by lowering the two racks 10 and 20, then dismantling the frames 80 and 85 and turning up the contractible rods 70 and 75 (see FIG. 10).
FIG. 11 shows a third application of the present invention. As shown, the user can sit on a cushion 95, with his feet operating the pedals 25 so that he can fully exercise his foot muscles.
FIG. 12 shows a fourth application of the present invention. The frames 80 and 85 are first removed and then the racks 10 and 20 are lowered. The user grasps the racks 10 and 20 with his two hands and operate the pedals 15 and 25 with both feet.
FIG. 13 shows a fifth application of the present invention. In use, first adjust the distance between the two racks 10 and 20 so that the user may sit thereon. Then, remove the contractible rods 70 and 75 and insert them into respective one of the racks 10 and 20 so that they are fixedly connected with corresponding sleeves 333 and 334 which are welded or otherwise joined to the extension rods 311 and 312. As a result, the present invention can also be used as a rowing exerciser.
Other embodiments and modifications will occur to those skilled in the art. No attempts has been made to illustrate all possible embodiments of the invention, but rather intended such alternations and further modifications in the illustrated device, and such further applications as illustrated herein being contemplated as would normally occur to one skilled in the art to which the invention relates. | This invention relates to a multi-purpose exerciser and in particular to one utilizing a throttling valve for presenting a selectable number of operable speeds to the user. The exerciser mainly includes two racks, a controlling button, a cross rod, an upright stand, a base, two contractible rods, two frames and a supporting rod stand, whereby it can be used to exercise rowing, climbing, skating etc. The force required to operate the pedals of the exerciser is established by the throttling valve which controls the rate of oil passing through a pair of rubber tubes into cylinders housing pistons driven by the pedals. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a Continuation-In-Part (CIP) based on, and claims the benefit of U.S. Ser. No. 11/409,868 filed Apr. 24, 2006; Ser. No. 11/409,570 filed Apr. 24, 2006, and Ser. No. 11/409,871 filed Apr. 24, 2006, and which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the use of Abnormal Cannabidiols to lower the intraocular pressure of mammals and thus are useful in treating glaucoma.
[0004] 2. Background of the Related Art
[0005] Ocular hypotensive agents are useful in the treatment of a number of various ocular hypertensive conditions, such as post-surgical and post-laser trabeculectomy ocular hypertensive episodes, glaucoma, and as presurgical adjuncts.
[0006] Glaucoma is a disease of the eye characterized by increased intraocular pressure. On the basis of its etiology, glaucoma has been classified as primary or secondary. For example, primary glaucoma in adults (congenital glaucoma) may be either open-angle or acute or chronic angle-closure. Secondary glaucoma results from pre-existing ocular diseases such as uveitis, intraocular tumor or an enlarged cataract.
[0007] The underlying causes of primary glaucoma are not yet known. The increased intraocular tension is due to the obstruction of aqueous humor outflow. In chronic open-angle glaucoma, the anterior chamber and its anatomic structures appear normal, but drainage of the aqueous humor is impeded. In acute or chronic angle-closure, the anterior chamber is shallow, the filtration angle is narrowed, and the iris may obstruct the trabecular meshwork at the entrance of the canal of Schlemm. Dilation of the pupil may push the root of the iris forward against the angle, and may produce pupilary block and thus precipitate an acute attack. Eyes with narrow anterior chamber angles are predisposed to acute angle-closure glaucoma attacks of various degrees of severity.
[0008] Secondary glaucoma is caused by any interference with the flow of aqueous humor from the posterior chamber into the anterior chamber and subsequently, into the canal of Schlemm. Inflammatory disease of the anterior segment may prevent aqueous escape by causing complete posterior synechia in iris bombe, and may plug the drainage channel with exudates. Other common causes are intraocular tumors, enlarged cataracts, central retinal vein occlusion, trauma to the eye, operative procedures and intraocular hemorrhage.
[0009] Considering all types together, glaucoma occurs in about 2% of all persons over the age of 40 and may be asymptotic for years before progressing to rapid loss of vision. In cases where surgery is not indicated, topical α-adrenoreceptor antagonists have traditionally been the drugs of choice for treating glaucoma.
[0010] Certain Abnormal Cannabidiols are disclosed in Howlett et al, “International Union of Pharmacology. XXVII. Classification of Cannabinoid Receptors”, Pharmacological Reviews 54: 161-202, 2002.
[0011] Reference is made to Published U.S. Patent Application Numbers 2005/0282902, 2005/0282912 and 2005/0282913 to Chen et al which were published on Dec. 22, 2005 and are herein incorporated by reference thereto. (June Chen is a co-inventor of each of said published patent applications and the present patent application.)
SUMMARY OF THE INVENTION
[0012] We have found that Abnormal Cannabidiols are potent ocular hypotensive agents. We have further found that Abnormal Cannabidiols and homologues and derivatives thereof, are especially useful in the treatment of glaucoma and surprisingly, cause no or significantly lower ocular surface hyperemia than the other compounds that are useful in lowering intraocular pressure, e.g. PGF 2α and lower alkyl esters thereof.
[0013] The present invention relates to methods of treating ocular hypertension which comprises administering an effective amount of a compound represented by
[0000]
[0014] wherein Y is selected from the group consisting of keto and hydroxyl;
[0015] Y 1 is selected from the group consisting of hydroxyl, keto, halogen and C 1 -C 5 alkyl;
[0016] Z is N or C;
[0017] Q is selected from the group consisting of phenyl, halogen-substituted phenyl, 5 or 6 member heterocyclic radicals, wherein the hetero atom is nitrogen, oxygen or sulfur,
[0000]
[0018] wherein W is a direct bond or C(R 11 )(R 12 );
[0019] a dotted line represents the presence or absence of a double bond;
[0020] the wavy line represents a direct bond;
[0021] Q and Y may form a condensed ring wherein Y is —C(O)—NR3— and Q is —C(Q′)- wherein Q′ is R3 or said C is a spiro atom and Q′, together with said C, represents a carbocyclic or heterocyclic ring having from 3 to 6 carbon atoms and said hetero atom is N, O or S;
[0022] R is selected from the group consisting of H, halogen and C 1-5 alkyl;
[0023] R 1 is selected from the group consisting of H and halogen;
[0024] R 2 is selected from the group consisting of H, C 1-5 alkyl, halogen, XC 1-5 alkyl,
[0025] C 1-5 alkylOR 13 , C 1-5 alkylN(R 13 ) 2 ,
[0026] N(R 13 ) 2 , XC 1-5 alkylN(R 13 ) 2 and XC 1-5 alkylOR 13 ; wherein
[0027] X is O or S(O) n ;
[0028] n is 0 or an integer of from 1 to 2;
[0029] R 3 is selected from the group consisting of H, hydroxyl, oxo, C 1-5 alkyl, C 1-5 alkylOR 13 and C 1-5 alkylN(R 13 ) 2 ;
[0030] R 4 is selected from the group consisting of H, C 1-5 alkenyl, C 1-5 alkyl, C 1-5 alkylOR 13 and C 1-5 alkylN(R 13 ) 2 ;
[0031] R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 are independently selected from the group consisting of H, C 1-5 alkyl, C 1-5 alkylOR 13 and OR 13 ; and
[0032] R 13 is selected from the group consisting of H, C 1-5 alkyl and C 3-8 cyclic alkyl, or two R 13 groups, together with N, may form a cyclic ring such as a piperidine or morpholine ring; and provided that R 8 and R 12 may, together, form a cyclic ring, and R 3 and R 5 may, together, represent O, and
[0033] when Q is menthadiene, R 1 and R 2 are H and Y is hydroxyl, R may not be H or alkyl.
[0034] Preferably, the compound of formula I is
[0000]
[0035] wherein Y is selected from the group consisting of keto and hydroxyl;
[0036] Z is N or C;
[0037] Q is selected from the group consisting of
[0000]
[0038] wherein W is a direct bond or C(R 11 l)(R 12 );
[0039] a dotted line represents the presence or absence of a double bond;
[0040] wherein R is selected from the group consisting of H, halogen, e.g. bromo or chloro; and C 1-5 alkyl; R 1 is selected from the group consisting of H, halogen, e.g. bromo or chloro;
[0041] R 2 is independently selected from the group consisting of H, C 1-5 alkyl, halogen, XC 1-5 alkyl, C 1-5 alkylOR 13 , C 1-5 alkylN(R 13 ) 2 , N(R 13 ) 2 , XC 1-5 alkylN(R 13 ) 2 and XC 1-5 alkylOR 13 ;
[0042] X is O or S(O) n ;
[0043] n is 0 or an integer of from 1 to 2;
[0044] R 3 is selected from the group consisting of H, hydroxyl, C 1-5 alkyl, C 1-5 alkylOR 13 and C 1-5 alkylN(R 13 ) 2 ;
[0045] R 4 is selected from the group consisting of H, C 1-5 alkenyl, e.g. isopropenyl, C 1-5 alkyl, C 1-5 alkylOR 13 and C 1-5 alkylN(R 13 ) 2 ;
[0046] R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 are independently selected from the group consisting of H, C 1-5 alkyl, C 1-5 alkylOR 13 and OR 13 ; and
[0047] R 13 is selected from the group consisting of H, C 1-5 alkyl and C 3-8 cyclic alkyl, or two R 13 groups, together with N, may form a cyclic ring such as a piperidine or morpholine ring; and provided that any of said alkyl groups may be substituted with a hetero atom containing radical, wherein said heteroatom is R 8 and R 12 may, together, form a cyclic ring;
[0048] and R 3 and R 5 may, together, represent 0 , and
[0049] when Q is menthadiene, R 1 and R 2 are H and Y is hydroxyl, R may not be H or alkyl.
[0050] In a further aspect, the present invention relates to pharmaceutical compositions comprising a therapeutically effective amount of a compound of formulae (I) or (I′), in admixture with an non-toxic, pharmaceutically acceptable liquid vehicle. Such pharmaceutical compositions may be ophthalmic solutions which are useful in treating ocular hyptension and/or glaucoma. Finally, the present invention provides certain novel compounds which are useful in treating ocular hypertension and/or glaucoma.
BRIEF DESCRIPTION OF THE FIGURES
[0051] FIG. 1 shows the effect of abnormal cannabidiol on intraocular pressure.
[0052] FIG. 2 shows the effect of the compound of Example 4 intraocular pressure.
[0053] FIG. 3 shows the effect of the compound of Example 3 intraocular pressure.
[0054] FIG. 4 shows the effect of the compound of Example 6 intraocular pressure.
[0055] FIG. 5 shows the effect of the compound of Example 5 intraocular pressure.
DETAILED DESCRIPTION OF THE INVENTION
[0056] The present invention relates to the use of Abnormal Cannabidiols as ocular hypotensives. These therapeutic agents are represented by compounds having the formula I or I′, above.
[0057] In one embodiment of the invention, the compound is selected from the group consisting of abnormal Cannabidiols and analogues thereof represented by formula II
[0000]
[0058] wherein Q is selected from the group consisting of
[0000]
[0059] A particularly preferred group represented by Q is menthadiene or
[0000]
[0060] In this class of compounds, preferably, R is selected from the group consisting of hydrogen, methyl, bromo and chloro and R 1 is selected from the group consisting of hydrogen, methyl and chloro.
[0061] Compounds of this type may be prepared by condensation of a cyclic alkene or cyclic alcohol with a suitably substituted benzene-1,3-diol. The reaction is catalysed by an acid such as oxalic acid dihydrate or p-toluenesulphonic acid. The reaction is carried out in a solvent or mixture of solvents such as toluene, diethyl ether or dichloromethane. A mixture of the two isomers is obtained and the desired product is separated by chromatography. The reaction scheme is illustrated below.
[0000]
[0062] The synthesis of the starting materials is well known.
[0063] The mechanism of the reaction is the result of the formation of a carbocation by elimination of OH or a starting material containing a functional group such as acetate which can also be eliminated to give the carbocation can be used.
[0000]
[0064] In another embodiment of the invention the compound is tetrahydropyridine represented by formula III
[0000]
[0065] These tetrahydropyridine compounds may be synthesized according to the following reaction scheme wherein Me is methyl, Bu is butyl and iPr is isopropyl.
[0000]
[0066] In a further embodiment of the invention, the compound is a piperidinedione represented by the formula IV
[0000]
[0067] These compounds may be synthesized according to the following reaction scheme wherein Et is ethyl, THF is tetrahydrofuran and DMF is dimethyl formamide.
[0000]
Where L is a leaving group such bromine, iodine or tosyl.
[0068] Compounds of formula I′ wherein Y and Y 1 are keto are known as piperidine-2,4-diones and may be synthesized as described by H. Nishino, et al., Teterahedron 2005, 11107-11124. The corresponding cyclohexane-1,3 diones may be prepared as described in EP 291114 and EP 310186. Compounds of formula I′ wherein Y is keto and Y 1 is hydroxyl are known as 4-hydroxypyridin-2-ones and may be prepared as described by Castillo, et al. in Bull. Soc. Chim. Fr. 1982, 257-261.
[0069] The compounds wherein Y═Y 1 =hydroxyl may be prepared by dehydrogenation of the corresponding cyclohexane-1,3 diones by the method described by E. D. Berymann, et a., JACS, 1953, 3226. Compounds of formula I′ wherein both of Z is N, Y is oxo and Y 1 is hydroxyl may be prepared as described in WO 2005/007632 and J. Het. Chem. 1989, 169-176.
[0070] In all of the above formulae, as well as in those provided hereinafter, the straight lines represent bonds. Where there is no symbol for the atoms between the bonds, the appropriate carbon-containing radical is to be inferred.
[0071] Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, as an active ingredient, with conventional ophthalmically acceptable pharmaceutical excipients, and by preparation of unit dosage forms suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.0001 and about 5% (w/v), preferably about 0.001 to about 1.0% (w/v) in liquid formulations.
[0072] For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 4.5 and 8.0 with an appropriate buffer system, a neutral pH being preferred but not essential. The formulations may also contain conventional, pharmaceutically acceptable preservatives, stabilizers and surfactants.
[0073] Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose and purified water.
[0074] Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
[0075] Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
[0076] In a similar vein, an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
[0077] Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place or in conjunction with it.
[0078] The ingredients are usually used in the following amounts:
[0000]
Ingredient
Amount (% w/v)
active ingredient
about 0.001–5
preservative
0–0.10
vehicle
0–40
tonicity adjustor
1–10
buffer
0.01–10
pH adjustor
q.s pH 4.5–7.5
antioxidant
as needed
surfactant
as needed
purified water
as needed to make 100%
[0079] The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
[0080] The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate application to the eye. Containers suitable for dropwise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution. One package may contain one or more unit doses.
[0081] Especially preservative-free solutions are often formulated in non-resealable containers containing up to about ten, preferably up to about five unit doses, where a typical unit dose is from one to about 8 drops, preferably one to about 3 drops. The volume of one drop usually is about 20-35 μl.
[0082] The compounds disclosed herein for use in the method of this invention, i.e. the treatment of glaucoma or elevated intraocular pressure, may also be used in combination with other drugs useful for the treatment of glaucoma or elevated intraocular pressure.
[0083] For the treatment of glaucoma or elevated intraocular pressure, combination treatment with the following classes of drugs are contemplated: β-Blockers (or β-adrenergic antagonists) including carteolol, levobunolol, metipranolol, timolol hemihydrate, timolol maleate, β1-selective antagonists such as betaxolol, and the like, or pharmaceutically acceptable salts or prodrugs thereof;
[0084] Adrenergic Agonists including
[0085] non-selective adrenergic agonists such as epinephrine borate, epinephrine hydrochloride, and dipivefrin, and the like, or pharmaceutically acceptable salts or prodrugs thereof; and
[0086] α 2 -selective adrenergic agonists such as apraclonidine, brimonidine, and the like, or pharmaceutically acceptable salts or prodrugs thereof;
[0087] Carbonic Anhydrase Inhibitors including acetazolamide, dichlorphenamide, methazolamide, brinzolamide, dorzolamide, and the like, or pharmaceutically acceptable salts or prodrugs thereof;
[0088] Cholinergic Agonists including
[0089] direct acting cholinergic agonists such as carbachol, pilocarpine hydrochloride, pilocarpine nitrate, pilocarpine, and the like, or pharmaceutically acceptable salts or prodrugs thereof;
[0090] chlolinesterase inhibitors such as demecarium, echothiophate, physostigmine, and the like, or pharmaceutically acceptable salts or prodrugs thereof;
[0091] Glutamate Antagonists such as memantine, amantadine, rimantadine, nitroglycerin, dextrophan, detromethorphan, CGS-19755, dihydropyridines, verapamil, emopamil, benzothiazepines, bepridil, diphenylbutylpiperidines, diphenylpiperazines, HOE 166 and related drugs, fluspirilene, eliprodil, ifenprodil, CP-101,606, tibalosine, 2309BT, and 840S, flunarizine, nicardipine, nifedimpine, nimodipine, barnidipine, lidoflazine, prenylamine lactate, amiloride, and the like, or pharmaceutically acceptable salts or prodrugs thereof;
[0092] Prostamides such as bimatoprost, or pharmaceutically acceptable salts or prodrugs thereof; and
[0093] Prostaglandins including travoprost, UFO-21, chloprostenol, fluprostenol, 13,14-dihydro-chloprostenol, isopropyl unoprostone, latanoprost and the like.
[0094] The invention is further illustrated by the following non-limiting Examples.
EXAMPLE 1
Intraocular Pressure
[0095] Intraocular pressure was measured by applanation pneumatonometry in conscious animals. The test compound was administered topically to one eye while vehicle was given to the fellow eye in a masked fashion. Ocular normotensive Beagle dogs (males, females) were dosed once daily for five days. Laser-induced unilaterally ocular hypertensive Cynomolgus monkeys (females) were dosed once daily for 4 days. Student's paired t-test was used for statistical comparisons. Differences were considered statistically significant if the P-value is less than 0.05.
[0096] The results are shown in the Figures.
[0097] The figures show the change from baseline IOP of Monkey dosed with 0.1% of the active compound versus time.
EXAMPLE 2
Determination of Abnormal Cannabidiol Activity
[0098] Abnormal Cannabidiol receptor activity may be measured in accordance with the procedure disclosed in (Wagner J A et al., Hypertension 33 [part II], 429 (1999); Járai Z et al., PNAS 96, 14136 (1999), which is hereby incorporated by reference in its entirety.
Experimental Details for Synthesis of Abnormal Cannabidiols
General Route
[0099]
EXAMPLE 3
5-methyl-4-(6-Isoprenyl-3-methylcyclohex-2-enyl)benzene-1,3-diol
[0100] (4R)-1-Methyl-4-isoprenylcyclohex-2-ene-1-ol (300 mg, 2 mmoles) was dissolved in toluene (20 ml) and 5-methylresorcinol (248 mg, 2 mmoles) was added in diethyl ether (5 ml). Oxalic acid dihydrate (252 mg, 2 mmoles) was added and the reaction mixture heated with stirring at 80° for 5 hours. The reaction mixture was allowed to cool and diluted with diethyl ether (30 ml). The ether solution was washed twice with aqueous sodium bicarbonate and dried over anhydrous magnesium sulphate. The solvents were evaporated under reduced pressure to give the crude product as a brown oil (800 mg). The product was purified using a silica column eluted with ethyl acetate:isohexane 1:9 going to ethyl acetate: isohexane 2:8.
[0101] The product was isolated as a yellow gum (106 mg)
EXAMPLE 4
4-(6-Isoprenyl-3-methylcyclohex-2-enyl)benzene-1,3-diol
[0102] The named compound is prepared according to the method described in Example 3 except that resorcinol is substituted for 5-methylresorcinol.
[0103] 1 H NMR (300 MHz, CDCl 3 ) 6.2 (M, 2H), 6.1 (S, 1H), 5.55 (M, 1H), 4.7 (M, H), 4.55 (S, 1H), 4.5 (M, 1H), 3.55 (M, 1H), 2.5 (M, 1H), 2.2 (M, 2H), 2.15(S,3H), 1.85(M,2H), 1.8(S,3H), 1.6(S,3H)
[0104] Also prepared in a similar manner were
EXAMPLE 5
5-Chloro-4-(6-Isoprenyl-3-methylcyclohex-2-enyl)benzene-1,3-diol
[0105] 1 H NMR (300 MHz, CDCl 3 ) 6.4 (M, 1H), 6.3 (M, 1H), 6.25 (S, 1H), 5.6 (M, 1H), 4.7 (brS, 1H), 4.65 (M, 1H), 4.4 (M, 1H), 4.0 (M, 1H), 2.5 (M, 1H), 2.25 (M, 1H), 2.15 (M, 1H), 1.85 (M, 2H), 1.8 (S, 3H), 1.6 (S, 3H)
EXAMPLE 6
4-(6-Isoprenyl-3-methylcyclohex-2-enyl)-5-methoxybenzene-1,3-diol
[0106] 1 H NMR (300 MHz, CDCl 3 ) 6.15 (brS, 1H), 6.0 (M, 2H), 5.6 (M, 1H), 4.65 (brS, 1H), 4.5(M, 1H), 4.35 (M, 1H), 3.95(M, 1H), 3.7(S,3H), 2.4(M, 1H), 2.25 (1H, M), 2.1 (M, 1H), 1.8 (M, 2H), 1.8 (S, 3H), 1.65 (S, 3H)
EXAMPLE 7
2-(6-Isoprenyl-3-methylcyclohex-2-enyl)-5-methoxybenzene-1,3-diol
[0107] 1 H NMR (300 MHz, CDCl 3 ) 6.0 (brS, 2H), 5.55 (M, 1H), 4.7 (M, 1H), 4.6(M, 1H), 3.8 (M, 1H), 3.75 (S, 3H), 2.4 (M, 1H), 2.2 (M, 1H), 2.1 (M, 1H), 1.8 (S, 3H), 1.8 (M, 2H)
EXAMPLE 8
Synthesis of 6-Chloro-4-(6-Isoprenyl-3-methylcyclohex-2-enyl)benzene-1,3-diol
[0108] 4-Chlororesorcinol (350 mg, 2.4 mmoles) was dissolved in toluene (30 ml) and diethyl ether (20 ml) and p-toluenesulphonic acid (91 mg, 0.48 mmoles) was added.
[0109] (4R)-1-Methyl-4-isoprenylcyclohex-2-ene-1-ol (500 mg, 3 mmoles) in toluene (10 ml) was added and the reaction mixture was stirred at room temperature for 6 hours. Diluted with diethyl ether (30 ml) and washed twice with aqueous sodium bicarbonate. Dried over anhydrous magnesium sulphate and the solvent was evaporated under reduced pressure to give a yellow gum (800 mg). Purified using a silica column eluted with ethyl acetate:isohexane 9:1 going to ethyl acetate:isohexane 8:2. The product was isolated as a yellow gum (95 mg)
[0110] 1 H NMR (300 MHz, CDCl 3 ) 6.9 (S, 1H), 6.5 (S, 1H), 5.5 (S, 1H), 5.45 (M, 1H), 5.35 (S, 1H), 4.7 (M, 1H), 4.6 (M, 1H), 3.35 (M, 1H), 2.2 (M, 3H), 1.8(M,3H), 1.75(M,2H), 1.6(S,3H)
EXAMPLE 9
Synthesis of 4-Cyclohexylbenzene-1,3-diol
[0111] This compound was prepared as described in JACS, 1953, 2341.
[0112] Resorcinol (2.2 g, 0.02 moles) was mixed with cyclohexanol (1 g, 0.01 moles) and zinc (II) chloride (0.48 g, 0.0035 moles) and the reaction mixture heated to 150° with stirring. After heating 2 hours, the reaction mixture was allowed to cool and then dissolved in ethyl acetate. Washed with water and dried over anhydrous magnesium sulphate. The solvent was evaporated to give a brown oil (3.0 g). Excess resorcinol was evaporated by heating in a Kugelrohr oven under reduced pressure (200°, 2 mmHg). Purified using a silica column eluted with ethyl acetate: isohexane 2:8 to give the product as a yellow oil (0.5 g). Trituration with isohexane gave the product as a white solid (0.2 g).
[0113] 1 H NMR (300 MHz, CDCl 3 ) 7.0 (D, 1H J=8 Hz), 6.4 (M, 1H), 6.3 (M, 1H), 4.7(S, 1H), 4.55(S, 1H), 2.7(M, 1H), 1.8(M,5H), 1.4(M,5H)
EXAMPLE 10
Synthesis of 4R-Isoprenyl-1-methylcyclohex-2-enol
[0114] The synthesis of 4R-Isoprenyl-1-methylcyclohex-2-enol was carried out as described in WO2004096740.
[0000]
EXAMPLE 11
4-Isoprenyl-1-methyl-2-morpholin-4-yl-cyclohexanol
[0115] (+)-Limonene oxide (13.2 g, 0.087 moles) was dissolved in ethanol (40 ml) and lithium chloride (5.9 g, 0.14 moles) was added with stirring. Morpholine (11.4 g, 0.13 moles) was added and the reaction mixture was heated at 60° for 48 hours. The solvent was evaporated under reduced pressure and the residue taken up in dichloromethane. Washed with water. Extracted into 2M hydrochloric acid and washed with dichloromethane. Basified to pH 10 by addition of 2M sodium hydroxide. Extracted with diethyl ether and washed with water. Dried over anhydrous magnesium sulphate and evaporated the solvent under reduced pressure to give the product as a yellow oil (10.3 g)
[0116] 1 H NMR (300 MHz, CDCl 3 ) 4.95 (M, 1H), 4.85 (M, 1H), 3.7 (M, 4H), 2.75 (M, 2H), 2.5 (M, 4H), 2.1 (M, 1H), 1.95 (M, 1H), 1.75 (S, 3H), 1.6 (M, 4H), 1.2 (S, 3H)
EXAMPLE 12
4-Isoprenyl-1-methyl-2-(4-oxy-morpholin-4-yl)-cyclohexanol
[0117] 4-Isoprenyl-1-methyl-2-morpholin-4-yl-cyclohexanol (17.7 g, 0.074 moles) was dissolved in ethanol (100 ml) and 35% hydrogen peroxide (37 ml, 0.325 moles) was added. Heated with stirring at 50° for 6 hours. 5% palladium on carbon (100 mg) was added in order to decompose the excess peroxide. Stirred at room temperature for 3 hours. (Peroxide test papers gave a negative result.)
[0118] Filtered through a pad of HiFlo to remove the palladium on carbon and the solvent was evaporated under reduced pressure to give the product as a yellow oil (22.2 g).
[0119] 1 H NMR (300 MHz, CDCl 3 ) 5.5 (M, 1H), 4.85 (M, 1H), 4.5 (M, 2H), 3.7 (M, 4H), 3.4 (M, 3H), 2.95 (M, 1H), 2.65 (M, 1H), 2.25 (M, 1H), 2.0 (M, 1H), 1.85 (M, 1H), 1.75 (M, 1H), 1.75 (S, 3H), 1.55 (M, 1H), 1.55 (S, 3H)
EXAMPLE 13
4R-Isoprenyl-1-methylcyclohex-2-enol
[0120] 4-Isoprenyl-1-methyl-2-morpholin-4-yl-cyclohexanol (4.6 g, 0.018 moles) was dissolved in toluene (80 ml) and silica (1.1 g) was added. The reaction mixture was heated to reflux with stirring. Water generated in the reaction was removed using Dean and Stark apparatus. After refluxing overnight, the silica was removed by filtration and the filtrate evaporated under reduced pressure to give a brown oil
[0121] (4.0 g). Dissolved in dichloromethane and washed with 2M hydrochloric acid. Washed with water and dried over anhydrous magnesium sulphate. The solvent was removed by evaporation under reduced pressure to give the product as a brown oil (1.3 g).
[0122] 1 H NMR (300 MHz, CDCl 3 ) 5.7 (M, 2H), 4.8 (M, 2H), 2.7 (M, 1H), 1.8 (M,2H), 1.75(S,3H), 1.65(M,2H), 1.3(S,3H)
[0123] Experimental details for Synthesis of Tetrahydropyridines
[0000]
EXAMPLE 14
Preparation of 2-(2,4-Dimethoxyphenyl)-1,4-dimethyl-1,2-dihydropyridine.
[0124] To a stirred solution of 2,4-dimethoxybromobenzene (1) (0.5 g, 2.3 mmol) in diethyl ether (10 ml) cooled at −78° C. under nitrogen was added a solution of n-butyl lithium (1.0 ml, 2.5 mmol of 2.5M solution in hexane) drop wise. The mixture was stirred at −78° C. for 2 hours and then 1,4-dimethyl pyridinium iodide (2) (0.54 g, 2.5 mmol) was added as a solid. The resultant mixture was allowed to warm to room temperature and stirred at room temperature for 18 hours. The mixture was diluted with water (20 ml) and extracted with diethyl ether (2×15 ml). The combined organic extracts were dried over anhydrous magnesium sulphate, filtered and evaporated to yield 2-(2,4-dimethoxyphenyl)-1,4-dimethyl-1,2-dihydropyridine (4) (0.5 g, 93%) as a brown oil, 1 H NMR CDCl 3 ??1.7 (s, 3H), 2.7 (s, 3H), 3.8(s, 6H), 4.45 (dd, 1H, J=2,7) 4.85 (m, 1H), 5.4 (d, 1H, J=4), 6.05 (d, 1H, J=7), 6.45 (d, 1H, J=3), 6.55 (m, 1H), 7.5 (d, 1H, J=9).
[0125] By proceeding in a similar manner starting from 2,4-dimethoxybromobenzene (1) and 1-isopropyl-4-methyl pyridinium iodide (3), 2-(2,4-dimethoxyphenyl)-1-isopropyl-4-methyl-1,2-dihydropyidine (5) was prepared, 1 H NMR CDCl 3 ? (d, 6H J=7), 1.7 (s, 3H), 3.15 (m, 1H), 3.7 (s, 6H), 4.5 (d, 1H J=8), 4.8 (m,1H), 5.5(5, 1H J=5), 6.3 (d, 1H J=7), 6.45 (d, 1H J=2), 6.55 (m, 1H), 7.55 (d, 1H J=8).
EXAMPLE 15
Preparation of 6-(2,4-Dimethoxyphenyl)-1,4-dimethyl-1,2,3,6-tetrahydro-pyridine (6).
[0126] To a stirred solution of 2-(2,4-dimethoxyphenyl)-1,4-dimethyl-1,2-dihydropyridine(4) (0.48 g, 2.06 mmol) in methanol (5 ml) at room temperature was added sodium borohydride (98 mg, 2.51 mmol), gas evolution commenced immediately, the resulting mixture was stirred for 3 hours. At this time the solvent was evaporated and the residue suspended in water (5 ml) and extracted with ethyl acetate (2×10 ml). The organic extract was then extracted with 2M hydrochloric acid (2×15 ml). The aqueous layer was basified with 2M sodium hydroxide and extracted with ethyl acetate (2×20 ml), the organic extract was dried over anhydrous magnesium sulphate, filtered and evaporated to yield 6-(2,4-dimethoxyphenyl)-1,4-dimethyl-1,2,3,6-tetrahydropyridine (6) (350 mg, 73%) as a yellow oil, 1 H NMR CDCl 3 δ?1.55 (s, 3H), 1.9 (m, 1H), 2.2 (s, 3H), 2.5(m, 2H), 2.95 (m, 1H), 3.8 (s, 6H), 4.1 (m, 1H), 5.2 (m, 1H), 6.5 (m, 2H), 7.3 (d, 1H J=4).
[0127] By proceeding in a similar manner starting from 2-(2,4-dimethoxyphenyl)-1-isopropyl-4-methyl-1,2-dihydropyidine (5), 6-(2,4-dimethoxyphenyl)-1-isopropyl-4-methyl-1,2,3,6-tetrahydropyridine (7) was prepared, 1 H NMR CDCl 3 δ 0.95 (d, 3H J=6), 1.05 (d, 3H J=6), 1.7 (s, 3H), 1.9 (m, 1H), 2.5 (m, 1H), 2.85 (m, 1H), 3.0 (m,1H), 3.8 (s, 6H), 4.6 (s, 1H), 5.2 (s, 1H), 6.45 (d, 1H J=3), 6.5 (dd, 1H J=3,8), 7.4 (d, 1H J=8).
EXAMPLE 16
Preparation 4-(1,4-Dimethyl-1,2,5,6-tetrahydropyridin-2-yl)-benzene-1,3-diol (8)
[0128] To a stirred solution of 6-(2,4-dimethoxyphenyl)-1,4-dimethyl-1,2,3,6-tetrahydro-pyridine (6) (300 mg, 1.27 mmol) in dichloromethane (20 ml) cooled at 0° C. under nitrogen was added boron tribromide (3.1 ml, 3.18 mmol of 1.0M solution in dichloromethane), the resultant dark solution was allowed to warm to room temperature and stirred for 1 hour. The solution was poured onto ice and basified with sodium bicarbonate. The layers were separated and the aqueous layer was extracted with dichloromethane (20 ml), the combined organic layers were dried over anhydrous magnesium sulphate, filtered and evaporated to a gum (200 mg). The material was purified on a 10 g silica cartridge eluting with methanol/dichloromethane/ammonia (7:92:1) to yield 4-(1,4-dimethyl-1,2,5,6-tetrahydropyridin-2-yl)-benzene-1,3-diol (8) (93 mg, 35%) as a gum, 1 H NMR D6-acetone ??1.67 (s, 3H), 1.97 (m,1H), 2.3 (s, 3H), 2.42 (m, 1H), 2.74 (m, 1H), 3.08 (m, 1H), 3.74 (s, 1H), 5.15 (s, 1H), 6.2 (d, 1H J=2), 6.27 (dd, 1H J=2,8), 6.82 (d, 1H J=8), 9.4 (bs, 2H).
[0129] By proceeding in a similar manner starting from 6-(2,4-dimethoxyphenyl)-1-isopropyl-4-methyl-1,2,3,6-tetrahydropyridine (7), 4-(1-isopropyl-4-methyl-1,2,5,6-tetra-hydropyridin-2-yl)-benzene-1,3-diol (9) was prepared, NMR D6-acetone δ 0.81 (d, 3H J=7), 0.98 (d, 3H J=7), 1.52 (s, 3H), 1.84 (m, 1H), 2.15(m, 1H), 2.29(m, 1H), 2.94 (m, 2H), 4.09 (s, 1H), 4.97 (s, 1H), 6.05 (d, 1H J=3), 6.11(dd, J=3,8), 6.68 (d, J=8), 9.6 (bs, 2H).
EXAMPLE 17
Preparation of 1-Isopropyl-4-methyl pyridinium iodide (3)
[0130] To a stirred solution of 4-picoline (2.5 g, 26.8 mmol) in acetonitrile (50 ml) was added isopropyl iodide (9.1 g, 53.6 mmol) drop wise, the resultant mixture was heated at 90° C. for 24 hours. After cooling the solvent was evaporated to give a red solid which on trituration with ethyl acetate yielded 1-isopropyl-4-methyl pyridinium iodide (6.01 g, 85%) as a cream solid, 1 H NMR D6-DMSO δ?1.6 (d, 6H, J=7), 2.6 (s, 3H), 4.95 (m, 1H), 8.0 (d, 2H J=6), 9.05 (d, 2H J=6).
Preparation of 1-Aryl-piperidine2,4-diones
[0131]
EXAMPLE 18
Preparation of Ethyl 3-(3-Chlorophenylamino)propionate
[0132] 3-Chloroaniline (3.8 g, 0.03 moles) was dissolved in ethanol (5 ml) and ethyl acrylate (3.3 g, 0.033 moles) was added in ethanol (5 ml). Concentrated hydrochloric acid (1 ml) was added and the reaction mixture was heated at reflux for 48 hours. Evaporated to a low bulk and dissolved the residue in dichloromethane and water. Basified to pH 9 with aqueous ammonia and separated. Evaporated off the dichloromethane under reduced pressure to give the crude product as a yellow oil (5.4 g) Purified using a silica column eluted with isohexane:ethyl acetate 9:1 to give the required product (3.5 g, 51%) as a colourless oil.
[0133] 1 H NMR CDCl 3 δ 1.30 (t, 3H, J=6.5 Hz), 2.65 (t, 2H, J=6 Hz), 3.45 (q, 2H J=6 Hz), 4.20 (q, 2H, J=6.5 Hz), 6.50 (m, 1H), 6.60 (m, 1H), 6.70 (m, 1H), 7.10 (m, 1H)
EXAMPLE 19
Preparation of N-(3-Chlorophenyl)-N-(2-ethoxycarbonyl-ethyl)-malonamic acid ethyl ester
[0134] Ethyl 3-(3-Chlorophenylamino)propionate (3.5 g, 0.0154 moles) was dissolved in dichloromethane (40 ml) and ethyl malonyl chloride (2.55 g, 0.017 moles) was added dropwise in dichloromethane (10 ml) with stirring and cooling in order to keep the reaction temperature below 20°. Triethylamine (1.72 g, 0.017 moles) was added dropwise in dichloromethane (10 ml). The reaction temperature was kept below 20° by ice bath cooling. The reaction mixture was allowed to warm to room temperature and stirred at room temperature overnight. Washed with 2M hydrochloric acid, water and sodium bicarbonate solution. Dried over anhydrous magnesium sulphate, filtered and evaporated to give the required product as an orange oil. (4.5 g, 86%)
[0135] 1 H NMR CDCl 3 δ 1.25 (m, 6H), 2.65 (t, 2H, J=7 Hz), 3.20 (s, 2H), 4.10 (m, 4H), 7.15 (m, 1H), 7.30 (m, 1H), 7.40 (m, 2H)
EXAMPLE 20
Preparation of Ethyl 1-(3-chlorophenyl)piperidine-2,4-dione carboxylate
[0136] Sodium (0.7 g, 0.029 moles) was dissolved in ethanol (90 ml) and N-(3-Chlorophenyl)-N-(2-ethoxycarbonyl-ethyl)-malonamic acid ethyl ester (4.5 g, 0.0132 moles) was added in ethanol (30 ml). The reaction mixture was heated at reflux overnight. The ethanol was evaporated off and the residue dissolved in water. Washed with diethyl ether and acidified to pH2 with concentrated sulphuric acid. Extracted with dichloromethane and the combined dichloromethane extracts were combined. Washed with water and dried over anhydrous magnesium sulphate. Filtered and evaporated to give the product as an orange oil (2.8 g, 72%)
[0137] 1 H NMR CDCl 3 δ 1.40 (t, 3H, J=5 Hz), 2.85 (t, 2H, J=6 Hz), 3.85 (t, 2H J=6 Hz), 4.40 (q, 2H, J=5 Hz), 7.20 (m, 2H), 7.30 (m, 1H), 7.35 (m, 1H)
EXAMPLE 21
Preparation of 1-(3-Chlorophenyl)piperidine-2,4-dione
[0138] Ethyl 1-(3-chlorophenyl)piperidine-2,4-dione carboxylate (2.8 g, 0.0095 moles) was dissolved in acetonitrile (100 ml)/water (10 ml) and refluxed for 2 hours. Evaporated to a low bulk and dissolved in dichloromethane. Washed with water and dried over anhydrous magnesium sulphate. Filtered and evaporated to give the product as an orange oil (2.2 g). Purified using a silica column eluted with dichloromethane:ethyl acetate 9:1 to give the required product as a pale yellow gum (1.2 g, 59%)
[0139] 1 H NMR CDCl 3 δ 2.80 (t, 2H, J=6 Hz), 3.55 (s, 2H), 4.05 (t, 2H, J=6 Hz), 7.20 (m, 1H), 7.30 (m, 1H), 7.35 (m, 1H), 7.40 (m, 1H)
[0140] Also prepared in a similar manner were
1-Phenylpiperidine-2,4-dione
[0141] 1 H NMR CDCl 3 , ppm) δ 2.80 (t, 2H, J=6 Hz), 3.6 (s, 2H), 4.05 (t, 2H, J=6 Hz), 7.30 (m, 3H), 7.45 (m, 2H)
1-(3-Methylphenyl)piperidine-2,4-dione
[0142] 1 H NMR (CDCl 3 , ppm) δ 2.40 (s, 3H), 2.80(t, 2H, J=6.5 Hz), 3.6 (s, 2H), 4.05 (t, 2H, J=6.5 Hz), 7.30 (m, 3H), 7.45 (m, 2H)
1-(4-Fluorophenyl)piperidine-2,4-dione
[0143] 1 H NMR CDCl 3 , ppm) δ 2.80 (t, 2H, J=6 Hz), 3.55 (s, 2H), 4.0 (t, 2H, J=6 Hz), 7.1 (m, 2H), 7.25 (m, 2H)
1-(3,5-Difluorophenyl)piperidine-2,4-dione
[0144] 1 H NMR (CDCl 3 , ppm) δ 2.80 (t, 2H, J=6 Hz), 3.58 (s, 2H), 4.04 (t, 2H, J=6 Hz), 6.68-6.83 (m, 1H), 6.84-6.99 (m, 2H).
1-(3,5-Dichlorophenyl)piperidine-2,4-dione
[0145] 1 H NMR (CDCl 3 , ppm) δ 2.80 (t, 2H, J=6 Hz), 3.58 (s, 2H), 4.02 (t, 2H, J=6 Hz), 7.20-7.36 (m, 3H).
1-(4-Methylpyrid-2-yl)piperidine-2,4-dione
[0146] 1 H NMR (CDCl 3 , ppm) δ 2.41 (s, 3H), 2.75 (t, 2H, J=6 Hz), 3.62 (s, 2H), 4.44 (t, 2H, J=6 Hz), 6.94-7.02 (m, 1H), 7.72-7.79 (m, 1H), 8.25-8.36 (m, 1H).
Preparation of Cyclohexane-1,3-diones
[0147]
EXAMPLE 22
Preparation of 4-(4-Fluorophenyl)cyclohexane-1,3-dione
[0148] Sodium (0.3 g, 0.013 moles) was dissolved in ethanol (50 ml) and 4-Fluorophenylacetone (2.0 g, 0.013 moles) was added in ethanol (10 ml). Ethyl acrylate (1.3 g, 0.013 moles) was and the reaction mixture was heated at reflux overnight. The reaction mixture was allowed to cool and evaporated under reduced pressure to give a brown gum. Dissolved in water and washed with diethyl ether. The aqueous layer was acidified to pH2 with conc. Hydrochloric acid and extracted with dichloromethane. The extracts were combined and washed with water. Dried over anhydrous magnesium sulphate and filtered. The filtrate was evaporated to give an orange oil. (1.7 g) This was purified using a silica column eluted with dichloromethane: ethyl acetate 8:2 and then dichloromethane:ethyl acetate 2:1 to give a colorless gum. (0.428 g) This was triturated with diethyl ether/isohexane to give 4-(4-Fluorophenyl)cyclohexane-1,3-dione (0.28 g) as a white solid.
[0149] 1 H NMR (CD 3 OD, ppm) δ 2.1 (m, 1H), 2.3 (m, 1H), 2.4 (m, 2H), 3.7 (m, 1H), 4.9 (s, 2H), 7.1 (m, 2H), 7.2 (m, 2H).
[0150] Also prepared in a similar manner
4-Phenylcyclohexane-1,3-dione
[0151] 1 H NMR (CD 3 OD, ppm) δ 2.15 (m, 1H), 2.3 (m, 3H), 3.7 (m, 1H), 4.9 (s, 2H), 7.2 (m, 3H), 7.3 (m, 2H).
Preparation of Pyridazin-3-ones
[0152]
EXAMPLE 23
3-Oxo-2-phenylhydrazono)pentanedioic acid dimethylester
[0153] To a mixture of aniline (1.86 g, 20 mmol) in concentrated hydrochloric acid (10 ml) and water (20 ml) at a temperature below 5° C. was added a solution of sodium nitrite (1.38 g, 20 mmol) in water (15 ml) drop wise. The resultant mixture was stirred for 15 minutes and then it was poured into a solution of dimethylacetonedicarboxylate (3.48 g, 20 mmol) and sodium acetate (12 g, 0.146 mol) in ethanol (12 ml) and water (40 ml) causing an immediate precipitation. The suspension was stirred for 1 hour and then extracted with ethyl acetate (3×125 ml). The combined organic extracts were dried over anhydrous magnesium sulphate, filtered and evaporated to yield 3-oxo-2-phenylhydrazono)pentanedioic acid dimethyl ester as a red oil (5.58 g, quantitative) consisting of a mixture of E and Z isomers about the hydrazone
[0154] 1 NMR CDCl 3 δ{tilde over (□)}{tilde over (□)}{tilde over (□)}(singlets, 8H), 7.1-7.5 (m, 5H), 12.8 (s, 1H).
EXAMPLE 24
Methyl 4-hydroxy-6-oxo-1-phenyl-1,6-dihydropyridazine-3-carboxylate
[0155] 3-Oxo-2-phenylhydrazono)pentanedioic acid dimethyl ester (12.5 mmol) was dissolved in dichlorobenzene and heated at reflux for 24 hours and then allowed to cool to room temperature. The solvent was evaporated and the residue triturated with ether to give methyl 4-hydroxy-6-oxo-1-phenyl-1,6-dihydropyridazine-3-carboxylate a beige solid (2.4 g, 78%)
[0156] 1H NMR CDCl 3 δ 4.0 (s, 3H), 6.4 (s, 1H), 7.4-7.6 (m, 5H), 10.3 (s, 1H).
EXAMPLE 25
4-Hydroxy-6-oxo-1-phenyl-1,6-dihydropyridazine-3-carboxylic acid
[0157] Methyl 4-hydroxy-6-oxo-1-phenyl-1,6-dihydropyridazine-3-carboxylate (0.8 g, 3.24 mmol) was suspended in sodium hydroxide solution (20 ml of 2.0M) and heated at reflux for 1 hour. The mixture was allowed to cool to room temperature, acidified with 2M hydrochloric acid and extracted with ethyl acetate (3×15 ml). The combined organic extracts were dried over anhydrous magnesium sulphate, filtered and evaporated to yield 4-hydroxy-6-oxo-1-phenyl-1,6-dihydropyridazine-3-carboxylic acid as a yellow solid (0.6 g, 80%)
[0158] 1 H NMR CDCl 3 δ 6.3 (s, 1H), 7.35-7.7 (m, 5H).
EXAMPLE 26
5-Hydroxy-2-phenyl-2H-pyridazin-3-one
[0159] 4-Hydroxy-6-oxo-1-phenyl-1,6-dihydropyridazine-3-carboxylic acid (400 mg, 1.72 mmol) was heated at 270° C. in a microwave for 3 minutes. The resultant black mixture was extracted into saturated sodium bicarbonate (15 ml). The sodium bicarbonate solution was acidified with concentrated hydrochloric acid and extracted with ethyl acetate (3×15 ml). The combined organic extracts were dried over anhydrous magnesium sulphate, filtered and evaporated to a crude solid (300 mg). This was purified on a 10 g SPE cartridge eluting with dichloromethane/ethyl acetate (80:20 to 60:40) to yield 5-hydroxy-2-phenyl-2H-pyridazin-3-one (60 mg) as a beige solid
[0160] 1 H NMR D6 DMSO δ 6.05 (d, 1H, J=2.7 Hz), 7.4-7.6 (m, 5H), 7.85 (d, 1H, J=2.7 Hz), 11.6 (s, 1H).
[0161] The following compounds are also active in the method of the present invention:
2-(4-Chlorophenyl )-5-hydroxy-2H-pyridazin-3-one
5-Hydroxy-2-(3-trifluoromethylphenyl)-2H-pyridazin-3-one
[0162] The following synthesis is described in J. Het. Chem. 1989, 26, 169-176
[0000]
EXAMPLE 27
2-(3,5-Difluorophenyl)-5-hydroxypyridazin-3-one
[0163] 4-Bromo-2-(3,5-difluorophenyl)-5-hydroxypyridazin-3-one (0.6 g, 1.98 mmoles) was dissolved in ethanol (50 ml) and 1M sodium hydroxide (4 ml) was added. 10% Palladium on carbon (0.15 g) was added and the flask was placed under an atmosphere of hydrogen (balloon) with stirring. The reaction mixture was stirred overnight at room temperature. Filtered off the catalyst using Hyflo and evaporated to dryness. Added 2M hydrochloric acid and extracted into ethyl acetate. Washed with water and dried over anhydrous magnesium sulphate. Filtered and evaporated the filtrate to give a white solid. Triturated with diethyl ether to give the product as a white solid. (0.32 g, 72%)
[0164] 1H NMR DMSOd6 δ 12.2 (br s, 1H), 7.9 (d, 1H, J=3 Hz), 7.3 (m, 5H), 6.1 (d, 1H, J=3 Hz)
[0165] Also prepared in a similar manner
2-(2,5-Difluorophenyl)-5-hydroxypyridazin-3-one
[0166] 1 H NMR DMSOd6 δ 11.8 (br s, 1H), 7.85 (d, 1H, J=2.5 Hz), 7.4 (m, 4H), 6.1 (d, 1H, J=2.5 Hz)
EXAMPLE 28
4-Bromo-2-(3,5-difluorophenyl)-5-hydroxypyridazin-3-one
[0167] 4,5-Dibromo-2-(3,5-difluorophenyl)pyridazin-3-one (1.5 g, 0.0041 moles) was suspended in ethanol (50 ml) and potassium hydroxide (0.8 g, 0.0123 moles) was added in water (8 ml). Refluxed for 4 hours with stirring. Evaporated to a low bulk and diluted with water. Acidified to pH2 with conc. hydrochloric acid and extracted with ethyl acetate. Washed with water and dried with anhydrous magnesium sulphate. Filtered and evaporated the filtrate to give an orange solid. Triturated with diethyl ether and dried in a desiccator to give the product as a cream solid. (0.7 g, 56%)
[0168] 1 H NMR DMSOd6 δ 12.5 (br s, 1H), 7.9 (s, 1H), 7.35 (m, 3H); 19 F NMR δ 110
[0169] Also prepared in a similar manner
4-Bromo-2-(2,5-difluorophenyl)-5-hydroxypyridazin-3-one
[0170] 1 H NMR DMSOd6 δ 7.9 (s, 1H), 7.5 (m, 3H); 19 F NMR δ 117, 126
4-Bromo-2-(2,5-dichlorophenyl)-5-hydroxypyridazin-3-one
[0171] 1 H NMR DMSOd6 δ 7.9 (s, 1H), 7.8 (d, 1H, J=2.5 Hz), 7.7 (d, 1H, J=8.5 Hz), 7.6 (d,d, 1H, J=2.5, 8.5 Hz)
EXAMPLE 29
4,5-Dibromo-2-(3,5-difluorophenyl)pyridazin-3-one
[0172] Mucobromic acid (2.8 g, 0.011 moles) was dissolved in ethanol (75 ml) and 3,5-difluorophenyl hydrazine hydrochloride (1.8 g, 0.01 moles) was added. After 30 minutes, triethylamine (1.4 ml, 0.01 moles) was added. The reaction mixture was stirred at room temperature for 3 hours. Evaporated to a low bulk and the residue was suspended in glacial acetic acid (80 ml). Refluxed with stirring overnight to give a brown solution. Evaporated to dryness and triturated with methanol to give the required product as a pale brown solid. (3.4 g, 93%)
[0173] 1 H NMR DMSOd6 δ 8.3 (s, 1H), 7.4 (m, 3H); 19 F NMR δ 109
[0174] Also prepared in a similar manner
4,5-Dibromo-2-(2,5-dichlorophenyl)pyridazin-3-one
[0175] 1 H NMR DMSOd6 δ 7.9 (s, 1H), 7.45 (m, 1H), 7.4 (m, 2H)
4,5-Dibromo-2-(3,5-dichlorophenyl)pyridazin-3-one
[0176] 1 H NMR DMSOd6 δ 8.35 (s, 1H), 7.8 (m, 1H), 7.7(m,2H)
4,5-Dibromo-2-(2,5-difluorophenyl)pyridazin-3-one
[0177] 1 H NMR DMSOd6 δ 8.35 (s, 1H), 7.5 (m, 3H)
[0000]
EXAMPLE 30
2-(3,5-Dichlorophenyl)-5-hydroxypyridazin-3-one
[0178] 2-(3,5-Dichlorophenyl)-5-methoxypyridazin-3-one (0.25 g, 0.92 mmoles) was suspended in ethanol (40 ml) and potassium hydroxide (0.12 g, 1.8 mmoles) was added in water (5 ml). Refluxed overnight with stirring to give a yellow solution. Evaporated to dryness and added 2M hydrochloric acid. Extracted with ethyl acetate (×2) and washed with water and dried over anhydrous magnesium sulphate. Filtered and evaporated to give a yellow solid. Triturated with dichloromethane to give a pale yellow solid. (0.1 g, 42%)
[0179] 1 H NMR DMSOd6 δ 7.75 (d, 1H, J=3 Hz), 7.6 (m, 2H), 7.5 (m, 1H), 6.25 (d, 1H, J=3 Hz)
[0180] Also prepared in a similar manner
2-(2,5-Dichlorophenyl)-5-hydroxypyridazin-3-one
[0181] 1H NMR DMSOd6 δ 10.9 (br s, 1H), 7.7 (d, 1H, J=3 Hz), 7.4 (m, 1H), 7.35 (m, 1H), 7.3 (m, 1H), 6.2 (d, 1H, J=3 Hz)
EXAMPLE 31
2-(3,5-Dichlorophenyl)-5-methoxypyridazin-3-one
[0182] 4-Bromo-2-(3,5-dichlorophenyl)-5-methoxypyridazin-3-one (2.5 g, 0.0071 moles) was dissolved in THF (250 ml) and cooled to −50° under nitrogen. 1.6M n-Butyl lithium (6.7 ml, 0.011 moles) was added dropwise with stirring. Allowed to warm to −20° over 1 hour. Added 1 equivalent of 1.6M n-Butyl lithium (4.4 ml, 0.0071 moles) dropwise. Stirred at −20° for 30 minutes. Poured into ammonium chloride solution and stirred for 15 minutes. Extracted with EtOAc (×2) and washed with water. Dried over anhydrous magnesium sulphate, filtered and evaporated to give a brown solid. (3.0 g) Purified using MPLC (silica, eluted with dichloromethane: EtOAc 9:1) to give a yellow solid. (0.25 g, 13%) Not pure used directly in the next reaction.
[0183] 1 H NMR DMSOd6 δ 7.7 (d, 1H, J=3 Hz), 7.6 (d, 2H, J=2 Hz), 7.5 (d, 1H, J=2 Hz), 6.2 (d, 1H, J=3 Hz)
[0184] Also prepared in a similar manner
2-(2,5-Dichlorophenyl)-5-methoxypyridazin-3-one
[0185] 1 H NMR DMSOd6 δ 7.95 (d, 1H, J=3 Hz), 7.75 (d, 1H, J=2.5 Hz), 7.7 (d, 1H, J=8 Hz), 7.6 (d, d, 1H, J=2.5, 8 Hz), 6.45 (d, 1H, J=3 Hz)
EXAMPLE 32
4-Bromo-2-(3,5-dichlorophenyl)-5-methoxypyridazin-3-one
[0186] Sodium (0.28 g, 0.012 moles) was dissolved in methanol (100 ml) and a suspension of 4,5-Dibromo-2-(3,5-dichlorophenyl)pyridazin-3-one (4.0 g, 0.01 moles) in methanol (60 ml) was added. Refluxed overnight. Evaporated to dryness and added water. Filtered off the solid and dried in a dessicator. Triturated with ether and dried in a dessicator. (3.1 g, 89%)
[0187] 1 H NMR DMSOd6 δ 8.35 (s, 1H), 7.75 (m, 1H), 7.7 (m, 2H), 4.15 (s, 3H)
[0188] Also prepared in a similar manner
4-Bromo-2-(2,5-dichlorophenyl)-5-methoxypyridazin-3-one
[0189] 1 H NMR DMSOd6 δ 8.35 (s, 1H), 7.8 (d, 1H, J=2.5 Hz), 7.7 (d, 1H, J=8.5 Hz), 7.65 (d of d, 1H, J=2.5, 8 Hz), 4.15 (s, 3H)
[0000]
EXAMPLE 33
4-Chloro-2-phenyl-5-hydroxypyridazin-3-one
[0190] 4,5-Dichloro-2-phenylpyridazin-3-one (2.4 g, 0.01 moles) was suspended in ethanol (50 ml) and potassium hydroxide (2.0 g, 0.03 moles) was added in water (20 ml). Refluxed for 4 hours. Evaporated to dryness and added water. Acidified to pH2 with c. hydrochloric acid. Filtered off the product as a buff solid and dried in a desiccator. (2.1 g) Took 0.5 g and dissolved in methanol, filtered and evaporated. Triturated with ether to give the product as a cream solid. (0.4 g, 76%)
[0191] 1 H NMR DMSOd6 δ 7.9, (s, 1H), 7.5 (m, 4H), 7.4 (m, 1H)
EXAMPLE 34
4,5-Dichloro-2-phenylpyridazin-3-one
[0192] Mucochloric acid (9.3 g, 0.055 moles) was dissolved in ethanol (60 ml) and phenyl hydrazine (5.4 g, 0.05 moles) was added. The reaction mixture was stirred at room temperature for 2 hours. Evaporated to a low bulk and the residue was suspended in glacial acetic acid (60 ml). Refluxed with stirring for 3 hours. Evaporated to dryness and triturated with methanol to give the required product as a pale brown solid. (11.0 g, 91%)
[0193] 1 H NMR DMSOd6 δ 7.95 (s, 1H), 7.5 (m, 4H), 7.4 (m, 1H)
[0194] The following compounds have also been found to be effective in treating glaucoma or ocular hypertension according to the method of the present invention.
[0000]
[0195] It is apparent to one of ordinary skill in the art that different pharmaceutical compositions may be prepared and used with substantially the same results. That is, other Abnormal Cannabidiols will effectively lower intraocular pressure in animals and are within the scope of the present invention. Also, the novel compounds of the present invention may be used in a method of providing neuroprotection to the eye of a mammal in a similar manner to the abnormal Cannabidiols of Published U.S. Patent Application 2005/0282912. | The present invention provides a method of treating glaucoma or ocular hypertension which comprises applying to the eye of a person in need thereof an amount sufficient to treat glaucoma or ocular hypertension of a compound of formula I
wherein Y, Q, Z, R, R 1 and R 2 are as defined in the specification.
The present invention further comprises pharmaceutical compositions, e.g. ophthalmic compositions, including said compound. | 0 |
BACKGROUND OF THE INVENTION
The present invention generally relates to an internal combustion engine for use in a motor vehicle and the like, having a self-idling governor which is capable of automatically controlling the engine speed at an idling operating condition of the engine to a target speed and more particularly, to an ignition timing control of the engine at the idling operating condition thereof.
A known internal combustion engine having a self-idling governor is disclosed in the Japanese Laid-open Patent Publication No. 54-76723 wherein a control valve is provided in a by-pass passage which communicates the upstream side and the downstream side of an intake passage by by-passing a throttle valve, with the control valve having the purpose of opening and shutting the by-pass passage and when the engine is in idling operating condition, an idling speed of the engine is controlled to become the target speed through the control of the amount of by-pass air by controlling the opening and shutting of the control valve.
Meanwhile, with respect to the ignition control of the engine, when the engine is in idling operating condition, the ignition timing thereof is usually fixed to an idling ignition timing in advance. This idling ignition timing is set to the spark delaying side in consideration of instability in combustion condition of the engine during idling operating condition thereof.
Upon continuation of engine loading condition during a certain period, immediately after the engine has been shafted to the idling operating condition from the speed decreasing condition, the engine is in relatively favorable combustion condition, since fuel injected into the combustion chamber is in favorable vaporized or atomized condition owing to the fact that the wall surface of the combustion chamber is high in temperature or the like.
Accordingly, immediately after the engine has been shifted to such an idling operating condition as described above, if the ignition timing is fixed to the idling ignition timing, it is delayed more than necessary with respect to the combustion condition of the engine and this results in that the engine is lowered in its speed. Therefore, in the above described engine having a self-idling governor, the self-idling governor is operated so as to raise the idling speed of the engine and the fuel is consumed more than necessary, with the increase of the amount of intake air.
SUMMARY OF THE INVENTION
Accordingly, an essential object of the present invention is to provide an improved ignition timing control device of the internal combustion engine having a self-idling governor which is capable of improving the fuel consumption rate at the time of shift of the engine condition to the idling operating condition by utilizing the self-idling governor, with the engine being noticed to be in favorable combustion condition, immediately after the engine has been shifted to the idling operating condition through a condition decreased in its speed after a continuation of running condition thereof.
Another important object of the present invention is to provide an ignition timing control device of the above described type which is simple in construction and stable in functioning, and can be readily incorporated into various internal combustion engines at low cost.
In order to accomplish these and other objects, according to one preferred embodiment of the present invention, there is provided a control device for an internal combustion engine having an ignition timing setting means for setting an ignition timing of the engine, an idling detecting means for detecting an idling operating condition of the engine, an idling speed control means for controlling the idling engine speed to a target speed by controlling the amount of intake air after having received a signal from the idling detecting means, and an ignition timing correcting means for advancing the ignition timing set by the ignition timing setting means than ordinary idling ignition timing during a certain period from the instance when the engine has entered into the idling operating condition after having received the signal from the idling detecting means.
By the construction according to the present invention as described above, the engine can be improved in fuel consumption rate thereof without interrupting the stability in idling operating condition thereof by advancing the ignition timing during a period wherein the engine is in favorable combustion condition immediately after the running condition thereof even in idling operating condition.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become apparent from the following description taken in conjunction with the preferred embodiment thereof with reference to the accompanying drawings, in which:
FIG. 1 is a fragmentary schematic diagram of a system construction of an internal combustion engine according to one preferred embodiment of the present invention;
FIG. 2 is a flow chart for explaining an ignition timing control executed by a control unit of FIG. 1;
FIG. 3 is a graph showing a map IGMAP of a basic ignition timing;
FIG. 4a is a graph showing a function which gives a spark advancing term at idling operating condition of the engine; and
FIGS. 4b through 4d are graphs similar to FIG. 4a which particularly show modifications thereof.
DETAILED DESCRIPTION OF THE INVENTION
Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals throughout the accompanying drawings.
Referring now to the drawings, FIG. 1 shows a schematic diagram of a system construction according to one preferred embodiment of the present invention.
In FIG. 1, an internal combustion engine 1 for use, for example, in a motor vehicle is provided with an intake passage 3 having an air flow sensor 4, a throttle valve 5 and a fuel injector 6 each disposed therein in turn from upstream side to downstream side, and an exhaust passage 8 having an exhaust gas purifying unit, for example, a catalytic converter 9 disposed therein, with the intake passage 3 and the exhaust passage 8 being opened and shut by an intake valve 2 and an exhaust valve 7, respectively. The intake passage 3 of the engine 1 is provided with a by-pass passage 11 which communicates the upstream side and the downstream side of the intake passage 3 by by-passing the throttle valve 5 and a control valve 12 operated by a duty solenoid is arranged in the course of the by-pass passage 11 so as to control the quantity of by-pass air passing through the by-pass passage 11 so that the engine speed becomes a target speed, when the engine is in idling operating condition. The control valve 12 is operatively controlled by control signals from a control unit 14, as well as the fuel injector 6 and a spark plug 13 disposed in a combustion chamber 1a of the engine 1.
The above described control unit 14 executes necessary controls by being applied with such input data as the quantity of intake air detected by the air flow sensor 4, a throttle opening detected by a throttle sensor 15, a suction pressure detected by a boost sensor 16 which is disposed in the intake passage 3 at the downstream side of the throttle valve 5, the engine speed detected by a revolution sensor 17, on-off signals of a neutral switch 18 of a transmission (not shown) and the like. The control with respect to the fuel injector 6 which is one of the controls executed by the control unit 14 is substantially a control wherein fuel is injected into the combustion chamber 1a during a given valve opening period, by determining each injection period in compliance with the quantity of intake air of every moment detected by the air flow sensor 4.
Furthermore, with respect to the control valve 12 disposed in the by-pass passage 11, as has been stated, the engine speed is controlled by the control unit 14 so as to coincide with the target speed set in advance, while the engine is in idling operating condition, by controlling a duty ratio of the control valve 12 in order to increase or decrease the quantity of by-pass air.
The above described two kinds of control are of known ones, and therefore, the details thereof will not be further described for the sake of brevity because they are not a part of the subject matter of the present invention.
In the next place, the control with respect to the spark plug 13 executed by the control unit 14 will be explained hereinafter.
In FIG. 2, there is shown a flow chart for explaining the control of ignition timing executed by the control unit 14.
At the beginning of this control, the engine speed, the suction pressure and the throttle opening are read into the control unit 14 at step 101. At the subsequent step 102, a basic ignition timing To is calculated by the use of, for example, a map IGMAP as shown in FIG. 3 for the determination of the basic ignition timing. As shown in the map IGMAP, the basic ignition timing To is suitably set in advance for each operating area divided by the engine speed and the suction pressure. At step 103, it is judged whether or not the throttle valve 5 is completely shut from the throttle opening read in. In case where the throttle valve 5 is completely shut, it is judged at step 104, whether or not the engine has just decreased in its speed and this judgement can be done by comparing the throttle opening of previous state with that of present state. When it is judged that the engine has just decreased in its speed at this step 104, a time t is set in a timer TM at the subsequent step 105 as a period during which the engine is favorably maintained in its combustion condition from the beginning of the idling operating condition.
Furthermore, when it is confirmed that TM is not equal to zero at step 106, an ignition timing advancing term or spark advancing term IGA is calculated at step 107 and is given as a function IGA(TM) of the present time TM of the timer TM, for example, as shown in FIG. 4a. The function IGA(TM) giving the ignition timing advancing term has a constant value, for example, 5° CA (Cranking Angle) until a certain time elapses from the beginning t of the idling operating condition and thereafter, it decreases, for example, at the rate of 0.35° CA per second in proportion to the decrease of the time TM in the timer. The function IGA(TM) decreases at the latter half of the time elapsed in the timer for desirably preventing a shock at the change of ignition timing advancing amount and for being caused to correspond to the combustion condition of the engine.
At the subsequent step 108, the above mentioned ignition timing advancing term IGA is added to the basic ignition timing To so as to obtain a desired final ignition timing T. At step 109, the spark plug 13 is ignited at the aforementioned ignition timing T so that one cycle of the ignition control is completed.
In addition, when the throttle valve 5 is completely shut (step 103) but in case where the engine has not just decreased in its speed, that is, in case where the engine is in the midst of decrease of its speed or in case where the engine is in idling operating condition, the procedure proceeds to step 110 from step 104, and at step 110, it is judged whether or not the neutral switch 18 is on and the engine is in idling zone, i.e., the engine speed is lower than the preetermined value. In case where the judgement at step 110 is YES, 1 is subtracted from the time value of the timer TM at step 111 and hereupon, when this value is not equal to zero, the spark plug 13 is ignited at the ignition timing T wherein the ignition timing advancing term IGA(TM) corresponding to the time in the timer TM is added to the basic ignition timing To in the order of steps 107, 108 and 109.
In other words, when the engine is shifted from speed decreasing condition to idling operating condition, the ignition timing advancing term IGA is added to the basic ignition timing To so that the ignition timing is set to the ignition timing advancing side during a certain period and upon the lapse of this period, the basic ignition timing To, that is, an idling ignition timing is finally set.
Moreover, when the engine is in an operating condition except those described above, that is, when the throttle valve 5 is not completely shut, the timer TM is reset to zero at step 112 and this results in that the ignition timing advancing term IGA is set to zero at the subsequent step 113.
In addition, in case where the throttle valve 5 is completely shut, but the neutral switch is off, or in case where the engine is not in idling zone, or in case where the time in the timer TM is up, i.e., TM equal zero, the ignition timing advancing term IGA is made to be zero at step 113 as well as the aforementioned case.
It is to be noted here that as shown in FIG. 4b, the time t in the timer may be such a variable value as t1 or t2 in accordance with the favorable extent of combustion conditions of the engine which is given by a coolant temperature, a period during which the engine is shifted to the idling operating condition from the beginning of speed decreasing condition.
It is further to be noted that as shown in FIG. 4c, the ignition timing advancing value may be changed in accordance with the favorable extent of the combustion condition of the engine.
Moreover, it should be noted that as shown in FIG. 4d, the ignition timing advancing value may be decreased in proportion to the time elapsed.
As described so far, immediately after the idling operating condition of the engine wherein the engine is maintained in favorable combustion condition, the ignition timing is set rather to the ignition timing advancing side than the ordinary idling ignition timing and this results in that the engine tends to be raised in its speed. Accordingly, the control valve 12 arranged in the by-pass passage 11 is controlled by the control unit 14 so as to lower the engine speed and as a result, since the amount of intake air is decreased as a whole, the engine is improved in fuel consumption rate thereof.
It is to be noted here that in the above described embodiment, although the timer TM is set when the engine has just decreased in its speed, the timer TM may be set at the beginning of idling operating condition of the engine.
Although the present invention has been fully described by way of example with reference to the accompanying drawings, it is to be noted here that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as included therein. | The disclosure is directed to a control device for an internal combustion engine for a motor vehicle such as an automobile or the like, having a control valve disposed in a by-pass passage for opening and shutting the by-pass passage which communicates the upstream side and the downstream side of an intake passage by by-passing a throttle valve, in which the engine speed in idling operating condition is controlled to a target speed. This control device is characterized in that the ignition timing is rather advanced than ordinary idling ignition timing during a certain period from the instance when the engine has entered into the idling operating condition after having received a signal detecting the idling operating condition of the engine. | 5 |
CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention concerns a rollup curtain, in particular a transparent rollup curtain. More precisely, it concerns a rollup curtain of the type featuring an apron composed of horizontal slats articulated between themselves and which rolls up on a horizontal shaft or drum placed above, the edges of this articulated apron moving within lateral guides or slides.
[0007] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98
[0008] Such rollup curtains are generally relied upon to be shaped and fitted to constitute rollup shutters or analog closures, or dividing partitions, or wall portions, or complete partitions of certain locations.
[0009] Such curtains permit the view and the passage of light from the inside to the outside and/or from the outside to the inside, and this even when the transparent rollup curtain is in the lowered position.
[0010] This type of transparent rolling curtain may be applied:
for creating secure closures of ingress to certain locales such as garages, stores . . . ; in this application, such rolling curtains allow passers-by to see the merchandise displayed, even when the curtain is lowered, while ensuring security, preventing theft and vandalism; for the installation of retractable transparent partitions permitting the transformation of certain covered spaces such as decks of individual houses, pool houses, swimming pool shelters, outdoor spaces of diverse commercial businesses, cafés, restaurants . . . , into winter gardens, game or reception areas, allowing these spaces to be occupied during the cold season or in any atmospheric conditions; for the erection of retractable partitions in certain work places such as workshops, offices, reception desks in hotels or hospitals; for the creation of retractable partitions in areas constituting chemical, thermal, acoustical or biological hazards (laboratories, nuclear power plants . . . ) or in places of high foot traffic (airports, railway stations . . . ); for the installation of retractable partitions in residential housing or other locales situated in zones exposed to cyclones and/or hurricanes while permitting to close and secure the openings without obstructing the view.
[0016] Document FR-2.945.313 describes a transparent security curtain composed of a number of horizontal transparent slats, interconnected in an articulated manner. Each flat slat consists of a plurality of modules abutting each other. It is furthermore connected, in an articulated manner, to the slat immediately above or below it through two different complementary joint sections on the neighboring edges of two adjacent slats and interlocked one in the other. Finally, a divisible blocking piece is positioned at the end of each plate to stabilize the system.
[0017] The transparent security curtain described in document FR-2.945.313 has notably these disadvantages:
a noisy operation during the lowering and raising movements; the need for two different joint sections to create the articulated link of the slats increases production costs and makes installation more difficult;—the flat slats it consists of result in an irregular roll-up of the apron and a significant volume and thereby in a very bulky casing for housing the rolled up curtain; the slats consists of butt-jointed modules and are assembled to each other through superposition of their ends which creates a large number of opaque, unattractive areas and which reduce visibility.
[0021] Document FR-2.941.989 describes a slat for roll-up shutters comprising a solid core, constituted of a transparent or translucent material, covered over a portion of each of its two sides by a coating consisting of an opaque material, this coating being applied on the back side and the front side of said core so that an incident ray of light cannot go through said slat without being stopped by at least one of the two coatings. Said slat presents an overall curved transversal section without any precision being applied to the desirability of this disposition.
[0022] According to an implementation of the invention described in this document, the slat for roll-up shutters has a curved outer surface and according to a preferred implementation the two surfaces of the core are concave. It is possible to vary the shape of the slat and notably the shape of the core, depending on the amount of light that the expert wants to see transmitted through said slat. This is the only function devolved to this shape.
[0023] Document FR-2.643.938, describes a transparent security roll-up shutter consisting of a number of horizontal slats articulated among themselves through hinges.
[0024] According to one implementation the apron of this roll-up shutter may be coiled around a drum. In this case the coiling obtained is also irregular and requires a very bulky casing for housing the coiled curtain. Furthermore, the linkage means of the interconnected slats seriously complicate the replacement of any one of them, should that ever become necessary.
[0025] Document EP-0.354.987 describes a transparent coiled shutter consisting of distinct coiled shutter slats, interconnected with tensile strength, made of transparent plastic, that can be coiled around a coil shaft and which can be linked together with the interposition of arched coupling sections, the latter being equipped on their longitudinal edges with receiving grooves for the stop heads presented by the horizontal edges of the slats of the coiled shutter. Said heads can be introduced into the receiving grooves of the coupling profiles and be maintained there with the possibility of swiveling.
[0026] The major disadvantage of this shutter is the complexity of its design, because it implies the utilization of several slats of different height which then need to be assembled in a strict sequence to obtain a coil of polygonal shape.
[0027] Document WO-2009/035701 describes a transparent coiled shutter consisting of flat slats of decreasing height from the top to the bottom. This coiled shutter presents thus the same disadvantage as the device disclosed in document EP-0.354.987.
[0028] Document GB-2.120.306 describes a coiled protective grating formed by a series of transparent slats produced all in one piece and extending horizontally and by metallic rods interconnected in a pivoting manner by means of preferably circular ribs extending along the upper and lower edge of each slat, which are received inside the bushings formed in the metal of the rods.
[0029] The main disadvantage of the slats produced all in one piece is that they are not very shock-resistant, making the transparent curtain very fragile. Furthermore the process of manufacturing, transporting and installing such slats which generally present significant lengths (in the order of 2 to 7 meters) is complex and costly.
[0030] It is also customary, especially when the articulated slats forming the apron of the coiled curtains are of relatively great length, to produce each of these slats in two or more than two modules or parts of abutting slats.
[0031] For example, document EP-0.445.064 describes a security grille featuring several parallel rows of sections; between each section is located a number of elements made of a transparent plastic material, preferably of polycarbonate, these elements being separated by intermediary stiffening elements made for example of aluminum. In this implementation of the grille featuring a plurality of polycarbonate elements, the stiffening elements are of aluminum, so they are opaque which changes the transparency of the grille, particularly in the implementation where the aluminum elements have the same dimension as the polycarbonate elements.
[0032] To remedy this problem of lack of transparency due to the presence of opaque stiffeners, a second implementation is proposed in which the transparent elements present the same length as the parallel sections. Now, as already explained for the GB-2.120.306 document, this implementation in which the transparent modules are made of a single piece, is only mildly shock-resistant, making the transparent curtain very fragile.
[0033] Document FR-2.955.885 describes a coiled shutter element consisting of an assembly of rows of modules where each module is overall of a rectangular shape and the large sides are parallel to the coiling axle of said shutter and where the modules of a same row are interconnected by way of a bar or tube of circular section passing through hinges with which the large sides are equipped.
[0034] According to this document two adjacent modules are joined at their small sides and one of the small sides of a module is provided with a lip that overlaps the small side of the adjacent module.
[0035] A product of this kind is also described in document FR-2.945.313, according to which the abutting ends of the parts of slats or modules are assembled through simple overlapping or are assembled by bracketing.
[0036] According to such an abutting mode, the ends assembled through simple overlapping or by bracketing are complex and not very compatible with a transparent curtain because they create areas of excessive thickness and non-transparent vertical zones preventing perfect visibility and forming unsightly darkened surfaces and which have, furthermore, the disadvantage of not offering complete imperviousness to air, water, heat and cold.
[0037] Document U.S. Pat. No. 6,263,943 describes a modular coiled shutter for store doors and windows, composed of a plurality of rows of slats. Each slat is connected by means of loops to a lower slat and to an upper slat, allowing for limited movement of the slats and loops so that the modular coiled shutter can be rolled up and let down. Each slat can consist of a plurality of thin strips with reinforced ends. In order to connect the adjacent strips, each reinforced piece is provided with a coupler, the adjacent couplers presenting complementary coupling shapes enabling the interconnection of two adjacent strips.
[0038] However, these reinforced parts create areas of excessive thickness and vertical non-transparent zones preventing perfect visibility and creating unsightly darkened surfaces. Furthermore, the proposed couplers allowing rigid locking of the strips are complex, as they are for instance dovetailed, or have cylindrical recesses suitable for working together with an insert, thereby making manufacturing and installation complex and costly.
[0039] Also known are means of preventing the lateral dislocation of the slats in the grooves of the assembly and articulation sections, by means of plugs or stop caps of various designs, located at the ends of said sections. The systems using such stop caps are generally complex and awkward to handle.
[0040] It is the particular aim of the present invention to remedy the afore-mentioned disadvantages of prior art.
BRIEF SUMMARY OF THE INVENTION
[0041] According to a first characteristic disposition, this aim has been achieved with a coiled curtain, in particular a transparent coiled curtain, of the kind featuring a roll-up apron comprising a number of horizontal slats articulated among themselves, by means of joint sections, said apron coiling up on an upper horizontal shaft or drum and its lateral edges are mounted with the ability of moving in vertical slides or guides, this transparent coiled curtain being especially remarkable in that each of said slats presents a transversal section of formed or curved shape, allowing the apron to be rolled up around the roll-up shaft or drum and assuming essentially the shape of said shaft or drum, the concavity of the slats being turned towards the roll-up shaft or drum when said apron is rolled up around the latter, and in that each slat of the plurality of horizontal slats consists of two or more than two modules or parts of slats abutted and assembled through fitting their ends together.
[0042] Thanks to this disposition it is possible to roll up the apron in a casing of reduced dimensions, the coiled shape thus obtained presenting a regular cylindrical shape.
[0043] For example, the invention makes it possible to roll up a coiled shutter of a height of more than 3 meters around an axis featuring a diameter of 133 mm, in a housing presenting a diameter of 300 mm.
[0044] According to one example of implementation, the abutting ends are provided with a groove and a rib respectively, extending over the entire height of said abutting ends of the modules, said groove being interlocked with said rib.
[0045] According to another example of implementation, the groove and the rib present a complementary triangular profile.
[0046] This kind of assemblage has the advantage of not creating any excessive thickness or alteration of visibility in the connecting zones and to ensure excellent imperviousness to air, water, heat and cold.
[0047] In a manner known as such, the slats are assembled to each other by means of joint and articulation sections the opposing longitudinal edges of which feature parallel grooves in which are engaged, for example by sliding, the opposite edges of said slats, and according to an advantageous implementation, these joint and articulation sections present a transversal curved profile the concavity of which is turned towards the coiling shaft or drum when said apron is rolled up around said shaft or drum.
[0048] According to an interesting implementation, the transparent coiled curtain is provided on its side with blocking caps in order to prevent any lateral sliding or pullout of the slats, and, according to a characteristic disposition of the invention, these blocking caps present a curved transversal profile the concavity of which is turned toward the coiling shaft or drum when said apron is rolled up on said shaft or drum.
[0049] According to a characteristic disposition of the invention, these blocking caps comprise a sealing body applied against the ends of the joint section, so as to close off the entrance of the articulation grooves made in said joint section. This body is fastened by at least one screw and preferably two screws penetrating into cavities made in the partition separating said grooves.
[0050] According to a preferred implementation, the internal face of said blocking ends presents excessive thickness which is engaged in the entrance of the articulation grooves of the joint sections, these thicker areas being shaped and dimensioned for being fitted into said entrances without any noticeable play.
[0051] The blocking caps according to the invention make it easier to keep the slats in position and to remove them if necessary which allows significant time savings.
[0052] According to another interesting characteristic disposition, the blocking caps present an upper fin or cap.
[0053] According to another characteristic disposition, the body of the blocking caps features, on its outside face, lateral, partly overlapping wings ensuring that the apron remain in the guiding slides thereby preventing any unhinging when faced with pullout forces, for example in case of violent winds generating such forces.
[0054] According to an advantageous implementation, the coiling curtain also features at least one ring, preferably a number of rings, to be positioned on the roll-up shaft and including a fin overreaching a portion of the ring and positioned away from the outer face of said ring, so that when the curtain goes up, the fins of the rings cover the first joint section in order to prevent the slats from rubbing on each other while the curtain is being rolled up and thus the deterioration of the latter through the appearance of unsightly scuff marks on the transparent slats affecting the visibility through the shutter and which would make said coiled shutter more fragile.
[0055] The device according to the invention offers several interesting advantages. Specifically:
the curved form of the slats permits the apron to coil around the shaft or drum presenting a regular, cylindrical shape so that it is possible to roll up the apron in a casing of reduced dimensions; as the slats consist of a plurality of modules, they provide better resistance in comparison with a slat consisting of a single piece; as the modules are assembled directly by fitting their ends together, without an opaque intermediary element, good transparency of the curtain is retained; the ring positioned on the roll-up shaft and the upper ribs of the blocking pieces prevent the formation of scuff marks on the slats forming the roll-up shutter, thereby ensuring durability of the latter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0060] The aforementioned aims, characteristics and advantages, and still more, will become clearer in the following description and the attached drawings in which:
[0061] FIG. 1 is a front view of an example of implementation of the roll-up curtain to which the invention can be applied.
[0062] FIG. 2 is a partial front view at a larger scale than FIG. 1 .
[0063] FIG. 3 is a partial, exploded front view of an example of implementation of the transparent roll-up curtain according to the invention.
[0064] FIG. 4 is a section view along line 4 - 4 of FIG. 1 .
[0065] FIG. 5 is a side view of a transparent slat.
[0066] FIG. 6 is an analog view showing the articulated assembly of a slat positioned between an upper slat and a lower slat.
[0067] FIG. 7 is a front view illustrating a slat portion consisting of two abutted modules.
[0068] FIG. 8 is a section view at a larger scale along line 8 - 8 of FIG. 7 .
[0069] FIG. 9 is a side view of a slat module.
[0070] FIG. 10 is a sectional view at a larger scale along line 10 - 10 of FIG. 9 .
[0071] FIGS. 11 and 12 are detail views illustrating, at a larger scale, the details B and C respectively, of FIG. 10 .
[0072] FIG. 13 is a view, at a larger scale, showing the abutment of two juxtaposed modules.
[0073] FIG. 14 is a partial perspective view of the joint and articulation sections.
[0074] FIG. 15 is a front view of one of the ends of this joint section.
[0075] FIG. 16 is a section view, at a larger scale, along line 16 - 16 of FIG. 15 .
[0076] FIG. 17 is an enlarged side-face view of a soundproofing joint housed in the grooves of the joint sections.
[0077] FIG. 18 is a partial perspective view of a slat where the upper and lower edges are inserted in joint sections according to the invention.
[0078] FIG. 19 is a perspective view of a first example of implementation of a blocking end.
[0079] FIG. 20 is a perspective view of a second example of implementation of the blocking end.
[0080] FIG. 21 is a partial perspective view illustrating the sliding assembly of this second example of implementation of blocking ends in one of the guiding slides of the roll-up curtain.
[0081] FIG. 22 is an exploded perspective view of an example of implementation of the final slat of the roll-up curtain according to the invention.
[0082] FIGS. 23A , 23 A′, 23 B, 23 B′ and 23 C, 23 are exploded detail perspective views showing the fastening of the two implementation methods of the blocking end.
[0083] FIG. 24 is a perspective view of the roll-up ring according to the invention.
[0084] FIGS. 25A , 25 B, 25 C, 25 D, and 25 E are schematic views illustrating the assembly stages of the roll-up ring and the transparent roll-up shutter on the roll-up shaft.
[0085] FIG. 26 is a partially exploded perspective view of the roll-up shutter according to the invention.
[0086] FIG. 27 is a perspective view showing the roll-up shutter mounted on the roll-up shaft equipped with a number of roll-up rings.
[0087] FIG. 28 illustrates the start of the roll-up of the roll-up shutter.
[0088] FIG. 29 is a detail view of FIG. 28 showing the support action of the rib that the ring is equipped with.
[0089] FIG. 30 is a cross section view showing the transparent curtain according to the invention while it is being rolled up.
[0090] Reference to said drawings is being made to describe interesting, although not limiting, examples of implementation of the transparent roll-up curtain according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0091] The transparent roll-up curtain 1 to which the invention applies is of the type consisting of a roll-up curtain 2 , comprising a number of transparent horizontal slats 3 that are articulated among themselves by means of articulation devices 9 . This curtain is rolled up around a horizontal shaft or drum positioned above said apron. The opposite vertical edges of this apron move in lateral guides or slides 5 .
[0092] The roll-up shaft or drum 4 is housed in a casing 6 positioned above the apron. Neither this casing nor the rotational drive of the roll-up shaft or drum are described here, as such devices, motorized or not, are well known by the expert and do not enter into the scope of the present invention.
[0093] According to a first characteristic of the invention, each of said slats presents a transverse profile of shaped or curved form the concavity 7 of which is turned towards the roll-up shaft or drum 4 , when the apron 2 is rolled up around the roll-up shaft or drum ( FIG. 30 ).
[0094] The opposite longitudinal edges of the slats 3 are provided with assembly and articulation rods 12 with a circular section. These rods with circular section are connected to the respective longitudinal edges of the plates through the intermediary of a small bar 13 of small height. These rods 12 and the joining bars 13 which constitute the upper and lower rims of the slats, are made as a single piece with the slats 3 or the modules 3 A, 3 B, 3 C composing these slats, during the manufacturing process by injection of said slats and/or modules.
[0095] The lower part 1 A of the apron 2 is constituted by a slat 8 that is different from the others, the so-called ‘final’ slat, which may present a flat transverse profile and a greater height than the slates 3 . As shown in FIG. 22 , the lower edge of the final slat is provided with a bulge 27 made of a material with elastic deformability, for example rubber or a synthetic elastomer. This bulge 27 is intended to absorb the shocks as the curtain descends and/or to ensure impermeability while the curtain is in the lowered position.
[0096] The slats 3 may be made of any material presenting the desirable rigidity, solidity and transparency. They may for example be of polycarbonate produced by an appropriate injection process known by the expert. Advantageously, they may be of polycarbonate that is sold under brand names like “Lexan” or “Makrolon” which, apart from remarkable optic quality, offer good rigidity and mechanical resistance. Anti-UV treatment may be applied in a manner known as such, through incorporation in the basic material of the plates prior to the injection process. This treatment permits dispensing with the application of an anti-UV varnish after producing the plates, as is usually the case.
[0097] The slats 3 may present a relatively significant height, for example in the order of 85 mm, considerably above that of traditional transparent roll-up shutter slats. They may have a thickness in the order of 4 mm which gives them great solidity while permitting them a certain degree of flexibility and a shape memory thanks to which the transparent roll-up curtain according to the invention presents good resistance to shocks and attempts to tamper with them. Said slats may be coated with a varnish for optimal resistance to friction and scratches.
[0098] They may be endowed with excellent transparency or may be lightly tinged or not, or translucent, or opaque, or sparkled.
[0099] The slats 3 are constituted by several abutting modules or parts 3 A, 3 B, 3 C . . . .
[0100] The bottom slat 8 may be made of aluminum using any convenient extrusion method.
[0101] The horizontal slats constituted by several modules or slat parts 3 A, 3 B, 3 C . . . , may be longer than 6 meters, and make it possible to produce roll-up curtains of essentially identical lengths.
[0102] According to another characteristic of the invention, the slats 3 are interconnected by means of a joint and articulation section 9 . Preferably, these joint sections are made of a material presenting the desirable rigidity and sturdiness, for example of extruded aluminum.
[0103] These sections 9 present a transverse profile that is approximately rectangular and slightly curved or arched, the concavity 10 of which is turned towards the roll-up shaft or drum when said apron 2 is rolled up on said shaft or drum ( FIG. 30 ).
[0104] These joint sections 9 are executed in one piece, their length corresponding to the length of the slats consisting of several abutting modules. They feature two opposing longitudinal grooves 11 A and 11 B, extending along their edges, over their entire length. These grooves 11 A and 11 B have a generally circular profile and are open towards the outside.
[0105] This opening, constituted by a longitudinal slot 23 , presents a width less than the diameter of the rods or assembly bars 12 of the slats 3 so that said rods constituting the upper and lower edges of the slats can be introduced by sliding into the grooves 11 A and/or 11 B of the joint profiles 9 and then find themselves maintained in said grooves, with the ability to swivel, by the inward-directed lips 23 A, 23 B delimiting said slot 23 .
[0106] During the pivoting movements of the slats 3 relative to the joint and articulation sections 9 , the joint bar 13 abuts against one or the other of the edges 23 A and 23 B of the slot 23 which limits the amplitude of the swivel of said slats.
[0107] On the other hand, along these upper and lower longitudinal edges, the slats 3 or the slat parts 3 A, 3 B, 3 C . . . , to be precise, present a projection 13 ′ that protrudes on the convex surface of said slats 3 or slat parts 3 A, 3 B, 3 C, these longitudinal projections 13 ′ thus constitute stops limiting the swivel of the latter relative to the joint sections 9 .
[0108] Advantageously and preferably, a soundproofing joint 14 in the shape of a C, for example made of polyvinyl chloride (PVC) is housed in the grooves 11 A and 11 B. This interposed joint between the groove 23 and the bar 12 ensures a perfectly silent operation during the roll-up and roll-down operations of the rollup curtain.
[0109] According to another characteristic disposition, of the invention, the abutted modules or slat parts 3 A, 3 B, 3 C . . . are assembled by jointing.
[0110] Preferably, the opposing abutment ends of the modules are provided, respectively, with a groove 16 and a rib 17 extending over the entire height of said abutment ends. Preferably, the groove 16 and the rib 17 present a triangular profile. More precisely, the groove 16 has a V-shaped profile, whereas the rib 17 has a beveled profile that imbricates itself exactly in said groove.
[0111] In this way, when the adjoining ends of two modules 3 A, 3 B, 3 C, . . . are abutted, the ribs 17 find themselves exactly fitted into the grooves 16 .
[0112] The slats 3 are kept in the joint and articulation sections through the intermediary of blocking caps 15 preventing any lateral sliding of said slats relative to said sections.
[0113] According to a characteristic disposition of the invention, these blocking caps 15 comprise an obturating body 18 applied on the ends 9 A and 9 B of the joint sections 9 so as to close off the entrance to the articulation grooves 11 A and 11 B made in said joint sections. This body is fastened against the end 9 A or 9 B of the joint sections 9 , by at least one screw 19 and, preferably, by two self-tapping screws penetrating into the holes 29 present in said cap and in the cavities 20 made in the partition 21 separating said grooves 11 A or 11 B, parallel to the latter. These blocking caps present an approximately rectangular transverse and slightly curved profile the concavity 28 of which is turned towards the drive shaft or drum 4 when the apron 2 is coiled around said roll-up shaft or drum.
[0114] According to a preferred implementation, the inside face of the blocking caps presents points of excessive thickness or humps 22 engaged in the entrance of the articulation grooves 11 A and 11 B of the joint sections 9 . These humps 22 of a generally cylindrical shape are shaped and dimensioned so they can be fitted without any noticeable play in said entrances. They serve to keep the blocking caps 15 in place on the ends of the joint sections 9 before the latter are fastened by means of self-tapping screws 19 .
[0115] Preferably, the blocking caps present an upper rib or cap 30 constituting a support of the transparent shutter during the superposition of the coils so as to prevent the slats from rubbing against each other while the curtain is being rolled up and thus [prevent] the deterioration of the latter through the appearance of unsightly scratches on the transparent slats which would affect the visibility through said shutter and which would lead to fragility of said roll-up shutter.
[0116] The blocking caps 15 are, for example, made of PVC or any other suitable material.
[0117] The upper part 1 B of the apron 2 is constituted by a first slat 34 , analog to slats 3 . The upper edge of the first slat is provided with at least one, and preferably several fastening plates 35 presenting a hole 36 for a fastening screw 37 .
[0118] Advantageously the roll-up curtain according to the invention also features a ring 31 , intended to be placed on the roll-up shaft 4 . This ring consists of a ring of the same diameter, or approximately identical to that of the roll-up shaft or drum 4 , comprising a slit 33 which permits its opening and deformation by spreading the edges of said slit ( FIG. 25A ).
[0119] This ring is also provided with a fin 32 surmounting a portion of the ring 31 and positioned at a distance from the outside face of said ring, so that during the installation of the curtain, the ribs ( 32 ) of the rings ( 31 ) cover the first joint section ( 9 ) in order to prevent the slats from rubbing on each other while the curtain is being rolled up and thus [prevent] the deterioration of the latter by the appearance of unsightly scratches on the transparent slats which would affect the visibility through said shutter and which would lead to fragility of said roll-up shutter.
[0120] Preferably, several rings 31 are placed on the roll-up shaft 4 so that they coincide with the intersection between two adjacent modules 3 A, 3 B, 3 C.
[0121] Thus, during the fastening of the apron 2 of the roll-up shutter on the horizontal roll-up shaft or drum 4 ( FIGS. 25A to 25E ) the ring ends are spread so as to place them around the roll-up drum and the rings are pivoted around the drum axle 4 so that the fin 32 of each ring 31 covers the first section 9 , the curtain is then fastened on the roll-up drum by turning screw 37 in the hole 36 of the fastening plates 35 on both sides of said rings 31 . This screwing action results in the blocking of the rings 31 on the drum 4 .
[0122] These roll-up rings are for example made of PVC or any other suitable elastic material permitting their deformation by spreading at the time of their placement on the roll-up shaft or drum 4 and the automatic return to their circular shape once they are positioned around said roll-up shaft.
[0123] The lateral ends of the aprons created according to the invention and featuring the afore-mentioned characteristics are mounted with an ability to slide in the vertical guiding slides 5 or gliding channels constituted by sturdy sections made for example of extruded aluminum or of steel in the manner known as such.
[0124] The vertical guiding slides have a general U-shaped profile the open side of which defines a longitudinal opening 24 extending over the entire height of said guiding slides. A vertical guiding channel 25 is made between the inward-directed front 5 a and rear 5 b wings of the slides 5 , and the ends of the slats 3 and 8 and the sections 9 move inside said vertical channel.
[0125] The entrance to the vertical channels 25 in which the ends of slats 3 and 8 and of the joint sections 9 are moving is delimited by inward-directed wings extending over the entire height of the guiding slides 5 and, according to another characteristic disposition, at least certain blocking caps are shaped so they resist any stripping force resulting, for example, from very strong winds or attempts at burglary. For example, these blocking caps 15 ′ are equipped with lateral wings or overlapping parts 26 , of greater width than the width of the entrance to the guiding channel. In the event of forces trying to unhinge the apron, the overlapping parts of the caps 15 ′ will hit against the inward-directed opposing wings 5 a and 5 b delimiting the vertical opening to the entrance of the guiding channels. This device prevents the slats from being ripped off when weather conditions are very severe, by ensuring better retention of the apron within the guiding slides. | A transparent roller shutter having an apron that can be wound about a horizontal shaft or drum positioned above said apron, the shutter having a plurality of transparent horizontal slats hinged together by hinge devices, the opposing vertical edges of the hinged apron moving in lateral guides or slides, wherein each of the slats has a transverse profile curved in shape of which the concavity faces towards the shaft or winding drum when the apron is wound onto the shaft or drum, and wherein each slat of the plurality of horizontal slats consists of two or more than two modules or portions of slats that are abutting and are assembled by engagement of the ends of same. | 4 |
RELATED APPLICATIONS
[0001] The present application claims the benefit of priority to U.S. Provisional Application No. 61/729,302, entitled “DYNAMIC DISCHARGE COMPENSATION FOR A SORTATION SYSTEM” filed Nov. 21, 2012, the entire contents of which are hereby incorporated by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates generally to an improvement in the precision and accuracy of sortation in material handling systems, and is particularly directed to an apparatus and method that consistently and reliably delivers articles to the desired discharge location at the desired time. The innovation will be specifically disclosed in connection with a unit sortation system which includes a crossbelt carrier.
[0003] Goals of sortation systems are accuracy and the maximization of throughput of articles. While increasing conveyance speed will increase throughput, the difficulty, and therefore the importance, of maintaining accuracy increases as the speed of conveyance increases.
[0004] While there are many aspects of accuracy, it ultimately comes down to overall system accuracy—getting each article to its intended discharge location. Sortation accuracy directly affects the overall system accuracy: inaccuracies are manifested by articles that are discharged to the wrong location (e.g., misdirected articles), jams, and by non-discharged product. In order to discharge articles to an intended location, the articles must be delivered to a designated discharge location at a specified time, and within acceptable tolerance ranges. As speed of conveyance increases the acceptable tolerance ranges decreases.
[0005] There are many systems and conditions upstream of the point of induction that directly influence sortation accuracy. In addition, the precision and accuracy of the systems between the point of induction and the discharge location have a substantial influence on the overall system accuracy and throughput. The present innovation may be used in a unit sortation system, such as crossbelt and tilt tray sorter, and more particularly is disclosed in connection with a crossbelt sortation subsystem system. Unit sorters are also known as loop sorters.
[0006] The location of an article on a carrier of a unit sortation conveyor is directly related to the ability to accurately deliver the article to its intended discharge location. Prior art solutions for crossbelt sorters have included the requirement to take a positive corrective action in order to reposition the article on the carrier laterally so as to relocate the article to the carrier's lateral center prior to instructing the carrier to discharge. This one dimensional adjustment becomes less effective as carrier width and carrier speed increases, and is not adequate to produce the desired accurate and precise discharge of articles. Such a solution is disadvantageous since it requires a wider discharge chute, consuming valuable floor space proximate to the sortation machine, thereby reducing the number of available discharge locations.
[0007] The present innovation results in articles being delivered through a selected point in space on a discharge trajectory, resulting, in the embodiment disclosed, in the article's own inertia in combination with gravity carrying that article to a selected destination.
[0008] Although an embodiment described herein in comprises a crossbelt unit sortation conveyor system, it will be understood that the present innovation is not limited in use or application thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings illustrate embodiments, and, together with specification, including the detailed description which follows, serve to explain the principles of the present innovation.
[0010] FIG. 1 is a diagrammatic representation of a section of a unit sortation conveyor system.
[0011] FIG. 2 illustrates discharge trajectories (right and left directions) which deliver respective articles to a desired point in space, overlaid on a portion of a crossbelt sortation conveyor system which is nearly an identical to the diagrammatic representation of FIG. 1 .
[0012] FIG. 3 is a diagrammatic representation of the reference system of a carrier.
[0013] FIG. 4 illustrates an exemplary crossbelt carrier belt lateral velocity profile during discharge.
[0014] FIG. 5 is similar to FIG. 2 and illustrates discharge trajectories (right and left directions) of another embodiment.
[0015] FIG. 6 is a diagrammatic representation of the unit sortation system of FIG. 2 with three articles ready for discharge from three carriers.
[0016] FIG. 7 is a diagrammatic representation of the unit sortation system of FIG. 6 with three articles ready for discharge from three carriers
[0017] FIG. 8 is a diagrammatic representation of the unit sortation system of FIG. 7 with three articles ready for discharge from three carriers
[0018] FIG. 9 is a diagrammatic representation of the unit sortation system of FIG. 8 with three articles on three carriers moving towards discharge.
[0019] FIG. 10 is a diagrammatic representation of the unit sortation system of FIG. 9 with three articles on three carriers moving farther towards discharge.
[0020] FIG. 11 is a diagrammatic representation of the unit sortation system of FIG. 10 showing three articles with two articles discharged and one moving towards discharge.
[0021] FIG. 12 is similar to FIG. 2 and illustrates discharge trajectories (right and left directions) of another embodiment.
[0022] FIG. 13 is a diagrammatic representation of a carrier discharge control board, a specific embodiment of a carrier discharge control.
[0023] FIG. 14 is a process flow diagram illustrating an embodiment method for compensating a discharge from a sortation system of an article positioned off-center on a carrier.
[0024] FIG. 15 is a process flow diagram for a machine element embodiment for compensating a discharge from a sortation system of an article positioned off-center on a carrier.
[0025] FIG. 16 is a process flow diagram for a controller embodiment for compensating a discharge from a sortation system of an article positioned off-center on a carrier.
DETAILED DESCRIPTION
[0026] In the following description, like reference characters designate like or corresponding parts throughout the several views. Also, in the following description, it is to be understood that terms such as front, back, inside, outside, and the like are words of convenience and are not to be construed as limiting terms. Terminology used in this patent is not meant to be limiting insofar as devices described herein, or portions thereof, may be attached or utilized in other orientations.
[0027] Referring to FIG. 1 , sortation system, generally indicated at 2 , is a unit sortation conveyor subsystem that can sort articles 12 received from a material handling system. Sortation system 2 can be connected to a host control 56 of the material handling system. The sortation system 2 is diagrammatically represented in FIG. 1 as an oval 44 , having an endless conveyor 3 moving at a constant speed in a direction such as counterclockwise as indicated by the direction of travel arrows on the oval. Moving conveyor 3 is flanked by a plurality of discharge locations 6 L, 6 R that are stationary thereto, and can include discharge locations 6 L, 6 R at more than one side of the oval 44 . The endless conveyor 3 can comprise a plurality of carriers 4 linked together with a conveying surface 5 on each carrier 4 for conveying an article 12 placed thereon. Each moving carrier 4 can receive article 12 from an induction, and each can discharge the article 12 into a selected one of the stationary lateral discharge locations 6 L, 6 R at a specified time. After induction, the location of the article can be anywhere on the conveying surface 5 and this imprecision can affect discharge accuracy. To deliver the article 12 to the selected one of discharge locations 6 L, 6 R with a high degree of accuracy, the present innovation can take a snapshot of the article 12 on the moving conveying surface 5 , can use the snapshot information to calculate a compensating time-to-intercept point on a pre-calculated article discharge trajectory, and can, at the appropriate time, initiate one movement of the conveying surface 5 to discharge the article 12 from any position on the conveying surface 5 onto a trajectory that places the article 12 into the selected one of discharge locations 6 L, 6 R.
System Overview
[0028] To accomplish this, the present innovation can: scan the article 12 on the conveying surface 5 with an item detection system 16 , process the scan information to define the location of the article 12 on the conveying surface 5 , deliver the location information to the moving the carrier 4 carrying the scanned article 12 , and provide the carrier 4 with a discharge direction that will place the article 12 into a selected one of the discharge locations 6 L, 6 R. To ensure that the article 12 arrives into the selected one of the discharge locations 6 L, 6 R, the present innovation can also calculate a compensating time-to-intercept point (or release point) to place the article 12 on a discharge trajectory based on: the location information of the article 12 on the conveying surface, the direction of article discharge, the longitudinal speed of the endless conveyor 3 , and lateral speed of the conveying surface 5 . At the appropriate time (interception point), the present innovation can initiate one discharge movement of the conveying surface 5 to discharge the article 12 into the selected one of discharge locations 6 L, 6 R.
[0029] In the exemplary embodiment depicted, the sortation system 2 is described as an endless conveyor 3 of carriers 4 such as crossbelt sorters. The conveying surface 5 of each carrier 4 can comprise a conveyor belt 7 oriented to discharge articles 12 crosswise or at a right angle to the direction of travel. Each carrier 4 can include a carrier discharge control 28 located under the conveyor belt 7 that comprises a microprocessor and memory that can receive and store article positional information, can calculate the time-to-intercept point described above, and at the appropriate time, initiate the discharge of the article 12 along the discharge trajectory while the carrier 4 is moving. Carrier discharge control 28 can also comprise a motor control that actuates, on command, motors or other elements of the carrier 4 to discharge the article 12 therefrom. The present innovation is not limited to the embodiment depicted, and may be advantageously used with other unit sortation systems, such as by way of non-limiting example, a tilt tray sorter.
[0030] As depicted in at least FIGS. 1 and 2 , sortation system 2 receives articles 12 from the material handling system via the induction 14 . As shown, induction 14 can induct articles onto endless conveyor 3 with any of an overhead merge, or an angle merges 14 a , 14 b . An item detection system 16 is located downstream from the induction 14 and can scan the carriers 4 passing underneath. The item detection system 16 can identify articles 12 on carriers 4 passing underneath, and as will be described below, can derive locational or positional information of the article 12 on the carrier. And, the item detection system 16 can detect a relative location of the article positioned off-center on a selected carrier of the sortation system 2 The positional information is sent to a PLC 24 which can include a microprocessor and memory to translate the article location information from the item detection system 16 into a form that the carrier 14 can use. The PLC 24 communicates the location information, as off-center values such as an X axis deviation and a Y axis deviation from a conveying surface reference point, to the carrier control 28 of the corresponding carrier 14 via transmitter 26 . The carrier control 28 stores the information within until moving downstream to receiving a discharge direction command of “discharge left” or “discharge right” from transmitter 40 that directs the carrier 14 to place the article 12 into the selected one of the discharge locations 6 L, 6 R.
[0031] The discharge direction command is sent from the PLC 24 to the transmitter 40 and can be based at least in part on information from a sortation control 24 and a host control 56 . The host control 56 can provide the PLC 24 with a map of which discharge location 6 L, 6 R that article 12 is to be discharged into after induction, and identification of the article on the sorter 2 . Article weight, article volume, and article shape can be taken into consideration. For example, the host control 56 can provide information on whether the article shape is a sphere or a rectangular box, and can provide parameters or characteristics that can be used to modify the discharge compensation. For example, but not limited thereto, in the case of a sphere, the belt speed may be adjusted to prevent rolling of the article 12 as it is discharged from the carrier 4 . A sortation control 54 provides unified operational control and alarm surveillance for the subsystems that make up the sorter 2 . Sortation control 54 can make the article 12 routing decisions based on information provided by the host control 56 . In the depicted embodiment, PLC 24 is utilized for most of the control of sortation system 2 since output results must be produced in response to input conditions within a limited time, otherwise unintended operation may result. Sortation conveyor system 2 includes processing system 52 , which includes one or more processors, such as PLC 24 and sortation control 54 , and can include memory or recordable media. To the extent, if any, that host control 56 is involved in control of sortation system 2 , host control 56 may be considered part of processing system 52 . In the depicted embodiment, PLC 24 is utilized for most of the control of sortation system 2 since output results must be produced in response to input conditions within a limited time, otherwise unintended operation may result.
[0032] The PLC 24 can transmit the discharge trajectories 30 L, 30 R to the carrier discharge control 28 of the carrier 4 with a transmitter 26 located downstream from the item detection system 16 . The PLC 24 waits until the carrier 4 approaches a transmitter 40 related to a discharge location 6 L, 6 R, and initiates the article discharge by transmitting a “discharge left” or a “discharge right” signal from transmitter 40 that is received by the carrier discharge control 28 with transmitter 40 . After receiving the discharge direction command, the carrier discharge control 28 begins determining the steps necessary, at the appropriate time, to release or discharge the article 12 along the selected one of the discharge trajectories 30 L, 30 R to place the article 12 into the selected one of the discharge locations 6 L, 6 R. In response to reaching the release point, the processing system 52 can initiate the discharge of the article 12 by the selected carrier 4 .
Discharge Locations
[0033] The plurality of stationary discharge locations 6 L, 6 R positioned downstream from the shown on both sides of the oval 44 of FIG. 1 with one set of opposing discharge locations shown as solid lines, and a second set of discharge locations shown as dashed lines. All discussions below will be about the solid line stationary discharge locations 6 L, 6 R shown in FIG. 1 . Discharge locations 6 L, 6 R are disposed adjacent each other in rows extending from each side of sortation system 2 . Discharge locations 6 L, 6 R can receive articles 12 from the endless conveyor 3 and can discharge the articles The pluralities of discharge locations 6 L, 6 R are also known as chute banks, but are not limited to chutes. Each discharge location 6 L is shown aligned laterally with a discharge location 6 R disposed on the opposite side of endless conveyor 3 . Although sortation system 2 is depicted as a double sided sorter, one sided sorters and configurations without aligned left and right side discharge locations may be used. It is noted that the representations of the configuration of discharge locations 6 L, 6 R is not to be considered as limiting.
[0034] In at least FIGS. 1 and 2 , the left side discharge locations 6 L are diagrammatically illustrated as chutes or angled discharge locations designated as 6 La- 6 Le having entrances 8 L which are disposed generally at an angle relative to the longitudinal Y direction (the direction of travel arrow). The right side discharge locations 6 R are diagrammatically illustrated as chutes or discharge locations designated as 6 Ra- 6 Re having a combination of one straight discharge location 6 Ra and four angled discharge locations 6 Rb- 6 Re and entrances 8 R. It is not unusual for the entrance characteristics of the discharge locations on each side to be the same.
[0035] FIG. 2 is an enlarged view of the right side of the sortation system 2 shown in FIG. 1 . In the embodiment depicted in at least FIG. 2 , sortation system 2 can include surfaces 10 L flanking the disposed between discharge ends 4 L of carriers 4 , and entrances 8 L of discharge locations 6 L and surface 10 R disposed between discharge ends 4 R of carriers 4 and entrances 8 R of discharge locations 6 R. Surfaces 10 L, 10 R, can be a portion of the entrances 8 R, 8 L, or can be an interface surface which may be referred to as through-going-wood which serves as passive interfaces between carriers 4 and the discharge locations 6 L, 6 R. It is desirable that surfaces 10 L, 10 R present no significant impediment to the discharge of articles transitioning from carriers 4 (even if inaccurately discharged), and present a low coefficient of friction to the articles. Once on surfaces 10 L, 10 R, the articles are no longer receiving kinetic energy from sortation system 2 , with the articles' trajectories being a function of gravity, the configuration of surfaces 10 L, 10 R, and the articles' own momenta. The resulting behavior is that the article 12 will tend to move away from the carrier 4 toward the discharge location 6 L, 6 R, along a predictable course of trajectory. Thus, the articles are controllably caused to travel along a nominal trajectory, having a high probably, with a low standard deviation, of reaching their intended destinations.
Article Induction
[0036] The material handling system (not shown) advances articles 12 to induct 14 , which inducts articles 12 onto sortation system 2 at a point of induction, thereby associating each article 12 with at least one carrier 4 . The point of induction is generally stationary relative to the moving carriers 4 . In the embodiment depicted and discussed in more detail, one article 12 is associated with one carrier 4 . As depicted in at least FIGS. 2-5 , it is typical that articles 12 are not placed on the conveying surface 5 of carriers 4 in a consistent, repeatable location, but instead are located almost anywhere on the conveying surface 5 of carriers 4 . Unlike many sortation systems, the sortation system 2 of the current innovation can carry the article in the “as placed” location until discharged on a discharge trajectory that places the article 12 into a selected one of the discharge locations 6 L, 6 R. To accomplish this, the location of the “placed” article 12 can be determined relative to the conveying surface 5 .
[0037] The practice of this invention innovation may involve knowledge of the position of the article relative to the carrier 4 . There are many ways to have such article position information. For example, the relative positions would be known if articles 12 are accurately placed on respective carriers 4 in known respective locations relative to the carrier 4 , even though such known locations varies from carrier 4 to carrier 4 .
[0038] Article position may be expressed in any suitable way, such as Cartesian coordinates and polar coordinates. For each article 12 , at least one article reference point ( 109 in FIGS. 3-5 ) may be selected for use in indicating the location of that article 12 . Examples of an article reference point include the article's centroid and center of mass (which could be determined dynamically or could be a defined attribute for a particular type of article which is maintained in a database).
Item Detection System
[0039] As shown in FIG. 2 , item detection system 16 , is located downstream from the induct 14 and above the endless conveyor 3 , and can determine the location of the article 12 a as lateral and longitudinal positions relative to the conveying surface 5 a of the moving carrier 4 a . In this embodiment, item detection system 16 includes camera 18 , infrared light LED light array 20 , photo eye 22 , PLC 24 and transmitter 26 . In the embodiment depicted, camera 18 may be mounted 40 inches above the top surface of carrier 4 , offset slightly from the center of carrier 4 , having a field of view of 56 inches (horizontal), a 3.5 mm lens and an infrared bandpass filter attached behind the lens. Camera 18 may be any suitable device and may be mounted in any suitable location. Light array 20 may be 1160 mm long IR linear array light mounted horizontally parallel to carrier 4 , 40 inches above the center of carrier 4 .
[0040] When an article 12 is inducted onto a moving carrier 4 and passes beneath the stationary item detection system 16 , a scan or snapshot may be taken of the moving conveying surface 5 to determine the location of the article 12 on the conveying surface 5 of the carrier 4 . Item detection system 16 can include a microprocessor and memory that can process the information received from a snapshot of the carrier 4 and the article 12 to determine the location of the article 12 relative to the carrier 4 . The snapshot of the article 12 on the conveying surface 5 of the carrier 4 can be triggered by the passage of a leading edge of the carrier discharge control 28 in front of the photo eye 22 . Although the detection of the edge of carrier discharge control 28 is described, any suitable event may be used to trigger the detection snapshot. Although the depicted embodiment illustrates one article 12 per carrier 4 , a single article may be carried by more than one carrier 4 , with the discharge operation of multiple carriers 4 being coordinated so as to discharge the associated article 12 .
[0041] In FIG. 2 , carrier 4 a and article 12 a are moving underneath the item detection system 16 . Camera 18 is suspended above the conveyor surface 5 a and has snapped a snapshot of the moving carrier 4 a and article 2 a.
[0042] FIGS. 3-5 are enlarged schematic views of the snapshot of the moving carrier 4 a in the position shown in FIG. 2 . As shown in the snapshot view of FIG. 3 , the item detection system 16 may use the snapshot or scan information to identify the corners of the conveying surface 5 a . Next, a first cross line 102 and a second cross line 104 can be drawn across the snapshot image. The intersection of cross lines 102 , 104 identifies an origin 100 at the center of the conveying surface 5 a which for this embodiment can be carrier reference point CR P . The item detection system 16 can also determine whether carrier 4 a is occupied by article 12 a . In the embodiment depicted, if article 12 a is detected, item detection system 16 can use the previously described corner and cross line technique or edge detection to determine the center or centroid of article 12 (see FIG. 3 ) and uses the centroid as the reference point defining the article's position. Whereas a center of the conveying surface 5 is used as the origin, the present invention is not limited thereto and other locations can be used.
[0043] In FIG. 4 , the item detection system 16 places a Cartesian coordinate system onto the origin 100 of the snapshot or scan with the X axis oriented in the lateral direction and the Y axis oriented in the direction of motion. In the embodiment depicted, item detection system 16 determines the centroid of article 12 and uses it as the article's article reference point 109 as an indicator of the article's position information. As shown in FIG. 5 , the 1400 mm by 510 mm carrier 4 has the X axis range from 700 mm to −700 mm and the Y axis range from 255 mm to −255 mm. FIG. 3 indicates the signs of the X and Y coordinates in each of the four quadrants. Corners of the carrier 4 are located at (700, 255), (700, −255), (−700, −255) and (−700, 255). Article 12 a is shown positioned in quadrant 4 a ΔX distance 106 from the X axis and origin 100 , and a ΔY distance 108 from the Y axis and origin 100 .
[0044] FIG. 5 shows numerical positional information that can be generated to locate the article 12 a on the conveying surface 5 of carrier 4 a . As shown, the positional data for the centroid of the article 12 a is at (+350, −115) which defines an article reference point 109 . The article reference point 109 of the example has a value of +350 mm for ΔX, and a value of −115 for ΔY. With the ΔX, ΔY location values for article 12 a , discharging the article 12 a to the left requires article 12 a moves a distance of slightly more than 1050 mm. Discharging the article 12 a to the right requires the article 12 a to move to the right a distance of slightly more than 350 mm before the centroid of article 12 a is discharged from the conveying surface 5 a . This ΔX, ΔY article position information will be sent to the PLC 24 to compute the left and right trajectories 30 L, 30 R as well as the discharge compensations described below.
Calculating Cartesian Coordinate Discharge Compensations
[0045] Once the article position information is received, the PLC 24 calculates article discharge compensations DA X , DA Y of the present innovation, as a time value based on the lateral deviation and the longitudinal deviation of the article reference point ( 109 in FIGS. 3-5 ) from the carrier reference point CR P , the nominal center of carrier 4 in the embodiment depicted. In the depicted embodiment as best shown in FIG. 2 , the article discharge compensations DA X , DA Y includes X direction article discharge compensation (lateral article discharge compensation) DA X based on the lateral position of the article's article reference point 109 and a Y direction article discharge compensation DA Y (longitudinal article discharge compensation) based on the longitudinal position of the article's article reference point 109 , calculated according to the formulas
[0000]
DA
x
=
N
(
Δ
X
/
SS
)
+
C
(
i
)
=
M
(
Δ
Y
/
CBS
)
+
B
(
ii
)
[0046] Where DA Y is the Y direction article discharge compensation (milliseconds)
DA X is the X direction article discharge compensation (milliseconds) ΔY=Y displacement from carrier center (mm) ΔX=X displacement from carrier center (mm) CBS=cross belt sorter speed in X direction (when belt 7 is moving) (M/s) SS=sorter speed in Y direction (sorter direction of travel) during operation (M/s)
Although the units indicated are metric, any suitable measurement system is applicable. Four adjustment parameters allow for iterative field tuning of the calculation on an empirical basis when commissioning the system:
M=Y axis scaling factor (nominal value 1.0) N=X axis scaling factor (nominal value 1.0) B=Y Offset factor (nominal value 0.0) C=X Offset factor (nominal value 0.0)
[0056] For each article, the respective X direction article discharge compensation, DA X , and the Y direction article discharge compensation, DA Y , are communicated to the respective carrier discharge control 28 through transmitter 26 , which is, in the present embodiment, an infrared transmitter, although any suitable transmitter and transmission method may be utilized. Alternatively, DA X and DA Y could be communicated to the carrier discharge control 28 by respective transmitters. As described previously, each carrier discharge control 28 stores the longitudinal and lateral article discharge compensations DA X and DA Y in the memory of carrier discharge control 28 until such time as carrier discharge control 28 receives a discharge command. DA X and DA Y may be updated if another item detection system is passed.
[0057] In the embodiment depicted, carrier discharge control 28 applies the article discharge compensations DA X and DA Y at the time discharge is initiated, which either advances or retards the time of discharge relative to a nominal or reference discharge compensation D R according to the adjustment and in accordance with the commanded direction of discharge. The reference discharge compensation D R represents the time required for the carrier reference point CR P (origin 100 in FIG. 5 ), to travel laterally from the discharge command location to the discharge trajectory (both discussed below). The article discharge compensation DA Y compensates for the position of the article relative to the carrier reference point CR P .
[0058] The discharge command is the final communication act which causes the carrier discharge control to execute predetermined acts necessary to discharge an article, which, in this embodiment, is the movement of the carrier 4 through a programmed motion profile in the desired direction.
[0059] It is desirable that carriers 4 discharge the articles to the target discharge point TDP L , TDP R at the velocity required for the articles to travel ultimately to the desired discharge location (e.g., a chute). Referring to FIG. 2 , there are illustrated discharge trajectories 30 L, 30 R which deliver an article to a desired point in space, target discharge points TDP L , TDP R , overlaid on a portion of a crossbelt sortation system which is nearly an identical to the diagrammatic representation of FIG. 1 . As can be seen, target discharge points TDP L , TDP R are located beyond the respective discharge ends 4 L, 4 R of carriers 4 , at a distance W TPD apart. Target discharge points TDP L , TDP R may be located at any desired target point, so long as the article dynamics meet the requirements of the downstream system to which the articles are being transferred. Although termed a “point”, a target discharge point may be multi-dimensional, such as but not limited to a two dimensional area. In the depicted embodiment, the downstream system includes surfaces 10 L, 10 R and discharge locations 6 . In the depicted embodiment, W TDP is the total distance between target discharge points TDP L and TDP R .
[0060] Discharge trajectories 30 L, 30 R are defined to represent the vector path along which each carrier 4 will drive an article's reference point such that the article reaches the target discharge point TDP L , TDP R and thereafter travel to its desired discharge location, once a reference point on the article intercepts the line of trajectory. In the embodiment depicted, for analytical, computational purposes, discharge trajectories 30 L, 30 R are represented as vectors in a two-dimensional or X-Y reference system, it being recognized that such purposes can be achieved through many representational methods, including for example as vectors of a real reference system. For purposes of this explanation, a real reference frame is used to describe the discharge reference system, with the origin (0, 0) of the discharge reference system relative to chutes 6 R and 6 L (since chutes 6 R and 6 L align, one reference system may be used) is assigned to point 36 a , the location of the lateral center of carrier 4 ′ when carrier 4 ′ receives a discharge command from carrier transmitter 40 . In this depiction, the Y axis represents the movement of the carriers of the sortation conveyor in the longitudinal direction and the X axis represents lateral movement of an article on the carrier (which for a crossbelt carrier, corresponds to lateral movement of the upper conveying surface of the crossbelt). In the embodiment depicted, the magnitude of the crossbelt speed CBS is the same for both directions of discharge.
[0061] In the embodiment depicted, each discharge trajectory vector 30 L, 30 R, originates at a respective location, O L , O R , and terminates at the respective target discharge point, TDP L , TDP R . Lines 34 L, 34 R respectively pass through target discharge points TDP L , TDP R parallel to the direction of travel, and are intersected by discharge trajectories 30 R, 30 L respectively at points O L and O R , on line 36 . Definitionally, the time required to for the carrier to be advanced laterally a length of W TPD at the crossbelt speed CBS is equal to the time required for the sorter to travel, at the sorter speed SS, the longitudinal distance between O L , O R and TDP L , TDP R (the distance between lines 36 and 38 ) is the same. Thus, the coordinates of the discharge trajectory origins are
[0000] O L (½W TDP , 0) (iii)
[0000] O R (−½W TDP , 0) (iv)
[0000] The coordinates of TDP L , TDP R are
[0000] TDP L (−½W TDP , W TDP ×SS/CBS) (v)
[0000] TDP R (½W TDP , W TDP ×SS/CBS) (vi)
[0000] With the left and right target discharge points TDP L , TDP R being spaced symmetrically from discharge ends 4 L, 4 R of carriers 4 , discharge trajectories 30 L, 30 R intersect each other at a point 32 equidistant from discharge ends 4 L, 4 R, located at (0, ½W TDP ×SS/CBS).
[0062] In FIG. 2 , carrier 4 ′ is illustrated as having advanced to the discharge command location at which, in the embodiment depicted, a discharge command is given to carrier discharge control 28 ′ to initiate discharge of the article either to the right or left. The discharge command location is spaced upstream of the target discharge point a distance sufficient for the carrier to discharge the article to the discharge location associated with the discharge command location.
[0063] A nominal or reference discharge delay may be determined or established by the physical set up of the conveyor, representative of the time delay between when carrier 4 ′ reaches the discharge command location and the carrier's reference point reaches a discharge trajectory, the location at which discharge actuation—actuating the carrier, (e.g., the crossbelt in the embodiment is driven by the motor)—occurs. In the embodiment depicted, the carrier reference point CR P is the carrier center point (origin of the X-Y reference frame). Since the center aligns with the intersection of the right discharge and left discharge trajectories, the nominal or reference discharge delay is the same for right discharge and left discharge. In the depicted embodiment, if the article centroid were located at the center of the carrier (0, 0) (the carrier reference point CR P ), the carrier discharge control 28 would delay discharge actuation until the carrier center (0,0) intercepted the trajectories at point 32 , at which location discharge actuation would begin, actuating the carrier to discharge, which for the crossbelt carrier depicted, is actuation of the motor. Since point 32 is equidistance between line 36 and line 38 , which passes through TDP L and TDP R , the nominal or reference discharge delay time, D R , is calculated by the equation:
[0000]
D
R
=
1
2
W
TDP
(
SS
/
CBS
)
SS
(
vii
)
[0000] which is equal to:
[0000] D R =½ W TDP /CBS (viii)
[0000] which is the same amount of time required for the belt to travel half of the width of W TDP .
[0064] Discharge is initiated when a discharge command is transmitted via the stationary carrier transmitter 40 to the carrier discharge control 28 , which is carried by the carrier 4 . Discharge comprises discharge compensation and discharge (carrier) actuation, For the embodiment depicted, discharge is initiated when carrier 4 ′ has reached the appropriate location 36 as depicted in FIG. 2 , whereat the discharge command is given. The discharge command also includes whether to discharge an article, indicated at A, left or right. Upon receipt of the discharge command, carrier discharge control 28 ′ will apply the article discharge compensations (the X direction article discharge compensation DA X and the Y direction article discharge compensation DA Y ) which it previously stored to modify the reference discharge compensation D R to compensate for the actual position of article A on the carrier. The Y direction article discharge compensation DA Y is subtracted from the reference discharge compensation D R regardless of the direction, bearing in mind DA Y is positive for articles disposed forward of the carrier reference point and negative for articles disposed rear of the carrier reference point. The X direction article discharge compensation DA X is subtracted from the reference discharge compensation D R if the discharge is to the right and added to the reference discharge compensation D R if the discharge is to the left, bearing in mind that DA X , in the embodiment depicted, is positive for articles disposed to the right of the carrier reference point CR P and negative for articles disposed to the left of the carrier reference point CR P.
[0000] total discharge compensation (right discharge)= D R −DA Y +DA X (ix)
[0000] total discharge compensation (left discharge)= D R −DA Y −DA X (x)
[0000] As can be seen the difference between right discharge and left discharge whether the X direction discharge compensation is added or subtracted.
[0065] By way of example, FIGS. 7-11 illustrate how three articles 12 a , 12 b , 12 c are discharged from the endless conveyor 3 in three different trajectories that utilize the above described article discharge compensations DA x , DA y . Each of articles 12 a , 12 b , and 12 c are being conveyed on carriers 4 a , 4 b , 4 c respectively and in each consecutive Fig., the carriers 4 move downstream one carrier so that the movements of the of articles 12 a - 12 c along the discharge trajectories 30 L, 30 R can be shown. The article 12 a is located laterally from the origin 100 in the position shown in FIGS. 2-5 and 7 . In FIG. 7 , the centers or centroids of articles 12 a and 12 c are in line laterally to the right of the origin 100 ( FIG. 5 ) of carrier 4 a and will travel along a first path A P in the direction of motion of the endless conveyor 3 . Article 12 b is following a second path B P that parallels path A P.
[0066] In FIG. 7 , the carrier discharge control 28 a of carrier 4 a is in line with transmitter 40 a and has received a “discharge left” command from transmitter 40 a discharge article 12 a . Since the location of article 12 A does not fall on the calculated trajectory 30 L, the carrier discharge control 28 a begins counting down until the article 12 a follows first path A P and crosses the calculated trajectory 30 L.
[0067] By way of example, in FIG. 7 , article 12 a will travel along path A P . If article 12 a is to be discharged left, carrier 4 a needs to be actuated when article 12 a reaches point A L on discharge trajectory 30 L. The time required to reach this point is equal, the total discharge compensation, is determined by subtracting the Y direction discharge compensation DA Y from the reference discharge compensation D R and subtracting the X direction discharge compensation DA X from the reference discharge compensation D R . Article 12 b is traveling on carrier 4 b and moving along path B P and article 12 c is traveling on carrier 4 c along path A P .
[0068] In FIG. 8 article 12 a has moved downstream along path A P to reach point A L on discharge trajectory 30 L and the leftward discharge of article 12 a is starting. Article 12 b is to be discharged right, and carrier 4 b will not be actuated until article 12 b reaches the intersection B R of path B P with discharge trajectory 30 R (intercepts trajectory 30 R). For article 12 c , this is accomplished by applying the article discharge compensation DB X and DB Y relative to the reference discharge compensation D R . Point 42 ′ on line 42 represents the location of articles 12 a - 12 c after a period of time equal to the reference discharge compensation D R has passed. Point B R is before this point and article 12 b will fall on point 42 ′ when article 12 b reaches line 42 . The total discharge compensation for article 12 b is determined by subtracting the Y direction discharge compensation DB Y and adding the X direction discharge compensation DB X to the reference discharge compensation D R . Once a period of time representative of the total discharge compensation has passed, article 12 b will be at point B R and carrier 4 b will be actuated. Article 12 c continues traveling on carrier 4 c along path A P .
[0069] In FIG. 9 , article 12 a continues to move to the left along discharge path 30 L on carrier 4 a article 12 b has passed intersection B R of path B P with discharge trajectory 30 R and is moving along discharge trajectory 30 R. Article 12 c has moved downstream along path A P to reach point A L on discharge trajectory 30 L and carrier discharge control 28 a of carrier 4 a is in line with transmitter 40 a . Carrier discharge control 28 a has received a “discharge right” command from transmitter 40 a to discharge article 12 c along trajectory 30 R. Article 12 c is to be discharged right, and carrier 4 c will not be actuated until article 12 c reaches the intersection C R of path A P with discharge trajectory 30 R (intercepts trajectory 30 R). For article 12 c , this is accomplished by applying the article discharge compensation DC X and DC Y relative to the reference discharge compensation D R . Point 42 ′ on line 42 represents the location of articles 12 a - 12 c after a period of time equal to the reference discharge compensation D R has passed. An additional period of time must pass until article 12 c reaches point C R before carrier 4 c can be actuated. The total discharge compensation for article 12 c is determined by subtracting the Y direction discharge compensation DC Y and adding the X direction discharge compensation DC X to the reference discharge compensation D R . Once a period of time representative of the total discharge compensation has passed, article 12 c will be at point C R and carrier 4 c will be actuated.
[0070] In FIG. 10 , article 12 a continues to move to the left along discharge path 30 L and is partially discharged from carrier 4 a . Article 12 b continues to be carried on carrier 4 b and is moving to the right along discharge trajectory or path 30 L. Article 12 c continues to follow path A P while being carried on carrier 4 c.
[0071] In FIG. 11 , article 12 a is discharged from carrier 4 a , has successfully been placed into discharge location 6 La and is moving to the left therein. Article 12 b is discharged from carrier 4 b and is following discharge trajectory 30 R as it moves into entrance 8 L of discharge location 6 Ra. Article 12 c is being discharged to the right towards discharge location 6 Ra as article 12 c has passed the intersection C R of path A P with discharge trajectory 30 R (intercepts trajectory 30 R). Article 12 c will continue to follow a short path 30 R to discharge into discharge location 6 Ra.
Carrier Motion Profiles
[0072] Carriers 4 have carrier motion profiles based on the carriers' movement upon being actuated. For example, a crossbelt carrier, such as in the embodiment depicted, may have a carrier motion profile as seen in FIG. 6 , which illustrated the ramping up of the crossbelt from zero to full speed, resulting from the fact that the speed of the motor does not instantaneously reach its maximum discharge speed. Additionally, the carrier motion profile of the crossbelt may also be regulated in order to provide for efficient transfer of energy to the article so that the article will reach and travel along the desired discharge trajectory without rolling, skidding or shifting. A tilt tray will also have a carrier motion profile as the tilting is actuated and the tray moves to its full tilt position.
[0073] Articles have article initial motion profiles, which is the article motion from the start of actuation of the carrier (portion A) until the moment the article reaches its steady state velocity (portion B) (relative to the carrier), resulting from the carriers' motion profile. Although the articles' physical attributes may also affect the motion of the article during actuation, a single article initial motion profile may be considered as being applicable to all articles or a group of articles, or respective article initial motion profiles may have determined or designated for respective articles. Since, upon actuation of the carrier, the article does not reach the full speed of discharge instantaneously (e.g., ramping up the crossbelt to full speed or the article reaching full discharge speed on a tray as tilting goes from nominal to maximum), actuation of the carrier may be advanced ahead of (begin in less time than) the total discharge compensation, timed so that the article motion profile matches the discharge trajectory when the two first coincide. The discharge velocity of the article reference point is reached when the article reference point 109 actually reaches the discharge trajectory, with the article reference point 109 then following the discharge trajectory. As used herein and in the claims, determining when an article's article reference point 109 has reached the discharge trajectory of the discharge location at which that article is to be discharged may include accounting for the article's initial motion profile such that the article reference point 109 is considered to have reached its discharge trajectory at the time or location when discharge actuation has to occur in order for the article, following its article initial motion profile substantially reaches its steady state velocity at the moment the article's article reference point 109 actually reaches the article's discharge trajectory, that is the article motion profile matches the discharge trajectory when the two first coincide.
[0074] In the embodiment depicted, the lateral motion of the carrier belt, driven by known brushless DC motor, follows an exponential curve that approximates the curve:
[0000] CurrentBeltSpeed( Ts )=MaxBeltSpeed×(1−exp(− Ts )) (xi)
for Ts=0 to infinity.
Complex Reference Frame Example
[0076] FIG. 12 depicts a specific embodiment, described using a complex reference frame, in which the magnitude of the sorter speed is 2.5 M/s, the magnitude of the carrier speed is 2.0 M/s, the distance between the target discharge points is 1.5M and the width of the carrier is 1.4M, yielding the following formulae:
[0000] Sorter Speed (SS)=(0+2.5 j ) M/s (xii)
[0000] Crossbelt Speed (CBS)=(−2.0+0 j ) M/s (left discharge) (xiii)
[0000] Crossbelt Speed (CBS)=(2.0+0 j ) M/s (right discharge) (xiv)
[0000] Velocity(right discharge)=CBS+SS=(2.0+2.5 j ) M/s (xv)
[0000] |Velocity(discharge)|=abs(Velocity(right discharge))=3.2016 M/s (xvi)
[0000] Direction of discharge(θ)=arg(Velocity(right discharge))=0.8961 radian (xvii)
[0077] FIG. 6 is a diagrammatic representation of an entire sortation system 2 . Oval 44 represents a plurality of carriers (not specifically illustrated in FIG. 6 ) as described above, arranged in an endless loop in the shape of oval 44 . The endless loop of carriers, also known as a carrier train, may be propelled by any suitable means, including for example, by one or more linear synchronous motors. The speed and position of the train are controlled by PLC 24 , represented by 46 .
[0078] The left and right sides of oval 44 are illustrated as being the same. The right side of sortation system 44 will be discussed herein, the discussion being applicable to the left side. Sortation conveyor system 2 includes stray parcel sensor 48 , induct 14 , item detection system 16 , scanner 50 , and discharge locations 6 L and 6 R.
[0079] Immediately upstream of induct 14 is stray parcel sensor 48 which functions to detect whether any articles are present on carriers after the carriers have passed upstream discharge locations. Information from stray parcel sensor 48 is used to verify whether an article was actually discharged. If the carrier discharge control 28 indicates that no discharge occurred (such as no command to discharge was received or the carrier did not actuate in response to a received command) or if stray parcel sensor 48 detects an article, an appropriate condition is set in PLC 24 .
[0080] As discussed above, item detection system 16 localizes locations of respective articles on respective carriers relative to the carrier reference point CR P , and signals these data to PLC 24 . PLC 24 executes instructions to perform a function on the data in order to calculate a discharge delay adjustment that includes the X direction discharge delay parameter and the Y direction discharge delay parameter. The discharge delay adjustment is signaled to carrier discharge control 28 through transmitter 26 by PLC 24 .
[0081] Scanner 50 identifies the articles on carriers and communicates this information to PLC 24 . Scanner 50 may be a bar code reader, or any device suitable for identifying the unique articles. PLC 24 communicates the article information to sortation control 54 which assigns a discharge location for each carrier based on the specific article or articles on the carrier. Alternatively, the article information could be passed from sortation control 54 to host control 56 and host control 56 could assign the discharge location. The discharge location is communicated to PLC 24 .
[0082] PLC 24 is connected to the plurality of transmitters 40 respectively associated with a specific discharge location of the plurality of discharge locations 6 L, 6 R. When a carrier reaches the transmitter 40 associated with the assigned discharge location for that carrier (based on the article it is carrying), PLC 24 communicates the discharge command, which for a double sided chute bank includes direction of discharge, through transmitter 40 to that carrier's carrier discharge control 28 . Carrier discharge control 28 applies the discharge delay adjustment and then actuates discharge.
[0083] The functions performed by PLC 24 could be performed by a plurality of PLCs performing one or more of the functions.
[0084] FIG. 13 diagrammatically illustrates carrier discharge control 28 , which may be a carrier discharge control board as indicated. Each carrier 4 has an associated carrier discharge control 28 associated. Carrier discharge control 28 includes power supply 58 which regulates the low voltage power for electronics and pre-amplifies for power amps 60 which power the windings of the carrier's motor 62 . In the embodiment depicted, motor 62 is a brushless DC motor. This embodiment of carrier discharge control 28 includes microcontroller 64 which comprises a central processing unit, flash memory 68 , static RAM memory 70 , EEPROM 72 , universal asynchronous receive/transmitter block 74 , position sense block and current sense block 76 and pulse width modulator 78 . Carrier discharge control 28 also includes infra-red receiver/transmitter opto-electronics 80 and servo carrier discharge control 82 , which commutates power amps 60 sequentially to cause motor 62 to rotate in the desired angular direction and speed.
[0085] FIG. 14 illustrates an embodiment method 200 for discharging an article from a sortation system when the article is positioned off-center on a selected moving carrier of the sortation system. In the embodiment, the method for discharging an article from the sortation may be performed by the sortation system depicted in at least FIGS. 1-2 by a processor of a controller such as processing system 52 described above. In Block 202 , the method includes detect a relative location of the article positioned off-center on the selected moving carrier. The relative location of an article positioned off-center on a selected carrier may be detected by an item detection system that is linked to the processing system. In this manner, the location of the article relative to the carrier can be determined as off-center values.
[0086] In Block 204 , the processing system 52 can determine a release point for discharging (the article) to a selected stationary discharge location, the release point compensating for the relative location of the article positioned off-center. The processing system 52 may use the off-center detection values to determine discharge compensation that can alter the release point to ensure the article is discharged from the moving carrier and into the selected stationary discharge location. In this manner, the processing system can determine the release point for discharging the article 12 into a selected stationary discharge location 6 L, 6 R where the determined release point compensates for the relative location of the article to the carrier 4 .
[0087] In Block 206 , in response to reaching the release point, initiate a discharge of the article positioned off-center by the selected moving carrier. In this manner, the processing system may release the article at the release point where the release point includes compensation for the off-center location of the article on the carrier, and place the article into the selected stationary discharge location.
[0088] FIG. 15 illustrates a machine element embodiment 300 where a material handling system has an endless conveyor having more than one moving carrier that moves past more than one stationary discharge location, and an image device positioned to detect an article positioned off-center on a selected moving carrier. A controller is provided and in communication with the endless conveyor and the image device, to perform operations as follows. In the embodiment, the controller may be the processing system 52 described above and depicted in at least FIGS. 1-2 . In Block 302 , the material handling system may detect a relative location of the article positioned off-center on a selected carrier of the endless conveyor. The relative location of an article positioned off-center on a selected carrier may be detected by an item detection system that is linked to the processing system. In this manner, the location of the article relative to the carrier can be determined as off-center values.
[0089] In Block 304 , the processing system 52 can determine a release point for discharging the article to a selected stationary discharge location where the determined release point compensates for the relative location of the article to the carrier. The release point may be determined by the processing system 52 which may use the off-center detection values to determine discharge compensation that can alter the release point to ensure the article is discharged from the moving carrier and into the selected stationary discharge location. In this manner, the processing system can determine the release point for discharging the article 12 into a selected stationary discharge location 6 L, 6 R where the determined release point compensates for the relative location of the article to the carrier 4 .
[0090] In Block 306 , in response to reaching the release point, the processing system can initiate the discharge of the article by the selected carrier. In this manner, the processing system may release the article at the release point where the release point includes compensation for the off-center location of the article on the carrier, and place the article into the selected stationary discharge location.
[0091] FIG. 16 illustrates a controller embodiment 400 where a controller has an interface to an endless conveyor, at least one processor, and a memory. In the embodiment, the controller, the processor and the memory may be the processing system 52 described above and depicted in at least FIGS. 1-2 . The at least one processor is coupled to the memory and the interface and configured with processor-executable instructions to perform operations as follows. In Block 402 , the material handling system may detect a relative location of the article positioned off-center on a selected carrier of the endless conveyor. The relative location of an article positioned off-center on a selected carrier may be detected by an item detection system that is linked to the processing system. In this manner, the location of the article relative to the carrier can be determined as off-center values.
[0092] In Block 404 , the processing system 52 can determine a release point for discharging the article to a selected stationary discharge location where the determined release point compensates for the relative location of the article to the carrier. The release point may be determined by the processing system 52 which may use the off-center detection values to determine discharge compensation that can alter the release point to ensure the article is discharged from the moving carrier and into the selected stationary discharge location. In this manner, the processing system can determine the release point for discharging the article 12 into a selected stationary discharge location 6 L, 6 R where the determined release point compensates for the relative location of the article to the carrier 4 .
[0093] In Block 406 , in response to reaching the release point, the processing system can initiate the discharge of the article by the selected carrier. In this manner, the processing system may release the article at the release point where the release point includes compensation for the off-center location of the article on the carrier, and place the article into the selected stationary discharge location.
Explicit Definitions
[0094] In accordance with various aspects of the disclosure, an element, or any portion of an element, or any combination of elements may be implemented with a “processing system” that includes one or more physical devices comprising processors. Non-limiting examples of processors include microprocessors, microcontrollers, digital signal processors (DSPs), field programmable gate arrays (FPGAs), programmable logic devices (PLDs), programmable logic controllers (PLCs), state machines, gated logic, discrete hardware circuits, and other suitable hardware configured to perform the various functionality described throughout this disclosure. One or more processors in the processing system may execute instructions. A processing system that executions instructions to effect a result is a processing system which is configured to perform tasks causing the result, such as by providing instructions to one or more components of the processing system which would cause those components to perform acts which, either on their own or in combination with other acts performed by other components of the processing system would cause the result. Software shall be construed broadly to mean instructions, instruction sets, code, code segments, program code, programs, subprograms, software modules, applications, software applications, software packages, routines, subroutines, objects, executables, threads of execution, procedures, functions, etc., whether referred to as software, firmware, middleware, microcode, hardware description language, or otherwise. The software may reside on a computer-readable medium. The computer-readable medium may be a non-transitory computer-readable medium. Computer-readable medium includes, by way of example, a magnetic storage device (e.g., hard disk, floppy disk, magnetic strip), an optical disk (e.g., compact disk (CD), digital versatile disk (DVD)), a smart card, a flash memory device (e.g., card, stick, key drive), random access memory (RAM), read only memory (ROM), programmable ROM (PROM), erasable PROM (EPROM), electrically erasable PROM (EEPROM), a register, a removable disk, and any other suitable medium for storing software and/or instructions that may be accessed and read by a computer. The computer-readable medium may be resident in the processing system, external to the processing system, or distributed across multiple entities including the processing system. The computer-readable medium may be embodied in a computer-program product. By way of example, a computer-program product may include a computer-readable medium in packaging materials. Those skilled in the art will recognize how best to implement the described functionality presented throughout this disclosure depending on the particular application and the overall design constraints imposed on the overall system.
[0095] “Processor” means devices which can be configured to perform the various functionality set forth in this disclosure, either individually or in combination with other devices. Examples of “processors” include microprocessors, microcontrollers, digital signal processors (DSPs), field programmable gate arrays (FPGAs), programmable logic devices (PLDs), programmable logic controllers (PLCs), state machines, gated logic, and discrete hardware circuits. The phrase “processing system” is used to refer to one or more processors, which may be included in a single device, or distributed among multiple physical devices.
[0096] “Instructions” means data which can be used to specify physical or logical operations which can be performed by a processor. Instructions should be interpreted broadly to include, code, code segments, program code, programs, subprograms, software modules, applications, software applications, software packages, routines, subroutines, objects, executables, threads of execution, procedures, functions, hardware description language, middleware, etc., whether encoded in software, firmware, hardware, microcode, or otherwise.
[0097] A statement that a processing system is “configured” to perform one or more acts means that the processing system includes data (which may include instructions) which can be used in performing the specific acts the processing system is “configured” to do. For example, in the case of a computer (a type of “processing system”) installing Microsoft WORD on a computer “configures” that computer to function as a word processor, which it does using the instructions for Microsoft WORD in combination with other inputs, such as an operating system, and various peripherals (e.g., a keyboard, monitor, etc. . . . ).
[0098] The foregoing description has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the innovation to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to illustrate the principles of the innovation and its application to thereby enable one of ordinary skill in the art to utilize the innovation in various embodiments and with various modifications as are suited to the particular use contemplated. Although only a limited number of embodiments of the invention is explained in detail, it is to be understood that the innovation is not limited in its scope to the details of construction and arrangement of components set forth in the preceding description or illustrated in the drawings. The innovation is capable of other embodiments and of being practiced or carried out in various ways. Also, specific terminology was used herein for the sake of clarity. It is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. It is intended that the scope of the innovation be defined by the claims submitted herewith. | The discharge accuracy of unit sortation is improved by making real time adjustments to the discharge timing of the carrier based on the determined actual position of each article on respective carriers. The adjustments are applied at the time the discharge command is given. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to tree delimbing apparatus, and more particularly pertains to a new and improved delimbing apparatus wherein the same is directed to the ease and efficiency in the delimbing of a felled tree.
2. Description of the Prior Art
Subsequent to the felling of a tree, the tree is to be delimbed to permit ease of manipulation, transport, and storage of the tree as a log. Delimbing apparatus in the prior art has addressed this problem, but has frequently been of a cumbersome and awkward nature in use and construction. Examples of such tree delimbing apparatus are available in the prior art and U.S. Pat. No. 4,823,850 to Strean sets forth a pull-through delimbing apparatus disclosed for simultaneously delimbing a single or group of felled trees by directing the trees through jaw structure.
U.S. Pat. No. 4,898,218 to Linderholm sets forth a tree delimbing organization wherein cooperating jaws grasp a tree for the delimbing of a tree directed therethrough.
U.S. Pat. No. 4,738,292 to Turpeinen sets forth a tree delimbing apparatus wherein tree stems are longitudinally directed along a shaft then in turn utilizes helical blade structure for removing bark and branches from an associated tree.
Further examples of prior art are set forth in U.S. Pat. Nos. 4,919,175 to Samson and 4,719,950 to Peterson, et al., as further and varying examples of delimbing structure.
As such, it may be appreciated that there continues to be a need for a new and improved delimbing apparatus as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of delimbing apparatus now present in the prior art, the present invention provides a delimbing apparatus wherein the same is directed for the delimbing of a felled tree for subsequent manipulation and storage thereof. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved delimbing apparatus which has all the advantages of the prior art delimbing apparatus and none of the disadvantages.
To attain this, the present invention provides a tree delimbing structure arranged to include a plurality of biased gates arranged in a first position in a parallel relationship relative to one another to a second position to receive a tree therethrough. The gates are hingedly mounted at opposed ends of the gate relative to confronting edges, wherein the confronting edges include aligned slots to receive a tree trunk therethrough to guide the tree trunk when the tree is directed rearwardly into the gate once the tree is passed through the gates. Biasing structure is provided to bias the gates to the first position from a second displaced position.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved delimbing apparatus which has all the advantages of the prior art delimbing apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved delimbing apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved delimbing apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved delimbing apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such delimbing apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved delimbing apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of a prior art delimbing apparatus.
FIG. 2 is an isometric illustration of the instant invention.
FIG. 3 is an orthographic top view of the invention illustrated in a first position displaced to a second position, as illustrated in phantom.
FIG. 4 is an orthographic top view of the invention directing a felled tree rearwardly into the gate structure of the invention.
FIG. 5 is an orthographic top view of an example of a biasing structure to direct the gates and bias the gates to the first position.
FIG. 6 is an orthographic side view of a further example of a biasing structure to bias the gate structures in the first position.
FIG. 7 is an isometric illustration of the biasing structure as set forth in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 7 thereof, a new and improved delimbing apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
FIG. 1 illustrates a prior art delimbing apparatus directing a felled tree through spaced jaws, as set forth in U.S. Pat. No. 4,823,850.
More specifically, the delimbing apparatus 10 of the instant invention essentially comprises a platform base 11, including a base front edge 11a spaced from a base rear edge 11b, including respective first and second side edges 13 and 14. At least one row of spikes 12 are orthogonally and fixedly mounted to a bottom surface of the base adjacent the front edge 11a projecting downwardly to enhance adjacency of the base with an underlying surface.
First gate post 15 is orthogonally mounted to a top surface of the base 11 adjacent the first edge 13 spaced between the front and rear edges 11a and 11b. A second gate post 16 is in a like manner mounted to a top surface of the platform base 11 adjacent the second edge 14 spaced an equal distance relative to the front edge 11a as the first gate post 15. First and second gate hinges 17 and 18 respectively are mounted to the respective first and second gate posts 15 and 16 and may be of a spring return type, wherein the hinges 17 and 18 are mounted to respective first and second gates 19 and 20 at exterior edges of the first and second gates 19 and 20. Each gate 19 and 20 includes respective first and second gate arcuate top edge 21 and 22 to permit ease of guidance of a tree limb or branch relative to the top edge, including respective first and second gate slotted interior edges 23 and 24 that are in a confronting relationship in a first position, wherein the first and second gates 19 and 20 are coplanar relative to one another. A first gate ramp 25 and a second gate ramp 26 are mounted to a frontal surface and bottom edge of the respective first and second gates 25 and 26 to permit ease of projecting of a tree "T" rearwardly into the gate structure in the manner as illustrated in the FIG. 4 for example. An entrance ramp 27 is mounted coextensively between the first and second side edges 13 and 14 orthogonally oriented relative to the first and second edges, and positioned adjacent the gates 19 and 20 when in the first position. The gates 19 and 20 are displaced to a second position defining a generally acute angle therebetween when a tractor vehicle "V" directs a tree "T" between the gates 19 and 20 permitting the gates to swing in an opened orientation permitting the vehicle and tree to be directed therethrough, with the entrance ramp 27 permitting ease of guidance between the gates, as well as an abutment surface for the gates in the first position, in a manner as illustrated in the FIG. 3 and the FIG. 7 for example.
First and second gate slotted interior edges 23 and 24 define respective first and second slots 28 and 29 in aligned orientation and confronting relative to one another within the respective first and second gates, as well as a third and fourth slot 30 and 31 within the respective first and second gates that are also in aligned orientation when the gates are in a first position to guide a tree trunk between each pair of slots as desired, i.e. the first and second slots 28 and 29 or the third and fourth slots 30 and 31, wherein the branches are thereafter delimbed between the gates 19 and 20 that are generally in adjacency and about the interior edges 23 and 24. The first and second slots 28 and 29 as well as the third and fourth slots 30 and 31 may be in varying widths relative to the pairs of slots 28-29, or 30-31 to accommodate varying sizes of tree trunks therethrough. The gate posts 15 and 16 include respective first and second gate post braces 32 and 33 mounted from the gate posts rearwardly to the rear edge 11b to brace the gate structure on the tree and directed rearwardly, in a manner as illustrated in FIG. 4 for example.
The FIG. 5 illustrates the use of a return piston 34 that is pivotally mounted relative to each gate rearwardly of each gate adjacent the associated gate post, with the piston reciprocated and biased within a cylinder 35 that is mounted to a pivot axle 36 at its rear distal end, with the pivot axle 36 mounted to the platform.
An alternative manner of biasing and assisting the gate to the first position is illustrated in the FIGS. 6 and 7, wherein a first actuator flange 37 is pivotally mounted to a second actuator flange 38 about a second hinge 40, with a first hinge 39 mounted to a rear distal end of the first actuator flange 37 that in turn is mounted coextensive with the rear edge 11b of the platform 11. The actuator flanges 37 and 38 may in this manner be substantially coextensive between the first and second edges 13 and 14. A first support clevis joint 41 is mounted to the second flange 38, with one such clevis joint oriented per each gate 19 and 20, wherein for purposes of illustration, only one such organization is illustrated, where it is understood that a mirror image of such construction is mounted adjacent the second gate 20. A second support clevis joint 43 is mounted to the first gate 19, as well as the second gate 20 to a rear surface thereof, with an actuator rod 42 secured between the first and second clevis joints 41 and 43. A biasing spring 34 is mounted below the second hinge 40 between the second hinge 40 and a top surface of the platform 11 to bias the first and second actuator flanges 37 and 38 upwardly relative to the top surface of the platform base and thereby bias the associated gate rearwardly in association with the spring hinge construction 17, as well as with the spring hinge construction 18 relative to the second gate 20.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A tree delimbing structure is arranged to include a plurality of biased gates arranged in a first position in a parallel relationship relative to one another to a second position to receive a tree therethrough. The gates are hingedly mounted at opposed ends of the gate relative to confronting edges, wherein the confronting edges include aligned slots to receive a tree trunk therethrough to guide the tree trunk when the tree is directed rearwardly into the gate once the tree is passed through the gates. Biasing structure is provided to bias the gates to the first position from a second displaced position. | 0 |
FIELD OF THE INVENTION
This invention relates generally to inspecting primed circuit boards and more particularly to an apparatus and method for automatically identifying defective conductors including plated through holes and multilayer, inner layer, interconnects on printed circuit boards which have a reduced cross sectional area over part or all of their length.
BACKGROUND OF THE INVENTION
In the manufacturing process for primed circuit boards, a layer of conductive material is applied by various methods onto each printed circuit board substrate and then the conductors on the printed circuit board are imaged and etched. The conductors are used to interconnect components which will be later connected to the printed circuit board. During the manufacturing and or etching process, defects in the conductors and plated through holes (PTH) sometimes occur. Since correcting printed circuit boards at the site of the consumer is expensive, manufacturers attempt to identify and if possible correct the defective conductors before the printed circuit boards are sent out.
The manner in which defects in conductors can occur include, over etching, thin plating, handling scratches, "mouse bites," and voids or defective interconnects in PTHs. The types of defects which can occur include open circuits in the conductor or PTH, areas of reduced cross-sectional area, known as "necked-down" regions, in the conductor, and areas of reduced cross-sectional area along the entire length of the conductor. Other detectable defects include partial voiding in PTH and defective inner layer interconnects on multilayer PCBs.
One example of a conductor C1 with a necked down region NDR1 on a printed circuit board PCB1 is illustrated in top and side views, shown in FIGS. 1(a-b). At the necked down region NDR1, the thickness of conductor C1 is substantially reduced. Since the current carrying capacity a conductor is dependent on the cross-sectional area of the conductor, a reduced cross-sectional area along a portion or the entire length of the conductor will effect the conductor's capacity to carry current. As a given current flows through a conductor with a reduced cross sectional area over part or all of its length, the higher current density in the section of reduced area will result in greater power dissipation in that area and a corresponding larger temperature rise in that area. Eventually, the conductor with a necked down region or a reduced cross-sectional area along its entire length may burn out from the thermal stress. Defect areas in conductors where there is an open circuit are easy to detect, but defects in conductors where the region is necked down as shown in FIGS. 1(a-b) or where the entire length is reduced are difficult to detect. Standard methods for electrical testing of PCBs only reveal complete open or short circuits.
Existing techniques for detecting partially defective conductors are imprecise and often fail to identify partially defective conductors. For example, one prior technique identifies defective conductors by applying a high current pulse to each conductor on the printed circuit board to burn open any defective conductors. However, this technique is imprecise because some conductors which are defective will not be identified because the high current pulse is insufficient to burn open the defective conductor. Another technique applies a continually increasing current signal to each conductor on the printed circuit board, measures the voltage drop across each conductor, and monitors the voltage and current waiting for the voltage to start varying nonlinearly with the current signal. Again this technique is imprecise because some conductors which are defective will not be identified because the nonlinear fluctuation of the voltage with respect to the current may not be sufficient to identify a defective conductor. Additionally, prior techniques often are unable to accurately control the amplitude or magnitude and duration of the current pulses used to test conductors and as a result conductors and printed circuit boards which are acceptable are damaged.
SUMMARY OF INVENTION
A test apparatus which provides an accurate automatic analysis of conductors on a printed circuit board includes a control unit which is coupled to a current source, a measuring unit, a plurality of switches, and connectors. In one embodiment, the apparatus and method operate by first generating a set of reference voltage rises. Each reference voltage rise in the set is associated with one conductor on the reference printed circuit board and represents the difference between a first voltage drop reading and a subsequent voltage drop reading taken across that one conductor while a constant current pulse is applied. Once the set of reference voltage rises is generated, then the apparatus and method generate a set of test voltage rises. Each test voltage rise in the set is associated with one conductor on the test printed circuit board and represents the difference between the first and the subsequent voltage drop readings taken across that one conductor while the constant current pulse is applied. When the sets of reference and test voltage rises are generated, then the apparatus and method compare the test voltage rise for each conductor on the test printed circuit board against the reference voltage rise for the corresponding conductor on the reference printed circuit board to determine if the test voltage rise exceeds the reference voltage rise. If the test voltage rise exceeds the reference voltage rise, then the apparatus and method identify the conductor as defective. The apparatus and method may multiply each reference voltage rise in the set of reference voltage rises by a set factor to establish a table of adjusted reference voltage rises and then use the adjusted set of reference voltage rises when comparing and evaluating the test voltage rises. This permits the operator to dynamically adjust the parameters for identifying defective conductors and allows for manufacturing tolerances normally associated with the manufacturing process.
In an alternative embodiment, the apparatus and method operate by first generating a set of amplitudes for a constant current pulse. Each amplitude in the set is associated with one conductor on the reference printed circuit board and represents the amplitude which generates a determined voltage rise in that one conductor that is within a set range of a desired voltage rise for that one conductor. Each determined voltage rise representing the difference between a first and a subsequent voltage drop readings taken across each conductor while the constant current pulse is applied. Once the set of amplitudes is generated, the apparatus and method generate a set of test voltage rises. Each test voltage rise is associated with one conductor on the test printed circuit board and represents the difference between the first and the subsequent voltage drop readings taken across that one conductor when the constant current pulse with the amplitude from the set of amplitudes for the corresponding conductor on the reference printed circuit board is applied to that one conductor. Once the test voltage rises are generated, then the apparatus and method compare the test voltage rise for each conductor on the test printed circuit board against the desired voltage rise for the corresponding conductor on the reference printed circuit board to determine if the test voltage rise exceeds the desired voltage rise. If the test voltage rise exceeds the desired voltage rise, then the apparatus and method identify the conductor as defective. Again, the apparatus and method may multiply each reference voltage rise in the set of reference voltage rises by a set factor to establish a table of adjusted reference voltage rises and then use the adjusted set of reference voltage rises when comparing and evaluating the test voltage rises.
With the present invention, an accurate automatic analysis for defects in conductors on printed circuit boards can be carried out. Conductors with open circuits, areas of reduced cross-sectional, and areas of reduced cross-sectional area along their entire length can be easily identified. The apparatus and method will not damage other acceptable conductors or the printed circuit boards being tested and is dynamic allowing the operator to adjust the parameters for identifying defective conductors to the particular printed circuit boards being inspected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(a) is a top view of a conductor on a printed circuit board with a necked down region;
FIG. 1(b) is a side view of the conductor on the printed circuit board with the necked down region shown in FIG. 1(a); and
FIG. 2 is a block diagram of a test apparatus in accordance with the present invention.
DETAILED DESCRIPTION
A test apparatus 10 in accordance with the present invention is illustrated in FIG. 2. Test apparatus 10 includes a control unit 12 which is coupled to a current source 14, a measuring unit 16, a plurality of switches 18, 20, 22, 23, 24, 26, 28, 30, 31, 32, 34, 36, 38, 39, 40, 42, 44, 46, 47, and 48 ("18-48"), and connectors 50, 52, 54, 55, and 56. Test apparatus 10 and method provide an accurate automatic analysis of conductors on printed circuit boards being tested. In particular, test apparatus 10 and method test each conductor for open circuits and areas of reduced cross-sectional area along all or part of their length. Test apparatus 10 and method will not damage printed circuit boards being tested or other acceptable conductors on the printed circuit boards and is dynamic allowing the operator of test apparatus 10 and method to adjust the parameters for identifying defective conductors.
Basically, to test a conductor C2, C3, or C4 on a printed circuit board PCB2, test apparatus 10 and method send a constant current pulse through the conductor for a certain period of time and monitor the voltage drop across the conductor during the duration of the current pulse. An open circuit in the conductor is detected by a lack of current flow. An area of reduced cross sectional area along part or all of the length of the conductor is detected by noting that the conductor will heat up more rapidly than a matching conductor in a reference printed circuit board which does not have a reduced cross sectional area along part or all of its length. The amount of heating in the conductor is determined by monitoring the voltage rise over the time the constant current pulse is applied. As current flows through the conductor, the conductor dissipates power according to the equation: P=I 2 R, where P=power in watts; I=current in amps; R=the resistance of the conductor in ohms. In this case, the current is held constant by the apparatus. The power dissipation in the conductor results in a heating and temperature rise in the conductor which typically causes an increase in resistance of the conductor in accordance with the thermal coefficient of resistance for the material from which the conductor is made. This increase in resistance results in a commensurate increase in the voltage drop across the conductor. This characteristic is repeatable and unique for a particular conductor. As energy is absorbed, the conductor heats and the resistance increases and the increase in resistance results in an increase in the voltage drop across the conductor during the duration of the current pulse. The difference between the voltage drop at various times during the constant current pulse provides the voltage rise.
Referring to FIG. 2, control unit 12 is a programmed computer system which executes a set of instructions to identify defective conductors on printed circuit boards. The set of instructions carried out by control unit 12 are set forth in greater detail later. Control lines 58 couple control unit 12 to current source 14, measuring unit 16 and each switch 18-48. Control unit 12 controls the magnitude or amplitude and duration of current pulses output by current source 14, controls the timing of and the type of measurements made by measuring unit 16 and controls which switches 18-48 coupled to current source 14 and measuring unit 16 are open and which are closed.
Current source 14 is coupled through switches 18-48 to connectors 50, 52, 54, 55, and 56. Current source 14 can output a constant current pulse for a time interval to connectors 50, 52, 54, 55, and 56. In this particular embodiment, the constant current pulse can have a constant amplitude between 0.1 to 40.0 amps and a pulse duration of 0.1 to 220 milliseconds. The particular amplitude and duration of the constant current pulse output by current source 14 can be adjusted as necessary for the particular application.
Measuring unit 16 is coupled through switches 18-48 to connectors 50, 52, 54, 55, and 56. In this particular embodiment, measuring unit 16 is a voltmeter and m ammeter which can be coupled by switches 18-48 to be in series or in parallel with each conductor C2, C3, and C4 on printed circuit board PCB2.
Each switch 18-48 is coupled to one end of connectors 50, 52, 54, 55, and 56. In this particular embodiment, switches 18-48 are implemented using field effect transistors although other types switches could be used. The other end of each connector 50, 52, 54, 55, and 56 is adapted to be brought into electrical and mechanical contact with test points T1, T2, T3, T4, and T5 ("T1-T5"). In this particular embodiment, connector 50 is coupled to test point T1, connector 52 is coupled to test point T2, connector 54 is coupled to test point T3, connector 55 is coupled to test point T4, and connector 56 is coupled to test point T5. Test points T1 and T2 are located at the end of conductor C2, test points T1 and T3 are located at the ends of conductor C3, and test points T4 and T5 are located at the ends of conductor C4. Although only five connectors 50, 52, 54, 55 and 56 and three conductors C2, C3, and C4 are shown, test apparatus 10 could have as many connectors as needed and desired to test as many conductors as there were on printed circuit board PCB2. Typically, test apparatus 10 will have about 1500 connectors. Although not shown, a "bed of nails" type fixture could be used to bring connectors 50, 52, 54, 55 and 56 into electrical and mechanical contact with test points T1-T5.
Test apparatus 10 and method operate in two phases to identify conductors which have open circuits or have a reduced cross-sectional area over part or all of their length: a learn routine; and then a test routine.
LEARN ROUTINE
In the learn routine, a reference printed circuit board is selected from two or more printed circuit boards to be tested and then each conductor on the reference printed circuit board is inspected to ensure that each conductor has an acceptable cross-sectional area along its entire length and thus is not defective. In this particular embodiment, a visual inspection is used although other types of inspection techniques could be used.
I. Identification of Conductors on the Reference Printed Circuit Board
Once a reference printed circuit board is located, test apparatus 10 and method identify the location of conductors C2, C3, and C4 on reference print circuit board PCB 2 (which for purposes of illustration at this point is representative of the reference printed circuit board). To identify the location of each conductor, one end of each of connector 50, 52, 54, 55, and 56 is coupled to one of the test points T1, T2, T3, T4, or T5 on reference printed circuit board PCB2. In this particular embodiment, test apparatus 10 has 1500 connectors, of which only connectors 50, 52, 54, 55, and 56 are shown for ease of illustration. Once connectors 50, 52, 54 55, and 56 have been coupled to test points T1-T5, control unit 12 sequentially tests for a connection between each set of two connectors 50, 52, 54, 55, and 56.
First, control unit 12 closes switches 18 and 28 and commands current source 14 to apply a low current pulse between connectors 50 and 52, and commands measuring unit 16 to monitor for any current flow. The amplitude and duration of the low current pulse applied would be selected to be at a level which the conductor with the smallest cross-sectional area on reference printed circuit board PCB2 could withstand. In this particular embodiment, conductor C2 has a cross sectional area of 30 mils 2 so a low current pulse having an amplitude of 0.5 amps for 1 milliseconds is used. If current flow between test points T1 and T2 is detected, then measuring unit 16 signals control unit 12 that a conductor C2 has been detected. Control unit 12 stores the location of the identified conductor and then signals current source 14 to turn off the low current pulse, signals measuring unit 16 to stop taking measurements, and opens switches 18 and 28.
Next, control unit 12 closes switches 18 and 30 and commands current source 14 to apply the same low current pulse between connectors 50 and 54, and commands measuring unit 16 to monitor for any current flow. Again, if a current is detected, then measuring unit 16 signals control unit 12 that a conductor has been detected and control unit 12 stores the location of the identified conductor. The process is repeated for all possible combinations of connections between connectors 50, 52, 54, 55, and 56.
When the process is completed, control unit 12 has a first learn file which has the stored location of all of the conductors C2, C3, and C4. An example of such a first learn file is set forth below:
______________________________________Starting Test Point Coupled to theTest Point Starting Test Point______________________________________T1 T2, T3T4 T5______________________________________
Once the first learn file is created, then control unit 12 continues with the learn routine by recording the heating response of conductors C2, C3, and C4 on the reference printed circuit board.
II. Heating Response of Each Conductors on the Reference Printed Circuit Board
A. Constant Current--Heating Response
In this embodiment, control unit 12 commands current source 14 to apply the same constant current pulse for a time interval to each conductor C2, C3, and C4, sequentially. The amplitude or magnitude and the duration of the constant current pulse which is applied to all of the conductors on the reference printed circuit board is less than or equal to the maximum amplitude and duration for a current pulse that the conductor with the smallest cross-sectional area on the reference printed circuit board could withstand. In this particular embodiment, the smallest cross sectional area for a conductor is 30 mils 2 so a constant current pulse of 30 amps for 5 milliseconds is used to test the heating response of conductors C2, C3, and C4. Control unit 12 has the location of each conductor C2, C3, and C4 stored in the first learn file. Although in this particular embodiment, a constant current pulse of 30 amps for 5 milliseconds is used, the amplitude and duration of the pulse can be adjusted as needed and desired for the particular type of conductor. The apparatus 10 is fully adjustable for a wide range of conductor geometries.
To test the heating response of conductor C2, control unit 12 closes switches 18, 28, 34 and 44, commands current source 14 to apply the constant current pulse to conductor C2, and commands measuring unit 16 to record the voltage drop across conductor C2 at set intervals. In this particular embodiment, current source 14 applies a constant current pulse of 30 amps for 5 milliseconds and measuring unit 16 measures the voltage drop across conductor C2 at 0.1 millisecond intervals. The voltage drop readings are transmitted by measuring unit 16 to control unit 12. Control unit 12 stores each voltage drop reading in a memory (not shown) and as all of the voltage drop readings are being taken and stored, control unit 12 determines the voltage rise for conductor C2.
As discussed earlier, a voltage rise occurs between the first and last voltage drop readings for conductor C2 because as current flows through conductor C2, conductor C2 absorbs energy. As energy is absorbed, conductor C2 heats and the conductor's resistance increases. The increase in resistance during the duration of the current pulse results in an increase in the voltage drop readings across conductor C2.
In this particular embodiment, the reference voltage rise is calculated by determining the difference between the first and last voltage drop reading, although any other set of two voltage drop readings could be used. For conductor C2, if the first voltage drop reading was 5.5 volts and the last voltage drop reading was 5.7 volts then control unit 12 would subtract 5.5 volts from 5.7 volts to obtain a voltage rise of 0.2 for conductor C2.
Once the voltage rise for conductor C2 is determined, then the heating response of the remaining conductors are determined. Once the heating response of each conductor C2, C3, and C4 has been determined, then control unit 12 will have a second learn file stored which includes the conductor C2, C3, and C4, the first and last voltage drop readings and the voltage rise. One illustrative example of a second learn file is set forth below:
______________________________________ First Last Voltage VoltageConductor Drop Drop Voltage Rise______________________________________C2 5.500 5.700 0.200C3 4.425 4.485 0.060C4 3.262 3.397 0.135______________________________________
Next, control unit 12 determines what deviation above the voltage rise recorded in the second learn file would be acceptable for a conductor in a printed circuit board which is being tested ("test printed circuit board"). In this particular embodiment, control unit 12 allows each conductor on a test printed circuit board to have a voltage rise which is up to 10% higher than the voltage rise recorded in the second learn file. Accordingly, control unit 12 multiplies the voltage rise stored in the second learn file by 1.1 to obtain the maximum voltage rise. The maximum voltage rise permitted for each conductor C2 is added to the second learn file:
______________________________________Con- First Voltage Last Voltage Voltage Max Voltageductor Drop Drop Rise Rise______________________________________C2 5.500 5.700 0.200 0.220C3 4.425 4.485 0.060 0.066C4 3.262 3.397 0.135 0.149______________________________________
The amount of deviation from the voltage rise which control unit 12 allows can be adjusted by the operator of the test apparatus 10 to whatever level is desired.
B. Constant Voltage Rise--Heating Response
In an alternative embodiment, control unit 12 commands current source 14 to sequentially apply a constant current pulse to each conductor C2, C3, and C4 and to increase the amplitude of each successive application of the constant current pulse to each conductor C2, C3, and C4 until a set voltage rise is obtained or until a maximum amplitude for the constant current pulse is reached. The maximum amplitude for the constant current pulse depends upon the cross sectional area of each conductor being tested. In this particular embodiment, the constant current pulse has a starting amplitude of 1 amp which is applied for a duration of 5 milliseconds. As with the prior embodiment, control unit 12 has the location of each conductor C2, C3, and C4 to be tested stored in the first learn file.
To test the heating response of conductor C2, control unit 12 closes switches 18, 28, 34, and 44, commands current source 14 to apply a constant current pulse with an initial amplitude, and commands measuring unit 16 to measure the voltage drop across conductor C2 at set time intervals. In this particular example, the initial amplitude of the constant current pulse is 1 amp and the duration of the constant current pulse is 5 milliseconds. Measuring unit 16 measures the voltage drop across conductor C2 at periodic intervals, in this particular embodiment every 0.1 milliseconds. Control unit 12 receives the voltage drop readings from measuring unit 16 and calculates the difference between the first and last voltage drop readings to determine the voltage rise.
Once the voltage rise is calculated, then control unit 12 compares the determined voltage rise with the desired voltage rise. In this particular example, a voltage rise of 0.200 volts is desired. If the determined voltage rise is equal to or within a fixed percentage of the desired voltage rise, then the amplitude and duration of the current pulse is stored in a third learn file and the heating response other conductors C3 and C4 are tested. In this particular embodiment, the determined voltage rise must be within 10% of the desired voltage rise.
If the voltage rise is not equal to or within a fixed percentage of the set voltage rise, then testing of the heating response of conductor C2 continues. Conductor C2 is allowed to cool off for a set period of time. In this particular example, conductor C2 would be allowed to cool for 500 milliseconds.
Once the cool off time period has expired, then control unit 12 commands current source 14 to increase the initial amplitude of the constant current pulse and then to apply the constant current pulse with the increased amplitude to conductor C2. In this particular example, the constant current pulse is increased in increments of 1 amp, although the amount the amplitude of the constant current pulse is increased can vary as desired. Control unit 12 also commands measuring unit 16 to monitor the voltage drop across conductor C2 at the same set time intervals and carries out the same voltage rise calculation and comparison described previously for this embodiment.
Control unit 12 will continue to increase the amplitude of the constant current pulse applied by current source 14 until the determined voltage rise is equal to or within a fixed percentage of the desired voltage rise or a maximum amplitude for the constant current pulse is reached.
When either condition is satisfied, then control unit 12 stores the amplitude of the constant current pulse in a third learn file. Control unit 12 will repeat this process for all of the other conductors C3 and C4. One illustrative example of a third learn file is set forth below:
______________________________________ First Last Voltage Voltage VoltageConductor Current Drop Drop Rise______________________________________C2 20 4.800 5.000 0.200C3 21 4.355 4.555 0.200C4 18 4.142 4.342 0.200______________________________________
Although in this illustrative example of the third learn file, the voltage rise for each conductor is 0.200 volts the voltage rise can vary. For example, if the maximum amplitude for the current pulse for a conductor was reached before the desired voltage rise was obtained, then the determined voltage rise for the maximum amplitude for the current pulse would be recorded by control unit 12 as the voltage rise.
Next, control unit 12 determines what deviation above the voltage rise recorded in the third learn file would be acceptable for a conductor in a printed circuit board which is being tested. In this particular embodiment, control unit 12 will allow a conductor on a printed circuit board being tested to have a voltage rise which is up to 10% higher than the voltage rise recorded in the second learn file. Accordingly in this particular embodiment, control unit 12 multiplies the voltage rise stored in the third learn file by 1.1 to obtain the maximum voltage rise which would be acceptable for each conductor. The maximum voltage rise permitted is added to the third learn file:
______________________________________ First Last Max Voltage Voltage Voltage VoltageConductor Current Drop Drop Rise Rise______________________________________C2 20 4.800 5.000 0.200 0.220C3 21 4.355 4.555 0.200 0.220C4 18 4.142 4.342 0.200 0.220______________________________________
Once test apparatus 10 has completed the learn routine, then the reference printed circuit board is disconnected and a test printed circuit board is connected to the test apparatus 10. For purposes of illustration at this point, printed circuit board PCB2 will now be representative of the test printed circuit board.
TEST ROUTINE
A. Constant Current--Heating Response
One end of connectors 50, 52, 54, 55, and 56 for test apparatus 10 are coupled to test points T1-T5 on test printed circuit board PCB2. Once connectors 50, 52, 54, 55, and 56 are coupled to test points T1-T5, then control unit 12 again uses the first learn file to identify the location of each conductor C2, C3, and C4 on test printed circuit board PCB2 and tests each conductor C2, C3, and C4 sequentially.
To test the heating response of conductor C2, control unit 12 closes switches 18, 28, 34, 44, commands current source 14 to apply the constant current pulse which was used to test all of the conductors on the reference printed circuit board to conductor C2, and commands measuring unit 16 to measure the voltage drop at set time intervals during the constant current pulse. In this particular embodiment, the constant current pulse has an amplitude o30 amps and a duration of 5 milliseconds and measuring unit 16 measures a voltage drop across conductor C2 every 0.1 milliseconds.
Typically, control unit 12 will first conduct a preliminary test to verify the integrity of the connection between connectors 50 and 52 and test points T1 and T2 on the printed circuit board PCB 2 being tested. To perform this preliminary test, control unit 12 compares the first voltage drop reading measured for conductor C2 against the first stored voltage drop reading for the matching conductor on the reference printed circuit board and obtains a difference between the two readings. If the difference is less than or equal to a preset amount, then control unit 12 continues with the test routine. If the difference is greater then the preset amount, then control unit 12 signals an error with either the connections of connectors 50 and 52 to test points T1 and T2 the conductor C2 or, in this particular embodiment, the voltage drop readings of the test board must be within 20% of the learned value.
Next, control unit 12 calculates the voltage rise between the present voltage reading and the first voltage reading to obtain a determined voltage rise and then compares the determined voltage rise against the maximum voltage rise acceptable for the conductor which is stored in the second learn file. If the determined voltage rise exceeds the maximum voltage rise for the conductor, then control unit 12 stops the current pulse and identifies that conductor as defective. In this particular embodiment, the maximum voltage rise for conductor C2 is 0.220 volts. The above described test for heating response is then repeated for each of the conductors C3 and C4 on printed circuit board PCB 2 using the maximum voltage rise stored in the second learn file.
B. Constant Voltage Rise--Heating Response
To test the heating response of conductor C2, control unit 12 selects the amplitude of the current pulse stored in the third learn file which achieved the desired voltage rise or was the maximum allowable current pulse for the particular conductor. In this particular embodiment, the amplitude of the constant current pulse for conductor C2 was 20 amps.
Once the proper amplitude for the constant current pulse is selected, then control unit 12 signals switches 18, 28, 34, and 44 to close, commands current source 14 to apply the constant current pulse stored in the third learn file to conductor C2, which is 20 amps in this particular example, and commands measuring unit 16 to measure the voltage drop across conductor C2 at set time intervals.
Again, control unit 12 may conduct the preliminary test described above to verify the integrity of the connection between connectors 50 and 52 and test points T1 and T2 on the printed circuit board PCB 2 being tested may be conducted. If the outcome of the preliminary test is satisfactory, then current source 14 continues to output the constant current pulse and measuring unit 16 continues to measure voltage drop readings across the conductor C2 at the same set intervals used during the learn routine and transmits them to control unit 12.
Control unit 12 receives the voltage drop readings and calculates the voltage rise between the two voltage drop readings selected for determining the voltage rise during the learn routine and compares the determined voltage rise against the maximum voltage rise acceptable for conductor C2 stored in the third learn file. If the determined voltage rise exceeds the maximum voltage rise for conductor C2, then control unit 12 identifies conductor C2 as defective. In this particular embodiment, the maximum voltage rise for conductor C2 is 0.220 volts. The above described test for heating response is then repeated for each of the conductors C3 and C4 on printed circuit board PCB 2 using the amplitude of the constant current pulse and the maximum voltage rise stored in the third learn file.
Having thus described the basic concept of the invention, it will be readily apparent to those skilled in the art that the foregoing detailed disclosure is intended to be presented by way of example only, and is not limiting. Various alterations, improvements and modifications will occur and are intended to those skilled in the art, though not expressly stated herein. These modifications, alterations and improvements are intended to be suggested hereby, and are within the spirit and scope of the invention. Accordingly, the invention is limited only by the following claims and equivalents thereto. | The apparatus and method operate by first generating a set of amplitudes for a constant current pulse. Each amplitude in the set is associated with one conductor on the reference printed circuit board and represents the amplitude which generates a determined voltage rise in that one conductor that is within a set range of a desired voltage rise for that one conductor. Each determined voltage rise representing the difference between a first voltage drop reading and a subsequent voltage drop reading taken across each conductor while the constant current pulse is applied. Once the set of amplitudes is generated, the apparatus and method generate a set of test voltage rises. Each test voltage rise is associated with one conductor on the test printed circuit board and represents the difference between the first and the subsequent voltage drop readings taken across that one conductor when the constant current pulse with the amplitude from the set of amplitudes for the corresponding conductor on the reference printed circuit board is applied to that one conductor. Once the test voltage rises are generated, then the apparatus and method compare the test voltage rise for each conductor on the test printed circuit board against the desired voltage rise for the corresponding conductor on the reference printed circuit board to determine if the test voltage rise exceeds the desired voltage rise. If the test voltage rise exceeds the desired voltage rise, then the apparatus and method identity the conductor as defective. The test apparatus and method may multiply each reference voltage rise in the set of reference voltage rises by a set factor to establish a table of adjusted reference voltage rises and then use the adjusted set of reference voltage rises when comparing and evaluating the test voltage rises. | 6 |
FIELD OF THE INVENTION
This invention relates to a process for preparing small crystals. In particular, the invention relates to a process for preparing small crystals of a size of up to about 10 μm.
BACKGROUND OF THE INVENTION
The control of crystal and precipitate particle size is very important in some circumstances, in particular in the pharmaceutical and agro-chemical industries in which the final product form of the active principal of interest is in the form of a fine powder. The manner in which an active principal behaves in a biological system depends upon many factors inter alia the size of the particle and the crystal form. Small particles may be made by processes such as milling, but such processes may have a detrimental effect on the material properties and may also produce a significant proportion of particles which are unsuitable for the desired use, for example, they may be too small or of an inappropriate shape. Such particles may undergo morphological alterations, leading to undesirable surface polymorphological transformation which in turn may give rise to the formation of amorphous structures. The particles may become highly charged which may also contribute to undermining flow-rates. Also, particles destined for use in aerosols may be compromised should they become highly charged. Crystallisation of crystals in the desired size range directly from solution would be desirable.
For many years it has been known to bring about crystallisation by mixing a solvent containing an active principal to be crystallised with an anti-solvent, so that after mixing the solution is supersaturated and crystallisation occurs. The mixing may occur in the presence of ultrasonic irradiation or in a different manner in which ultrasonic irradiation is not used eg fluid vortex mixing. The term “anti-solvent” means a fluid which promotes precipitation from the solvent of the active principal of interest (or of a precursor of the active principal). The anti-solvent may comprise a cold gas, or a fluid which promotes the precipitation via a chemical reaction, or which decreases the solubility of the active principal of interest in the solvent; it may the same liquid as the solvent but at a different temperature, or it may be a different liquid from the solvent.
EP 1144065 describes a system in which mixing of anti-solvent with solvent comprising an active principal to be crystallised is achieved by using a flow rate ratio of anti-solvent: solvent of up to 10:1 in the presence of ultrasonic irradiation in a continuous flow cell. It is described that a warm solvent is mixed with a cold miscible anti-solvent, although the actual temperature of the cold anti-solvent is not disclosed.
EP 1469938 describes a system in which the flow rate of mixing of anti-solvent with solvent comprising an active principal to be crystallised exceeds that of the solvent, at a flow rate ratio of up to 10:1, typically of from 2:1 up to 5:1. The mixing is carried out in the presence of ultrasonic radiation.
The prior art processes enable the production of crystals using flow rate ratios of anti-solvent: solvent that are generally lower than 20:1 (i.e. towards a flow rate ratio of 10:1 to as low as 1:1).
SUMMARY OF THE INVENTION
According to the present invention there is provided a process for preparing crystalline particles of a substance in the presence of ultrasonic irradiation that comprises contacting at least one solute in a solvent in a first flowing stream with an anti-solvent in a second flowing stream wherein the flow rate ratio of the anti-solvent: solvent is higher than 20:1, and collecting crystals that are generated.
The anti-solvent stream is typically re-circulated, for example, in a continuously re-circulating flowing stream, that is to say, in a second flowing stream as described herein. Typically, there is provided a process according to the invention wherein the second flowing stream is a continuously recycling anti-solvent stream that can also comprise added solute in solvent, wherein the flow rate ratio of the said second flowing stream (ie anti-solvent): solvent is higher than 20:1.
By manipulating the flow rate ratio of anti-solvent to solvent in the process of the present invention the inventors have now made it possible to provide crystals of active principals of interest of a desired size of up to about 10 μm in size. The mean diameter size of particles that are able to be attained using the method of the invention lies in the range of from 500 nm up to 10 μm, preferably from about 600 nm to about 5 μm and most preferably from 650 nm to about 2 μm, for example, 700 nm or 1 μm.
The solute can be an active principal or a desired precursor thereof, such as a drug or an agro-chemical of interest that is able to form crystals in the process of the invention. There may be more than one solute comprised in the first flowing stream, for example, a mixture of two or more solutes of interest, such as two or more active principals of interest, for example, two or more drugs or two or more agro-chemicals, depending on the proposed end use of the said solutes. Suitable solutes that are able to crystallise under the process conditions of the invention include active principals or drugs which can be formed into crystalline particles by the process of the present invention such as corticosteroids, b2-agonists, anticholinergics, leukotriene antagonists, inhalable proteins or peptides, mometasone furoate; beclomethasone dipropionate; budesonide; fluticasone; dexamethasone; flunisolide; triamcinolone; salbutamol; albuterol; terbutaline; salmeterol; bitolterol; ipratropium bromide; oxitropium bromide; sodium cromoglycate; nedocromil sodium; zafirlukast; pranlukast; formoterol; eformoterol; bambuterol; fenoterol; clenbuterol; procaterol; broxaterol; (22R)-6a,9a-difluoro-11b,21-dihydroxy-16a,17a-propylmethylenedioxy-4-pregnen-3,20-dione; TA-2005; tipredane; insulin; interferons; calcitonins; parathyroid hormones; and granulocyte colony-stimulating factor.
Other particles which may be made according to the invention include any drugs or active principals usefully delivered by inhalation for example, analgesics, e.g. codeine, dihydromorphine, ergotamine, fentanyl or morphine; anginal preparations, e.g. diltiazem; antiallergics, e.g. cromoglycate, ketotifen or nedocromil; anti-infectives, e.g. cephalosporins, penicillins, streptomycin, sulphonamides, tetracyclines or pentamidine; antihistamines, e.g. methapyrilene; anti-inflammatories, e.g. beclomethasone, flunisolide, budesonide, tipredane, triamcinolone acetonide or fluticasone antitussives, e.g. noscapine; bronchodilators, e.g. ephedrine, adrenaline, fenoterol, formoterol, isoprenaline, metaproterenol, phenylephrine, phenylpropanolamime, pirbuterol, reproterol, rimiterol, salbutamol, salmeterol, terbutalin; isoetharine, tulobuterol, orciprenaline or (−)-4-amino-3,5-dichloro-a[[[6-[2-(2-yridinyl) ethoxy]hexyl]amino]methyl]benzenemethanol; diuretics, e.g. amiloride; anticholinergics e.g. ipratropium, atropine or oxitropium; hormones, e.g. cortisone, hydrocortisone or prednisolone; xanthines e.g. 25 aminophylline, choline theophyllinate, lysine theophyllinate or theophylline; and therapeutic proteins and peptides, e.g. insulin or glucagon. It will be appreciated by the person skilled in the art that, where appropriate, medicaments comprising active principals or drugs may be used in the form of salts (e.g. as alkali metal or amine salts or as acid addition salts) or as esters (e.g. lower alkyl esters) or as solvates (e.g. hydrates) to optimise the activity and/or stability of the medicament.
Particularly suitable medicaments for preparation with particles obtained in accordance with the process of the invention include anti-allergics, bronchodilators and anti-inflammatory steroids of use in the treatment of respiratory disorders such as asthma by inhalation therapy, for example cromoglycate (e.g. as the sodium salt), salbutamol (e.g. as the free base or as the sulphate salt), salmeterol (e.g. as the xinafoate salt), terbutaline (e.g. as the sulphate salt), reproterol (e.g. as the hydrochloride salt), beclomethasone dipropionate (e.g. as the monohydrate), fluticasone propionate or (−)-4-amino-3,5-dichloro-.alpha.-[[[6-[2-(2-pyridinyl)ethoxy]hexyl]amino]-methyl]benzenemethanol and physiologically acceptable salts and solvates thereof.
It will be appreciated by the man skilled in the art that particles made by the process of the invention may contain a combination of two or more active principals. Active principals may be selected from suitable combinations of the active principals mentioned hereinbefore. Thus, suitable combinations of bronchodilatory agents include ephedrine and theophylline, fenoterol and ipratropium, and isoetharine and phenylephrine.
Further suitable combinations of particles of active principals made according to the process of the invention include combinations of corticosteroids, such as budesonide, beclomethasone dipropionate and fluticasone propionate, with b2-agonists, such as salbutamol, terbutaline, salmeterol and fluticasone, salmeterol and formoterol and physiologically acceptable derivatives thereof, especially salts including sulphates.
Other examples of particles obtainable by the process of the invention may include a cromone which may be sodium cromoglycate or nedocromil, or may include carbohydrate, for example, heparin.
The particles made by the process of the invention may comprise an active principal suitable for inhalation and may be a pharmacologically active agent for systemic use. For example, such active particles may comprise peptides or polypeptides or proteins such as Dase, leukotines or insulin (including pro-insulins), cyclosporin, interleukins, cytokines, anticytokines and cytokine receptors, vaccines, growth hormone, leuprolide and related analogues, intereferons, desmopressin, immmunoglobulins, erythropoeitin and calcitonin.
Alternatively, the active principal made by the process of the invention may be suitable for oral administration. A drug for oral administration may be one of the systemic drugs mentioned above. The active principal may be a substance which exhibits low solubility in the digestive tract, for example, magnesium trisilicate, calcium carbonate and bismuth subnitrate. Organic compounds may include, for example, all products of combinatorial chemistry, rosiglitazone and other related glitazone drugs, hydrochlorothiazide, griseofulvin, lamivudine and other nuclease reverse transciptase inhibitors, simvastatin and other statin drugs, benzafibrate and other fibrate drugs and loratidine, and any other physiologically tolerable salts and derivatives thereof.
Pharmaceutical excipients suitable for adding to particles made according to the process of the invention include, for example, carbohydrates especially monosaccharides such as fructose, glucose and galactose; non-reducing disaccharides such as sucrose, lactose and trehalose; non-reducing oligosaccharides such as raffinose and melezitose; non reducing starch derived polysaccharides products such as maltodextrins, dextrans and cyclodextrins; and non-reducing alditols such as mannitol and xylitol.
Where the particles of active principal(s) prepared by the process of the present invention are agro-chemically active, the active principal may for example be a plant growth regulator, herbicide, and/or pesticide, for example insecticide, fungicide, acaricide, nematocide, miticide, rodenticide, bactericide, molluscicide or bird repellant.
Examples of organic water-insoluble agrochemical active principals made according to the process of the invention include insecticides, for example selected from the group consisting of carbamates, such as methomyl, carbaryl, carbofuran, or aldicarb; organo thiophosphates such as EPN, isofenphos, isoxathion, chlorpyrifos, or chlormephos; organo phosphates such as terbufos, monocrotophos, or terachlorvinphos; perchlorinated organics such as methoxychlor; synthetic pyrethroids such as fenvalerate; nematicide carbamates, such as oxamyl herbicides, for example selected from the group consisting of triazines such as metribuzin, hexaxinone, or atrazine; sulfonylureas such as 2-chloro-N-[(4-methoxy-6-methyl-1,3,5-triazin-2-yl)aminocarbonyl]-benzenesulfonamide; uracils (pyrimidines) such as lenacil, bromacil, or terbacil; ureas such as linuron, diuron, siduron, or neburon; acetanilides such as alachlor, or metolachlor; thiocarbamates such as benthiocarb (SATURN), triallate; oxadiazol-ones such as oxadiazon; phenoxyacetic acids such as 2,4-D; diphenyl ethers such as fluazifop-butyl, acifluorfen, bifenox, or oxyfluorfen; dinitro anilines such as trifluralin; glycine phosphonates such as glyphosate salts and esters; dihalobenzonitriles such as bromoxynil, or ioxynil; fungicides, for example selected from the group consisting of nitrilo oximes such as cymoxanil (curzate); imidazoles such as benomyl, carbendazim, or thiophanate-methyl; triazoles such as triadimefon; sulfenamides such as captan; dithiocarbamates such as maneb, mancozeb, or thiram; chloronated aromatics such as chloroneb; dichloro anilines such as iprodione; aphicides, for example selected in the group consisting of carbamates, such as pirimicarb; miticides, for example selected from the group consisting of propynyl sulfites such as propargite; triazapentadienes such as amitraz; chlorinated aromatics such as chlorobenzilate, or tetradifan; and dinitrophenols such as binapacryl.
The organic water-insoluble agrochemical active principals may be comprised in the particles produced according to the present invention as a mixture of several ingredients. Especially preferred organic water-insoluble agrochemical active ingredients are atrazine, cymoxanil, chlorothalanil, cyproconazole, and tebuconazole.
The flowing stream of solvent comprising solute (i.e. the ‘solution’) and the flowing stream of anti-solvent may be contacted or mixed together such that the two streams flow along a single path or axis in the same direction, for example, within the lumen of a suitable delivery means and into a suitable receptacle or chamber, such as an ultrasonic continuous flow cell. Each of the said flowing streams may be pumped at a pre-determined rate of flow from an initial source reservoir into the delivery means. A suitable delivery means may comprise a tubular means such as a straight or curved conduit, for example a pipe, and the two streams may be mixed coaxially therein. Alternatively, the two streams may be introduced into a receptacle or chamber, such as an ultrasonic continuous flow cell, via pumping through separate delivery means, such as two separate tubular means, for example, two pipes.
The flow rate ratio of anti-solvent: solvent (the “flow rate ratio” hereinafter) of the invention is higher than 20:1, and may be of any flow rate ratio depending on design and the end purpose for the crystals that are obtained using the process of the invention. The flow rate ratio employed in the process of the invention may be decided taking into account the substance of interest, the desired size of the crystals required for a given purpose, and how the crystals are to be administered to a subject, such as to a mammal (e.g. a human being; a horse; a bovine animal; or a sheep) in the form of a suitable medicament, or to a plant in the form of a suitable agrochemical, for example a pesticide, a herbicide, a fungicide, bactericide, or a virucide. Suitable flow rate ratios for use in the process of the invention may be any flow rate ratio of the second flowing stream:first flowing stream, up to 1000:1, for example, 900:1, 800:1, 700:1, 600:1, 500:1, 400:1, 300:1, 200:1, 100:1, 50:1, 40:1, or 30:1 or any flow rate ratio there between, such as 380:1, 330:1, 333:1, 165:1, 80:1 and the like. The flow rate ratio will be governed by the size of the crystals that are required for a given end purpose and the proposed delivery vehicle for them that is to be used in a subject organism.
Typically, the flow rate of the anti-solvent stream through an apparatus suitable for producing crystalline particles using the process of the invention is in the range of liters per hour (1/hr) [e.g. 20 L/hr] rather than milliliters per hour (ml/hr) and may be any flow rate suitable for the end purpose in question so long as the flow rate of the anti-solvent is higher than that of the solvent system (ie solute in solvent) by a factor of at least 20:1 and higher as herein defined. For example, the flow rate for the first stream flow of the invention may be 20 l/hr and that of the second stream flow 60 ml/hr for a bench top apparatus. Where the process is employed in a larger apparatus, for example, a 100 liter (100 l) vessel the throughput flow rates for the first stream may be 2400 l/hr and for the second stream 120 l/hr. Naturally, the man skilled in the art will appreciate that the rate of flow for each of the said streams can be at any desired rate of flow provided that the flow rate ratio of the two streams is that described for the present invention
The flow rate of the anti-solvent, in a small scale apparatus, such as one having a 1 liter capacity, 5 liter or 10 liter capacity, may be up to 50 l/hr, typically up to 40 l/hr, 30 l/hr, 20 l/hr 10 l/hr or 5 l/hr or of any value in between, such as 4 l/hr, 8 l/hr, 15 l/hr and so on. The flow rate may be decided upon by the skilled addressee depending on the size of particles required for a chosen administration route to a site of interest for a particular end purpose. Correspondingly, the flow rate of the added solution of solute in solvent will be at least 20 times less than that of the anti-solvent with which it is to be placed in contact. An example of a flow rate ratio (333:1) used in the present invention is to be found in the examples wherein the anti-solvent flows at 20 l/hr and the solute in solvent at 60 ml/hr.
It will be appreciated that the anti-solvent and the solvent should be selected as being suitable for a particular active principal or active precursor thereof. The anti-solvent and solvent pair may be miscible with each other. Examples of miscible pairs include water and 2-propanol; and ethanol and water. Alternatively, the anti-solvent and solvent pair may be the same liquid but at different temperatures. Typically, the temperatures of the liquid may lie between −10° C. and +120° C., but with a substantial temperature difference between the two. The temperatures may be separated by a temperature difference of 50° C. or more, for example, where the solvent is hot water (e.g. 80° C.) and the anti-solvent is cold water (e.g. 10° C.). The selection of appropriate solvent and anti-solvent must be made in accordance with the substance to be crystallised.
Once inside the receptacle, for example a continuous ultrasonic flow cell, the combined streams of anti-solvent and solvent are subjected to ultrasonic irradiation to form crystals of a desired mean size. The ultrasonic energy induces nucleation and subsequent crystallisation of the solute in the anti-solvent in the operating vicinity of the ultrasonic probe if used, or of an ultrasonic energy transducer, such as a wrap-around ultrasonic energy transducer, if such a configuration is employed. The ultrasonic energy may be applied continuously or in a discontinuous manner, such as by pulsed application. Any suitable source of ultrasonic irradiation may be used. An ultrasonic probe may, for example, be inserted into a mixing vessel, such as a continuous ultrasonic flow cell, an ultrasonic emitter may be contained in the mixing vessel, or the mixing vessel may be housed in an ultrasonic bath or it may have an ultrasound transducer fixed to the external walls of the mixing vessel. The amplitude and frequency of the ultrasound waves affects the rate of nucleation and crystal growth. The frequency of the ultrasound waves may for example be from 20 kHz to 1 MHz, preferably from 10-500 kHz, more preferably from 10-100 kHz such as at 10, 20, 40, 60, 80, or 100 kHz or at any frequency thereinbetween, such as, 20 kHz or 40 kHz.
The ultrasonic irradiation is employed at an amplitude that is appropriate for the formation of crystals of the desired size, for a pre-determined application. For laboratory probe systems with an emitting face of for example, 80 cm 2 , the amplitude selected may be from about 1-30 μm, typically from 3-20 μm, preferably from 5-10 μm, for example, 5 μm. Probes having a probe face surface area of 8 cm 2 and a power requirement of from 5-80 W, provide a power density of from 0.6-12.5 W/cm 2 using an amplitude of 2-15 micron. In larger systems, comprising transducers bonded onto the flow cell, for example a 6 liter flow cell, the power density for the transducers employed may be from 150-600 W/l, preferably from 250-600 W/l, and more preferably from 300-600 W/l, for example 250 W/l or 450 W/l.
The residence time of the mixed components in the ultrasonic flow cell may be from 10 ms up to about 10 s. For re-circulation systems the residence time can be longer depending on design. The skilled addressee will appreciate that the residence time in the ultrasonic flow cell for each volume of fluid that is placed in it will be of the order of 10 ms up to 10 s, depending on design.
The process may be employed in reactors employed in the art such as in a batch fed reactor or in a continuous flow reactor, depending on design. The man skilled in the art is well acquainted with such reactor types and their operation. Generated crystals may be gathered or harvested from the batch chamber by drawing off crystals using conventional means in the art, such as by the process described in WO 03/092851.
The invention will now be described with reference to the accompanying examples and figures. It is to be understood that the examples and figures are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
The process of the invention may be carried out using conventional equipment as shown in the accompanying figures in which:
FIG. 1 shows a longitudinal sectional view of a crystallisation apparatus incorporating two separate feed stream delivery means for the solvent and anti-solvent leading into an ultrasonic continuous flow cell having an ultrasonic probe placed therein;
FIG. 2 shows a longitudinal sectional view of a crystallisation apparatus incorporating a single feed stream delivery means where the solvent and anti-solvent are introduced coaxially, mixed, and driven in a single stream into an ultrasonic continuous flow cell having an ultrasonic transducing apparatus bonded onto it.
FIG. 3 shows the results for Example 1.
FIG. 4 shows the results for Example 2.
FIG. 5 shows the results for Example 3.
FIG. 6 shows the results for Example 4.
Turning to FIG. 1 , closed loop crystallisation apparatus 10 comprises an impeller 5 in a first feed chamber 4 (surrounded by a thermal jacket 3 ), with an axial outlet 6 through which liquid anti-solvent flows into a delivery means 7 and is pumped at a first flow rate via pump 8 into an ultrasonic flow cell chamber 12 . Concurrently, a liquid solute in solvent is pumped via a pump 9 at a flow rate different from that of the anti-solvent from a second chamber (not shown) via delivery means 10 through to delivery means 11 and into ultrasonic flow cell chamber 12 where the two liquids are mixed. Ultrasonic probe 1 irradiates the mixture with ultrasonic energy and the mixture flows through an outlet 2 and into the first feed chamber 4 , completing a continuous closed flow loop. The flow cycle is repeated until crystallised particles of a desired size are attained. Thus in use of the apparatus 10 , the saturated solution is thoroughly and rapidly mixed with the anti-solvent, the volume of the chamber 4 and the flow rates being such that the residence time in the ultrasonic flow cell chamber 12 is for example, 10 s. The ultrasonic energy from the probe 1 insonates the entire volume of the chamber 12 with sufficient intensity to cause dispersion and nucleation, as localised cavitation occurring on a microscopic scale promotes changes in fluid temperature and pressure that induce nucleation (and also promotes formation of the stable polymorph). By adjusting the power of the ultrasound, and the residence time in chamber 12 , the degree of nucleation can therefore be controlled. The ultrasound has the additional benefit that any crystal deposits within the chamber 12 tend to be removed from the surfaces.
The skilled addressee will appreciate that the closed loop crystallisation apparatus 10 of FIG. 1 may be configured differently, for example, by replacing delivery means 11 with a single delivery means wherein the two liquid feeds from delivery means 7 and 10 may be contacted coaxially therein, prior to being fed into ultrasonic flow cell chamber 12 through a single inlet.
Referring to FIG. 2 , closed loop crystallisation apparatus 20 is of a similar configuration to that of FIG. 1 except that chamber 22 has a wrap-around ultrasonic transducer 23 located on the external surface of it. The wrap-around transducer 23 insonates the entire volume of the chamber 22 with sufficient intensity to cause nucleation and by adjusting the power of the ultrasound, and the residence time in the chamber 22 , the degree of nucleation can therefore be controlled. The ultrasound has the additional benefit that any crystal deposits within the chamber 22 tend to be removed from the surfaces.
A further difference of the configuration of FIG. 2 from that of FIG. 1 is that the two liquid feeds from delivery means 7 and 10 are contacted coaxially within a single delivery means 21 and fed into the ultrasonic chamber 22 via a single inlet.
The skilled addressee will again appreciate that the delivery means to the ultrasonic flow chamber 22 could also follow the configuration of that of FIG. 1 .
The skilled addressee will appreciate that the thermal jacket is designed to help maintain the temperature of the anti-solvent at a desired temperature, depending on design.
Example 1
2-Propanol (0.7 L) was charged to a 1 L stirred crystallizer (200 rpm) fitted with a thermo-regulation jacket. The temperature was adjusted to 16° C. The 2-propanol was pumped around a recirculation loop using a diaphragm pump (operating at 20 l/h) and a 60 ml thermo-regulated glass ultrasonic flow-cell fitted with a 30 mm diameter 20 kHz ultrasonic probe. The probe was held at the highest position in the flow-cell and sealed/clamped at a point of zero vibration (node point). The flow-cell was thermo-regulated at 16° C. Continuous ultrasound was applied at 15 W power, 5 μm amplitude. L-Valine (1.5 g) was dissolved in water (35 ml) and then pumped into the ultrasonic flow-cell using a second inlet on the underside of the flow-cell at a rate of 60 ml/h. Upon complete addition of the L-valine solution the microcrystalline product was isolated by micro-filtration or spray drying.
Results are shown in FIG. 3 .
Example 2
2-Propanol (1 L) was charged to a 1 L stirred crystallizer fitted with thermo-regulation jacket. The temperature was adjusted to 16° C. The 2-propanol was pumped around a recirculation loop using a diaphragm pump (operating at 20 l/h) and a 60 ml thermo-regulated glass ultrasonic flow-cell fitted with a 30 mm diameter 20 kHz ultrasonic probe. The probe was held at the highest position in the flow-cell and sealed/clamped at a point of zero vibration (node point). The flow-cell was thermo-regulated at 16° C. Continuous ultrasound was applied at 15 W power, 5 μm amplitude. L-glutamic acid (4.5 g) was dissolved in water (100 ml) to form a saturated solution and then pumped into the ultrasonic flow-cell using a second inlet on the underside of the flow-cell at a rate of 60 ml/h. Upon complete addition of the L-glutamate solution the microcrystalline product was isolated by micro-filtration or spray drying.
Results are shown in FIG. 4 .
Example 3
Heptane (0.75 L) was charged to a 1 L stirred crystallizer (250 rpm) fitted with a thermo-regulation jacket. The temperature was adjusted to 5° C. The heptane was pumped around a recirculation loop using a diaphragm pump (operating at 20 L/h) and a 60 ml thermo-regulated glass ultrasonic flow-cell fitted with a 30 mm diameter 20 kHz ultrasonic probe. The probe was held at the highest position in the flow-cell and sealed/clamped at a point of zero vibration (node point). The flow-cell was thermo-regulated at 5° C. Continuous ultrasound was applied at 15 W power, 5 micron amplitude. Budesonide (1.5 g) was dissolved in methanol (100 mL) and then pumped into the ultrasonic flow-cell using a second inlet on the underside of the flow-cell at a rate of 20 mL/h. Upon complete addition of the budesonide solution, the mixture was kept under recirculation for further 30 minutes. The microcrystalline product was isolated by either supercritical carbon dioxide assisted drying (to remove non-polar solvents), micro-filtration or spray drying.
Results are shown in FIG. 5 .
Example 4
Water (0.7 L) was charged to a 1 L stirred crystallizer (200 rpm) fitted with a thermo-regulation jacket. The temperature was adjusted to 16° C. The water was pumped around a recirculation loop using a diaphragm pump (operating at 20 l/h) and a 60 ml thermo-regulated glass ultrasonic flow-cell fitted with a 30 mm diameter 20 kHz ultrasonic probe. The probe was held at the highest position in the flow-cell and sealed/clamped at a point of zero vibration (node point). The flow-cell was thermo-regulated at 16° C. Continuous ultrasound was applied at 15 W power, 5 micron amplitude. Olmesartan (2.1 g) was dissolved in butanone (70 mL) and then pumped into the ultrasonic flow-cell using a second inlet on the underside of the flow-cell at a rate of 20 mL/h. Upon complete addition of the olmesartan solution the microcrystalline product was isolated by micro-filtration or spray drying.
Results are shown in FIG. 6 . | A process for preparing crystalline particles of an active principal in the presence of ultrasonic irradiation that comprises contacting a solution of a solute in a solvent in a first flowing stream with an anti-solvent in a second flowing stream causing the mixing thereof, wherein the flow rate ratio of the anti-solvent: solvent is higher than 20:1, and collecting crystals that are generated. | 1 |
[0001] This application is based on Japanese Patent Application 2000-173244, filed on Jun. 9, 2000, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] a) Field of the Invention
[0003] The present invention relates to a laser processing apparatus and method, and more particularly to a laser processing apparatus and method for applying a pulse laser beam having a wavelength in an ultraviolet range to a workpiece and forming a hole in or through the workpiece.
[0004] b) Description of the Related Art
[0005] A conventional laser processing method will be described by taking as an example a method of forming a hole in or through a multi-layer wiring substrate. An infrared pulse laser beam radiated from a carbon dioxide gas laser oscillator is converged at a resin layer of a multi-layer wiring substrate. Organic substance in the region applied with the laser beam is thermally decomposed and a hole is formed in this region. With this method, a through hole 100 to 200 μm in diameter can be formed through a resin layer about 40 to 80 μm thick. A carbon dioxide gas laser oscillator can radiate a pulse laser beam having a high energy per one pulse. This pulse laser beam can form a through hole, for example, by three shots.
[0006] Holes having shorter diameters are desired to be formed in a multi-layer wiring substrate of a semiconductor integrated circuit device which is implemented at a higher integration density. A lower limit of the diameter of a hole is about five times the wavelength of a laser beam used. If a carbon dioxide laser is used, the lower limit of a hole is about 50 μm. It is practically difficult to form a hole having a diameter smaller than 50 to 60 μm by using a carbon dioxide gas laser.
[0007] If a laser beam having a wavelength in the ultraviolet range is used, a hole having a smaller diameter can be formed. It is difficult, however, to generate a laser beam having a wavelength in the ultraviolet range and a large power. If a laser beam having a small power is used for processing a multi-layer wiring substrate, a process time prolongs and productivity lowers.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a laser processing apparatus and method capable of shortening a process time by using a laser beam having a wavelength in the ultraviolet range.
[0009] According to one aspect of the present invention, there is provided a laser processing apparatus comprising: controller for outputting a first event signal having a periodical waveform and a second event signal having a periodical waveform synchronizing with the first event signal; a first laser source for radiating a first pulse laser beam having a wavelength in an ultraviolet range, synchronously with the first event signal; a second laser source for radiating a second pulse laser beam having a wavelength in the ultraviolet range, synchronously with the second event signal; a converging optical system for converging the first and second pulse laser beams at a same point; and holder for holding a workpiece at a position where a pulse laser beam converged by the converging optical system is applied.
[0010] According to another aspect of the present invention, there is provided a laser processing method comprising the steps of: radiating a first pulse laser beam from a first laser source, the first pulse laser beam having a wavelength in an ultraviolet range; radiating a second pulse laser beam from a second laser source synchronously with the first pulse laser beam, the second pulse laser beam having a wavelength in the ultraviolet range; and applying the first and second pulse laser beams to a same processing area of a workpiece to form a hole in the same processing area.
[0011] When the pulses of the first and second pulse laser beams are alternately applied to the same point of a workpiece, a process speed can be approximately doubled. When the pulses of the first and second pulse laser beams are overlapped, the energy per one pulse can be increased so that a workpiece can be processed which requires a large energy for forming a hole.
[0012] According to another aspect of the present invention, there is provided a laser processing method comprising the steps of: preparing a workpiece having a first layer and a second layer formed under the first layer, wherein a hole can be formed in the first layer by applying an ultraviolet pulse laser beam having a first energy per one pulse, and a hole can be formed in the second layer by applying an ultraviolet pulse laser beam having not the first energy per one pulse but a second energy per one pulse higher than the first energy; applying a first pulse laser beam and a second pulse laser beam to the first layer in a processing area thereof under a timing condition that pulses of the first and second pulse laser beams are alternately applied to the first layer, to form a first hole in the first layer and expose a partial surface of the second layer under the first layer, the first pulse laser beam being radiated from a first laser source and having a wavelength in an ultraviolet range, and the second pulse laser beam being radiated from a second laser source and having a wavelength in the ultraviolet range; and applying the first and second pulse laser beams to the second layer exposed on a bottom of the first hole under a timing condition that pulses of the first and second pulse laser beams are at least partially overlapped, to form a second hole in the second layer, the first pulse laser beam being radiated from the first laser source and having the wavelength in the ultraviolet range, and the second pulse laser beam being radiated from the second laser source and having the wavelength in the ultraviolet range.
[0013] By chanting the timing conditions of the first and second pulse laser beams, the first and second layers can be processed continuously.
[0014] According to another aspect of the present invention, there is provided a laser processing apparatus comprising: controller for outputting a first event signal having a periodical waveform and a second event signal having a periodical waveform synchronizing with the first event signal; a first laser source for radiating a first pulse laser beam having a wavelength in an infrared or visual range, synchronously with the first event signal; a second laser source for radiating a second pulse laser beam having a wavelength in the infrared or visual range, synchronously with the second event signal; an optical propagation system for changing an optical axis of at least one of the first and second laser beams so as to make the first and second pulse laser beams propagate along a same optical axis; a non-linear optical component for generating a harmonic wave having a wavelength in an ultraviolet range, from the first and second pulse laser beams made to have the same optical axis by the optical propagation system; a converging optical system for converging the harmonic wave; and holder for holding a workpiece at a position where the harmonic wave converged by the converging optical system is applied.
[0015] As the pulses of the first and second pulse laser beams alternately reach the non-linear optical component, a harmonic wave is generated having a repetition frequency twice as high as the repetition frequency of each of the input pulse laser beams. A process time can therefore be shortened. When the pulses of the first and second pulse laser beams are overlapped and become incident upon the non-linear optical component, the energy per one pulse of the harmonic wave increases so that a workpiece can be processed which requires a large energy for forming a hole.
[0016] As above, by combining the pulse laser beams radiated from the two laser sources to have a predetermined phase difference, the hole forming time can be shortened. By overlapping the pulses of the first and second pulse laser beams, the energy per one pulse can be increased. Even if a sufficient energy per one pulse cannot be obtained by one laser source, a sufficient energy can be obtained by using two laser sources. A hole can be formed in a workpiece even if it requires a large energy per one pulse.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a block diagram showing a laser processing apparatus according to an embodiment of the invention.
[0018] [0018]FIG. 2 is a timing chart showing the operation of a first control mode of the laser processing apparatus according to the embodiment.
[0019] [0019]FIG. 3 is a timing chart showing the operation of a second control mode of the laser processing apparatus according to the embodiment.
[0020] [0020]FIG. 4 is a graph showing an example of the output characteristics of a third harmonic wave of an Nd:YAG laser.
[0021] [0021]FIG. 5 is a cross sectional view of a multi-layer wiring substrate.
[0022] [0022]FIG. 6 is a block diagram showing a laser processing apparatus according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] [0023]FIG. 1 is a block diagram showing a laser processing apparatus according to an embodiment of the invention. First and second laser sources 1 and 2 radiate pulse laser beams pl 1 and pl 2 having a wavelength in the ultraviolet range, synchronously with event signals sig 1 and sig 2 . The first and second laser sources 1 and 2 each include, for example, an Nd:YAG laser oscillator and non-linear optical components. The pulse laser beams pl 1 and pl 2 each are, for example, a third harmonic wave (355 nm in wavelength) of a pulse laser beam radiated from an Nd:YAG laser oscillator. The pulse laser beams pl 1 and pl 2 are linearly polarized, respectively in vertical and horizontal directions.
[0024] The pulse laser beam pl 1 radiated from the first laser source 1 is reflected by a turn-around mirror 5 and becomes incident upon the front surface of a polarizer 6 at an incidence angle of 45°. The pulse laser beam pl 2 radiated from the second laser source 2 is incident upon the back surface of the polarizer 6 at an incidence angle of 450. The polarizer 6 reflects the pulse laser beam pl 1 which was linearly polarized in the vertical direction, and transmits the pulse laser beam pl 2 which was linearly polarized in the horizontal direction.
[0025] The pulse laser beams pl 1 and pl 2 are combined on the same optical axis by the polarizer 6 to form a pulse laser beam pl 3 . The pulse laser beam pl 3 is reflected by a turn-around mirror 9 . The reflected pulse laser beam pl 4 becomes incident upon a galvano scanner 10 . The galvano scanner 10 scans the optical axis of the pulse laser beam pl 4 in a two-dimensional direction in response to a command signal sig 0 .
[0026] The pulse laser beam passed through the galvano scanner 10 is converged by a converging lens 11 to form a pulse laser beam pl 5 . For example, the converging lens 11 is an fθ lens. A workpiece 20 is held by a holder 12 at a converging position of the pulse laser beam pl 5 .
[0027] A control unit 13 supplies the first and second laser sources 1 and 2 with the event signals sig 1 and sig 2 having a periodical waveform. The control unit 13 selects one of first and second control modes and can supply the event signals sig 1 and sig 2 having a phase difference specific to each control mode. The control unit 13 also supplies the galvano scanner 10 with the control signal sig 0 .
[0028] Next, with reference to FIGS. 2 and 3, timings of the pulse laser beams used by the laser processing apparatus shown in FIG. 1 will be described.
[0029] [0029]FIG. 2 is a timing chart of the first control mode. The event signals sig 1 and sig 2 are pulse signals having the same frequency and synchronized with each other. The phase of the event signal sig 2 lags by 180 degrees from the phase of the event signal sig 1 . The pulse laser beam pl 1 is synchronous with the event signal sig 1 , whereas the pulse laser beam pl 2 is synchronous with the event signal sig 2 . The pulse laser beam pl 2 lags therefore by 180° in phase from the pulse laser beam pl 1 . The pulse repetition frequencies of the pulse laser beams pl 3 to pl 5 formed through combination of the pulse laser beams pl 1 and pl 2 are twice the frequency of the event signals sig 1 and sig 2 .
[0030] [0030]FIG. 4 is a graph showing an example of the output characteristics of a third harmonic wave of each of the first and second laser sources 1 and 2 using Nd:YAG laser oscillators. The abscissa represents a pulse repetition frequency in the unit of “kHz”, and the ordinate represents a laser output in the unit of “W”. At the repetition frequency of about 5 kHz, the laser output takes a maximum value. In the repetition frequency range not lower than 5 kHz, the laser output gradually lowers as the repetition frequency becomes high. This tendency is not limited only to an Nd:YAG laser oscillator, but other solid state lasers have similar tendency.
[0031] In order to form a hole in or through a resin film, an energy density per one pulse of a pulse laser beam is generally required to have some threshold value or higher. For example, if a hole is to be formed in an epoxy resin film, the energy density per one pulse is required to have about 1 J/cm 2 or higher. An energy per one pulse necessary for forming a hole is determined from the area of the hole. The energy per one pulse is given by P/f [J], where P [W] is an output of the pulse laser beam and f [Hz] is a pulse repetition frequency. The range where the energy P/f per one pulse takes the necessary threshold value or higher can be determined from the output characteristics shown in FIG. 4. If the laser sources 1 and 2 are operated in this range, a hole can be formed in a resin film.
[0032] The repetition frequency of the pulse laser beam pl 5 applied to the workpiece 20 is 10 kHz which is a twofold of the frequency of the event signals sig 1 and sig 2 . The hole forming time can be shortened by about {fraction (1/2)} as compared to using one laser oscillator.
[0033] [0033]FIG. 3 is a timing chart of the second control mode. In the first control mode shown in FIG. 2, the phase of the event signal sig 2 lags by 180° from the phase of the event signal sig 1 . In the second control mode, the phase lag is small. Accordingly, the pulse laser beams pl 1 and pl 2 partially overlap to form the pulse laser beams pl 3 to pl 5 formed through combination of the pulse laser beams pl 1 and pl 2 . The width of each pulse is hence broadened and the energy per one pulse is doubled. The phases of the event signals sig 1 and sig 2 may be set equal to completely superpose each pulse of the pulse laser beam pl 1 upon each pulse of the pulse laser beam pl 2 . In this case, the pulse width does not broaden but the peak power is approximately doubled.
[0034] In order to form a hole in a copper foil, the energy density per one pulse is generally required to be about 10 J/cm 2 or higher. If the diameter of a hole is 100 μm, the energy per one pulse is required to be about 7.9×10 −4 J or higher. In the first control mode shown in FIG. 2, it is difficult to set the energy per one pulse to about 7.9×10 −4 J or higher. By partially overlapping the two pulse laser beams as shown in FIG. 3, the energy per one pulse necessary for forming a hole in a copper foil can be obtained.
[0035] Even if the energy per one pulse is insufficient, the necessary energy per one pulse may be obtained by converging the laser pulse and reducing the beam diameter. However, in this case, since the laser diameter is small, it is necessary to move the application position of the laser beam in order to form a hole having a desired size. For example, trepanning or spiral working becomes necessary. As in this embodiment, by increasing the energy per one pulse, a hole having a diameter of about 100 μm can be formed without trepanning or the like.
[0036] For example, if the repetition frequency is set to 10 kHz, the output of one laser source is about 4 W as determined from FIG. 4. The power of each of the laser beams pl 3 to pl 5 shown in FIG. 3 is therefore 8 W. The energy per one pulse is 8×10 −4 J. Although one laser source is difficult to form a hole in a copper foil, the energy per one pulse can be made sufficiently large for forming a hole in a copper foil by using two laser sources and superposing pulses.
[0037] The pulse width and peak intensity of the laser beams pl 3 to pl 5 shown in FIG. 3 depend on the phase difference between the pulse laser beams pl 1 and pl 2 . By adjusting the phase difference between the event signals sig 1 and sig 2 , the pulse width and peak intensity of the pulse laser beams pl 3 to pl 5 can be controlled with ease.
[0038] [0038]FIG. 5 is a cross sectional view of a multi-layer wiring substrate. A package board 22 is mounted on the surface of a mother board 21 . A semiconductor integrated circuit chip 23 is mounted on the package board 22 . The mother board 21 and package board 22 are made of epoxy resin which contains glass cloth.
[0039] Copper wiring layers 25 are formed embedded in the mother board 21 . A via hole 26 extends from the surface of the mother board 21 to the copper wiring layer 25 . A through hole 27 is formed through the mother board 21 . Copper is filled in the via hole 26 and through hole 27 . Similarly, a copper wiring layer 28 and a via hole 29 are formed in the package board 22 . The via holes 26 and 29 and through hole 27 are formed by using the laser processing apparatus shown in FIG. 1. The laser processing is executed for separate mother board 21 and package board 22 before the latter 22 is mounted on the former 21 .
[0040] The via holes 26 and 29 are formed in the first control mode shown in FIG. 2. In this case, the energy per one pulse of the pulse laser beam pl 5 is sufficiently large for forming a hole in the resin layer. However, since the energy is insufficient for forming a hole in the copper wiring layer, the copper wiring layer 25 is left unetched on the bottom of the via hole.
[0041] In order to form the through hole 27 , after a hole is formed through the resin layer in the first control mode, another hole is formed through the copper wiring layer in the second control mode shown in FIG. 3. In this latter case, the energy per one pulse of the pulse laser beam pl 5 is sufficiently large for forming a hole in the copper foil layer. The through hole 27 can be formed in this manner by alternately repeating the laser processing in the first and second control modes.
[0042] If a hole is to be formed through a copper foil layer formed on the surface of a resin substrate, the hole is formed through the copper foil layer first in the second control mode. This laser processing can be stopped automatically when the hole is formed through the copper foil layer, by setting beforehand the number of pulses to be applied, in accordance with the thickness of the copper foil layer. After the hole is formed through the copper foil layer, then the mode is switched to the first control mode and another hole is formed through the resin layer. The number of pulses applied during the laser processing in the first control mode is also set beforehand.
[0043] In this embodiment, a third harmonic wave of an Nd:YAG laser is used as the pulse laser beam having a wavelength in the ultraviolet range. Other laser beams may also be used. For example, a fourth or fifth harmonic wave of an Nd:YAG laser may be used, and a YLF laser or YVO 4 laser may be used instead of an Nd:YAG laser. A fundamental wave of a KrF excimer laser or XeCl excimer laser may also be used.
[0044] Also in this embodiment, the pulse laser beam pl 1 radiated from the first laser source 1 and the pulse laser beam pl 2 radiated from the second laser source 2 are propagated along the same optical axis and converged at a working position of a workpiece. It is not necessarily required to propagate the pulse laser beams pl 1 and pl 2 along the same optical axis. For example, the first and second pulse laser beams pl 1 and pl 2 may be propagated along different optical axes which are crossed at the working position of a workpiece.
[0045] Next, with reference to FIG. 6, another embodiment of the invention will be described. In the first embodiment, third harmonic waves of the two Nd:YAG lasers are combined, whereas in the second embodiment, fundamental waves are combined and then the third harmonic wave is formed. The fundamental structure of a laser processing apparatus shown in FIG. 6 is similar to that of the laser processing apparatus shown in FIG. 1. Only different points between the two apparatus will be described.
[0046] As shown in FIG. 6, first and second laser sources 1 and 2 radiate pulse laser beams pl 1 and pl 2 having a wavelength in the infrared or visual range. A non-linear optical component 15 is disposed on the optical axis of a pulse laser beam pl 3 formed through combination of the two pulse laser beams pl 1 and pl 2 . The non-linear optical component 15 generates a harmonic wave, e.g., third harmonic wave, of the pulse laser beam pl 3 . The non-linear optical component 15 may be disposed anywhere along the optical path of the pulse laser beam from a polarizer 6 to a workpiece 20 .
[0047] The present invention has been described in connection with the preferred embodiments. The invention is not limited only to the above embodiments. It is apparent that various modifications, improvements, combinations, and the like can be made by those skilled in the art. | A controller outputs a first event signal having a periodical waveform and a second event signal having a periodical waveform synchronizing with the first event signal. A first laser source radiates a first pulse laser beam having a wavelength in an ultraviolet range, synchronously with the first event signal. A second laser source radiates a second pulse laser beam having a wavelength in the ultraviolet range, synchronously with the second event signal. A converging optical system converges the first and second pulse laser beams at the same point. A holder holds a workpiece at a position where a pulse laser beam converged by the converging optical system is applied. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a new route for the preparation and purification of substituted 1,5-naphthyridine-3-carboxyamides and the pharmaceutically acceptable non-toxic salts thereof. These compounds are highly selective agonists, antagonists or inverse agonists for GABAa brain receptors or prodrugs of agonists, antagonists or inverse agonists for GABAa brain receptors. These compounds are useful in the diagnosis and treatment of anxiety, Down Syndrome, sleep, cognitive and seizure disorders, and overdose with benzodiazepine drugs and for enhancement of alertness.
[0002] The substituted 1,5-naphthyridine-3-carboxyamides that are prepared in accord with the process of the present invention are disclosed in U.S. Pat. No. 6,143,760 and PCT International Publication No. WO99/10347 A1, each of which is incorporated herein by reference in its entirety.
SUMMARY OF THE INVENTION
[0003] The present invention provides a process of preparing a compound of the following formula
wherein X is hydrogen, halogen, —OR 1 , C 1 -C 6 alkyl optionally substituted with up to three groups selected independently from halogen and hydroxy, or —NR 2 R 3 ; phenyl, naphthyl, 1-(5,6,7,8-tetrahydro)naphthyl or 4-(1,2-dihydro)indenyl, pyridinyl, pyrimidyl, isoquinolinyl, 1,2,3,4-tetrahydroisoquinolinyl, benzofuranyl, benzothienyl, each of which is optionally substituted with up to three groups selected from halogen, C 1 -C 6 alkyl, C 1 -C 4 alkoxy, C 1 -C 6 alkylthio, hydroxy, amino, mono or di(C 1 -C 6 )alkylamino, cyano, nitro, trifluoromethyl or trifluoromethoxy; or a carbocyclic group (“the X carbocyclic group”) containing from 3-7 members, up to two of which members are optionally hetero atoms selected from oxygen and nitrogen, where the X carbocyclic group is optionally substituted with one or more groups selected from halogen, alkoxy, mono- or dialkylamino, sulfonamide, azacycloalkyl, cycloalkylthio, alkylthio, phenylthio, or a heterocyclic group;
Y is lower alkyl having 1-8 carbon atoms optionally substituted with up to two groups selected from halogen, alkoxy, mono- or dialkylamino, sulfonamide, azacycloalkyl, cycloalkylthio, alkylthio, phenylthio, a heterocyclic group, —OR 4 , —NR 5 R 6 , SR 7 , or aryl; or a carbocyclic group (“the Y carbocyclic group”) having from 3-7 members atoms, where up to three of which members are optionally hetero atoms selected from oxygen and nitrogen and where any member of the Y carbocyclic group is optionally substituted with halogen, —OR 4 , —NR 5 R 6 , SR 7 , aryl or a heterocyclic group; R 1 and R 4 are independently hydrogen, lower alkyl having 1-6 carbon atoms, or cycloalkyl having 3-7 carbon atoms, where each alkyl may be optionally substituted with —OR 4 , or —NR 5 R 6 ; R 2 , R 3 , R 5 and R 6 are independently the same or different and represent hydrogen, lower alkyl optionally mono- or disubstituted with alkoxy, aryl, halogen, or mono- or di-lower alkyl; aryl or aryl(C 1 -C 6 )alkyl where each aryl is optionally substituted with up to three groups selected from halogen, hydroxy, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, or mono- or di (C 1 -C 6 ) alkylamino; cycloalkyl having 3-7 carbon atoms optionally mono or disubstituted with halogen, alkoxy, or mono- or di-lower alkyl; or —SO 2 R 8 ; R 7 is hydrogen, lower alkyl having 1-6 carbon atoms, or cycloalkyl having 3-7 carbon atoms; and
[0009] R 8 is lower alkyl having 1-6 carbon atoms, cycloalkyl having 3-7 carbon atoms, or optionally substituted phenyl;
which comprises treating a compound of the formula
wherein X, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and R 8 are as defined above, and R is (C 1 -C 6 )alkyl with a primary amine of the formula
wherein Y is as defined above.
[0013] The compounds which may be prepared by the process of the present invention can be described by general formulas I-III set forth above. In a further embodiment of the process of the present invention, in any of the aforesaid general formulas I-IV, X or Y may be —NR 2 R 3 which is a heterocyclic group such as, for example, piperidine in the case where R 2 and R 3 together form a C 5 -alkylene group. Further, R 2 and R 3 together may represent an alkylene or alkenylene group optionally containing up to two heteroatoms selected from nitrogen and oxygen. The resulting groups include imidazolyl, pyrrolidinyl, morpholinyl, piperazinyl, and piperidinyl.
[0014] Similarly, the —NR 5 R 6 group in formula I above can also represent a heterocyclic group such as, for example, piperidine in the case where R 5 and R 6 together form a C 5 -alkylene group. Further, R 5 and R 6 together may represent an alkylene or alkenylene group optionally containing up to two heteroatoms selected from nitrogen and oxygen. The resulting groups include imidazolyl, pyrrolidinyl, morpholinyl, piperazinyl, and piperidinyl.
[0015] Preferred compounds of formulas II and III are those where X represents (C 1 -C 6 ) alkoxy, more preferably (C 1 -C 3 )alkoxy. Particularly preferred compounds of formulas II and III include methoxy or ethoxy as the X group.
[0016] For the process of the present invention other preferred compounds of formulas I-III include those where the Y is lower alkyl, e.g., methyl or ethyl, substituted with phenyl, pyridyl, or pyrimidinyl. A more preferred Y group is benzyl optionally substituted with halogen, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, amino, or mono- or di(C 1 -C 6 ) alkyl.
[0017] Where R 2 and R 3 in Formulas I-III represent optionally substituted aryl or aryl(C 1 -C 6 )alkyl, the aryl group is preferably phenyl, pyridyl, or pyrimidinyl and the alkyl groups are preferably methyl and ethyl. More preferred are benzyl and phenyl. Particularly preferred is benzyl.
[0018] Where X is optionally substituted C 1 -C 6 alkyl, the alkyl group is preferably optionally substituted methyl, ethyl, or propyl. More preferred are perhalomethyl and trihaloethyl. Preferred halogens are fluorine. Particularly preferred is 2,2,2-trifluoroethyl.
[0019] X in formulas II and III may be an optionally substituted phenyl, naphthyl, 1-(5,6,7,8-tetrahydro)naphthyl, 4-(1,2-dihydro)indenyl, pyridinyl, pyrimidyl, isoquinolinyl, benzofuranyl, or benzothienyl group, or preferably a 1,2,3,4-tetrahydroisoquinolinyl group.
[0020] In addition to the compounds of formula III the process of the present invention encompasses the preparation of compounds of the formula
from compounds of the formula
and
H 2 N—Y IA
wherein substituent group X and substituent group Y when present either together or separately in any of the aforesaid general formulas IIA or IIIA are defined as follows:
X is: (i) hydrogen, halogen, mono- or dialkylamino, alkoxy, (ii) a group of the formula:
where G is lower alkylene having 1-6 carbon atoms, or a cyclic group of the formula
where n is 0, 1, or 2, and m is an integer of from 1 to 5, with the proviso that the sum of n+m is not less than 1 or greater than 5; and R 1 is hydrogen, lower alkyl, or (C 3 -C 7 )cycloalkyl, where the alkyl or cycloalkyl is optionally substituted with halogen, lower alkoxy, or mono- or di(C 1 -C 6 )alkylamino;
(iii) a group of the formula:
where G is as defined above for ii; and R 2 and R 3 independently represent hydrogen, lower alkyl having 1-6 carbon atoms, cycloalkyl having 3-7 carbon atoms, —SO 2 R 8 where R 8 is (C 1 -C 6 )alkyl, (C 3 -C 7 )cycloalkyl, or optionally substituted phenyl, or R 2 and R 3 together with the nitrogen atom to which they are attached form a heterocyclic moiety such as imidazolyl, pyrrolidinyl, morpholinyl, piperazinyl, or piperidinyl; (iv) a group of the formula:
where
R 2 is as defined above for iii; R 4 is hydrogen, lower alkyl having 1-6 carbon atoms, or cycloalkyl having 3-7 carbon atoms, and may be optionally substituted with one or more (C 1 -C 6 )alkoxy or mono- or di(C 1 -C 6 )alkylamino groups; and G is as defined above for ii; (v) a group of the formula:
where
R 2 and G are as defined above for iv and ii, respectively, and R 5 and R 6 independently represent hydrogen, lower alkyl having 1-6 carbon atoms, cycloalkyl having 3-7 carbon atoms, —SO 2 R 8 where R 8 is (C 1 -C 6 )alkyl, (C 3 -C 7 )cycloalkyl, or optionally substituted phenyl, or R 5 and R 6 together with the nitrogen atom to which they are attached form a heterocyclic moiety such as imidazolyl, pyrrolidinyl, morpholinyl, piperazinyl, or piperidinyl; (vi) a group of the formula:
where G is as defined above for ii; or (vii) a group of the formula:
where each G is as defined above for ii; and
Y is (viii) lower alkyl having 1-8 carbon atoms or cycloalkyl having 3-7 carbon atoms, any of which may be optionally substituted with one or more hydroxy, halogen, (C 1 -C 6 )alkoxy, alkoxyalkoxy where each alkoxy is (C 1 -C 6 )alkoxy, (C 1 -C 6 ) alkylthio, (C 3 -C 7 )cycloalkylthio, aryl, heteroaryl, or mono- or di(C 1 -C 6 )alkylamino groups; (ix) a group of the formula:
where K is lower alkylene having 1-6 carbon atoms optionally substituted with (C 1 -C 6 )alkyl or alkylene, or a cyclic group of the formula
where K′ independently represents hydrogen or (C 1 -C 6 ) alkyl or alkylene, n is 0, 1, or 2, and m is an integer of from 1 to 5, with the proviso that the sum of n+m is not less than 1 or greater than 5; and R 9 is hydrogen, lower alkyl, or (C 3 -C 7 )cycloalkyl, where the alkyl or cycloalkyl is optionally substituted with halogen, lower alkoxy, or mono- or dialkylamino;
(x) a group of the formula:
where K is defined as above in ix;
(xi) a group of the formula:
where
K is as defined above for ix, and R 13 is hydrogen, lower alkyl having 1-6 carbon atoms, or cycloalkyl having 3-7 carbon atoms, where the alkyl and cycloalkyl groups are optionally substituted with one or more (C 1 -C 6 )alkoxy or mono- or di(C 1 -C 6 )alkylamino groups; and (xii) a group of the formula:
where
K is as defined above for ix, and R 7 is hydrogen, lower alkyl having 1-6 carbon atoms, or cycloalkyl having 3-7 carbon atoms; and (xiii) a group of the formula:
where
K is as defined above for ix; and R 14 and R 15 independently represent hydrogen, lower alkyl having 1-6 carbon atoms, cycloalkyl having 3-7 carbon atoms, —SO 2 R 8 where R 8 is as defined above, or R 14 and R 13 together with the nitrogen atom to which they are attached form a heterocyclic moiety such as imidazolyl, pyrrolidinyl, morpholinyl, piperazinyl, or piperidinyl; (xiv) a group of the formula:
where K and R 15 are as defined above in ix and xii, respectively;
(xv) a group of the formula:
where
K is as defined above for ix; R 10 and R 10′ are the same or different and are selected from hydrogen, (C 1 -C 6 )alkyl, halogen, hydroxy, lower alkoxy having 1-6 carbon atoms, or cycloalkoxy having 3-7 carbon atoms; R 11 , R 11′ , and R 12 are the same or different and are selected from hydrogen, C 1 -C 6 alkyl, halogen, hydroxy, —OR 4 , —CR 7 (R 9 )NR 5 R 6 , —CR 9 (R 16 ) OR 4 , or R 11 , and R 12 taken together with the atoms to which they are attached form a (hetero)cyclic ring; and
[0072] R 16 is hydrogen, lower alkyl having 1-6 carbon atoms, or cycloalkyl having 3-7 carbon atoms;
(xvi) a group of the formula:
where K is as defined above for ix; and W is heteroaryl;
(xvii) a group of the formula:
where
K is as defined above for ix; R 10 and R 1 are as defined above for xv, and R 17 is hydrogen, lower alkyl, or (C 3 -C 7 )cycloalkyl, where the alkyl or cycloalkyl is optionally substituted with halogen, lower alkoxy, or mono- or di(C 1 -C 6 )alkylamino; (xviii) a group of the formula:
where K, R 10 , R 12 , and R 17 are as defined above;
(xix) a group of the formula:
where each K is independently as defined above for ix and R 10 is defined above;
(xx) a group of the formula:
where K, R 10 , R 11 , R 14 , and R 15 are as defined above;
(xxi) a group of the formula:
where K, R 10 , R 12 , R 14 , and R 15 are as defined above;
(xxii) pyrimidinyl(C 1 -C 6 )alkyl or pyridyl(C 1 -C 6 )alkyl; or (xxiii) a group of the formula:
where R 18 represents hydrogen, amino, mono-, or di(C 1 -C 6 )alkylamino, or C 1 -C 6 alkyl optionally substituted with a R 19 where R 19 represents:
where V and V′ are independently CH or nitrogen; A″ is C 1 -C 6 alkylene; and
R 20 is phenyl, pyridyl, or pyrimidinyl, each of which is optionally mono-, di-, or trisubstituted independently with halogen, hydroxy, C 1 -C 6 alkoxy, amino, or mono- or di(C 1 -C 6 )alkylamino.
[0091] Specific compounds made by the process of the invention include those having pyrimidinyl(C 1 -C 6 )alkyl Y groups, wherein Y is more specifically 2- and 4-pyrimidinylmethyl, or having pyridyl(C 1 -C 6 )alkyl Y groups, wherein Y is more specifically 2- and 4-pyridylmethyl.
[0092] Specific benzyl Y groups are those where R 18 is amino or a substituted methyl or ethyl group. More specific R 18 substituents are piperazin-1-yl or piperidin-1-yl substituted at the 4-position with a halogenated benzyl group.
[0093] Other specific benzyl Y groups are 4-[1-[4-(4-Fluorobenzyl)piperazinyl]methyl]benzyl and 4-[1-[4-(4-Fluorobenzyl)piperidinyl]methyl]benzyl.
[0094] Specific “X” groups in formulas IIIA and IIA are various quinolinyl, isoquinolinyl, tetrahydroquinolinyl, or tetrahydroisoquinolinyl groups, e.g., groups of the formulas:
[0095] The following formulae represent specific compounds prepared by the process of the present invention:
wherein Y is defined above.
wherein Z represents halogen and Y is as defined above.
wherein R 1 and Y are defined above.
wherein R 2 , R 3 , and Y are defined above.
wherein R 2 , R 8 , and Y are defined above.
wherein R 1 , G and Y are defined above.
wherein R 2 , R 3 , G, and Y are defined above.
wherein R 2 , R 4 , G, and Y are defined above.
wherein R 2 , R 5 , R 6 , G, and Y are defined above.
wherein G and Y are defined above.
wherein R 2 , G, and Y are defined above.
wherein X is defined above and U is (C 1 -C 6 ) lower alkyl or (C 1 -C 6 )cycloalkyl.
wherein X, K, and R 1 are defined above.
wherein X and K are defined above.
wherein X, K, and R 4 are defined above.
wherein X, K, and R 7 are defined above.
wherein X, K, R 14 , and R 15 are defined above.
wherein X, K, and R 15 are defined above.
wherein:
R 10 , R 17 are the same or different and may be selected from hydrogen, (C 1 -C 6 )alkyl, halogen, hydroxy, lower alkoxy having 1-6 carbon atoms, or cycloalkoxy having 3-7 carbon atoms; R 11 , R 11′ , and R 12 are the same or different and may be selected from hydrogen, (C 1 -C 6 )alkyl, halogen, hydroxy, —OR 4 , —CR 7 (R 9 )NR 5 R 6 , —CR 7 (R 9 )OR 4 ; or R 11 , and R 12 taken together with the atoms to which they are attached form a (hetero)cyclic ring; and R 9 is as defined above.
wherein X and K are defined above; and W is heteroaryl.
wherein X, K, R 1 , R 10 , and R 11 are defined above.
wherein X, K, R 1 , R 10 , and R 12 are defined above.
wherein X, K, R 10 , and G are defined above.
wherein X, K, R 14 , R 15 , R 10 , and R 11 are defined above.
[0124] Specific compounds prepared by the process of the present invention are encompassed by the following formula:
wherein A is C 1 -C 6 alkylene;
R a is phenyl optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl; and R b is lower alkyl or lower cycloalkyl.
[0128] Other specific compounds of Formula XXIX made in accord with the invention are those wherein A is methylene, R a is phenyl optionally substituted with methyl or ethyl, and R b is lower alkyl. Still other specific compounds of Formula XXIX are those wherein A is methylene, R a is phenyl and R b is C 1 -C 3 alkyl
wherein A is C 1 -C 6 alkylene;
R a and R a are independently phenyl groups optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl; and R c is hydrogen or lower alkyl.
[0132] Specific compounds of Formula XXX made in accord with the invention are those where A is methylene, R a and R a are independently phenyl optionally substituted with methyl or ethyl, and R c is lower alkyl. Other specific compounds of Formula XXX are those where A is methylene, R a is phenyl substituted in the para position with lower alkyl, R a is phenyl, and R c is C 1 -C 3 alkyl.
wherein A is C 1 -C 6 alkylene;
R d and R e are independently lower alkyl groups.
[0135] Specific compounds of Formula XXXI made in accord with the invention are those where A is C 2 -C 4 alkylene. Other specific compounds of Formula XXXI are those where A is C 2 -C 4 alkylene, Rd is C 1 -C 3 alkyl, and R d is C 2 -C 4 alkyl.
wherein A is C 1 -C 6 alkylene;
R d is lower alkyl; and R f is a group of the formula:
where E is oxygen or nitrogen; and
M is C 1 -C 3 alkylene or nitrogen.
[0141] Specific compounds of Formula XXXII made in accord with the invention are those where A is C 1 -C 3 alkylene. Other specific compounds of Formula XXXII are those where A is C 2 -C 4 alkylene, R d is C 1 -C 3 alkyl, and R e is C 2 -C 4 alkyl. Yet other specific compounds of Formula XXXII are those where A is C 2 -C 4 alkylene, R d is C 1 -C 3 alkyl, R e is C 2 -C 4 alkyl, and E is nitrogen and M is methylene, E is oxygen and M is methylene or ethylene, or E and M are both nitrogen. Further specific compounds of Formula XXXII are those where R f is furanyl, tetrahydrofuranyl, or imidazolyl.
wherein
A is C 1 -C 6 alkylene; Rd is lower alkyl optionally substituted with amino or mono- or di(C 1 -C 6 )alkylamino; and
[0144] R a is phenyl optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl.
[0145] Other specific compounds of Formula XXXIII are those where A is C 1 -C 3 alkylene, R a is phenyl optionally substituted with methyl or ethyl, and R d is C 1 -C 3 alkyl. Still other specific compounds of Formula XXXIII are where A is methylene, R a is phenyl optionally substituted with methyl or ethyl, and R d is C 3 -C 6 alkyl. Other specific compounds of Formula XXXIII are those where R a is phenyl substituted with mono- or di-(C 1 -C 6 ) alkylamino lower alkyl
wherein
A is C 1 -C 6 alkylene; R d is lower alkyl; and R a ″ is phenyl, pyridyl, imidazolyl, pyrimidinyl, or pyrrolyl, each of which is optionally substituted with up to two groups selected from halogen, lower alkyl, lower alkoxy, mono- or di(C 1 -C 6 )alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl.
[0150] Other specific compounds of Formula XXXIIla are those where R a ″ is imidazolyl and R d is C 1 -C 3 alkyl. Still other preferred compounds of Formula XXXIIla are where A is methylene, R a ″ is imidazolyl, and R d is C 3 -C 6 alkyl.
wherein
A is C 1 -C 6 alkylene; and R d and R e are independently lower alkyl groups.
[0154] Specific compounds of Formula XXXIV are those where A is C 1 -C 3 alkylene. Other specific compounds of Formula XXXIV are those where A is C 1 -C 3 alkylene, R d is C 1 -C 3 alkyl, and R e is C 1 -C 3 alkyl.
wherein
D is nitrogen or CH; D′ is nitrogen or oxygen; A is C 1 -C 6 alkylene; and R a ′ is phenyl, pyridyl, or thiazolyl, each of which is optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl.
[0160] Specific compounds of Formula XXXV are those where A is C 1 -C 3 alkylene, R a is phenyl optionally substituted with lower alkyl or halogen, and D is nitrogen. Other specific compounds of Formula XXXV are where A is methylene, R a is phenyl optionally substituted with lower alkyl or halogen, D is nitrogen, and D′ is oxygen.
wherein
A is C 1 -C 6 alkylene; and R a ′ is hydrogen; R a is thienyl or phenyl, each of which is optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 , alkylamino lower alkyl.
[0165] Specific compounds of Formula XXXVI are those where A is C 1 -C 3 alkylene, and R a is phenyl optionally substituted with lower alkyl or halogen. Other specific compounds of Formula XXXVI are where A is methylene, R a is phenyl optionally substituted with lower alkyl, lower alkoxy or halogen.
wherein
A is C 1 -C 6 alkylene; and R d is lower alkyl; A′ represents oxygen or methylene; and r is an integer of from 1-3.
[0171] Specific compounds of Formula XXXVII are those where A is C 1 -C 3 alkylene. Other specific compounds of Formula XXXVII are those where A is C 1 -C 3 alkylene, and R d is C 1 -C 3 alkyl.
wherein A is C 1 -C 6 alkylene; and
R h and R h ′ are independently hydrogen or lower alkyl, where each alkyl is optionally substituted with lower alkoxy; A′ represents oxygen or methylene; and r is an integer of from 1-3.
[0176] Specific compounds of Formula XXXVIIa are those where A is C 1 -C 3 alkylene. Other specific compounds of Formula XXXVIIa are those where A is C 1 -C 3 alkylene, and R h is C 1 -C 3 alkyl.
wherein A is C 1 -C 6 alkylene;
R 9 is lower alkoxy lower alkyl; and R a ′ is phenyl optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl.
wherein
R j is halogen or lower alkoxy; and R k is lower alkyl or cycloalkyl each of which is optionally substituted with hydroxy, lower alkyl, or lower alkoxy; or R k is phenyl (C 1 -C 6 ) alkyl where the phenyl group is optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl.
wherein
A is C 1 -C 6 alkylene; R l is lower alkoxy, benzyloxy, lower alkoxy lower alkoxy, amino, or mono- or di-(C 1 -C 6 )alkylamino; and R m is pyranyl, dihydropyranyl, tetrahydropyranyl, or hexahydropyranyl, pyridine, dihydropyridine, tetrahydropyridine, or piperidine.
[0188] Specific compounds of Formula XXXX are those where R l is lower alkoxy and R m is tetrahydropyranyl.
wherein
A is C 1 -C 6 alkylene; R n is lower alkoxy, benzyl, or a group of the formula:
where
D is nitrogen or CH; and D′ is nitrogen or oxygen; and R o is pyranyl, 2- or 3-thienyl; or R o is 2-, 4-, or 5-thiazolyl or 2-, 4-, or 5-imidazolyl, each of which may be optionally substituted with lower alkyl
wherein
A is C 1 -C 6 alkylene; R h and R h ′ are independently hydrogen or lower alkyl, where each lower alkyl is optionally substituted with lower alkoxy; and R a ′ is phenyl optionally mono-, di-, or trisubstituted with halogen, lower alkyl, lower alkoxy, or mono- or di-C 1 -C 6 alkylamino, or mono- or di-C 1 -C 6 alkylamino lower alkyl; or R a ′ is thienyl optionally substituted with lower alkyl
wherein A is C 1 -C 6 alkylene;
D is nitrogen or CH; D′ is nitrogen or oxygen; and R p is lower alkyl or lower alkyl optionally substituted with lower alkoxy.
wherein
A is C 1 -C 6 alkylene; X is defined as above for Formula IV; and R 18 is (i) amino or mono- or di(C 1 -C 6 )alkylamino; or (ii) lower alkyl optionally substituted with
where
V and V′ are independently CH or nitrogen; A″ is C 1 -C 6 alkylene; and R 20 is phenyl, pyridyl, or pyrimidinyl, each of which is optionally mono-, di-, or trisubstituted independently with halogen, hydroxy, C 1 -C 6 alkoxy, amino, or mono- or di(C 1 -C 6 )alkylamino.
[0215] Specific compounds of Formula XXXXIV are those where V is nitrogen and X is C 1 -C 6 alkoxy or C 1 -C 6 alkyl optionally substituted with up to three halogen atoms. Other specific compounds of XXXXIV are those where V and V′ are nitrogen; X is C 1 -C 3 alkoxy or C 1 -C 3 alkyl optionally substituted with up to three halogen atoms; A″ is methylene or ethylene; and R 20 is halogenated phenyl. A specific R 20 group is 4-fluorophenyl. Yet other specific compounds of XXXXIV are those where X is 2,2,2-trifluoroethyl; V and V′ are nitrogen; R 20 is halogenated phenyl; and A and A″ are methylene or ethylene.
[0216] In certain situations, compounds of Formulas II and III may contain one or more asymmetric carbon atoms, so that the compounds can exist in different stereoisomeric forms. These compounds can be, for example, racemates or optically active forms. In these situations, the single enantiomers, i.e., optically active forms, can be obtained by asymmetric synthesis or by resolution of the racemates. Resolution of the racemates can be accomplished, for example, by conventional methods such as crystallization in the presence of a resolving agent, or chromatography, using, for example a chiral HPLC column.
[0217] Representative compounds which are encompassed by Formula III, and may be prepared by the process of the present invention include, but are not limited to, the compounds in Table I and their pharmaceutically acceptable acid and base addition salts. In addition, if the compound of the invention is obtained as an acid addition salt, the free base can be obtained by basifying a solution of the acid salt. Conversely, if the product is a free base, an addition salt, particularly a pharmaceutically acceptable addition salt, may be produced by dissolving the free base in a suitable organic solvent and treating the solution with an acid, in accordance with conventional procedures for preparing acid addition salts from base compounds.
[0218] Non-toxic pharmaceutical salts include salts of acids such as hydrochloric, phosphoric, hydrobromic, sulfuric, sulfinic, formic, toluenesulfonic, methanesulfonic, nitric, benzoic, citric, tartaric, maleic, hydroiodic, alkanoic such as acetic, HOOC—(CH 2 )n-COOH where n is 0-4, and the like. Non-toxic pharmaceutical base addition salts include salts of bases such as sodium, potassium, calcium, ammonium, and the like. Those skilled in the art will recognize a wide variety of non-toxic pharmaceutically acceptable addition salts.
[0219] The process of the present invention also encompasses the acylated prodrugs of the compounds of Formula III. Those skilled in the art will recognize various synthetic methodologies which may be employed to prepare non-toxic pharmaceutically acceptable addition salts and acylated prodrugs of the compounds encompassed by Formula III.
[0220] By lower alkyl in the present invention is meant straight or branched chain alkyl groups having 1-6 carbon atoms, such as, for example, methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, pentyl, 2-pentyl, isopentyl, neopentyl, hexyl, 2-hexyl, 3-hexyl, and 3-methylpentyl.
[0221] By cycloalkyl in the present invention is meant cycloalkyl groups having 3-7 atoms such as, for example cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl.
[0222] By aryl is meant an aromatic carbocyclic group having a single ring (e.g., phenyl), multiple rings (e.g., biphenyl), or multiple condensed rings in which at least one is aromatic, (e.g., 1,2,3,4-tetrahydronaphthyl, naphthyl, anthryl, or phenanthryl), which is optionally mono-, di-, or trisubstituted with, e.g., halogen, lower alkyl, lower alkoxy, lower alkylthio, trifluoromethyl, lower acyloxy, aryl, heteroaryl, and hydroxy.
[0223] By lower alkoxy in the present invention is meant straight or branched chain alkoxy groups having 1-6 carbon atoms, such as, for example, methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, sec-butoxy, tert-butoxy, pentoxy, 2-pentyl, isopentoxy, neopentoxy, hexoxy, 2-hexoxy, 3-hexoxy, and 3-methylpentoxy.
[0224] By cycloalkoxy in the present invention is meant cycloalkylalkoxy groups having 3-7 carbon atoms where cycloalkyl is defined above.
[0225] By halogen in the present invention is meant fluorine, bromine, chlorine, and iodine.
[0226] By heteroaryl (aromatic heterocycle) in the present invention is meant one or more aromatic ring systems of 5-, 6-, or 7-membered rings containing at least one and up to four hetero atoms selected from nitrogen, oxygen, or sulfur. Such heteroaryl groups include, for example, thienyl, furanyl, thiazolyl, imidazolyl, (is)oxazolyl, pyridyl, pyrimidinyl, (iso)quinolinyl, naphthyridinyl, benzimidazolyl, and benzoxazolyl.
[0227] Specific examples of heteroaryl groups are the following:
wherein Q is nitrogen or —CR 9 ;
T is —NR 7 , oxygen, or sulfur; and R 9 , R 10 , R 10 ′, R 11 , R 11 ′, R 12 are as defined above, where Y represents a carbocyclic group, it is attached to the amide nitrogen by a single bond. The result is an amide of the formula:
where X is defined as above and
represents the Y carbocyclic group.
[0234] Where X is a carbocyclic group, such moiety or group includes both aromatic heterocycles (heteroaryl), unsaturated heterocylic ring systems, and saturated heterocyclic ring systems. Examples of such groups are imidazolyl, pyrrolidinyl, morpholinyl, piperazinyl, or piperidinyl. Specific X carbocyclic groups are linked to the parent naphthyridine moiety by a nitrogen atom in the X carbocyclic group. Thus, for example, when pyrrolidinyl is the X carbocyclic group, it is specifically a 1-pyrrolidinyl group of the formula:
[0235] Where Y is a carbocyclic group, such moiety or group includes both aromatic heterocycles (heteroaryl groups), unsaturated heterocylic ring systems, and saturated heterocyclic ring systems. Examples of such groups are imidazolyl, pyrrolidinyl, morpholinyl, piperazinyl, or piperidinyl. Specific Y carbocyclic groups are linked to the parent naphthyridine carboxamide group by a nitrogen atom in the Y carbocyclic group. Thus, for example, when piperidinyl is the Y carbocyclic group, it is specifically a 1-piperidinyl group of the formula:
[0236] By “optionally substituted phenyl” as used herein is meant phenyl groups that are unsubstituted or substituted with up to 3 groups selected independently from halogen, hydroxy, lower alkyl, lower alkoxy, trifluoromethyl, and mono- or di-lower alkylamino.
[0237] Representative compounds that may be prepared by the process of the present invention are shown below in Table 1.
TABLE 1 X Y 1. C 6 H 5 CH 2 NH— —CH 2 CH 2 CH 2 CH 3 2. p-CH 3 C 6 H 4 SO 2 N(CH 3 )— —CH 2 C 6 H 5 3. CH 3 CH 2 O— —CH 2 CH 2 CH 2 OCH(CH 3 ) 2 4. CH 3 CH 2 O— 5. CH 3 O— —CH 2 CH 2 SCH 2 CH 3 6. CH 3 CH 2 O— 7. O(CH 2 CH 2 ) 2 N— —CH 2 C 6 H 4 F-o 8. (CH 2 CH 2 CH 2 CH 2 )N— —CH 2 C 6 H 4 OCH 3 -p 9. CH 3 CH 2 O— 10. CH 3 CH 2 O— —CH 2 C 6 H 4 CH 2 NHCH 3 -p 11. CH 3 CH 2 O— —CH 2 C 6 H 5
DETAILED DESCRIPTION OF THE INVENTION
[0238] The process of the present invention and the preparation of the compounds of the present invention are illustrated in Scheme 1. The preparation of the compound of Formula III from the compound of Formula II is described in Scheme 1 and the discussion that follows, wherein, unless otherwise indicated, X and Y are as defined above.
[0239] Overall the synthetic sequence of the scheme involves a single step which is direct reaction of the ester having structure II with primary amine I to form the carboxyamide having structure III.
[0240] In Scheme 1 the ester having structure II is treated with a primary amine, preferably an excess of primary amine, and heated to form carboxyamide III directly. Scheme 1 may be carried out without a solvent other than the amine but the use of a solvent, especially a polar solvent, is preferred. Preferred solvents include amide solvents such as dimethylacetamide (DMAc), dimethylformamide (DMF) or N-methylpyrollidone (NMP), or a sulfoxide solvent, such as dimethylsulfoxide (DMSO). Scheme 1 is carried out by heating the ester of formula II from about 90° C. to approximately the reflux temperature of the solvent, preferably to about 150° C., more preferably to about 105° C. to about 1100 C for about 1 hour to about 24 hours, with about 14 hours preferred. The process of Scheme 1 is preferably carried out under an inert atmosphere such as nitrogen or argon although this is not essential. The solution is cooled to about 5° C. to about 35° C., with about 22° C. preferred. The solution is then poured into water and the precipitated solid washed filtered and dried and optionally recrystallized. In a preferred variation, the reaction mixture is filtered and the residue is washed with solvent with the washings added to the filtrate. While maintaining the filtrate below about 35° C. equal quantities of acetone and water are added and the mixture is acidified to about pH 3 with an acid, preferably HCl to form a slurry which is then filtered dried and optionally recrystallized. Other variants on this general procedure will be evident to those skilled in the art.
[0241] The present invention is illustrated by the following examples, but it is not limited to the details thereof.
EXAMPLE 1
[0242] N-benzyl-6-ethoxy-4-oxo-1,4-dihydro-1,5-naphthyridine-3-carboxamide
[0243] A mixture of 6-ethoxy-4-oxo-1,4-dihydro-1,5-naphthyridine-3-carboxylic acid ethyl ester (0.964 g, 4.1 mM) and benzylamine (1.97 g, about 5 equivalents) in 10 mL of DMAc was heated at 150° C. overnight. The clear solution was cooled to room temperature and poured into 50 mL water. The precipitated solid was filtered and dried. HPLC showed about 9% of the title product was present with the remainder unreacted starting material.
EXAMPLE 2
[0244] N-benzyl-6-ethoxy-4-oxo-1,4-dihydro-1.5-naphthyridine-3-carboxamide—DMSO Solvent
[0245] A slurry of 6-ethoxy-4-oxo-1,4-dihydro-1,5-naphthyridine-3-carboxylic acid ethyl ester (10 g, 0.038 M) and 50 ml dimethylsulfoxide (DMSO) were heated to 105°-110° C. Benzylamine (12.5 g, 0.12 M −15.0 g, 0.14 M) was added to the heated slurry. The addition flask was rinsed with 5 ml DMSO which was also added to the slurry. The heated reaction mixture was stirred for 2-6 hours and then cooled to room temperature. The reaction mixture was filtered and the residue rinsed with 5 ml DMSO. Acetone (25 mL) and water 25 mL were added to the filtrate while maintaining it at a temperature below 35° C. The acidity of the mixture was adjusted to pH 3 with 6-8 mL of concentrated HCl. The slurry was diluted with 23 mL water and cooled to about 50 C. The product was collected by filtration and washed with 100 mL water and then dried under vacuum at about 70° C. to give an average of 12 g (97.4% yield) of the title compound.
[0246] The product was recrystallized by dissolving the solid in 120 mL acetic acid at temperatures greater than 90° C. and filtering the resultant solution. The filtrate was cooled to about 60° C. and then diluted with 32-50 mL of water having a temperature of approximately 55° C. The filtrate was slowly cooled to about 3° C. The product was collected and washed with 60 mL water and dried under vacuum at about 70° C. to recover an average of 8.35 g (69.6% recovery) for an average overall yield of 67.5%. The product was milled through a 0.05 round hole screen.
EXAMPLE 3
[0247] N-benzyl-6-ethoxy-4-oxo-1,4-dihydro-1,5-naphthyridine-3-carboxamide—DMF Solvent
[0248] A slurry of 6-ethoxy-4-oxo-1,4-dihydro-1,5-naphthyridine-3-carboxylic acid ethyl ester (10 g, 0.038 M) and 50 ml dimethylformamide (DMF) were heated to 1050-1100 C. Benzylamine (17 g, 0.16 M) was added to the heated slurry. The addition flask was rinsed with 5 ml DMSO which was also added to the slurry. The heated reaction mixture was stirred at least 14 hours and then cooled to about 40° C. The reaction mixture was filtered and the residue rinsed with 5 ml DMF. Water (120 mL) was added to the filtrate while maintaining it at a temperature below 45° C. The acidity of the mixture was adjusted to pH 4 with about 15 mL of concentrated HCl. The mixture was cooled to about 5° C. The product was collected by filtration and washed with 40 mL water and then dried under vacuum at about 70° C. to give 8.9 g (72.2% yield) of the title compound.
[0249] The product was recrystallized by dissolving the solid in 89 mL acetic acid at temperatures greater than 90° C. and filtering the resultant solution. The filtrate was cooled to about 55° C. and then diluted with 22 mL of water having a temperature of approximately 50° C. The filtrate was slowly cooled to about 3° C. The product was collected by filtration and washed with 53 mL water and dried under vacuum at about 70° C. to recover 6.3 g (70.8% recovery) for an average overall yield of 51%. The product was milled through a 0.05 round hole screen. | A new route for the preparation of substituted 1,5-naphthyridine-3-carboxyamides, useful in the diagnosis and treatment of anxiety, Downs Syndrome, sleep, cognitive and seizure disorders, and overdose with benzodiazepine drugs and for enhancement of alertness, is provided. These compounds may be readily prepared by heating the corresponding 1,5-naphthyridine-3-carboxylic acid ester with a primary amine in a polar solvent such as dimethylformamide or dimethylsulfoxide. | 2 |
RELATED APPLICATION DATA
This application is a continuation of U.S. application Ser. No. 14/248,057, filed Apr. 8, 2014 (now U.S. Pat. No. 9,325,819) which is a continuation of U.S. application Ser. No. 11/198,004, filed Aug. 5, 2005 (now U.S. Pat. No. 8,694,049), which claims the benefit of U.S. Provisional Application No. 60/599,479, filed Aug. 6, 2004, which is hereby incorporated by reference.
TECHNICAL FIELD
The invention relates to signal processing and distributing computing, particularly in portable computing devices such as mobile phones.
BACKGROUND AND SUMMARY
Portable computing devices, like mobile phones, are becoming increasingly more powerful and functional. For example, these devices include cameras, video capabilities, television tuners, audio recording and playback capabilities, etc. Further, since these devices are also communication devices, they also provide network computing services, like access to the Internet, synchronization of data with other devices, etc.
Despite the increasing functional capabilities and increases in computing power, there is still significant strain on the computing power of a small, hand held device. As such, there is a need for enhanced architectures and computing methods that support the vast variety of functions becoming available while making the best use of the computing resources on the device.
One major drain on the computing resources of a mobile phone, for example, is multimedia signal processing. Examples of applications include capturing and sending photos, playing music, playing video, etc. One particular application is associating various actions with multimedia content, such as linking a photo of a product in a catalog or magazine to a web site providing more information or purchase opportunities. Another example is linking a picture of musician or advertisement to an action of downloading a related ring tone to a phone or downloading related music in streaming mode or file format to a mobile phone handset. Implementations of this application are described in WO00/70585 and U.S. Pat. No. 6,505,160, which are hereby incorporated by reference.
These types of applications present major challenges for system developers:
1. how can these applications be implemented in software that runs on the phone hand set?
2. can these applications be implemented to run efficiently on a handset?
3. do these applications have unique hardware or software requirements that are not currently available on the handset alone?
4. can the application be widely deployed across handsets with different computing platforms, operating systems, and processors? (e.g., some handsets only execute programs written Java, yet the application may not run efficiently in Java).
In the network computing world, distributing computing schemes have been developed to take complicated software tasks, break them into modules and distribute execution of these modules across networked and/or parallel processors. Because of the unique architecture of the mobile phone handset, these schemes may not directly translate to the mobile phone computing architectures now available. As such, there is a need for new computing schemes and new distributing computing architectures for this environment.
The invention provides a reader for content identification and related content identification methods for mobile computing devices such as cellular telephone handset. One aspect of the invention is a reader including a reader library that reads device capabilities and business model parameters in the device, and in response, selects an appropriate configuration of reader modules for identifying a content item. The reader modules each perform a function used in identifying a content item. The modules are selected so that the resources available on the device and in remote devices are used optimally, depending on available computing resources on the device and network bandwidth.
Additional aspects of the invention are methods for identifying a content item captured from a mobile telephone handset, as well as methods for using combinations of signal filtering, watermark detection and fingerprinting to identify content using a combination of handset processing and server processing.
One example of a reader module is a fast watermark detection module that quickly detects the presence of a watermark, enabling resources to be focused on portions of content that are most likely going to lead to successful content identification. A watermark signal structure for fast watermark detection is comprised of a dense array of impulse functions in a form of a circle in a Fourier magnitude domain, and the impulse functions have pseudorandom phase. Alternative structures are possible.
Further features will become apparent with reference to the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a mobile device handset and its communication with a network.
FIG. 2 is a diagram illustrating an expanded reader architecture that adapts based on device capabilities and business model parameters.
FIG. 3 is a diagram illustrating interaction between the reader library and tables that store parameters that the reader library uses to adapt its operation as a function of device capabilities, time, location, business model, etc.
FIG. 4 is an example of a signal structure in the Fourier magnitude domain used for fast signal detection.
FIG. 5 illustrates the signal structure of FIG. 4 in the spatial domain.
DETAILED DESCRIPTION
FIG. 1 is a diagram illustrating a mobile device handset 20 and its communication with a network. The handset includes a computing platform, including a processor, RAM, and persistent storage. On this platform, the handset processor executes programming instructions in functional modules on the device. While a typical handset may have many modules, this particular example shows a user interface 22 and a reader 24 .
The user interface controls basic input/output functions, including receiving input from the handset's control keys, and providing output via a display and audio output device. The reader 24 processes multimedia input, such as frames of video, still images, and/or audio streams.
For the purpose of illustrating the operation of the computing platform of our mobile computing device architecture, we focus on the application of “connected content.” Connected content refers to associating an action with content items. For example, the reader receives a content item, such as an image from email, the web, or captured from the device's camera, and the reader performs a series of actions to determine an action associated with that content item. This action may involve returning a web page for display, returning web links, playing music or video, downloading a ring tone, etc.
In the application of connected content, the reader illustrated in FIG. 1 performs a series of operations to compute an identifier (ID) of the content item. This identifier is then mapped to an action. This action is specifically represented in FIG. 1 as the return of a URL, which may represent a web page or some other network service delivered to the handset.
The handset communicates with a network 26 (e.g., an Internet Protocol network) via its built in mobile network connectivity system, which may be based on any of a variety of mobile communication technologies (e.g., 3G, GSM, CDMA, bluetooth, and combinations thereof). Within this network, there are various servers responsible for providing various services for handset users. These servers may include servers operated by the mobile telephone service provider, one or more Internet service providers, web servers on the Internet, content services, etc.
The challenge for this type of application is developing an efficient mechanism for mapping the content item to its corresponding action across different types of devices with varying software and hardware capabilities, and across different mobile telephone service providers with varying business models.
FIG. 2 is a diagram illustrating an expanded reader architecture that adapts based on device capabilities and business model parameters. The device capabilities may be fixed parameters, such as a particular type of processor, memory, signal processing modules (like optimized FFT module). They may also be variable, such as available computing cycles that vary with processing load and fluctuations in available bandwidth for transmitting content items to other processors (e.g., either network servers or neighboring devices connected via Bluetooth or other connections). The business model parameters also control computing by favoring certain types of operations over others to advance a desired business model. For example, it may be advantageous to use more bandwidth by sending content via the mobile service provider to a distributing computing resource rather than attempting to use only local computing resources on the handset. Other related parameters include location based services that vary based on location of the handset (e.g., determined by triangulation in the mobile phone network or via GPS hardware). The time of day and availability of processing resources on other connected devices may also control the reader operation.
To be adaptable, the reader is subdivided into modules that break down the reader application into functional blocks that can be executed separately, possibly in parallel and possibly taking advantage of distributed computing through mechanisms like Remote Procedure Calls to functions executing on other devices. The reader library 40 is a module that controls operation based on the device and business model parameters.
In this particular example, the reader library selects the combination of modules that are suited for the device and business model. The reader application process is divided into functions, such as filter 40 , fast detect 42 , fingerprint 44 , and full detect 46 . Each of these modules can play a role in the reader application process of receiving a content item and converting that content item into an action. Depending on the device and business model parameters, the reader library selects the modules on the handset that will participate. The rest of the functions, if any are left, are performed on one or more remote devices as explained below.
Depending on the selection of the reader library, part of the reader process is executed on the handset, and part is executed on a remote device (or multiple remote devices). As shown in box 50 , the nature of the data sent from the reader to a remote device depends on which functions of the reader process are executed on the handset. In one scenario, the reader sends the content item (e.g., frames or blocks of an image or an audio clip) to a remote device for determination of its ID. This uses minimal resources on the handset, but consumes more bandwidth.
In another scenario, the filter 42 filters the content item leaving only components of the content necessary to complete the remaining content identification tasks. Examples of this type of filtering are described in U.S. Pat. Nos. 6,724,914 and 6,483,927, which are hereby incorporated by reference. Pre-filters used for digital watermark detection are described further below. Pre-filtering uses more processing resources on the handset and less bandwidth.
In another scenario, the handset performs a fast detect 42 to quickly identify whether a content item includes a digital watermark signal, and to provide registration information (so that the content can be aligned for further ID extraction through fingerprint analysis or digital watermark message extraction). There are several possible ways to implement fast detect. Some examples are described below. If the content identification is performed using some other machine readable code other than a digital watermark (e.g., a bar code or other visible machine symbology), the fast detect can be used to quickly identify the presence and location of the machine readable symbology.
In the case of the fast detect, the handset sends only blocks of content (e.g., filtered and/or geometrically registered, and/or with registration parameters) for which a fast detection has identified the presence of a code signal. This may consume more processing resources on the handset, but uses less bandwidth than sending all or substantial parts of the content to a remote device for identification.
The fast detect may also be used in conjunction with a fingerprint identification scheme where the fast detect provides registration parameters that facilitate accurate computation of the content fingerprint. The content fingerprint is a form of robust hash that is matched against a database of fingerprints to identify the content item.
In another scenario, the handset computes the content item's fingerprint using a fingerprint module. There are a variety of content fingerprint schemes available for video, audio and images. One type of fingerprinting process is to hash features of the content, such as frequency domain features, to compute a vector of hashes that are then matched with corresponding vectors of hashes in a fingerprint database. Once a match is found, the database returns a content identifier. In this scenario, the handset computes the fingerprint, and sends it to a database for content identification.
Finally, another scenario is to perform a full detect using a full detect module 46 . This approach is premised on the existence of an identifier in machine readable form in the content item. This may constitute a digital watermark, bar code or other machine readable code. In this case, the handset uses the most processing resources and the least bandwidth because it does all the work necessary to identify the content item and only sends a small identifier to the network.
In the case where a URL represents the action to be performed, a device on the network looks up the identifier in a database and returns the corresponding URL to the handset. The action need not be represented by a URL. It can be some other process for returning programming or content to the handset or some device associated with the handset owner. For example, the database may return the name of an action, which in turn, triggers a server in the network to perform that action, either alone, or combination with other servers or devices. The action may include sending a video, music or image file, executing an electronic purchase transaction, downloading content or programming to the handset, etc.
FIG. 3 is a diagram illustrating interaction between the reader library and tables that store parameters that the reader library uses to adapt its operation as a function of device capabilities, time, location, business model, etc. In the illustration, the parameters used to control the reader library's selection of modules are represented in two tables: 1. A Device Capabilities Table, and 2. A Business Model Table. The first column in the device table lists device capabilities, like the processor type, the operating system, the existence of any special processing features that assist in signal processing like an FFT module, memory, memory bandwidth, network bandwidth, connection speed, and location service availability. This table acts as a registry of the available capabilities. Some of these capabilities are fixed, such as the processor; and others are variable depending on external conditions, such as the network bandwidth and connection speed. If a capability is present, then the items in the row corresponding to the capability are checked. The columns represent different possible configurations of the reader process, such as: “Extract ID on handset”, “Extract ID on server” and “Distribute reader process between handset and server According to Bandwidth.” In the latter example, the reader process adapts based on available bandwidth such that more processing is distributed to the server when more bandwidth is available.
The reader process may also adapt based on available computational cycles depending on other applications running on the handset at a particular time. If other higher priority applications are running, reader process functions are off loaded to the server.
The Business Model interacts with the reader library module in a similar way. The reader process can be configured differently based on, for example, the service provider, the calling plan for the phone, the time of day (use less bandwidth when bandwidth is more expensive to the user or provider), the ability of the service provider to manipulate images, video or audio on its or its partners' servers, etc. The reader process can also be adapted for different ISPs and web services that are available. For example some web services may support location based services, while others may not. Location based services enable the action performed in response to content identification to be tailored for the handset's location. Some providers may support ring tone downloading while others may not. There are many possible options, and the reader library can adapt depending on the settings in both the device and business model tables.
Distributed computing of the reader process is not limited to handset-server. Some handsets support bluetooth or other wireless connections to devices with additional processing power. Parts of the reader process can also be distributed to devices with range of a bluetooth connection, such as the user's home PC or other computing device.
Distributed processing can be implemented using Remote Procedure Calls. For example, the handset can make a call to a fingerprint module on a server and pass it a block of content. In response, the fingerprint module returns an ID, which is then mapped to an action.
Several processing threads can be spawned in parallel. For example, an image frame can be broken into blocks, each with its own reader process that is distributed between the handset and one or more remote devices networked with the handset. Once an ID is found or an action is correctly mapped to a content item, all concurrent reader processes are canceled. This is particularly useful when a stream of video frames captured by the handset camera are input to the reader library. In this case, the reader library distributes the reader process, frame by frame or block by block. The filter and fast detect blocks can be used to pre-process blocks of content before they are processed further for ID extraction. As explained below, the fast detect module can be used to weed out content that is unlikely to lead to a successful ID extraction.
The computing architecture described above can be used for other resource intensive processes to enhance the capability of mobile phone handsets. Below, we continue with the example of the reader application, and provide more information and digital watermarking and fingerprinting.
Digital Watermarking
Digital watermarking is a process for modifying physical or electronic media to embed a hidden machine-readable code into the media. The media may be modified such that the embedded code is imperceptible or nearly imperceptible to the user, yet may be detected through an automated detection process. Most commonly, digital watermarking is applied to media signals such as images, audio signals, and video signals. However, it may also be applied to other types of media objects, including documents (e.g., through line, word or character shifting), software, multi-dimensional graphics models, and surface textures of objects.
Digital watermarking systems typically have two primary components: an encoder that embeds the watermark in a host media signal, and a decoder that detects and reads the embedded watermark from a signal suspected of containing a watermark (a suspect signal). The encoder embeds a watermark by subtly altering the host media signal. The reading component analyzes a suspect signal to detect whether a watermark is present. In applications where the watermark encodes information, the reader extracts this information from the detected watermark.
Several particular watermarking techniques have been developed. The reader is presumed to be familiar with the literature in this field. Particular techniques for embedding and detecting imperceptible watermarks in media signals are detailed in the assignee's U.S. Pat. Nos. 6,122,403 and 6,614,914, which are hereby incorporated by reference.
Pre-Filtering for Signal Detection
In signal detection, and particularly digital watermark detection, a pre-filter may be used to de-correlate the signal being sought from the host signal. In particular for a digital watermark detector, a filter is used to de-correlate the digital watermark from the host signal.
One example of this type of de-correlating filter for digital image watermarks operates as follows. For each image sample, it compares the sample with each of its eight neighboring image samples. The filter replaces the value at the center sample with a value that is incremented each time the center sample value is greater than a neighbor value and decremented each time the center sample is less than the neighbor value. In particular, for each comparison, the filter increments by a value of 1 if the center sample is greater than its neighbor, it increments by a value of −1 if the center sample is less than its neighbor, and makes no change otherwise. The output of the filter will be between −8 and +8 when an eight neighborhood (3 by 3 sample region) is used in the filter implementation. Such type of a filter has a number of applications such as edge detection, signal enhancement, etc. in signal processing and operates on different media types (image, video and audio) and samples in various domains. For digital watermark applications, it may be used to estimate the original host signal and watermark signal, where the watermark signal is applied as an additive, antipodal PN signal.
The filter discussed in the previous paragraph may be implemented in variety of ways. One particular implementation makes comparisons between the center sample and each neighboring sample, and transforms the result of this comparison to an increment or decrement value (e.g., +k or −k, where k is a constant like 1, 2, 3, etc.). The filter sums each of the increment/decrement values from each neighbor, and then replaces the center sample value with the result of the summation. This type of filter can be implemented efficiently using a look up table. For example, the comparison operation is performed by subtracting the center sample value from a neighbor sample value to produce a difference value (−255 to +255 for an 8 bit sample). The result is then fed to a look-up table, which maps the difference value to an increment/decrement value and outputs that value. The filter sums the look-up table output for each neighbor in the neighborhood, and replaces the center sample with the result of the summation. This neighborhood may be the eight neighbors in 3 by 3 block of samples, the adjacent samples in a one-dimensional signal, the horizontally and/or vertically adjacent neighbors in a two or more dimensional signal, etc. The size of the neighborhood may be increased as well. The look-up table may be used to implement a variety of non-linear filters efficiently.
Fast Signal Detect
Very fast (computationally inexpensive) detection of the presence of a digital watermark signal is highly desired. Some existing digital watermark detectors employ 2D FFT, log-polar mapping and log-polar correlation for detecting the watermark signal and its registration parameters (e.g., rotation, scale, translation). The emphasis of fast detection is on alternative watermark signal designs and techniques that use substantially less processing than currently necessary for determining the presence of an embedded watermark signal.
A digital watermark may comprise several signal components, including a component used for fast detection and registration, a component for more accurate registration, and a component for conveying a variable message. These components can be integrated together or totally separate. For example, a signal component used for detection may also convey variable message bits. In this discussion, we focus on digital watermark structure design used for detection and registration. These watermark structures may also convey variable data, but this variable data carrying function is not the focus of this section. The patents incorporated above and the watermarking literature describe various schemes for conveying hidden data in digital watermarks.
FIG. 4 illustrates a watermark signal structure in the Fourier Magnitude domain enabling fast detection and registration information. The watermark structure in FIG. 4 includes a dense full circle in the frequency domain. This circle is made up of individual impulse functions (e.g., sine waves) with pseudorandom phase with respect to each other. A full circle is an excellent candidate for fast detection. Detection of this structure exploits the fact that for a circle in the 2D Fourier domain, a slice through any axis (irrespective of rotation or scale) passing through DC is a pair of symmetrical points.
Projection of the 2D FFT onto 1 dimension (either X or Y axis) provides a fast mechanism to detect the presence of this signal. Presence of the signal is detected by pre-filtering an image block (as explained in the previous section) followed by 1D FFTs along each row, and summing the FFTs across rows to obtain the projection. Detection of a strong peak in the 1D projection indicates the presence of the watermark. Note that detection includes filtering, 1D FFTs, and peak finding in the 1D FFT, which can be computed in a more efficient manner than techniques requiring multiple 2D FFTs.
FIG. 5 shows the spatial domain representation of the dense circle in FIG. 4 . The phases are randomized so that the signal can be embedded into an image in a substantially imperceptible manner. Techniques for hiding this type of signal in a host image are described in U.S. Pat. No. 6,614,914, incorporated above. For example, a perceptual mask can be used to adjust the watermark signal as a function of the data hiding capability of a host image. In addition, the signal can be embedded in a color channel that is less perceptible to humans, such as the yellow channel.
Detection of Watermark Signal Presence
This section describes a number of alternative methods for quickly detecting the presence of the watermark signal structure shown in FIGS. 4-5 . Methods 1-4 are different approximations to the actual 1D projection or 1D slice through the 2D transform and differ in computational complexity. Method 1 is the least expensive.
Method 1
Apply a 1D pre-filter on each row in the block (similar to 2D filter described in pre-filtering section above, but only performed on samples along a row)
Sum all rows in the block
Compute 1D FFT magnitude
Detect peaks
Method 2
Apply 2D pre-filter to block
Sum all rows in the block
Compute 1D FFT magnitude
Detect peaks
Method 3
Apply a 1D pre-filter on each row in the block
Compute 1D FFT magnitude of each row
Sum row FFT magnitudes
Detect peaks
Method 4
Apply 2D pre-filter to block
Compute 1D FFT magnitude of each row
Sum row FFT magnitudes
Detect peaks
Method 5
Apply 2D pre-filter to block
Compute 1D FFT of each row
Sum row FFTs
Compute magnitude of sum
Detect peaks
Advantages of Fast Detection
Fast watermark detection provides the ability to quickly ascertain watermark presence in computationally challenging environments such as cell phones and low-end devices. This can result in faster and more reliable overall detection
In server side detection, the fast detection process could be run on the client to identify signal-bearing image frames to be transmitted to the server. Using fast detection at the client side, the probability of not detecting at the server can be reduced. Only those frames in which fast detection is successful are transmitted to the server.
In client side detection, fast detection can be used to quickly discard frames that do not bear the watermark signal, rather than go through the entire registration and decoding processes. Frames in which the grid is detected are taken through subsequent watermark detection stages.
Fast detection is also useful in situations where it is necessary to quickly identify regions of interest for watermark detection. Additional processing resources can then be focused on particular regions of the signal where complete and accurate watermark reading is most likely.
Obtaining Registration Parameters
Although the full circle structure is primarily designed for fast watermark detection, it has interesting properties that can be exploited to provide registration parameters (i.e., synchronization).
1. The location of a peak relative to the x and y axes of the 2D FFT provides scale. Namely, the distance of the peak from the DC point in the x and y directions provides the scale in these directions.
2. When the distance of the peaks are computed for both the x and y axes as in 1, the location of the peaks also provides an indicator of differential scale.
3. Fitting an ellipse to the circle in the frequency domain (refer to the elliptical curve fitting technique in U.S. Pat. No. 6,483,927, incorporated herein) can help recover an affine transformation except rotation.
4. Rotation can be recovered either by exploiting the phases or by adding a few random impulse function points in addition to the dense circle.
Another approach to obtain registration parameters would be to use the full circle signal in the Fourier Magnitude domain in addition to a collection of other impulse functions. The full circle can provide fast detection and ability to recover from large differential scales, whereas the collection of other impulse functions can help recover any remaining parameters. See U.S. Pat. No. 6,614,914 for the use of a log polar transform to compute registration parameters from a collection of impulse function in the Fourier Magnitude domain.
Alternative Watermark Signal Design Choices
The dense circle is just one example of a signal that can be detected using the 1D projection. Other designs can be selected to reduce visibility of the signal in the spatial domain and make it easier to obtain other registration parameters. For example,
1. Concentric arcs
2. Non-symmetric arcs
3. Square centered at DC
4. Rhombus (or parallelogram) centered at DC
5. Signal designed such that there is an impulse function point at each possible rotation angle from 0 to 180 degrees. In this design, each point can be located at a unique radial distance from DC.
6. Multiple lines (not passing through DC) with different slopes in each quadrant.
Other Types of Fast Detection
The watermark signal (or other ID carrying signal) can be designed with distinct attributes that facilitate fast detection. These include unique colors, unique line structures, unique halftone screening structures used in printing (e.g., a unique screen angle or frequency), unique frequency content, a unique signature in the signal's histogram, etc. The fast detector is then tuned to measure evidence of these attributes, and if sufficiently present, direct further detection activities at the region where these attributes are found.
The Fast Detector as Positive Feedback
The fast detector enables the handset to display or emit a sound when the handset is close to capturing an image with a readable watermark (or other code signal). For many users, it may be difficult to position the handset's camera at the proper angle and distance from a watermarked object, leading to frustration. However, if the fast detector is constantly running on image frames captured while the handset is moving, the positive feedback from detection of the watermark signal can help guide the user to the correct location and orientation of the camera to ensure accurate watermark recovery. The user can then be instructed via a beep or light emitted by the handset to press a capture button to ensure that the image being captured is likely to contain a recoverable watermark signal.
Fingerprint Configurations
Below, we list several alternative approaches for using fingerprints, possibly in conjunction with fast detection of a watermark, to perform content identification on mobile computing device.
Approach 1 On capturing the image using the cell phone, calculate its fingerprint (i.e., some form of robust digital signature). Send the fingerprint to the server where it is matched with fingerprints in a database to identify the captured material. Further action can then be taken based on the ID returned by the database. Approach 2 Similar to approach 1 except that instead of calculating the fingerprint, the image is sent to the server where it is matched (correlated) directly with a database of stored images. Approach 3 Same as approach 1 except that a watermark template is embedded in the printed material to provide synchronization. Synchronization improves robustness of fingerprint extraction and matching because it allows the fingerprint to be computed after the content is aligned using the registration parameters from the synchronization process. Approach 4 Same as approach 2 except that a template is embedded to provide synchronization. Synchronization simplifies/improves the task of matching with the database of images. Approach 5 A payload message signal can additionally be used in approaches 3 and 4, making the system more robust. In other words, the system could rely on either the watermark or the fingerprint or both.
These scenarios are examples of alternative configurations that the reader library can select to adapt handset performance based on the device and business model parameters.
Concluding Remarks
Having described and illustrated the principles of the technology with reference to specific implementations, it will be recognized that the technology can be implemented in many other, different, forms. To provide a comprehensive disclosure without unduly lengthening the specification, applicants incorporate by reference the patents and patent applications referenced above.
The methods, processes, and systems described above may be implemented in hardware, software or a combination of hardware and software. For example, the auxiliary data encoding processes may be implemented in a programmable computer or a special purpose digital circuit. Similarly, auxiliary data decoding may be implemented in software, firmware, hardware, or combinations of software, firmware and hardware. The methods and processes described above may be implemented in programs executed from a system's memory (a computer readable medium, such as an electronic, optical or magnetic storage device).
The particular combinations of elements and features in the above-detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this and the incorporated-by-reference patents/applications are also contemplated. | This disclosure describes a distributed reader architecture for a mobile computing device such as cellular telephone handset. One claim recites a portable computing device including: memory for storing a library of processing components, the library including a signal detector component and an audio fingerprinting component; a microphone for capturing ambient audio; one or more processors configured for: invoking the audio fingerprinting component for processing captured audio to produce an audio fingerprint, wherein the audio fingerprinting component comprises a filtering process, in which the filtering process produces components of the captured audio that are used to produce the audio fingerprint; and invoking the signal detector component, in which the signal detector component comprises a fast detect process for analyzing the captured audio to determine the presence of an auxiliary signal within the captured audio, and when the presence of the auxiliary signal is detected, controlling the signal detector component for detecting the auxiliary signal to yield a detected auxiliary signal. The device further includes a communications output for communicating the audio fingerprint and the detected auxiliary signal to a remotely located server. Of course, other claims and combinations are provided as well. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of our copending application Ser. No. 612,975, filed Sept. 12, 1975, which in turn is a continuation-in-part of application Ser. No. 529,862, filed Dec. 5, 1974, both now abandoned.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a novel group of antibiotics and, more particularly, is concerned with a novel series of potent antibacterial agents derived by reductive alkylation of antiobiotic BM123γ with an aldehyde or ketone of the following general formulae: ##STR1## wherein R 1 is hydrogen, lower alkyl, halo substituted lower alkyl, lower alkenyl, phenyl, monosubstituted phenyl, phenyl lower alkyl, 2-furyl, methyl substituted 2-furyl, 2-thienyl, methyl substituted 2-thienyl, 2-pyrryl, methyl substituted 2-pyrryl, 2-pyridyl or 2-quinolyl; R 2 is lower alkyl, halo substituted lower alkyl or phenyl lower alkyl; R 3 is lower alkyl, halo substituted lower alkyl, lower alkenyl, lower cycloalkyl, phenyl, monosubstituted phenyl, phenyl lower alkyl or monosubstituted phenyl lower alkyl; and R 2 and R 3 taken together with the associated carbonyl group is cyclopentanone, mono-lower alkyl substituted cyclopentanone, di-lower alkyl substituted cyclopentanone, tri-lower alkyl substituted cyclopentanone, cyclohexanone, mono-lower alkyl substituted cyclohexanone, di-lower alkyl substituted cyclohexanone or tri-lower alkyl substituted cyclohexanone. Suitable lower alkyl and halo substituted lower alkyl groups contemplated by the present invention are those having up to six carbon atoms wherein halo is exemplified by chloro, bromo, and iodo such as methyl, ethyl, isopropyl, sec-butyl, n-amyl, dichloromethyl, 2-bromoethyl, 2,3-diiodopropyl, γ-chloropropyl, etc. Suitable lower alkenyl groups are those having up to four carbon atoms such as vinyl, allyl, propenyl, isopropenyl, 1-butenyl, 2-butenyl, 3-butenyl, isobutenyl, etc. Suitable lower cycloalkyl groups are cyclopenyl, cyclohexyl, and cycloheptyl. Suitable monosubstituted phenyl groups contemplated by the present invention are, for example, p-acetamidophenyl, m-nitrophenyl, m-mercaptophenyl, o-anisyl, p-anisyl, o-tolyl, p-tolyl, and the like whereas phenyl lower alkyl is exemplified by benzyl, α-phenylethyl, and β-phenylethyl. Suitable monosubstituted phenyl lower alkyl groups may be o, m, or p-chlorobenzyl, α-(p-aminophenyl)ethyl, β-(m-nitrophenyl)ethyl, etc. Suitable methyl substituted 2-furyl, 2-thienyl, and 2-pyrryl groups which may be employed are, for example, 5-methyl-2-furyl, 3,4-dimethyl-2-furyl, 4-methyl- 2-thienyl, 3,5-dimethyl-2-thienyl, 5-methyl-2-pyrryl, 1,3,4-trimethyl-2-pyrryl, and the like.
The reductive alkylation process whereby the novel antibacterial agents of the present invention may be prepared is carried out as follows. Antibiotic BM123γ, BM123γ 1 , or BM123γ 2 is dissolved in a suitable solvent such as water, methanol, methyl cellosolve, or mixtures thereof, an amount in excess of an equimolar amount of the desired aldehyde or ketone is then added followed by the addition of a reductive sufficiency of sodium cyanobrorohydride. The pH of the reaction mixture is maintained at 6.0-8.0 with dilute mineral acid during the course of the reaction. After one to 24 hours at ambient temperature (10°-35° C.), the reaction mixture is evaporated to dryness in vacuo and the residue is triturated with methanol and filtered. The filtrate is diluted with acetone and the solid product that precipitates is removed by filtration and dried in vacuo.
Aldehydes which may be so employed in the above process are, for example, acetaldehyde, propionaldehyde, butyraldehyde, isobutyraldehyde, crotonaldehyde, valeraldehyde, benzaldehyde, p-cyanobenzaldehyde, salicylaldehyde, cinnamaldehyde, trichloroacetaldehyde, etc. Ketones which may be so employed in the above process are, for example, acetone, 2-butanone, 1,3-dibromoacetone, chloroacetone, acetophenone, m-chloroacetophenone, p-bromoacetophenone, p-trifluoromethylacetophenone, m-nitroacetophenone, p-dimethylaminoacetophenone, etc.
The products are obtained from the reductive alkylation reaction mixtures by standard procedures such as precipitation, concentration, solvent extraction or combinations of these procedures. After isolation, the products may be purified by any of the generally known methods for purification. These include recrystallization from various solvents and mixed solvent systems, chromatographic techniques, and counter current distribution, all of which are usually employed for this purpose.
The novel antibacterial agents of the present invention are organic bases and thus are capable of forming acid-addition salts with a variety of organic and inorganic salt-forming reagents. Thus, acid-addition salts, formed by admixture of the antibacterial free base with up to three equivalents of an acid, suitably in a neutral solvent, are formed with such acids as sulfuric, phosphoric, hydrochloric, hydrobromic, sulfamic, citric, maleic, fumaric, tartaric, acetic, benzoic, gluconic, ascorbic, and related acids. The acid-addition salts of the antibacterial agents of the present invention are, in general, crystalline solids relatively soluble in water, methanol and ethanol but are relatively insoluble in non-polar organic solvents such as diethyl ether, benzene, toluene, and the like. For purposes of this invention, the antibacterial free bases are equivalent to their non-toxic acid addition salts.
DETAILED DESCRIPTION OF THE INVENTION
The antibiotics designated BM123β 1 , BM123β 2 , BM123γ 1 and BM123γ 2 are formed during the cultivation under controlled conditions of a new strain of an undetermined species of Nocardia. This new antibiotic producing strain was isolated from a garden soil sample collected at Oceola, Iowa, and is maintained in the culture collection of the Lederle Laboratories Division, American Cyanamid Company, Pearl River, N.Y. as Culture No. BM123. A viable culture of the new microorganism has been deposited with the Culture Collection Laboratory, Northern Utilization Research and Development Division, United States Department of Agriculture, Peoria, Illinois, and has been added to its permanent collection. It is freely available to the public in this depository under its accession No. NRRL 5646. Herein BM123β refers to a mixture in any proportion of BM123β 1 and BM123β 2 , and BM123γ refers to a mixture in any proportion of BM123γ 1 and BM123γ 2 .
The following is a general description of the microorganism Nocardia sp., NRRL 5646, based on diagnostic characteristics observed. Observations were made of the cultural, physiological, and morphological features of the organism in accordance with the methods detailed by Shirling and Gottlieb, Internat. Journ, of Syst, Bacteriol. 16:213-240 (1966). The chemical composition of the culture was determined by the procedures given by Lechevalier et al., Advan. Appl. Microbiol. 14:47-72 (1971). The underscored descriptive colors and color chip designations are taken from Jacobson et al., Color Harmony Manual, 3rd ed. (1948), Container Corp. of America, Chicago, Illinois. Descriptive details are recorded in Tables I through V below.
Amount of Growth
Moderate on yeast extract, asparagine dextrose, Benedict's, Bennett's potato dextrose and Weinstein's agars; light on Hickey and Tresner's, tomato paste, oatmeal, and pablum agars and a trace of growth on inorganic salts-starch, Kuster's oatflake, Czapek's solution, and rice agars.
Aerial Mycelium
Aerial mycelium whitish when present; produced only on yeast extract, asparagine dextrose, Benedict's, Bennett's and potato dextrose agars.
Soluble Pigments
No soluble pigments produced.
Reverse Color
Colorless to yellowish shades.
Miscellaneous Physiological Reactions
No liquefaction of gelatin; nitrates reduced to nitrites in 7 days; melanoid pigments not formed on peptone-iron agar; no peptonization or curd formation in purple milk; NaCl tolerance in yeast extract agar ≦ 4% but ≦ 7%; optimal growth temperature 32° C. Carbon source utilization, according to the Pyridham and Gottlieb method [J. Bacteriol. 56:107-114 (1948)] as follows: Good utilization of glycerol, salicin, d-trehalose and dextrose; fair utilization of i-inositol; and poor to non-utilization of d-fructose, maltose, adonitol, 1-arabinose, lactose, d-mannitol, d-melibiose, d-raffinose, 1-rhamnose, sucrose and d-xylose.
Chemical Composition
The organism belongs to cell wall type IV, i.e., contains meso-2,6-diaminopimelic acid and has a type A whole-cell sugar pattern, i.e., contains arabinose and galactose. methylated whose cell extracts, when subjected to gas chromatography, showed fatty acid patterns similar to those produced by Nocardia asteroides ATCC 3308.
Micromorphology
Aerial mycelium arises from substrate mycelium as sparingly branched moderately long flexuous elements that commonly terminate in elongated primitive spirals. The flexuous elements are irregularly segmented into short elliptical to cyclindrical sections (spores) which disarticulate readily. The spiral terminal portions are less conspicuously segmented. Segments generally range 0.8-1.7 μm × 0.3-0.5 μm, averaging 0.4 μm × 1.2 μm.
Diagnosis
The morphological characteristics of Culture No. BM123 are difficult to observe and interpret because of the poor development of aerial mycelium on most media. Hence, considerable importance is attached, out of necessity, to the chemical analysis in determining the generic relationship of the organism. On the basis of the system proposed by Lechevalier et al., Culture No. BM123 contains meso-2,6-diaminopimelic acid in its whole cells and sugar analysis shows arabinose and galactose to be present. Therefore, the culture belongs to cell wall type IV. A comparison of the gas chromatography pattern of Culture No. BM123 with that of Nocardia asteroides ATCC 3308 showed the two to be remarkably similar. Other characteristics of Culture No. BM123 that are in keeping with the Nocardia concept, are its fragmenting aerial growth on some media and the total absence of aerial growth on most media. In view of the lack of adequate criteria for the characterization of Nocardia to the species level, no attempt has been made to make this determination. Therefore, Culture No. BM123 will be considered an undetermined species of Nocardia until such a diagnosis is feasible.
TABLE I__________________________________________________________________________Cultural Characteristics of Nocardia sp. NRRL 5646__________________________________________________________________________Incubation: 14 days Temperature: 32° C.__________________________________________________________________________ Amount of Aerial Mycelium Soluble ReverseMedium Growth And/Or Spores Pigment Color Remarks__________________________________________________________________________Yeast Extract Agar Moderate Aerial mycelium whitish, None Mustard Darkened areas in sub- light strate mycelium. (3 ie) Coremia formed on sur- face myceliumHickey and Tresner's Light No aerial mycelium None Colorless Peripheral areas ofAgar to colonies becoming Yellowish- olive-green greenAsparagine dextrose Moderate Trace of whitish aerial None Amber Surface lightlyAgar mycelium (3 lc) wrinkledBenedict's Agar Moderate Aerial mycelium whitish None Nude Tan Coremia abundantly light (4 gc) formed on surface myceliumBennett's Agar Moderate Trace of whitish aerial None Camel Surface lightly mycelium (3 ie) wrinkledInorganic Salts- Trace No aerial mycelium None Colorlessstarch AgarKuster's Oatflake Trace No aerial mycelium None ColorlessAgarCzapek's Solution Trace No aerial mycelium None ColorlessAgarPotato dextrose Moderate Aerial mycelium whitish, None CamelAgar light (3 ie)Tomato Paste Light No aerial mycelium None ColorlessOatmeal AgarPablum Agar Light No aerial mycelium None ColorlessRice Agar Trace No aerial mycelium None ColorlessWeinstein's Agar Moderate No aerial mycelium None Colorless to yellowish__________________________________________________________________________
TABLE II______________________________________Micromorphology of Nocardia sp. NRRL 5646______________________________________ Aerial Mycelium and/or SporiferousMedium Structures______________________________________Yeast Extract Aerial mycelium arises from sub-Agar strate mycelium as sparingly branced, flexous elements that commonly terminate in elongated primitive spirals. The flexuous elements are irregularly segmented into short sections (spores?) which disarticulate readily. The spiral terminal portions are less conspicuously segmented. Segments generally range 0.8-1.7 μm × 0.3-0.5 μm, averaging 0.4 μm × 1.2 μm______________________________________
TABLE III__________________________________________________________________________Miscellaneous Physiological Reaction of Nocardia sp. NRRL__________________________________________________________________________5646Medium Incubation Period Amount of Growth Physiological Reaction__________________________________________________________________________Gelatin 7 days Light No liquefactionGelatin 14 days Good No liquefactionOrganic Nitrate 7 days Good Nitrates reduced to nitritesBrothOrganic Nitrate 14 days Good Nitrates reduced to nitrilesBrothPeptone-iron 24-48 hours Good No melanin pigments reducedAgarPurple Milk 7 days Good No peptonization or curd formationYeast extract 7 days Moderate NaCl tolerance ≧ 4 % but ≦ 7 %Agar plus (4, 7,10 and 13%) NaCl__________________________________________________________________________
TABLE IV______________________________________Carbon Source Utilization Pattern of Nocardia sp. NRRL 5646______________________________________Incubation: 10 days Temperature: 32° C.______________________________________Carbon Source Utilization*______________________________________Adonitol 01-Arabinose 0Glycerol 3d-Fructose 1i-Inositol 2Lactose 0d-Mannitol 0Salicin 2d-Melibiose 0d-Raffinose 0Rhamnose 0Maltose 1Sucrose 0d-Trehalose 3d-Xylose 0Dextrose 3Negative Control 0______________________________________ *3-Good Utilization 2-Fair Utilization 1-Poor Utilization 0-No Utilization
TABLE V______________________________________Chemical Composition of Nocardia sp. NRRL 5646______________________________________Cell Wall Type Major Constituents______________________________________Type IV meso-DAP, arabinose, galactose______________________________________
The production of BM123β and BM123γ is not limited to this particular organism or to organisms fully answering the above growth and microscopic characteristics which are given for illustrative purposes only. In fact, mutants produced from this organism by various means such as exposure to X-radiation, ultra-violet radiation, nitrogen mustard, actinophages, and the like, may also be used. A viable culture of a typical such mutant strain has been deposited with the Culture Collection Laboratory, Northern Utilization Research and Development Division, United States Department of Agriculture, Peoria, Illinois, and has been added to its permanent collection under its accession number NRRL 8050. Although the cultural, physiological, and morphological features of NRRL 8050 are substantially the same as those of NRRL 5646, it produces enhanced amounts of BM123γ during aerobic fermentation. Also, NRRL 8050 varies from the parent NRRL 5646 as follows:
a. slower reduction of nitrates to nitrites; and
b. production of a rosewood tan mycelial pigment on Bennett's and yeast extract agars.
The novel antibacterial agents of the present invention are, in general, crystalline solids of relatively limited solubility in non-polar solvents such as diethyl ether and hexane, but considerably more soluble in solvents such as water and lower alkanols. Antibiotics BM123γ 1 and BM123γ 2 are structural isomers and may be represented by the following structural formulae: ##STR2##
The reductive alkylation of BM123γ, BM123γ 1 or BM123γ 2 with ketones takes place on the spermadine side-chain to form derivatives of the formula: ##STR3## wherein R is a moiety of the formulae: ##STR4## and R 2 and R 3 are as hereinabove defined. The reductive alkylation of BM123γ, BM123γ 1 or BM123γ 2 with aldehydes takes place on the spermadine side-chain to form mono-, di-, and tri-substituted derivatives of the formulae: ##STR5## wherein R and R 1 are as hereinabove defined.
The usefulness of the alkylated derivatives of BM123γ is demonstrated by their ability to control systemic lethal infections in mice. These new substances show high in vivo antibacterial activity in mice against Escherichia coli US311 when administered by a single subcutaneous dose to groups of Carworth Farms CF-1 mice, weight about 20 gm., infected intraperitoneally with a lethal dose of this bacteria in a 10 - 3 trypticase soy broth TSP dilution of a 5 hour TSP blood culture. In Table VI below is set forth the in vivo activity of typical products of this invention (prepared from the indicated carbonyl reagents) against Escherichia coli US311 in mice. The activity is expressed in terms of the ED 50 or the dose in mg./kg. of body weight required to protect 50% of the mice against E. coli.
TABLE VI__________________________________________________________________________ ED.sub.50 in mg./kg.Carbonyl Reagent Employed Derivative Name of body weight__________________________________________________________________________1-dipropylamino-2-propanone 1-methyl-2-(N,N-dipropylamino)- 0.3ethyl-BM123γ1-chloro-3-pentanone 1-ethyl-3-chloropropyl-BM123γ 0.12cyclooctanone cyclooctyl-BM123γ 0.184-methyl-2-pentanone 1,3-dimethylbutyl-BM123γ <0.12phenylacetone 1-methyl-2-phenylethyl-BM123γ 0.18trans-4-phenyl-3-buten-2-one 1-methyl-3-phenylpropen(-2-)yl- 0.25BM123γ1-cyclohexyl-1-propanone 1-cyclohexylpropyl-BM123γ 0.376-methyl-5-hepten-2-one 1,5-dimethylhexen(-4-)yl-BM123γ 0.063-methyl-2-pentanone 1,2-dimethylbutyl-BM123γ 0.125-methyl-2-hexanone 1,4-dimethylpentyl-BM123γ 0.123-ethyl-2-pentanone 1-methyl-2-ethylbutyl-BM123γ 0.183,5-dimethyl-2-octanone 1,2,4-trimethylheptyl-BM123γ 0.373-octanone 1-ethylhexyl-BM123γ 0.183-methyl-2-hexanone 1,2-dimethylpentyl-BM123γ 0.183-indolylacetone 1-methyl-2-(β-indolyl)ethyl- 0.12 BM123γ2-pentanone 1-methylbutyl-BM123γ <0.122-butanone 1-methylpropyl-BM123γ <0.122-cyclopenten(-1-)yl-acetone 1-methyl-2-cyclopenten(-2-)- yl-ethyl-BM123γ <0.12acetone isopropyl-BM123γ <0.123-decanone 1-ethyloctyl-BM123γ 0.253-undecanone 1-ethylnonyl-BM123γ 0.38o-acetoacetotoluidide 1-methyl-2-o-[tolylcarbamoylethyl]- 0.25 BM123γmesityl oxide 1,3-dimethylbuten(-2-)yl-BM123γ 0.3methoxyacetone 1-methyl-2-methoxyethyl-BM123γ 0.3cyclohexylacetone 1-methyl-2-cyclohexylethyl-BM123γ 0.184-(p-hydroxyphenyl)-2-butanone 1-methyl-3-(4-hydroxyphenyl)ethyl- BM123γ 0.3dimethyl(2-oxoheptyl)phosphonate 1-[(dimethoxyphosphinyl)methyl]- hexyl-BM123γ 0.34-methyl-2-hexanone 1,3-dimethylpentyl-BM123γ <0.122,2,4,4-tetramethylcyclopentanone 2,2,4,4-tetramethylcyclopentyl-BM123γ 0.752,4,4-trimethylcyclopentanone 2,4,4-trimethylcyclopentyl-BM123γ 0.32-cyclopentylcyclopentanone 2-cyclopentylcyclopentyl-BM123γ 0.372-(cyclo-1-hexenyl)cyclohexanone 2-(1-cyclohexen)cyclohexyl-BM123γ 0.193-tert-pentylcyclopentanone 3-tert-pentylcyclopentyl-BM123γ 0.52-cyclohexylcyclohexanone 2-cyclohexylcyclohexyl-BM123γ 0.752-ethylcyclohexanone 2-ethylcyclohexyl-BM123γ 0.193,3-dimethyl-2-butanone 1,2,2-trimethylpropyl-BM123γ <0.122-undecanone 1-methyldecyl-BM123γ >2tetrahydrothiopyran-4-one 4-tetrahydrothiopyranyl-BM123γ 0.383,5-dimethylcyclohexanone 3,5-dimethylcyclohexyl-BM123γ <0.122-tetradecanone 1-methyltridecyl-BM123γ 2.01-methoxy-1-buten-3-one 1-methyl-3-methoxypropen(-2-)yl- BM123γ >2.04-hydroxy-3-methyl-2-butanone 1,2-dimethyl-3-hydroxypropyl-BM123γ 0.12menthone 3-methyl-6-isopropylcyclohexyl-BM123γ 0.38cyclononanone cyclononyl-BM123γ 0.181-methyl-2-decalone decahydro-1-methyl-2-naphthyl-BM123γ 0.25isophorone 3,3-dimethylcyclohexen(-4-)yl-BM123γ 0.373-methyl-2-decalone decahydro-3-methyl-2-naphthyl-BM123γ 0.371-(3,4-dimethoxyphenyl)-2-butanone 2-ethyl-2-(3,4-dimethoxyphenyl)ethyl- 1.0 BM123γ1-diethylamino-3-butanone 1-methyl-3-(N,N-diethylamino)propyl- BM123γ 0.18ethyl 2-chloroacetoacetate 1-methyl-2-chloro-2-carbethoxyethyl- 1.5BM123γ3-hydroxy-3-methyl-2-butanone 1,2,2-dimethylhydroxypropyl-BM123γ 0.183-pentanone 1-ethylpropyl-BM123γ 0.123-methyl-2-butanone 1,2-dimethylpropyl-BM123γ 0.19p-chlorophenylacetone 1-methyl-2-(4-chlorophenyl)ethyl- 0.25 BM123γN-(tert-butyl)acetoacetamide 2-(tert-butylcarbamoyl)-1-methyl- ethyl-BM123γ 0.381,1-dimethoxyacetone 1-methyl-2,2-dimethoxyethyl-BM123γ 0.54-heptanone 1-propylbutyl-BM123γ 0.253-methoxyphenylacetone 1-methyl-2-(3-methoxyphenyl)ethyl- BM123γ 0.301,3-acetonedicarboxylic acid (2-carboxy-1-carboxymethyl)ethyl- BM123γ 0.52-phenylcyclohexanone 2-phenylcyclohexyl-BM123γ 0.38phenoxy-2-propanone 1-methyl-2-phenoxyethyl-BM123γ 0.33-butyn-2-one 1-methyl-butyn(-2-)yl-BM123γ <2.0dimethylaminoacetone 1-methyl-2-(N,N-dimethylamino)propyl- BM123γ 1.55-diethylamino-2-pentanone 1-methyl-4-(N,N-diethylamino)butyl- BM123γ 0.52-cyclohexen-1-one 2-cyclohexenyl-BM123γ 0.25cyclopropylmethylketone 1-cyclopropylethyl-BM123γ 0.254,4-dimethoxy-2-butanone 1-methyl-3,3-dimethoxypropyl-BM123γ 0.751,3-dimethylacetonedicarboxylate 1-carbomethoxy-2-carbomethoxyethyl- BM123γ 0.752-methoxyphenylacetone 1-methyl-2-(2-methoxyphenyl)ethyl- 0.7 BM123γacetylacetone 1-methyl-2-acetylethyl-BM123γ 1.5cyclobutanone cyclobutyl-BM123γ 0.38p-chlorophenylacetone 1-methyl-2-(4-chlorophenyl)ethyl- BM123γ 0.252-octanone 1-methylheptyl-BM123γ 0.384-phenyl-2-butanone 1-methyl-3-phenylpropyl-BM123γ 0.385-chloro-2-pentanone 1-methyl-4-chlorobutyl-BM123γ 0.37o-chlorophenylacetone 1-methyl-2-(2-chlorophenyl)ethyl- BM123γ 0.37m-chlorophenylacetone 1-methyl-2-(3-chlorophenyl)ethyl- BM123γ 0.385-hexene-2-one 1-methyl-penten(-4-)yl-BM123γ 0.38cyclohexanone cyclohexyl-BM123γ 0.752-hexanone 1-methylpentyl-BM123γ 0.382-heptanone 1-methylhexyl-BM123γ 0.38cycloheptanone cycloheptyl-BM123γ 0.3cyclopentanone cyclopentyl-BM123γ 0.254,4-dimethyl-2-pentanone 1,3,3-trimethylbutyl-BM123γ 0.182-acetamido-3-butanone 2-acetamido-1-methylpropyl-BM123γ 0.502,6-dimethyl-3-heptanone 1-isopropyl-4-methylpentyl-BM123γ 0.394-octanone 1-propylpentyl-BM123γ 0.393-acetylpyridine 1-(3-pyridyl)ethyl-BM123γ 0.753-heptanone 1-ethylpentyl-BM123γ 0.25ethyl butyrylacetate 1-(carbethoxymethyl)butyl-BM123γ 0.751-benzyl-4-piperidone 1-benzyl-4-piperidyl-BM123γ 0.181-methyl-4-piperidone 1-methyl-4-piperidyl-BM123γ 0.753-methylcyclopentanone 3-methylcyclopentyl-BM123γ 0.253,3-dimethyl-2-butanone 1-methyl-2,2-dimethylpropyl-BM123γ 0.182-acetyl-5-norbornene 1-[5-norbornene(2)]ethyl-BM123γ <0.12bicyclo[3.2.1]octan-2-one bicyclo[3.2.1]octanyl-2-BM123γ <0.253-quinuclidinone 3-quinuclidinyl-BM123γ 0.395-methoxyl-2-tetralone 5-methoxyl-2-tetralyl-BM123γ 0.184-methyl-2-heptanone 1,3-dimethylhexyl-BM123γ 0.53,4-dimethyl-2-hexanone 1,2,3-trimethylpentyl-BM123γ 0.391,3,3-trimethylcyclopentanone 1,3,3-trimethylcyclopentyl-BM123γ 0.37acetylcyclopentanone 1-cyclopentylethyl-BM123γ 0.185-hexen-2-one 1-methyl-hexen-4-yl-BM123γ 0.182-methylcyclopentanone 2-methylcyclopentyl-BM123γ 0.252,4-dimethylcyclopentanone 2,4-dimethylcyclopentyl-BM123γ 0.182-ethylcyclopentanone 2-ethylcyclopentyl-BM123γ 0.122-adamantone adamantyl-2-BM123γ 0.253-hexanone 1-ethylbutyl-BM123γ 0.39ethyl 2-methylacetoacetate 1-methyl-2-carboethoxypropyl-BM123γ 0.18norbornanone norbornyl-BM123γ 0.185-hexene-2-one 1-methyl-5-pentenyl-BM123γ 0.183-hydroxy-2-butenone 1-methyl-2-hydroxypropyl-BM123γ 0.374-hydroxy-3-methyl-2-butanone 1-methyl-2-(3-hydroxy-2-methylpropyl)- BM123γ 0.182-nonanone 1-methyloctyl-BM123γ 0.375-hydroxy-2-pentanone 1-methyl-4-hydroxybutyl-BM123γ 0.182-decanone 1-methylnonyl-BM123γ 0.184-t-butylcyclohexanone 4-t-butylcyclohexyl-BM123γ 0.122-ethylidenecyclohexanone 2-ethylidenecyclohexyl-BM123γ 0.12phenylacetaldehyde 2-phenylethyl-BM123γ 0.18p-methoxyphenylacetaldehyde 2-(p-methoxyphenyl)ethyl-BM123γ 0.182-ethylhexanal 2-ethylhexyl-BM123γ 0.372,2-dimethylbutanal 2,2-dimethylbutyl-BM123γ 0.122,2-dimethylpropanal 2,2-dimethylpropyl-BM123γ 0.182-ethyl-2-butenal 2-ethyl-2-butenyl-BM123γ 0.18trans-2-methyl-2-butenal trans-2-methyl-2-butenyl-BM123γ 0.181-methylcyclo-3-hexenylmethanal (1-methylcyclo-3-hexenyl)methyl-BM123γ 0.18trans-2-methyl-2-pentenal trans-2-methyl-2-pentenyl-BM123γ 0.18formaldehyde methyl-BM123γ 0.12acetaldehyde ethyl-BM123γ 0.38__________________________________________________________________________
Fermentation Process Selected to Produce Primarily BM123β and BM123γ.
Cultivation of Nocardia sp. NRRL 8050 may be carried out in a wide variety of liquid culture media. Media which are useful for the production of the antibiotics include an assimilable source of carbon such as starch, sugar, molasses, glycerol, etc.; an assimilable source of nitrogen such as protein, protein hydrolyzate, polypeptides, amino acids, corn steep liquor, etc.; and inorganic anions and cations, such as potassium, magnesium, calcium, ammonium, sulfate, carbonate, phosphate, chloride, etc. Trace elements such as boron, molybdenum, copper, etc.; are supplied as impurities of other constituents of the media. Aeration in tanks and bottles is provided by forcing sterile air through or onto the surface of the fermenting medium. Further agitation in tanks is provided by a mechanical impeller. An antifoaming agent, such as Hodag® FD82 may be added as needed.
Inoculum Preparation for BM123β and BM123γ
Primary shaker flask inoculum of Nocardia sp. NRRL 8050 is prepared by inoculating 100 milliliters of sterile liquid medium in 500 milliliter flasks with scrapings or washings of spores from an agar slant of the culture. The following medium is ordinarily used:
______________________________________Bacto-tryptone 5 gm.Yeast extract 5 gm.Beef extract 3 gm.Glucose 10 gm.Water to 1000 ml.______________________________________
The flasks were incubated at a temperature from 25°- 29° C., preferably 28° C. and agitated vigorously on a rotary shaker for 30 to 48 hours. The inocula are then transferred into sterile screw cap culture tubes and stored at below 0° F. This bank of vegetative inoculum is used instead of slant scrapings for inoculation of additional shaker flasks in preparation of this first stage of inoculum.
These first stage flask inocula are used to seed 12 liter batches of the same medium in 20 liter glass fermentors. The inoculum mash is aerated with sterile air while growth is continued for 30 to 48 hours.
The 12 liter batches of second stage inocula are used to seed tank fermentors containing 300 liters of the following sterile liquid medium to produce the thrid and final stage of inoculum:
______________________________________Meat solubles 15 gm.Ammonium sulfate 3 gm.Potassium phosphate, dibasic 3 gm.Calcium carbonate 1 gm.Magnesium sulfate heptahydrate 1.5 gm.Glucose 10 gm.Water to 1000 ml.The glucose is sterilized separately.______________________________________
The third stage inoculum is aerated at 0.4 to 0.8 liters of sterile air per liter of broth per minute, and the fermenting mixture is agitated by an impeller driven at 150-300 revolutions per minute. The temperature is maintained at 25°-29° C., usually 28° C. The growth is continued for 48 to 72 hours, at which time the inoculum is used to seed a 3000 liter tank fermentation.
Tank Fermentation for BM123β and BM123γ
For the production of BM123β and BM123γ in tank fermentors, the following fermentation medium is preferably used:
______________________________________Meat solubles 30 gm.Ammonium sulfate 6 gm.Potassium phosphate, dibasic 6 gm.Calcium carbonate 2 gm.Magnesium sulfate heptahydrate 3 gm.Glucose 20 gm.Water to 1000 ml.The glucose is sterilized separately.______________________________________
Each tank is inoculated with 5 to 10% of third stage inoculum made as described under inoculum preparation. The fermenting mash is maintained at a temperature of 25°-28° C. usually 26° C. The mash is aerated with sterile air at a rate of 0.3-0.5 liters of sterile air per liter of mash per minute and agitated by an impeller driven at 70 to 100 revolutions per minute. The fermentation is allowed to continue from 65-90 hours and the mash is harvested.
The invention will be described in greater detail in conjunction with the following specific examples.
EXAMPLE 1
Inoculum preparation for BM123β and BM123γ
A typical medium used to grow the first and second stages of inoculum was prepared according to the following formula:
______________________________________Bacto-tryptone 5 gm.Yeast extract 5 gm.Beef extract 3 gm.Glucose 10 gm.Water to 1000 ml.______________________________________
Two 500 milliliter flasks each containing 100 milliliters of the above sterile medium were inoculated with 5 milliliters each of a frozen vegetative inoculum from Nocardia sp. NRRL 8050. The flasks were placed on a rotary shaker and agitated vigorously for 48 hours at 28° C. The resulting flask inoculum was transferred to a 5 gallon glass fermentor containing 12 liters of the above sterile medium. The mash was aerated with sterile air while growth was carried out for about 48 hours, after which the contents were used to seed a 100 gallon tank fermentor containing 300 liters of the following sterile liquid medium:
______________________________________Meat solubles 15 gm.Ammonium sulfate 3 gm.Potassium phosphate, dibasic 3 gm.Calcium carbonate 1 gm.Magnesium sulfate heptahydrate 1.5 gm.Glucose 10 gm.Water to 1000 ml.The glucose is sterilized separately.______________________________________
The third stage of inoculum mash was aerated with sterile air sparged into the fermentor at 0.4 liters of air per liter of mash per minute. Agitation was supplied by a driven impeller at 240 revolutions per minute. The mash was maintained at 28° C. and Hodag® FD82 was used as a defoaming agent. After 48 hours of growing time the inoculum mash was used to seed a 3000 liter fermentation.
EXAMPLE 2
Fermentation Employing Nocardia sp. NRRL 8050 and Medium Favoring the Production of BM123β and BM123γ
A fermentation medium was prepared according to the following formula:
______________________________________Meat solubles 30 gm.Ammonium sulfate 6 gm.Potassium phosphate, dibasic 6 gm.Calcium carbonate 2 gm.Magnesium sulfate heptahydrate 3 gm.Glucose 20 gm.Water to 1000 ml.The glucose is sterilized separately.______________________________________
The fermentation medium was sterilized at 120° C. with steam at 20 pounds pressure for 60 minutes. The pH of the medium after sterilization was 6.9. Three thousand liters of sterile medium in a 4000 liter tank fermentor was inoculated with 300 liters of inoculum such as described in Example 1, and the fermentation was carried out at 26° C. using Hodag® FD82 as a defoaming agent. Aeration was supplied at the rate of 0.35 liter of sterile air per liter of mash per minute. The mash was agitated by an impeller driven at 70-72 revolutions per minute. At the end of 67 hours of fermentation time the mash was harvested.
EXAMPLE 3
Isolation of BM123β and BM128γ
A 3000 liter portion of fermentation mash prepared as described in Example 2, pH 4.3, was adjusted to pH 7.0 with sodium hydroxide and filtered using 5% diatomaceous earth as a filter aid. The cake was washed with about 100 liters of water and discarded. The combined filtrate and wash was pumped upward through three parallel 81/4 inches × 48 inches stainless steel columns each containing 15 liters of CM Sephadex® C-25 [Na + ] resin (a cross-linked dextran-epichlorohydrin cation exchange gel available from Pharmacia Fine Chemicals, Inc.). The charged columns were washed with a total of about 390 liters of water and then developed with 200 liters of 1% aqueous sodium chloride followed by 560 liters of 5% aqueous sodium chloride. The 5% aqueous sodium chloride eluate was clarified by filtration through diatomaceous earth and the clarified filtrate passed through a 9 inches × 60 inches glass column containing 25 liters off granular Darco® G-60 (20-40 mesh) (a granular activated carbon available from Atlas Chemical Industries, Inc.). The charged column was washed with 120 liters of water and then developed with 120 liters of 15% aqueous methanol followed by 340 liters of 50% aqueous methanol and then 120 liters of 50% aqueous acetone. The 15% aqueous methanol eluate was concentrated in vacuo to about 7 liters of an aqueous phase and the pH adjusted from 4.5 to 6.0 with Amberlite® IR-45 (OH - ) resin (a weakly basic polystyrene-polyamine type anion exchange resin). The resin was removed by filtration and the filtrate was concentrated in vacuo to about 1 liter and then lyophilized to give 38 grams of material consisting primarily of BM123β along with a small amount of BM123γ (primarily BM123γ 2 ). The 50% aqueous methanol eluate was adjusted from pH 4.65 to 6.0 with Amberlite® IR-45 (OH - ) resin. The resin was removed by filtration and the filtrate was concentrated in vacuo to about 6.3 liters and then lyophylized to give 213 grams of material consisting primarily of BM123γ. The 50% aqueous acetone eluate was adjusted from pH 4.0 to 6.0 with Amberlite® IR-45 (OH - ) resin. The resin was removed by filtration and the filtrate was concentrated in vacuo to about 1.5 liters and then lyophylized to give 56 grams of impure BM123γ.
EXAMPLE 4
Further Purification of BM123γ
A slurry of CM Sephadex® C-25 [NH 4 + ] in 2% aqueous ammonium chloride was poured into a 2.6 centimeter diameter glass column to a resin height of approximately 62 centimeters. The excess 2% aqueous ammonium chloride was drained away and a 5.0 gram sample of BM123γ prepared as described in Example 3 was dissolved in about 10 milliliters of 2% aqueous ammonium chloride and applied to the column. The column was then eluted with a gradient between 6 liters each of 2% and 4% aqueous ammonium chloride. Fractions of about 75 milliliters each were collected automatically every 15 minutes. Antibiotic BM123γ was located by monitoring the column effluent in the ultraviolet and by bioautography of dipped paper disks on large agar plates seeded with Klebsiella pneumoniae strain AD. The majority of BM123γ was located between fractions 71-107 inclusive.
One hundred thirty milliliters of granular Darco® G-60 (2040 mesh) was suspended in water, transferred to a glass column, allowed to settle and the excess water was allowed to drain away. Fractions 84-96 inclusive from the above CM Sephadex chromatography were combined and passed through the granular carbon column. The charged column was washed with 600 milliliters of water and then developed with 1 liter of 50% aqueous acetone. The eluates, both of which contained BM123β, were concentrated to aqueous phases in vacuo and lyophilized to give a total of 886 milligrams of BM123γ as the hydrochloride salt. A microanalytical sample was obtained by subjecting the above material to a repeat of the above process.
Antibiotic BM123γ does not possess a definite melting point, but gradual decomposition starts in the vicinity of 200° C. Microanalysis of a sample equilibrated for 25 hours in a 72° F. atmosphere containing 23% relative humidity gave C, 39.44%; H, 6.10%; N, 16.19%; Cl(ionic), 11.54%; loss on drying, 8.19%. In water BM123γ gave a U.V. absorption maximum at 286 nm with E 1cm 1% = 250. The position of this maximum did not change with pH. BM123γ had a specific rotation of [α] D 25 ° +71° (C = 0.97 in water).
Antibiotic BM123γ exhibited characteristic absorption in the infrared region of the spectrum at the following wavelengths: 770, 830, 870, 930, 980, 1035, 1105, 1175, 1225, 1300, 1340, 1370, 1460, 1510, 1555, 1605, 1660, 1740, 2950 and 3350 cm - 1. A standard infrared absorption spectrum of BM123γ prepared in a KBr pellet is shown in FIG. 1 of the accompanying drawings.
EXAMPLE 5
Isolation of BM123γ 1
A slurry of CM Sephadex® C-25 [Na + ] in 2% aqueous sodium chloride was poured into a 2.6 centimeter diameter glass column to a resin heigh of approximately 70 centimeters. The excess 2% aqueous sodium chloride was drained away and 4.11 gram of a sample containing primarily BM123γ 1 along with some BM123γ 2 and other impurities, prepared as described in Example 3, was dissolved in about 10 milliliters of 2% aqueous sodium chloride and applied to the column. The column was then eluted with a gradient between 4 liters each of 2% and 4% aqueous sodium chloride. Fractions of about 75 milliliters each were collected automatically every 15 minutes. Antibiotic BM123γ was located by monitoring the column effluent in the ultraviolet and by bioautography of dipped paper disks on large agar plates seeded with Klebsiella pneumoniae strain AD. The majority of BM123γ was located between fractions 64-90 inclusive; the initial fractions (64-80) contained a mixture of BM123γ 1 and BM123γ 2 whereas the later fractions (81-90) contained essentially pure BM123γ 1 .
One hundred milliliters of granular Darco® G-60 (20-40 mesh) was suspended in water, transferred to a glass columm, allowed to settle and the excess water was allowed to drain away. Fractions 81-90 inclusive from the above CM Sephadex chromatography were combined and passed through the granular carbon column. The charged column was washed with 500 milliliters of water and then developed with 500 milliliters of 10% aqueous methanol followed by 1 liter of 50% aqueous methanol. The 50% aqueous methanol eluate, which contained the majority of BM123γ 1 , was adjusted from pH 5.9 to 6.0 with Amberlite® IR-45(OH -1 ) resin. The resin was removed by filtration and the filtrate was concentrated in vacuo to an aqueous phase and lyophilized to give 294 milligrams of white amorphous BM123γ 1 as the hydrochloride salt.
Antibiotic BM123γ 1 does not possess a definite melting point, but gradual decomposition starts in the vicinity of 200° C. Microanalysis of a sample equilibrated for 24 hours in a 70° F. atmosphere containing 60% relative humidity gave C, 37.84%; H, 5.73%; N, 15.58%; Cl(ionic), 10.01%, loss on drying 10.45%. In methanol BM123γ 1 gave a U.V. absorption maximum at 286 nm with E 1cm 1% = 225. The position of this maximum did not change with pH. BM123γ 1 had a specific rotation of +55° (C=0.803 in water).
Antibiotic BM123γ 1 exhibited characteristic absorption in the infrared region of the spectrum at the following wavelengths: 770, 830, 870, 930, 980, 1045, 1080, 1110, 1125, 1175, 1225, 1305, 1345, 1380, 1465, 1515, 1560, 1605, 1660, 1730, 2950 and 3350 cm -1 . A standard infrared absorption spectrum of BM123γ 1 prepared in a KBr pellet is shown in FIG. 2 of the accompanying drawings. A standard proton magnetic resonance spectrum of BM123γ 1 determined on a D 2 O solution in a 100 megacycle spectrometer is shown in FIG. 4 of the accompanying drawings.
EXAMPLE 6
Isolation of BM123γ 2
A 25 gram sample containing primarily BM123γ 2 and BM123β, prepared as described in Example 3, was dissolved in about 120 milliliters of 2% aqueous sodium chloride and applied to a column containing 1800 ml. of CM Sephadex® C-25 [Na + ] in 2% aqueous sodium chloride. The column was then eluted with a gradient between 20 liters each of 2% and 4% aqueous sodium chloride. The initial 12 liters of eluate was collected in a large bottle and discarded. Thereafter fractions of about 800 milliliters each were collected automatically every 40 minutes. Antiobiotic BM123γ was located by monitoring the column fractions in the ultraviolet. The majority of BM123γ was located between fractions 7-19 inclusive; the initial fractions (7-15) contained essentially pure BM123γ 2 and the later fractions (16-18) contained a mixture of BM123γ 1 and BM123γ 2 .
Six hundred milliliters of granular Darco® G-60 (20-40 mesh) was suspended in water, transferred to a glass column, allowed to settle and the excess water was allowed to drain away. Fractions 7-15 inclusive from the above CM Sephadex chromatography were combined and passed through the granular carbon column. The charged column was washed with 3 liters of water and then developed with 3 liters of 10% aqueous methanol followed by 6 liters of 50% aqueous methanol. The 10% aqueous methanol eluate was adjusted from pH 5.8 to 6.0 with Amberlite® IR 45 (OH - ) resin. The resin was removed by filtration and the filtrate was concentrated in vacuo to an aqueous phase and lyophilized to give 595 milligrams of white amorphous BM123γ 2 as the hydrochloride salt. The 50% aqueous methanol eluate was adjusted from pH 4.6 to 6.1 with Amberlite® IR 45 (OH - ) resin. The resin was removed by filtration and the filtrate was concentrated in vacuo to an aqueous phase and lyophilized to give 3.645 grams of slightly less pure white amorphous BM123γ 2 as the hydrochloride salt.
Antibiotic BM123γ 2 does not possess a definite melting point, but gradual decomposition starts in the vicinity of 200° C. Microanalysis of a sample equilibrated for 24 hours in a 70° F. atmosphere containing 60% relative humidity gave C, 36.14%; H, 5.67%, N, 15.1%; Cl(ionic), 11.11%; loss on drying 10.87%. In methanol BM123γ 2 gave a U.V. absorption maximum at 286 nm with E 1cm 1% = 220. The position of this maximum did not change with pH. BM123γ 2 had a specific rotation of +60° (C=0.851 in water).
Antibiotic BM123γ 2 exhibited characteristic absorption in the infrared region of the spectrum at the following wavelengths: 770, 830, 870, 950, 1035, 1110, 1175, 1225, 1285, 1345, 1380, 1470, 1515, 1560, 1605, 1660, 1755, 2950 and 3350 cm -1 . A standard infrared absorption spectrum of BM123γ 2 prepared in a KBr pellet is shown in FIG. 3 of the accompanying drawings. A standard proton magnetic resonance spectrum of BM123γ 2 determined on a D 2 O solution in a 100 megacycle spectrometer is shown in FIG. 5 of the accompanying drawings.
EXAMPLE 7
Paper Partition and Thin Layer Chromatography of BM123β and BM123γ
the BM123 antibiotics can be distinguished by paper chromatography. For this purpose Whatman No. 1 strips were spotted with a water or methanol solution of the substances and equilibrated for 1 to 2 hours in the presence of both upper and lower phases. The strips were developed overnight with the lower (organic) phase obtained from mixing 90% phenol:m-cresol:acetic acid:pyridine:water (100:25:4:4:75 by volume). The developed strips were removed from the chromatographic chamber, air dried for 1 to 2 hours, washed with ether to remove residual phenol and bioautographed on large agar plates seeded with Klebsiella peunmoniae strain AD. Representative Rf values are listed in Table VII below:
TABLE VII______________________________________Component RF______________________________________BM123γ 0.85BM123β 0.50, 0.70______________________________________
The β component was a mixture of two antibiotics using this system. BM123β was composed of a major antibiotic (Rf = 0.50) called BM123β 1 and a minor antibiotic (Rf = 0.70) called BM123β 2 .
The BM123 antibiotics can also be distinguished by thin layer chromatography. For this purpose pre-coated Cellulose F® plates (0.10 millimeters thick), a form of thick layer cellulose supplied by EM Laboratories Inc., Elmsford, N.Y. were spotted with a water solution of the substance to be chromatographed (about 20-40 micrograms per spot). The plates were developed overnight with the solvent obtained by mixing 1-butanol:water:pyridine:acetic acid (15:12:10:1 by volume). The developed plates were removed from the chromatographic chamber and air dried for about 1 hour. The antibiotics were detected by using either standard ninhydrin or Sakaguchi spray reagents. Representative Rf values are listed in Table VIII below:
TABLE VIII______________________________________Component Rf______________________________________BM123γ 0.17, 0.23BM123β 0.08, 0.14______________________________________
Both BM123β and γ were a mixture of two components using this system. BM123β was composed of a major component (Rf = 0.08) which was BM123β 1 and a minor component (Rf = 0.14) which was BM123β 2 . The less polar component of BM123γ (Rf = 0.23) was BM123γ 1 and the more polar component (Rf = 0.17) was BM123γ 2 .
EXAMPLE 8
General Procedure for Reductive Alkylation of Antibiotic BM123γ
To a stirred solution of 100 mg. of antibiotic BM123γ in 20 ml. of methanol is added 5 ml. (or 5 g.) of the appropriate aldehyde or ketone and 100 mg. of sodium cyanoborohydride. The pH of the resulting solution is maintained at about 7.0 with 0.1N methanolic hydrogen chloride over a 3 to 24 hour period. The reaction is monitored by thin layer chromatography to the disappearance of the BM123γ. The reaction mixture is then filtered and the filtrate is evaporated to dryness. The residue is triturated with 3 ml. of methanol and filtered. The filtrate is diluted with 50 ml. of acetone and the precipitate which forms is removed by filtration and dried. The methanol solvent may be replaced by 20 ml. of water wherever the starting aldehyde or ketone is water soluble.
EXAMPLE 9
Preparation of methyl-BM123γ
To a solution of 1.0 g. of BM123γ and 2.5 ml. of a 37% aqueous formaldehyde solution in 50 ml. of water was added, portionwise, 400 mg. of sodium cyanoborohydride. The pH of the reaction mixture was maintained at 7.0 with 1N hydrochloric acid during this addition. The reaction mixture was stirred an additional ten minutes at room temperature and then evaporated to dryness to vacuo. The residue was triturated with 20 ml. of methanol, filtered and the filtrate diluted with 250 ml. of acetone. The product which precipitated was removed by filtration and dried; yield, 667 mg.
EXAMPLE 10
Preparation of isopropyl-BM123γ
To a solution of 200 mg. of BM123γ in 30 ml. of methanol was added 5 ml. of acetone. To this solution was added 139 mg. of sodium cyanoborohydride and the reaction mixture was stirred at room temperature for 30 minutes. During this time the pH of the reaction mixture was maintained between 7.4 and 7.8 by the addition of 0.1N methanolic hydrogen chloride. The small amount of precipitate which had formed was removed by filtration and the filtrate was evaporated to dryness in vacuo. The residue was triturated with two ml. of methanol and filtered. The filtrate was diluted with 100 ml. of acetone and the solid product that separated was removed by filtration and dried; yield, 184 mg.
EXAMPLE 11
Preparation of β-phenylethyl-BM123γ
To a solution of 200 mg of BM123γ in 15 ml. of water and 25 ml. of acetonitrile was added a solution of 2 ml. of phenylacetaldehyde in 4 ml. of ethanol. To this was added 103 mg. of sodium cyanoborohydride. The reaction mixture was stirred at room temperature for 30 minutes during which time the pH of the mixture was maintained at 7 with 0.2N hydrochloric acid. The reaction mixture was then filtered and the filtrate was evaporated to dryness in vacuo. The residue was triturated with two ml. of methanol and filtered. The filtrate was diluted with 100 ml. of acetone and the product that separated was removed by filtration and dried; yield, 180 mg.
EXAMPLE 12
Preparation of 1,3,3-trimethylbutyl-BM123γ
To a solution of 200 mg. of BM123γ hydrochloride in 50 ml. of methanol was added 3 ml. of 4,4-dimethyl-2-pentanone and 106 mg. of sodium cyanoborohydride. The reaction solution was maintained at pH 7 by the dropwise addition of methanolic hydrogen chloride. The reaction was stirred at room temperature for 18 hours and filtered. The filtrate was evaporated to dryness in vacuo. The residue was dissolved in 3 ml. of methanol, diluted with 50 ml. of acetone and filtered, yield 125 mg.
EXAMPLE 13
Preparation of 1-methylphenethyl-BM123γ
To a solution of 200 mg. of BM123γ in 50 ml. of methanol was added 5 ml. of phenylacetone. To this solution was added 170 mg. of sodium cyanoborohydride and the reaction mixture stirred at room temperature for 3 and a half hours. During this time the pH of the reaction mixture was maintained at 7.0 with methanol saturated with hydrogen chloride gas. Reaction mixture was concentrated to about 5 ml. volume, diluted with two ml. of methanol, and filtered. Filtrate was poured into 100 ml. of acetone and the solid product that separated was removed by filtration and dried; yield, 233 mg.
EXAMPLE 14
Preparation of 1-methylnonyl-BM123γ
Sodium cyanoborohydride (100 mg.) was added to a solution of BM123γ (200 mg.) and 2-decanone (1 ml.) in 40 ml. of methanol. The pH of the solution was adjusted to 7.0 and maintained at 7.0 ± 0.2 by the addition of 0.1N methanolic hydrogen chloride as necessary. After 19.5 hours the reaction mixture was filtered and the filtrate was concentrated in vacuo at 35° C. The residue was slurried in 5 ml. of methanol and filtered. The filtrate was added to 50 ml. of acetone. The off white solid which precipitated was collected by filtration, washed with acetone, and dried in vacuo. The yield of crude 1-methylnonyl-BM123γ was 167 mg.
EXAMPLE 15
Preparation of 1,3-dimethylbutyl-BM123γ
To a solution of 210 mg. of BM123γ in 50 ml. of methanol was added 5 ml. of methyl isobutyl ketone. To this solution was added 166 mg. of sodium cyanoborohydride and the reaction mixture strired at room temperature for five hours. During this time the pH of the reaction mixture was maintained at 7.0 with methanol saturated with hydrogen chloride gas. Reaction mixture was evaporated to dryness, in vacuo. The residue was triturated with two ml. of methanol and filtered. The filtrate was diluted with 100 ml. of acetone and the solid product that separated was removed by filtration and dried; yield, 210 mg.
EXAMPLE 16
Preparation of 2-norbornyl-BM123γ
Sodium cyanoborohydride (100 mg.) was added to a solution of BM123γ (200 mg.) and 2-norbornanone (400 mg.) in 40 ml. of methanol. The pH of the solution was adjusted to 7.0 with 0.1N methanolic hydrogen chloride. The pH was maintained at 7.0 ± 0.2 by the addition of 0.1N hydrogen chloride as necessary. After 21.5 hours the reaction mixture was filtered and the filtrate was concentrated in vacuo at 35° C. The residue was slurried in 5 ml of methanol and filtered. The filtrate was added to 50 ml. of acetone. The off white solid which precipitated was collected by filtration, washed with acetone and dried in vacuo. The yield of crude 2-norbornyl-BM123γ was 175 mg.
EXAMPLE 17
Preparation of isopropyl-BM123γ 1
A mixture of 50 mg. of BM123γ 1 , 5 ml. of acetone and 60 mg. of sodium cyanoborohydride in 35 ml. of methanol was stirred at room temperature for 40 minutes. The pH of the solution was maintained at 7 by the dropwise addition of a methanolic hydrogen chloride solution. The mixture was evaporated to dryness in vacuo. The residue was triturated with 5 ml. of methanol and the resulting solution was diluted with 50 ml. of acetone; yield, 49 mg.
EXAMPLE 18
Preparation of isopropyl-BM123γ 2
A mixture of 41 mg. of BM123γ 2 , 5 ml of acetone and 50 mg. of sodium cyanoborohydride in 35 ml. of methanol was stirred at room temperature for 40 minutes. The pH of the solution was maintained at 7 by the dropwise addition of a methanolic hydrogen chloride solution (saturated). The mixture was filtered and evaporated to dryness in vacuo. The residue was triturated with 5 ml. of methanol and the resulting solution was diluted with 50 ml. of acetone; yield, 46 mg.
EXAMPLE 19
Preparation of 1-methyl-2-phenyl-ethyl-BM123γ 2
A mixture of 200 mg. of BM123γ 2 , 5 ml of phenylacetone and 170 mg. of sodium cyanoborohydride in 50 ml. of methanol was stirred at room temperature for 3 hours and 45 minutes. During this time the pH of the reaction mixture was maintained at 7 with dropwise addition of a methanolic hydrogen chloride solution (saturated). The mixture was evaporated to dryness in vacuo. The residue was triturated with 5 ml. of methanol and the resulting methanol solution was diluted with approximately 50 ml. of acetone; yield 233 mg.
EXAMPLE 20
Preparation of (2-ethylcyclopentyl) BM123γ
A solution of 200 mg. of BM123γ, 3 ml. of 2-ethylcyclopentanone and 101 mg. of sodium cyanoborohydride in 50 ml. of methyl alcohol was stored at room temperature for 18 hours. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction mixture was evaporated to dryness. The residue was triturated with 3 ml. of methanol, filtered and the filtrate was diluted with 40 ml. of acetone, yield, 157 mg.
EXAMPLE 21
Preparation of 3,5-dimethylcyclohexyl BM123γ
A solution of 200 mg. of BM123γ, 5 ml. of 3,5-dimethylcyclohexanone and 200 mg. of sodium cyanoborohydride in 50 ml. of methanol was stored at room temperature for 1 hour. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction was triturated with 3 ml. of methanol, filtered and the filtrate was diluted with 40 ml. of acetone, yield 200 mg.
EXAMPLE 22
Preparation of 2,4-dimethylcyclopentyl BM123γ
A solution of 206 mg. of BM123γ, 3 ml. of 2,4-dimethylcyclopentanone and 104 mg. of sodium cyanoborohydride in 50 ml. of methanol was stored at room temperature for 6 hours. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction was triturated with 3 ml. of methanol, filtered and the filtrate was diluted with 40 ml. of acetone, yield 101 mg.
EXAMPLE 23
Preparation of 2-ethylcyclohexyl BM123γ
A solution of 200 mg. of BM123γ, 5 of 2-ethylcyclohexanone and 213 mg. of sodium cyanoborohydride in 50 ml. of methanol was stored at room temperature for 3 hours. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction was triturated with 3 ml. of methanol, filtered and the filtrate was diluted with 40 ml. of acetone, yield 200 mg.
EXAMPLE 24
Preparation of 3-methylcyclohexyl BM123γ
A solution of 200 mg. of BM123γ, 1.5 ml. of 3-methylcyclohexanone and 200 mg. of sodium cyanoborohydride in 50 ml. of methanol was stored at room temperature for 2 hours. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction was triturated with 3 ml. of methanol, filtered and the filtrate was diluted with 40 ml. of acetone, yield 200 mg.
EXAMPLE 25
Preparation of 2,4,4-trimethylcyclopentyl BM123γ
A solution of 200 mg. of BM123γ, 5 ml. of 2,4,4-trimethylcyclopentanone and 179 mg. of sodium cyanoborohydride in 50 ml. of methanol was stored at room temperature for 24 hours. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction was triturated with 3 ml. of methanol, filtered and the filtrate was diluted with 40 ml. of acetone, yield 176 mg.
EXAMPLE 26
Preparation of 2-propylcyclohexyl BM123γ
A solution of 200 mg. of BM123γ, 3 ml. of 2-propylcyclohexanone and 157 mg. of sodium cyanoborohydride in 50 ml. of methanol was stored at room temperature for 4 hours. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction was triturated with 3 ml. of methanol, filtered an the filtrate was diluted with 40 ml. of acetone, yield 75 mg.
EXAMPLE 27
Preparation of 2-methylcyclopentyl BM123γ
A solution of 211 mg. of BM123γ, 3 ml. of 2-methylcyclopentanone and 98 mg. of sodium cyanoborohydride in 50 ml. of methanol as stored at room temperature for 3.5 hours. During this time the pH of the solution was maintained at 7 with the addition of a saturated solution of hydrogen chloride in methanol. The reaction was triturated with 3 ml. of methanol, filtered and the filtrate was diluted with 40 ml. of acetone, yield 157 mg. | This disclosure describes a novel series of potent antibacterial agents derived by reductive alkylation of antibiotic BM123γ with certain classes of aldehydes and ketones. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for identification and analyzing collagen quantitatively.
BACKGROUND OF THE INVENTION
[0002] Collagen extensively and massively exists in the extracellular matrix of connective tissues of animals. A research report (Moseley et al., 2004, Br J Dermatol 150:401-413) points out that collagen may function as a biological marker of disease activity or therapy prognosis. Another research report (Ruszczak, Z., 2003, Adv Drug Deliv Rev 55:1595-1611) points out that collagen scaffold may function as the regenerative environment of cells. Thus, how to accurately detect the quantity of collagen and estimate the rates of reconstruction and degradation of collagen becomes an important subject for the clinical application of collagen.
[0003] The conventional methods for quantitatively analyzing collagen include the colorimetric analysis (Stegemann et al., 1967, Clin Chim Acta 18:267-273; Moore, S., 1968, J Biol Chem 243:6281-6283), the high performance liquid chromatography (HPLC), the liquid chromatography tandem mass spectrometry (MS) (Ikeda et al., 1993, J Chromatogr 621:133-138; Kindt et al., 2000, Anal Biochem 283:71-76), and the enzyme linked immunosorbent assay (ELISA) (Bellon, G., 1985, Anal Biochem 150:188-202). However, the abovementioned methods are very complicated and expensive. Therefore, they are not ideal methods for identifying and analyzing collagen quantitatively.
[0004] Compared with the abovementioned methods, the capillary electrophoresis is a simpler method for analyzing collagen quantitatively (Deyl, Z & Adam, M, 1989, J Chromatogr 488:161-197; Novotna et al., 1996, J Chromatogr B Biomed Appl 681:77-82; Deyl et al., 1997, J Chromatogr B Biomed Sci Appl 689:181-194; Chalmers, et al., 1999, J Chromatogr Sci 37:443-447). The capillary electrophoresis covers both advantages of electrophoresis and chromatography and can be automated. Therefore, it has been widely used to analyze and identify molecules. In capillary electrophoresis, a voltage is applied to the sample containing different molecules inside a capillary, and different molecules are separated by different electrophoretic mobility and electro-osmotic flow thereof. The silanol groups on the inner wall of the capillary will be dissociated and slightly negatively charged in the solution inside the capillary, particularly in an acidic solution. The negative charges will attract the cations and make the cations distributed on the capillary. When a voltage is applied to the capillary, the cations attached to the inner wall of the capillary will be attracted to the negative pole. The aggregated cations result in viscosity, which will drag the entire solution inside the capillary toward the negative pole and cause a bulk flow of the solution, i.e. the so-called electroosmotic flow. Because of the electrophoretic mobility difference and the electroosmotic flow, the capillary electrophoresis method has a high resolution and a high separation effect. Further, the capillary electrophoresis needs only a small amount of sample because the capillary functions as the electrophoresis path.
[0005] In the conventional capillary electrophoresis technology for analyzing collagen quantitatively, the sample should be purified, extracted, and then processed with cyanogen bromide (CNBr) (Deyl, Z & Adam, M, 1989, J Chromatogr 488:161-197; Deyl et al., 1997, J Chromatogr B Biomed Sci Appl 689:181-194; Deyl et al. 1999, J Chromatography A, 852:325-336) or enzymes such as collagenase (Ivan Mik{hacek over ( )}s'ik et al. 2006, J Chromatography B, 841:3-13) to obtain polypeptide fragments. The cyanogen bromide enables the cracking reaction of the methionine on the amino acid sequences of protein, and the products of the cracking reaction are analyzed with the capillary electrophoresis method. The collagen cracking reaction is time-consuming and prolongs the process of the collagen analysis. The cyanogen bromide is a toxic material and needs processing and disposing carefully. After purified and extracted, the sample may be processed with enzyme. For example, Harada (Bull. Chem. Soc. Jpn. vol. 69, 1996, pp. 3575-3579) discloses a capillary electrophoresis method for quantitatively identifying the different polypeptides of the collagen. Harada uses commercial pepsin-solubilized collagens (PSCs) as samples, and further digested with pepsin to decrease the telopeptide region. Besides, Harada also discloses a capillary which has a non-charged layer (Brij 35). The Brij is a nonionic surfactant, and it would bind to the polypeptide to form a micelle without carrying any charge. The results of Harada show that a good peak separation for each polypeptide was achieved at pH 5.6-6.5 reflecting various residues of telopeptide. Further, the pretreatments, such as extraction and cracking, should inevitably reduce the total amount of collagen and thus affect the quantitative result of the capillary electrophoresis analysis. Another example is done by Eckhardt (Adam Eckhardt et al., 2004, Journal of Chromatography A, 1051:111-117) and he discloses a capillary electrophoretic system using alkylamines containing background electrolytes at acid pH. To be specific, Eckhardt discloses an analytical buffer with amines, and mix the analytical buffer with different peptides of collagens to form a mixed sample. After that, Eckhardt drives the mixed sample through the capillary and decreases the effects of electro-osmotic flow via the amines with positive charges result in separating the different peptides to measure each amount of peptides. This kind of process “dynamic coating” also can only measure each amount of different peptides with the inevitable reduction and errors on the quantity of total collagen. There are errors while accounting each amount of different peptides, so that when you sum the total amount of each peptide to calculate the total amount of collagen, there is a bigger error. Therefore, it is not accurate enough to measure total amount of collagen via the above methods.
[0006] In addition, there are some methods without cracking the native collagen such as the method from Zhang (Jing Zhang et al., 2004, Electrophoresis 25, 3416-3421). Zhang discloses a quantitative measurement of methylated collagen by capillary electrophoresis which proposes an index to quantify the degree of collagen methylation that also correlates with their effects on cell proliferation. Zhang uses a polyvinyl alcohol-coated fused-silica capillary and a phosphate buffer having 0.05% hydroxypropylmthylcellulose to quantify the collagens in which their carboxylic groups were esterified to obtain methylated collagens. In the results of Zhang, the methylated collagens were separated into different peaks using the phosphate buffer with 0.05% hydroxypropylmthylcellulose. Even if Zhang did not crack collagens as the analyte, Zhang can only quantify different methylated collagen respectively with his esterification pretreatment and separation condition rather than quantify the total amount of collagen.
[0007] With regard to the novelty, obviousness, and industrial application, an optimal condition for capillary electrophoresis method to identify collagen as a single peak in the chromatogram is required without pretreatment, extraction, purification or further processing the collagen containing sample. Yet, the single peak in the chromatogram can offer an accurate quantification way for total collagen.
SUMMARY OF THE INVENTION
[0008] The primary objective of the present invention is to simplify the analysis process of collagen using the capillary electrophoresis method and shorten the analysis time. To achieve the abovementioned objective, the present invention proposes a capillary electrophoresis method for identification and analyzing collagen without cracking into peptides quantitatively in a sample. The method of the present invention comprises steps: dissolving a collagen-containing sample in an acidic solution to form an acidic sample solution; preparing a capillary with the inner wall thereof pre-coated with positively-charged compounds and preferably with an amine group; introducing the acidic sample solution into the capillary containing an analytical solution to elute or separate collagen from other components; and driving the acidic sample solution to pass through the capillary. Preferably, the analytical solution contains phosphate buffer. Preferably, the analytical solution is sodium dihydrogen phosphate buffer solution. The resulting chromatogram has collagen in a single peak no matter types of collagen or with mixed types of collagen.
[0009] In comparison to the conventional capillary electrophoresis technology for analyzing collagen quantitatively, the present invention does not need to pre-treat the sample with cyanogen bromide or any enzyme but dissolve the sample directly in an acidic solution, whereby the present invention can greatly reduce the operation time for collagen identification and quantification, and whereby the present invention is exempt from the extraction process and the cracking process, wherefore less collagen is lost in the analysis process, and more accurate result is attained by the capillary electrophoresis method of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a chromatogram obtained from simultaneously detecting various types of collagen and other proteins according to the present invention.
[0011] FIG. 2A is a diagram showing the linear regression of the peak areas obtained from detecting collagen with concentrations between 0 and 60 ng according to the present invention;
[0012] FIG. 2B is a diagram showing the linear regression of the peak areas obtained from detecting collagen with concentrations between 0 and 300 ng according to the present invention; and
[0013] FIG. 3 is an electrophoresis chromatogram obtained in detecting collagen along and collagen with different concentrations of CTAB according to the present invention.
[0014] FIG. 4 is an electrophoresis chromatogram obtained in detecting collagen with 12 kD HA and collagen with 12 kD HA and different concentrations of CTAB according to the present invention.
[0015] FIG. 5 is an electrophoresis chromatogram obtained in detecting collagen with 780 kD HA and collagen with 780 kD HA and different concentrations of CTAB according to the present invention.
[0016] FIG. 6 is an electrophoresis chromatogram obtained in detecting collagen with 1500 kD HA and collagen with 1500 kD HA and different concentrations of CTAB according to the present invention.
[0017] FIG. 7 is an electrophoresis chromatogram obtained in detecting collagen along and collagen with different concentrations of chitosan according to the present invention.
[0018] FIG. 8 is an electrophoresis chromatogram obtained in detecting collagen with 12 kD HA and collagen with 12 kD HA and different concentrations of chitosan according to the present invention.
[0019] FIG. 9 is an electrophoresis chromatogram obtained in detecting collagen with 780 kD HA and collagen with 780 kD HA and different concentrations of chitosan according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention provides a capillary electrophoresis method for identification and analyzing collagen quantitatively, wherein a capillary electrophoresis system is used to separate and analyze the sample. The capillary electrophoresis system has an autosampler and at least one kind of wavelength detectors, such as an ultraviolet detector with choice of the detection wavelength. The autosampler includes at least one capillary or micro-channel. The capillary is filled with an analytical buffer solution and equipped with a driving-voltage device at two ends thereof. The operation of the autosampler includes a capillary flushing step, a pneumatic sample injection step, and a sample movement step within the capillary.
[0021] The buffer solutions used in the present invention contains an acid solution to effectively dissolve the collagen in the sample and an analytical buffer solution to separate collagen from other components in the capillary, whereby the capillary electrophoresis analysis can have stable results and a single peak indicating collagen can appear in the chromatogram. Both buffer solutions have a pH range between 0.5 to 7.0, preferably between pH 1.0 to 6.0. A better pH for both buffer solutions is about 2-3. The acidic buffer composition comprises at least one acid. The acid component of the buffer can be an inorganic or an organic acid or mixtures thereof. The buffer solution may contain the following components: phosphoric acid solutions, alkali phosphate solutions (such as a sodium dihydrogen phosphate solution), alkali chloride solutions (such as a hydrochloric acid/potassium chloride solution), amino acid solutions (such as a glycine/hydrochloric acid), citric acid solutions (such as a citric acid/sodium citrate), formic acid solutions, acetic acid solutions (such as sodium acetate/acetic acid solution), propionic acid solutions, butyric acid solutions, oxalic acid solutions, tartaric acid solutions, Shikimic acid solutions, and o-phthalic acid solutions (such as a potassium hydrogen phthalate/hydrochloric acid solution). However, the present invention does not limit the buffer solution to have to contain the abovementioned components or only contain the above-mentioned solutions.
[0022] The capillary used in the present invention may be a capillary having a positively-charged layer pre-coated on the inner wall thereof, particularly an amine capillary having a polymerized amine compound coated on the inner wall thereof. The positively-charged layer can be physically adsorbed or covalently bonded with positively-charged molecules. A great attention of the positively-charged molecules is thru that of amino modification. The amino modifier comprises a vast numbers of compounds, starting from monoamines, such as triethylamine and propylamine, morpholine, N,N-diethylethanolamine, triethanolamine, as well as the quaternary base tetramethylamonium chloride; diamines, such as 1,3 diaminopropane and ethylenediamine; polyamines, such as chitosan, polylysine, protamines, polyethyleneimine, etc. The amine compound may be a primary amine compound or a material containing ammonium ions. The flushing or pneumatic injection of the capillary will be undertaken in the autosampler of the capillary electrophoresis system.
[0023] The collagen sample used in the present invention is sourced from the collagen purified in the laboratory, a commercial available collagen in various forms or as a component of food, cosmetics, medical devices, etc., or the collagen from connective tissues of human beings or animals. The connective tissues may come from skin, intestine, cartilage, tendon, sponge bone, compact bone, and so on. The animal tissue is washed and then cut into pieces. The cut tissue is processed for water content analysis to obtain a dried sample. The dried sample is freeze-ground to obtain a sample, powder. Alternatively, the dried sample is dissolved in an appropriate acidic solution to obtain a sample solution.
[0024] To define the range in which the capillary electrophoresis method of the present invention can detect, the samples containing different concentrations of a single type of collagen or multiple types of collagens are respectively injected into the capillaries for analysis. Furthermore, the collagen can be a mixed types of collagen, a denatured collagen, a gelatin, or a mixture of denatured collagen and gelatin, wherein the gelatin has different bloom numbers or molecular weights. The peak areas are obtained by integration and the linear relationship of concentrations is determined to establish the standard curve.
[0025] The technical contents of the present invention are described below in details. However, the description is only to demonstrate the present invention but not to limit the scope of the present invention.
[0026] In the specification of the present invention, the Beckman P/ACE TE MDQ or PA800 or PA800plus instrument system is used to exemplify the capillary electrophoresis system. The instrument system includes an autosampler, a UV (ultraviolet) detector able to select the detection wavelength, a full-wavelength range PDA (Photodiode Array) detector, and an LIF (Laser Induced Fluorescence) detector. The light source of the UV detector and the full-wavelength range PDA detector is a deuterium lamp emitting light having a wavelength from 190 to 360 nm and the former is equipped with four filters for the wavelengths of 200 nm, 214 nm, 254 nm and 280 nm. The light source of the LIF detector is an argon laser having a wavelength of 488 mm and a diode laser having a wavelength of 635 nm. The autosampler has at least one capillary (or micro-channel) filled with an analytical buffer solution and a driving-voltage device arranged at two ends thereof.
[0027] Below are described the embodiments of the present invention and the test results.
Embodiment I
Collagen Specificity Analysis of the Capillary Electrophoresis Method
[0028] Prepare a sample of 10 μL of 1 mg/mL collagen solution containing phenylmethanol, wherein the collagen includes type I, II, III, IV, and V. Prepare a sample of a mixed solution of 10 μl of 1 mg/mL albumin and protein mixture (Beckman Cat. No. 477436), wherein the latter contains ribonuclease A, cytochrome C and lysozyme. The abovementioned samples are injected into an amine capillary (a product of Beckman USA and having an inner diameter of 50 μm, an outer diameter of 360 μm and a length of 65 cm) with an injection pressure of 2 psi and an injection time of 6 seconds. The capillary electrophoresis analysis of the abovementioned samples is undertaken in a sodium dihydrogen phosphate solution having a concentration of 50 mM and an acidity of pH2.5, at a temperature of 25° C., under an electrophoresis voltage of −25 KV, and with an UV absorption wavelength of 214 nm. The analysis result is shown in FIG. 1 . The peaks of phenylmethanol, collagen, ribonuclease A, albumin, cytochrome C and lysozyme sequentially appear in the migration time axis, which means that the capillary electrophoresis method of the present invention has a pretty high specificity in identifying collagen and can effectively measure the total amount of collagen.
Embodiment II
The Sensitivity of the Capillary Electrophoresis Method and the Standard Curve Analysis
[0029] To define the range the capillary electrophoresis method of the present invention can detect and to establish the standard curve for collagen analysis, different amounts of type I collagen are injected into an amine capillary (a product of Beckman USA and having an inner diameter of 50 μm, an outer diameter of 360 μm and a length of 65 cm) with an injection pressure of 2 psi and an injection time of 6 seconds. The type I collagen samples have amounts of 276.8, 207.6, 138.4, 83.6, 76.14, 69.21, 55.37, 54.58, 47.46, 41.53, 35.59, 33.22, 27.76, 23.73, 17.79, 13.76, 11.86, 6.29, 4.88, 3.46, 2.76, 1.73, 1.37, 1.09, 0.9, 0.46, 0.27, 0.16, 0.13, 0.09, 0.06, 0.05 ng respectively. The capillary electrophoresis analyses are undertaken in a sodium dihydrogen phosphate buffer solution having a concentration of 50 mM and an acidity of pH2.5, at a temperature of 25° C., under an electrophoresis voltage of −25 KV, and with an UV absorption wavelength of 214 nm. The peak areas are obtained by integration and the linear relationship of concentrations is determined to establish the standard curve.
[0030] The results of the abovementioned tests are shown in FIG. 2A and FIG. 2B . The maximum and minimum amounts of collagen detected by the capillary electrophoresis method of the present invention are 276.8 ng and 0.05 ng respectively. Therefore, the capillary electrophoresis method of the present invention has a larger detection range than the conventional technology. Furthermore, a linear relationship is obtained between the peak area and the collagen content. When the sample containing 0.05 ng of collagen is tested for 20 times successively, the average value of peak areas, the standard deviation, and the relative standard deviation of the peak areas are 14379, 940 and 6.5% respectively. Therefore, the capillary electrophoresis method of the present invention has high reproducibility and reliability. As the relative standard deviation in detecting 0.05 ng of collagen is lower than 15%, 0.05 ng may be used as the detection sensitivity of the capillary electrophoresis method of the present invention.
Embodiment III
Quantitative Analysis of Collagen in Connective Tissue
[0031] The connective tissues used in the tests may come from skin, intestines, cartilage, tendon, sponge bone or compact bone of pigs. All the connective tissues are divided into four groups of samples. The four groups of samples are analyzed respectively with (a) a hydroxypro line colorimetric reaction method, (b) a first capillary electrophoresis method for hydroxyproline detection, (c) a second capillary electrophoresis method for hydroxyproline detection, and (d) the capillary electrophoresis method of the present invention for collagen analysis.
[0032] Firstly, the redundant fat and muscle is removed from the connective tissues of pigs. Next, the connective tissues are flushed with pure water and a phosphate solution to remove blood and dirt. The connective tissues are then cut into tiny pieces (about 1 mm 3 ). Next, the cut tissues are weighed to get the wet weights thereof and then lyophilized for about 24 hours or more to get constant dry weights, whereby the water content of tissue samples is learned, and dried tissue samples are obtained. Next, the dried tissue samples are freeze-ground into powders with a cryogenic grinder (a product of SPEX CertiPrep, Inc.). The powders are then dissolved in a 0.5M acetic solution and the mixture is agitated with a homogenizer (a product of Polytron®, Kinematica AG, Switzerland) and a sonicator (a product of Quantrex 280H, Ultrasonices, L&R Manufacturing, Co., USA) to attain homogeneous collagen solutions with appropriate concentration. Then, the collagen solutions are stored at a temperature of 4° C. for analysis.
(A) Hydroxyproline Colorimetric Reaction Method
[0033] The connective tissues of pigs are freeze-ground into powders. The powders are decomposed in a 6N hydrochloric acid solution by a ratio of 0.5 mg sample and 0.5 ml hydrochloric acid solution at 110° C. for 24 hours. The product is then mixed with chloramines T and the Ehrlich's reagent for a colorimetric reaction (according to Huang-Lee, L L H & Nimni, M E, 1993, Biomed Eng Appl Basis Comm 5: 664-675). The products of the colorimetric reaction are analyzed with an enzyme-linked immunosorbent assay device (the ELISA reader and the VERSAmax microplate reader, Molecular Devices, USA). The content of hydroxyproline is calculated from the absorbance at a wavelength of 550 nm in comparison to a standard curve. The total amount of collagen is estimated according to the ratio that hydroxyproline conventionally exists in collagen. The calculation formula is collagen concentration=hydroxyproline concentration X 7.46.
(B) A First Capillary Electrophoresis Method for Hydroxyproline Detection
[0034] The connective tissues of pigs are freeze-ground into powders. The powders are decomposed in a 6N hydrochloric acid solution by a ratio of 0.5 mg sample and 0.5 ml hydrochloric acid solution at 110° C. for 24 hours. The decomposed product is vacuum-dried in the presence of sodium chloride to remove hydrochloric acid. The dried product is re-dissolved in a 0.5M sodium hydrogen carbonate buffer solution by a ratio of 0.5 mg dried product: 0.5 ml buffer solution. The re-dissolution liquid is mixed with a fresh 0.02M dansyl chloride/acetone solution by a volume ratio of 1:1, and the mixture solution is placed in a 65° C. dry bath incubator for 40 minutes to enable a derivative reaction. After the derivative reaction, the sample solution is injected into an uncoated capillary (a product of Beckman USA and having an inner diameter of 50 μm and a length of 60.2 cm) with an injection pressure of 0.5 psi and an injection time of 20 seconds. The capillary electrophoresis analysis is undertaken in a borate/phosphate buffer solution, at a temperature of 25° C., under an electrophoresis voltage of 27 kV, and, with an UV absorption wavelength of 214 nm, wherein the ratio of (0.02M borate/phosphate, 0.1M SDS, pH9): methanol=9:1. The result of the capillary electrophoresis analysis is compared with a hydroxyproline calibration curve to obtain the hydroxyproline content in the sample. The total amount of collagen is estimated according to the ratio that hydroxyproline conventionally exists in collagen.
(C) A Second Capillary Electrophoresis Method for Hydroxyproline Detection
[0035] The connective tissues of pigs are freeze-ground into powders. The powders are decomposed in a 6N hydrochloric acid solution by a ratio of 0.5 mg sample and 0.5 ml hydrochloric acid solution at 110° C. for 24 hours. After the decomposition reaction, sodium hydroxide is added to neutralize the hydrochloric sample solution. The neutralized sample solution is mixed with a 0.5M sodium hydrogen carbonate buffer solution by a volume ratio of 1:1. The buffered sample solution is mixed with a fresh dansyl chloride/acetone solution by a volume ratio of 1:1, and the mixture solution is placed in a 65° C. dry bath incubator for 40 minutes to enable a derivative reaction. After the derivative reaction, the sample solution is injected into an uncoated capillary (a product of Beckman USA and having an inner diameter of 50 μm and a length of 60.2 cm) with an injection pressure of 0.5 psi and an injection time of 20 seconds. The capillary electrophoresis analysis is undertaken in a borate/phosphate buffer solution, at a temperature of 25° C., under an electrophoresis voltage of 27 kV, and, with an UV absorption wavelength of 214 nm, wherein the ratio of (0.02M borate/phosphate, 0.1M SDS, pH9): methanol=9:1. The result of the capillary electrophoresis analysis is compared with a hydroxyproline calibration curve to obtain the hydroxyproline content in the sample. The total amount of collagen is estimated according to the ratio that hydroxyproline conventionally exists in collagen.
(D) Capillary Electrophoresis Method of the Present Invention for Collagen Analysis
[0036] The connective tissues of pigs are freeze-ground into powders. The powder is dissolved in a 0.5M acetic solution, and the mixture of the powder and the acetic solution is homogenized. The homogenized tissue solution is injected into an amine capillary (a product of Beckman USA and having an inner diameter of 50 μm, an outer diameter of 360 μm and a length of 65 cm) with an injection pressure of 2 psi and an injection time of 6 seconds. The capillary electrophoresis analysis is undertaken in a sodium dihydrogen phosphate buffer solution having a concentration of 50 mM and an acidity of pH2.5, at a temperature of 25° C., under an electrophoresis voltage of −25 KV, and with an UV absorption wavelength of 214 nm, whereby collagen can be directly identified. The content of collagen is worked out from the area of the peak.
[0037] The test results of the abovementioned four quantitative analysis methods for collagen in connective tissues are shown in Table 1.
[0000]
TABLE 1
Water
Method
Method
Method
Method
content (%)
(A) (%)
(B) (%)
(C) (%)
(D) (%)
Pig Skin
61.9 ± 0.6
23.7 ± 2.7
20.7 ± 2.8
22.3 ± 1.5
23.8 ± 2.9
Pig Intestine
84.9 ± 0.8
1.1 ± 0.3
1.1 ± 0.3
1.0 ± 0.2
0.8 ± 0.2
Pig Cartilage
70.1 ± 0.7
14.6 ± 1.2
12.5 ± 0.7
14.5 ± 0.7
10.1 ± 2.9
Pig Tendon
61.2 ± 0.6
32.9 ± 2.6
29.0 ± 4.3
28.7 ± 0.4
30.5 ± 2.7
Spongy Bone
34.5 ± 2.2
4.1 ± 1.5
4.1 ± 1.1
4.1 ± 0.7
4.1 ± 0.8
Compact
21.6 ± 1.4
15.2 ± 0.9
12.9 ± 3.1
11.8 ± 0.6
15.1 ± 4.0
Bone
[0038] From the quantitative analysis results of collagen in connective tissues taken from the same source, the collagen contents detected by different analysis methods have negligible variation. Compared with the conventional technology that indirectly obtains the collagen content via analyzing the hydroxyproline content, the capillary electrophoresis method of the present invention can detect the collagen and measure the collagen content directly.
Embodiment IV
Quantitative Analysis of Collagen which Contaminated with Some Anion or Polyanion Compounds
[0039] In case of collagen samples contaminated with some anion or polyanion compounds such as hyaluronan (HA), the samples will be further treated with excess of cation or polycation compounds such as chitosan, polyamines, hexadecyltrimethylammonium bromide (CTAB), poly-allylamine hydrochloride, etc. to remove the anion or polyanion contaminants.
[0040] (A) Quantitative Analysis of Collagen with CTAB
[0041] Prepare a 1.0 ml 10% CTAB solution by dissolving 0.1 g hexadecyltrimethylammonium bromide (HTAB, Riedel-deHaen, Cat. No. 65015) into double distilled water and heat at 50° C. for 10 minutes until the CTAB solution is limpid. Prepare the samples of collagen with CTAB and the samples of collagen-HA (HA is 12 kD, 780 kD or 1500 kD) with CTAB by the ratio of table 2 and place at room temperature for 1 hour.
[0000]
TABLE 2
Collagen
10% CTAB
0.5M CH 3 COOH
(5 mg/ml)vol. (μl)
vol. (μl)
vol.(μl)
10
0
10
10
1
9
10
2
8
10
4
6
Collagen-HA (5 mg/ml-2
10% CTAB
0.5M CH 3 COOH
mg/ml) vol. (μl)
vol. (μl)
vol. (μl)
10
0
10
10
1
9
10
2
8
10
4
6
[0042] Centrifuge the samples for 5 minutes and mix 8 μl supernatant with 1.92 μl 0.5M CH 3 COOH to prepare the determinants. Take 200 μl of each determinant to mix with 100× 0.5 μl diluted neutral marker and then analyzed by the capillary electrophoresis. The results are shown in FIGS. 3 to 6 . In FIG. 3 , when the ratio of CTAB raising to 20% the peak of collagen without HA, the peak is more widely than the peak with collagen only. The results shown in FIGS. 4 and 6 find out that CTAB can decrease the influence from HA. In FIG. 4 the preferring ratio of CTAB is 5-20% when the HA is 12 kD. In FIG. 5 the preferring ratio of CTAB is 5% when the HA is 780 kD. In FIG. 6 the preferring ratio of CTAB is 10% when the HA is 1500 kD.
[0043] (B) Quantitative Analysis of Collagen with Chitosan
[0044] Prepare a 1% chitosan solution by dissolving 5 mg chitosan (Wako, Cat. No. 031-14301, FW=2000-5000) into 0.5 ml double distilled water and diluted to 0.5% chitosan solution with double distilled water. Prepare the samples of collagen with chitosan solution and the samples of collagen-HA (12 kD and 780 kD) with chitosan solution by the ratio of table 3 and place at 4° C. for 16˜18 hours.
[0000]
TABLE 3
0.5% Chitosan
Collagen (5 mg/ml)vol. (μl)
solution vol. (μl)
0.5M CH 3 COOH vol.(μl)
10
0
10
10
1
9
10
2
8
10
4
6
Collagen-HA(5 mg/ml-2
0.5% Chitosan
mg/ml) vol. (μl)
solution vol. (μl)
0.5M CH 3 COOH vol. (μl)
10
0
10
10
1
9
10
2
8
10
4
6
[0045] Centrifuge the samples for 5 minutes and mix 8 μl supernatant with 192 μl 0.5 M CH 3 COOH to prepare the determinants. Take 200 μl of each determinants to mix with 100× 0.5 μl diluted neutral marker and then analyzed by the capillary electrophoresis. The results are shown in FIGS. 7 to 9 . In FIG. 7 , chitosan seems to increase the signal of collagen without HA. The results shown in FIGS. 4 and 6 find out that chitosan can also decrease the influence from HA. In FIG. 8 the preferring ratio of chitosan to collagen with HA is 1:1 or 2:1 when the HA is 12 kD. In FIG. 9 the preferring ratio of chitosan to collagen with HA is 1:1 when the HA is 780 kD.
[0046] As the capillary electrophoresis method for analyzing collagen of the present invention is exempt from the pre-treatment of purification, extraction, and processing with cyanogen bromide used in the conventional technology, the present invention can greatly shorten the time for analysis. From the embodiments described above, it is known that the capillary electrophoresis method of the present invention can detect a large range of collagen concentration and quantify the total amount of collagen in tissue. Furthermore, the method of the present invention has high specificity for collagen identification and sensitivity when the collagen is mixed with other types of proteins. Therefore, the present invention has improvements over the conventional technology and possesses novelty and non-obviousness—the conditions for a patent. Comparing with the dynamic coating method, the pre-coated capillary of the present invention can apply to directly measure the total amount of collagen of the sample accurately and decrease the errors of calculating. The current invention provides a special condition for using capillary electrophoresis method to identify collagen as a single peak in the chromatogram disregarding its typing and thus the total amount of collagen can be accurately quantitated. Thus, the inventor files the application for a patent. It will be appreciated if the patent is approved fast.
[0047] The present invention has been described in detail with the embodiments. However, the embodiments are only to exemplify the present invention but not to limit the scope of the present invention. Any equivalent modification or variation according to the spirit of the present invention is to be also included within the scope of the present invention. | A capillary electrophoresis method for identification and analyzing collagen quantitatively, which is used to identify and quantify collagen in a sample, comprises the steps of: (a) dissolving a collagen-containing sample to form a sample solution; (b) preparing a capillary with an inner wall thereof having a positively-charged layer; (c) introducing the sample solution into the capillary filled with an analytical buffer solution; and (d) driving the sample solution to pass through the capillary. The method of the present invention does not need the purifying pre-treatment and cracking the collagen-containing sample but directly performs the capillary electrophoresis analysis of collagen. Therefore, the present invention can shorten the time for analyzing collagen quantitatively. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present non-provisional application claims under 35 U.S.C. §119(e) the benefit of priority of U.S. Provisional Application Ser. No. 61/542,151, filed Sep. 30, 2011, and entitled “Edgelesss Unions of Concentric Members,” the contents of which is expressly incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The invention relates to the field of medical devices, and more particularly a vascular implant delivery system.
[0004] 2. Related Devices and Methods
[0005] Vascular disease is a leading cause of premature mortality in developed nations. Treatment of vascular disease may include implantation of tissue supporting stents or prosthetic vasculature, e.g., grafts, stent-grafts, etc., which are delivered through the vasculature at a reduced dimension for ease of navigation in, and reduced chance of injury to, the tortuous vasculature from entry point to the diseased location. These vascular implant delivery devices typically include an elongated shaft around which the vascular implant is disposed at a distal end, that is the end furthest from the medical professional implanting the vascular implant. Such shafts may have variable designs as best suited to deliver the vascular implant from the point of entry to the vasculature to the intended implantation site. Some delivery devices further include additional features such as soft tips on the distal ends of the elongated shafts, sheaths or outer members disposed about much of the length of the elongated shaft and about the vascular implant, and various features on the proximal end, that is, the end closest to the medical professional to perform varied functions, e.g., release of dye or other visualization agent, valved access to a lumen running through the elongated shaft for inserting a guide wire, sealed attachment of a pressurized fluid to inflate balloons at the distal end, or other mechanisms involved in the controlled delivery of the vasculature to its intended site. Unless otherwise stated, the other variations in the construction of the medical device to which the present invention is coupled or is otherwise a physical part of are not germane to the present invention.
[0006] It is desirable to have a smooth transition at any union of two concentric members, such as at the tip of inner and outer members of vascular implant delivery systems, that is expected to interact with the patient's vasculature to prevent inadvertent injury to the vessel from insertion and tracking of the device to the target location. Such interactions with the vessel wall can cause vessel spasm, damage to health intima or even vessel perforation or dissection.
[0007] Secondly any edge created by such a union might be a liability for any procedure that introduces more than one stent or stent-graft. After delivery of the first implant, the delivery system of the second implant is required to be inserted in to the lumen of the deployed implant to create an overlap. Upon introduction of the second delivery system any edge on the delivery system that is exposed can potentially snag on the deployed first implant. Unintended interactions, such as snagging, may cause problems with the placement of the first implant, interaction of the first implant and the vessel wall or fatigue of the first implant itself
SUMMARY
[0008] In some embodiment according to the invention, grooves or impressions made in the outer surface of an inner member of two concentric member hides the leading edge of the tip of the outer concentric member allowing for a more continuous unified transition. These grooves or impression may be angled to match the outer tip design or may be generic grooves that are intended just to hide the edge of the outer tip. There can be a single groove or there could also be more than one groove.
[0009] These and other features, benefits, and advantages of the present invention will be made apparent with reference to the following detailed description, appended claims, and accompanying figures, wherein like reference numerals refer to structures that are either the same structures, or perform the same functions as other structures, across the several views.
BRIEF DESCRIPTION OF THE FIGURES:
[0010] The figures are merely exemplary and are not meant to limit the present invention.
[0011] FIG. 1A is a top view of an inner member, near the distal tip.
[0012] FIG. 1B is a cross-sectional view of the inner member of FIG. 1A .
[0013] FIG. 2 is a top view of the inner member of FIG. 1A assembled with a concentric outer member, showing the union of the distal tip of the concentric outer member with the inner member.
[0014] FIG. 3 is a cross sectional view of an enlarged portion of the assembly of FIG. 2 .
[0015] FIG. 4A is a top view of a three dimensional rendering of a distal portion and tip of an inner member with a second embodiment of grooves.
[0016] FIG. 4B is a top view of an enlarge portion of FIG. 4A .
[0017] FIG. 5A is a top view of the inner member of FIG. 3 assembled with a concentric outer member, showing the union of the distal tip of the concentric outer member with the inner member.
[0018] FIG. 5B is a cross-sectional view of an enlarged portion of the assembly of FIG. 5A .
[0019] FIG. 6A is a top view of an assembly of yet a third inner member, without circumferential grooves, assembled with another embodiment of an outer concentric member, showing the union of the distal tip of the concentric outer member with the inner member.
[0020] FIG. 6B is an enlargement of a portion of FIG. 6A .
[0021] FIG. 6C is a cross section of an enlarged portion of FIG. 6A .
DETAILED DESCRIPTION
[0022] An edgeless union of two concentric members is a feature that is designed to be used where two tips (an inner and outer member) come together and form a union. Without the benefit of embodiments of this invention, a solid tubular inner tip would have a tip of a concentric outer member resting on its outer groove-less surface creating a bump/step transition, such as depicted in FIGS. 6A , 6 B, and 6 C, that can lead to tissue damage and/or procedural issues due to the tip of the concentric outer member snagging.
[0023] Edgeless unions of concentric members may include grooves, such as those depicted on inner member in FIGS. 1A-1B and 4 A- 4 B to hide the edge of the tip of the concentric outer member allowing for a more continuous, unified transition, as depicted in FIGS. 2 , 3 , and 5 A- 5 B instead of the bump or step transition. In some embodiments, grooves may be angled to match the outer tip design, such as depicted in FIGS. 1A-3 , or may be generic grooves, such as those depicted in FIGS. 4A-5B , that are intended just to hide the edge of the tip of the outer concentric member. In some embodiments there is a single groove. In some embodiments, more than one groove can be included to provide a length of the inner member along which the edge of the concentric outer member will “land” upon final assembly, taking into account length tolerances of the inner and outer concentric members.
[0024] In some embodiments, the depth, width (longitudinal length) and angle of these grooves are enough to allow hiding of the edge but still allow for linear retraction of the inner member back through the concentric outer member.
[0025] One embodiment is illustrated in FIGS. 6A through 6C where the leading edge of the outer member is given a radius. However, this embodiment fails to hide the edge and just simply attempts to make the edge less sharp.
[0026] A second embodiment is illustrated in FIGS. 6A-6C includes drawing down the diameter of the tip of the concentric outer member. This embodiment puts a taper on some distal portion of the outer member in an attempt to have an angle of transition to the outer member body. This embodiment works well for preventing of “fish mouthing” (a condition of the outer member becoming oval and gapping on opposite sides, resembling an open fish mouth) because of tight conformance of the outer member to the inner member and does provide an angle of transition instead of a true step transition. However this taper does not hide the edge that is created going from a smaller diameter of the outer diameter of the inner member to the larger diameter of the inner diameter of the concentric outer member on it.
[0027] Yet another embodiment of an edgeless union is an inner member with a smaller outer diameter on the proximal end and a larger outer diameter on the distal end (much like an arrow) to essentially create a plug when inserted into the outer member. However, in these embodiments, the tip of the concentric inner member is not made to be withdrawn back through the concentric outer member; it would not be able to be retracted back due to large sharp change in diameter.
[0028] Other embodiment of edgeless unions of concentric members has impressions (circumferential angulated or non angulated impressions) in the outer surface of the inner member that will allow the concentric outer member to conform to it, thereby hiding the edge while still achieving a tight conformance to the inner member and allowing the retraction of the inner member back through the outer. It is counterintuitive that impressions are put onto the inner member tip making it less smooth in order to achieve a smoother transition as an assembly when mated with the outer member. In some embodiments, one circumferential angulated or non angulated impression will be on the inner concentric member. In some embodiments, any number of circumferential angulated or non angulated impressions may be made in the inner concentric member to allow easier assembly in manufacturing.
[0029] Embodiments including the impressions on the inner member could also allow physicians the ability to initiate deployment, decide to abort deployment to reposition or retract completely. In doing so the physician would just retract to the next impression which would ensure the edge is hidden and the physician may maneuver the delivery system with the same performance as he or she did during initial insertion.
[0030] FIG. 1A is a top view of an inner member 100 , near the distal tip (not shown). Inner member 100 has an outer diameter with a cylindrical outer surface 102 in which three circumferential grooves 104 are formed. Each groove 104 has two opposing tapered faces, tapered face 106 with a decreasing diameter along the proximal to distal length, and tapered face 108 with an increasing diameter along the proximal to distal length. The tapered face 108 has a much steeper taper, such that the groove is not symmetric.
[0031] FIG. 1B is a cross-sectional view of the inner member of FIG. 1A . It may be seen that in this embodiment, inner member 100 has a lumen 110 therethrough.
[0032] FIG. 2 is a top view of inner member 100 of FIG. 1A assembled (assembly 200 ) with a concentric outer member 202 , showing the union of distal tip 204 of concentric outer member 202 with inner member 100 . It may be seen that distal tip 204 is hidden within the second of the three grooves 104 .
[0033] FIG. 3 is a cross sectional view of an enlarged portion of the assembly of FIG. 2 , and illustrates the leading edge of distal tip 204 within groove 104 , resulting in an edgeless union of two concentric members.
[0034] FIG. 4A is a top view of a three dimensional rendering of a distal portion and tip 126 of an inner member 120 with a second embodiment of grooves 124 in outer cylindrical surface 122 of inner member 120 . Inner member 120 has three circumferential grooves in this embodiment, spaced unevenly along the longitudinal length.
[0035] FIG. 4B is a top view of an enlarge portion of FIG. 4A illustrating that grooves 124 have two opposing tapered faces 128 and 130 . The taper of tapered face 128 is an increasing diameter in the distal direction and the taper of tapered face 130 is a decreasing diameter in the distal direction, and the tapers are the same, such that the groove 124 is symmetric.
[0036] FIG. 5A is a top view of the inner member 120 of FIG. 3 assembled (assembly 220 ) with a concentric outer member 222 , showing the union of the distal tip 224 of the concentric outer member 222 with the second groove 124 of inner member 120 .
[0037] FIG. 5B is a cross-sectional view of an enlarged portion of the assembly of FIG. 5A , which illustrates that inner member 120 has a lumen 226 therethrough.
[0038] FIG. 6A is a top view of an assembly 230 of yet a third inner member 130 , without circumferential grooves, assembled with another embodiment of an outer concentric member 232 , showing the union of the distal tip 234 of the concentric outer member 232 with outer cylindrical surface 132 of the inner member 130 .
[0039] FIG. 6B is an enlargement of a portion of FIG. 6A illustrating the tapered distal tip 234 ending in an exposed leading edge 236 .
[0040] FIG. 6C is a cross section of an enlarged portion of FIG. 6A illustrating that in this embodiment, inner member 130 has a lumen 238 therethrough and the step or bump transition presented by the leading edge of the tapered distal tip 234 of outer concentric member 232 .
[0041] Aspects of the present invention have been described herein with reference to certain exemplary or preferred embodiments. These embodiments are offered as merely illustrative, not limiting, of the scope of the present invention. Certain alterations or modifications possible include the substitution of selected features from one embodiment to another, the combination of selected features from more than one embodiment, and the elimination of certain features of described embodiments. Other alterations or modifications may be apparent to those skilled in the art in light of instant disclosure without departing from the spirit or scope of the present invention, which is defined solely with reference to the following appended claims. | Leading edges of concentric members are desirably hidden in unions of two concentric members intended for advancement through the vasculature for vasculature implant delivery. Grooves or impressions on the inner concentric member provide spaces for the leading edge of the distal tip of the outer concentric member to create edgeless unions of two concentric members for safe and unimpeded advancement and operation of vascular implant delivery devices which include the two concentric members. | 5 |
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to an apparatus for cleaning a rotor revolving in a rotor housing of an open-end spinning unit, having a scraper that can be positioned in a fiber collecting groove of the rotor.
Such apparatuses are known from numerous publications.
German Published, Non-Prosecuted Application DE-OS 26 18 094 A1, for instance, describes a cleaning apparatus disposed in an automatic maintenance unit, which has a scraper element that is drivable into the spinning rotor and is adapted to the contour of the fiber collecting groove. The scraper element is secured to one end of a rod. The scraper element also has an injection device for a liquid cleaning agent. Through the use of such a device, the fiber collecting groove can be mechanically cleaned, and in addition a mixture of cleaning agent or detergent and air can be blown into the rotor.
A cleaning apparatus which was especially conceived of for small rotor diameters is known from German Published, Non-Prosecuted Application DE-OS 39 11 946 A1. The actual cleaning apparatus is disposed in a housing, which is positioned in front of the opened spinning box. A carrier is supported pivotably inside the housing, with its pivot axis being offset from the rotor axis and inclined at an acute angle. The carrier is given a three-dimensional shape in such a way that the end occupied by the cleaning tool, when rotated about the axis, describes a circular arc that intersects the plane of the fiber collecting groove of the rotor.
In a forward-oriented motion, the cleaning tool is moved through the rotor opening to the part of the rotor to be cleaned.
A cleaning device is also known from German Published, Non-Prosecuted Application DE 37 15 934 A1, corresponding to U.S. Pat. No. 4,897,993. Its scraper, which is disposed on the end of the piston rod of a pneumatic thrust piston mechanism, is movable in the direction of the fiber collecting groove into the rotor of an open-end spinning unit. The scraper has a knife-like end piece that extends into the fiber collecting groove and is bent in the plane of the knife in such a way that counter to the direction of rotation of the rotor, the front edge extends in inclined fashion counter to the direction of rotation of the rotor.
In both German Patent DE-PS 26 29 161 C2 and German Published, Non-Prosecuted Application DE 33 13 926 A1, cleaning devices for rotor spinning apparatuses are also described that have rotatably supported cleaning tools. Scraper inserts that are positioned at their ends on spiral springs are used as the cleaning tools. During the cleaning process, under the influence of centrifugal force, the revolving scraper inserts press into the rotor groove and clean it of any dirt particles adhering to it.
Since the position of the scraper inserts is radially adjustable because of their disposition on the elastic spiral springs, there is automatic compensation for abrasion from wear of the scraper inserts.
However, that kind of elastic support of the cleaning tools has the disadvantage of the danger that the scraper elements will not be positioned far enough forward, or will bounce back, if firmly adhering contamination is present. In those cases, perfect cleaning of the fiber collecting groove of the spinning rotor is not assured.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an apparatus for cleaning a rotor revolving in a rotor housing of an open-end spinning unit, which overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type.
With the foregoing and other objects in view there is provided, in accordance with the invention, an an open-end spinning unit including a rotor housing and a rotor revolving in the rotor housing and having a fiber collecting groove formed therein defining a groove bottom, an apparatus for cleaning the rotor, comprising a cleaning device having a scraper to be positioned in a predetermined position in the fiber collecting groove of the rotor, the scraper automatically assuming an optimal length independently of its abrasion from wear upon entry of the cleaning device into the rotor, for assuring a secure placement or contact of the scraper in the bottom of the fiber collecting groove.
An advantage of the embodiment of the scraper according to the invention is that the scraper automatically assumes an optimal length upon entry of the cleaning device into the rotor, which assures contact of the scraper with the bottom of the fiber collecting groove, regardless of any scraper abrasion from wear. This assures that the scraper remains equally effective from the first cleaning process to the last, regardless of the degree of soiling of the spinning rotor.
In accordance with another feature of the invention, the scraper is constructed as a strip-like wear part, so that the surface life of such cleaning devices can be prolonged markedly as compared with known devices. Since moreover the optimal length of the scraper strip is automatically readjusted upon its entry into the fiber collecting groove, control inspections by the operators can be dispensed with to the maximum extent or can be markedly reduced. Overall, the apparatus according to the invention makes the work of machine operators considerably easier.
In accordance with a further feature of the invention, the scraper strip is force-lockingly connected to a displacement device. A force-locking connection is one which connects two elements together by force external to the elements, as opposed to a form-locking connection which is provided by the shapes of the elements themselves. A pressure roller resting by spring force on the scraper strip generates just enough friction between the scraper strip and the driven feed roller of the displacement device to make the scraper strip come into adequately firm contact with the fiber collecting groove of the spinning rotor, or in other words to assure reliable cleaning of this critical region. On the other hand, once the scraper strip has come into contact inside the fiber collecting groove, the feed roller can slip freely beneath the scraper strip, so that excessive wear from an overly firm contact is averted.
Preferably, the displacement device for the scraper strip includes a feed roller that has a pivot lever, a spring-actuated pressure roller, and a pneumatic cylinder that is connected by a piston rod to the pivot lever. Upon extension and retraction of the piston rod, the feed roller is rotated clockwise and counterclockwise, respectively, and in so doing carries the scraper strip clamped between the feed roller and the pressure roller along with it by way of frictional engagement, in the applicable direction of rotation of the feed roller.
In accordance with an added feature of the invention, the feed motion of the scraper strip, initiated by the feed roller or the pneumatic cylinder, is limited by the contact of the tip of the strip in the fiber collecting groove. In other words, in the last stage of its rotation, the feed roller slips underneath the scraper strip, which has been optimally moved inward.
Such an embodiment on one hand assures that the scraper strip is inserted properly into the fiber collecting groove, and on the other hand the contact pressure of the tip of the strip against the fiber collecting groove wall is prevented from becoming too great.
In accordance with an additional feature of the invention, for the sake of satisfactory automatic readjustment, the feed path that the scraper strip covers upon the inward motion of the cleaning apparatus into the rotor is longer than the restoring path of the scraper strip when the cleaning device is withdrawn.
In accordance with yet another feature of the invention, there is provided a stroke limiter for this purpose, which is constructed in such a way that the scraper strip can pass the stroke limiter unhindered in the forward feed direction, while in the return direction it is clamped and therefore blocked in the stroke limiter after a certain path distance. In that case as well, the feed roller can slip unhindered under the scraper strip to reach its outset position.
In accordance with a concomitant feature of the invention, there is provided a sensor device in the outlet region of the scraper strip reservoir, the sensor detects when the strip-like wear part is becoming depleted, so that operators can intervene and put a new scraper strip in place at the proper time. In this way, maintenance unit down time or spinning unit malfunctions resulting from inadequate cleaning can be reliably avoided.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an apparatus for cleaning a rotor revolving in a rotor housing of an open-end spinning unit, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary, diagrammatic, longitudinal-section view of a cleaning device positioned in front of an open-end rotor spinning unit;
FIG. 2 is a plan view of the cleaning device shown in FIG. 1; and
FIG. 3 is a partly broken-away plan view taken along a line III--III of FIG. 1, in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the operation of open-end rotor spinning machines, it is customary to clean the rotor before restarting a spinning unit. In particular, the fiber collecting groove of the rotor must be cleaned of any fluff and other soil sticking to it, otherwise a proper outcome of spinning cannot be attained.
Maintenance units that patrol in the region of the spinning machines and automatically correct yarn breaks as they occur therefore have a cleaning device, by means of which cleaning of the rotor and in particular of its fiber collecting groove is possible.
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen a cleaning head 5 of such a cleaning device, in a sectional view. The cleaning head 5 is positioned in front of an opened rotor housing 1 of an open-end rotor spinning unit. A spinning rotor 2 is disposed inside the rotor housing 1. The spinning rotor 2 is supported by a rotor shaft 3 on a rotor disk bearing in a manner which is known and is therefore not shown in detail herein, and the spinning rotor has a fiber collecting groove 4 in the region of its rotor head.
As is indicated in FIG. 2, the cleaning head 5 has a drive device 6, for example with a rubber-tired drive wheel 7, which can be positioned from the outside against the rotor head, and a cleaning device 8 seen in FIG. 1 that can be moved into the fiber collecting groove 4. The cleaning device 8 is constructed with a scraper 9 that can be moved outward in the direction of the fiber collecting groove 4. The scraper 9 includes a scraper strip 11, which is kept on hand in the reservoir 10 and can be moved outward or inward in the direction of the fiber collecting groove 4 by means of a displacement device 12.
In detail, the displacement device 12 includes a drive element in the form of a triggerable pneumatic cylinder 13, having a piston rod 19 which is connected to a pivot lever 20. The pivot lever 20 is in turn connected to a feed roller 14 in such a manner as to be fixed against relative rotation. Resting on the feed roller 14 is a pressure roller 15 which is loaded by a spring element 21. The scraper strip 11 is force-lockingly clamped between the feed roller 14 and the pressure roller 15, and upon extension of the piston rod 19 of the pneumatic cylinder 13 in the forward direction V shown in FIG. 3, the scraper strip is pushed outward in the direction of the fiber collecting groove 4. In order to adjust the contact pressure of the pressure roller 15, a non-illustrated adjusting element may be provided in the exemplary embodiment. An example of such an adjusting element is a pressure screw acting upon the spring element 21.
On the outlet side, the flexible, relatively thin scraper strip 11 is supported in a guide channel 22, so that drifting or kinking of the scraper strip 11 upon movement into the fiber collecting groove 4 is reliably prevented.
The fill level or the depletion of the scraper strip reservoir is monitored by a sensor device 18, which is disposed at the outlet of the reservoir. By way of example, the sensor device 18 may be constructed as an end switch, which rests with a small pressure roll on the scraper strip 11 and switches a contact if the scraper strip is absent.
The displacement device 12 furthermore has a stroke limiter 17, which is constructed in such a way that unhindered sliding of the scraper strip in the direction toward the fiber collecting groove 4 is permitted, while in the opposite direction the passage of the scraper strip is blocked by the stroke limiter. The stroke limiter 17 is in turn longitudinally movably supported in a guide 24 of the cleaning head 5 and its displacement path is the measure for the return course of the scraper strip 11. The stroke limiter 17 may take various forms. For instance, it is possible to prevent the sliding of the scraper strip in the return direction by using a clamp element 23. Such a clamp element may, for instance, be constructed as a wedge element, an eccentric roller, or the like.
The mode of operation of the cleaning apparatus is as follows:
As soon as the maintenance unit is positioned in front of a spinning unit and the spinning box is opened, the cleaning head 5 is put into position in front of the opened rotor housing 1. The pneumatic cylinder 13 is acted upon through a line 24', so that its piston rod 19 moves outward and shifts the pivot lever 20 in a direction S. As a result, the feed roller 14 which is connected to the pivot lever 20 in such a manner as to be fixed against relative rotation, is rotated clockwise, and the scraper strip 11 that is clamped between the feed roller 14 and the spring-actuated pressure roller 15 is force-lockingly pushed outward in the direction of the fiber collecting groove 4. The outward thrust path of the scraper strip 11 is limited by contact of a tip 16 of the strip in the fiber collecting groove 4. At the same time, the rotor 2 is rotated slowly by the drive device 6, or in other words by the drive wheel 7 resting on the outside of the rotor head, as is seen in FIG. 2. The material of the scraper strip 11 which, for example, is a relatively easily worn plastic, assures good conformance of the tip 16 of the strip to the shape of the fiber collecting groove, so that the entire fiber collecting groove is thus reliably cleaned.
Once the cleaning process has ended, the pneumatic cylinder 13 retracts the piston rod 19 in the reverse or return direction R shown in FIG. 3, and as a result the feed roller 14 is rotated counterclockwise. This means that the scraper strip 11 is retracted. The stroke limiter 17 assures that the retrieval path of the scraper strip 11 is shorter than its forward feed path. This assures that the shortening of the scraper strip caused by wear is automatically compensated for the next time the scraper strip is driven outward, and the optimal length is established when the scraper strip 11 is moved into the fiber collecting groove of the spinning rotor.
The sensor device 18 indicates the correct time at which the scraper strip 11 that is held in reserve in the scraper strip reservoir 10 has attained a length that makes it appear advisable to change the scraper strip soon. A sensor element 25 which is constructed as a pressure roller of the sensor 18 is shown in FIGS. 1 and 3. The pressure roller 25 initially lies against the scraper strip 11 from below and keeps a contact open in the sensor 18. When the scraper strip is worn out to such an extent that the pressure roller 25 is no longer in contact with the scraper strip 11, the contact in the sensor 18 is connected and a signal shows an operator that a scraper strip change will be necessary shortly.
The invention is not limited to the exemplary embodiment described above. Both in terms of the displacement device or its drive and in terms of the stroke limiter or the scraper strip reservoir, other embodiments which are not described in detail in the present application are also conceivable, without departing from the spirit and scope of the invention. What is essential to the invention is above all that upon entry of the cleaning device into the rotor, the optimal length of the scraper strip is automatically established. | An open-end spinning unit includes a rotor housing and a rotor revolving in the rotor housing and having a fiber collecting groove formed therein defining a groove bottom. An apparatus for cleaning the rotor includes a cleaning device having a scraper to be positioned in a predetermined position in the fiber collecting groove of the rotor. The scraper automatically assumes an optimal length independently of its abrasion from wear upon entry of the cleaning device into the rotor, for assuring a secure placement of the scraper in the bottom of the fiber collecting groove. | 3 |
[0001] This application claims priority under 35 USC 119(e) based on application No. 61/779,067, filed on Mar. 13, 2013.
FIELD OF THE INVENTION
[0002] The present invention relates to the method of producing a concentrate of aqueous iodine, retaining said concentrate, reducing said concentrate, manipulating iodine species and controlling the retention of said iodine within the molecular water bond for use as general surface and aerosol disinfectant delivered through a humidification or spray system to control microbes in medical, industrial, agriculture and home environments.
BACKGROUND OF THE INVENTION
[0003] Iodine is currently used as a disinfectant in hospitals. Iodine is well recognized as world class disinfectant used against bacteria and viruses which constitute a major health risk to humans. Medical facilities due to their nature often propagate the proliferation of disease among both healthy and sick individuals.
[0004] The vectors for the transmission of disease within medical establishments are mainly air-borne and surface borne. Post operative infections are a common occurrence that cause pain and undue suffering for humans and create a cost increase in patient care and treatment in the 10 of millions of dollars annually. “Nosocomial Diseases” are a group infections acquired by a healthy person while visiting a hospital. Both the incidence and the cost of nosocomial diseases are on the rise.
[0005] Current air scrubber systems and filtration systems are not adequately controlling the microbiological loading being creating within a given medical environment. To date, no viable alternative has been found to address this growing concern.
[0006] The production of aqueous iodine solutions is well understood. However and under dynamic flow conditions, current technologies fail due changing water temperatures within the iodine bed and fluctuating dissolution rates caused by water channeling issues within the iodine bed.
[0007] Heating the primary water supply has been identified as a stabilizer in the dissolving of iodine crystals under dynamic flow conditions. This technology is described in U.S. Pat. Nos. 7,201,113, 6,139,731, 6,120,812, 5,919,374, 5,853,574, and 5,792,371, which are herein incorporated by reference in their entirety. The problems with this approach occur not during operation but when the system is dormant and or between operations. That is, exterior environmental temperatures change the iodine solution temperature and thereby the concentration within the cylinder. The systems then fails because it does not recognize this problem and relies only on temperature to determine iodine concentration. For example, if a known concentration is produced based on a given temperature and then the iodine bed sits dormant, the iodine concentration will change based on ambient or other external heat sources. If the temperature is then reduced in said iodine bed, the concentration will remain at its most concentrated level. So, temperature cannot be used as an indicator of iodine concentration within a solution or an iodine bed.
[0008] Iodophor/povodone are the current iodine technologies used in hospitals. The only active biocide is iodine with these technologies. By design, their molecular structures utilize materials within the matrices that are not suitable for human consumption or inhalation. Plastics, surfactants, and acids are among the inert materials.
[0009] It is also well understood that at low pH levels below (below 8), elemental iodine is the dominant species of iodine and is a superior biocide. On the other hand, hypoiodous acid, which is present at high pH levels (above 8) is the dominant species of iodine and a superior virucide. However, the manner of delivery of these products can affect their disinfection capabilities.
[0010] Aqueous iodine to date has not been utilized as a disinfectant through a humidification/spray system due to several factors including: surface retention and contact time of the disinfectant, premature release of the molecular iodine bonding with the carrier molecule, location and design of the humidification spray system and the inability to accurately deliver a known concentration of aqueous iodine therefore producing a known reconstituted iodine disinfectant concentration.
[0011] The present invention addresses and surmounts the hereinabove debilitating factors for delivery applications employing aqueous iodine as a disinfectant.
SUMMARY OF THE INVENTION
[0012] It is object of this present invention to provide an apparatus and method for producing iodine disinfectants that can be delivered through humidification/spray systems to provide surface and air microbial control. The iodine species is manipulated to target specific airborne and surface borne bacteria and viruses. The invention provides for the modulation and blending of iodine species. The invention also provides for the control of the retention bond between the iodine species and the carrier water molecule.
[0013] It is further object of this invention to sense the concentration being generated and retained in a first stage and provide mechanical adjustments to the blend ratio into a second stream of water to ensure accuracy of disinfection.
[0014] It is further object of this invention to provide a sealed, insulated, iodine cylinder with interior diffusers to reduce or negate the possibility of water channeling through the iodine bed and reduce ambient heat interference when making an iodine concentrate. The diffusers redirect the water path and would typically be spherical in nature and either fabricated from glass or plastic. These diffusers could be either solid or perforated. The diffusers are sized to ensure they do not block the aperture of the incoming water supply into the iodine cylinder. The diffusers can be placed at varying locations with the iodine bed.
[0015] It is further object of this invention to provide a replaceable iodine cylinder when the initial cylinder in expended.
[0016] It is further object of this invention to provide variable disinfection rates and microbiological species targeting through a programmable controller.
[0017] Accordingly, this invention provides for the broadest aspect a method for producing target specific iodine species in order to harness and maximize the disinfection capabilities of iodine within a dynamic system.
[0018] Accordingly, this invention also provides for modulation capabilities of the iodine species and iodine concentration.
[0019] The present invention includes devices to monitor and control the production of the aqueous iodine concentrate, an apparatus to retain and manipulate the iodine chemistry and the thermodynamics of the iodine disinfectant.
[0020] The invention provides for a safe, controlled broad band microbial aqueous iodine disinfectant that can be modulated to enhance efficacy.
[0021] In one mode, a method of providing a disinfecting spray using iodine comprises:
a) passing a water flow through an iodine cylinder to produce a definable saturate of iodine; b) retaining a determined volume of aqueous iodine concentrate in, for example, a tank; c) diminution blending of the iodine concentrates with a secondary water flow to produce a known volume of aqueous iodine disinfectant into different holding chambers; d) chemically adjusting the retained known volume of the iodine disinfectant to polarize the iodine species in each chamber; e) thermodynamically altering (heating or chilling) the retained known volume of the iodine disinfectant in each chamber; and f) plumbing a desired solution into the humidification/spray system, wherein an electronic controller can make the necessary valve adjustments to introduce a pre-selected iodine disinfectant program to the humidification/spray system.
[0028] In an alternate embodiment, the iodine concentrate is produced remotely and delivered manually to the tank for supply to make the iodine in the chambers or the iodine concentrate can be fed directly to the secondary chambers if desired.
[0029] In yet another alternative embodiment, the speciation adjustment of the iodine can be made under dynamic flow conditions and not in the retention tanks.
[0030] In yet a further embodiment, the aqueous iodine concentrate can be injected in several locations.
[0031] The method thus can, under low flow or high flow dynamic conditions with intermittent dormant periods, readily and accurately provide a controlled iodine disinfectant supply to a humidification/spray system within a hospital establishment or other location requiring the use of the disinfectant.
[0032] The invention also entails an apparatus, which in one embodiment, can be described below.
[0033] One embodiment of the apparatus is for producing a known concentration of aqueous iodine that is then reconstituted and manipulated to maximize the microbial interaction and efficacy of said iodine disinfectant when delivered through a humidification/spray system. The apparatus comprises:
a) an iodine cylinder with screening and directional diffusers to facilitate and control the dissolution of the solid iodine; b) means for providing and heating a first water flow; c) mixing capabilities for affecting the dissolution of solid iodine with said first water flow to produce a concentrate of aqueous iodine; d) mixing capabilities for the diminution of the aqueous iodine concentrate; e) means for retaining and polarizing the species of iodine; f) means for thermodynamically controlling the iodine disinfectant; and g) the ability to connect the apparatus providing the iodine disinfectant into a humidifier/spray delivery system or other system that can use the disinfectant.
[0041] The apparatus can have the ability to sense and retain the iodine concentration produced, can institute concentration dilution metering changes as required within or without the retention system, can sense and manipulate the iodine species within or without the retention system, and can thermodynamically control the iodine disinfectant. The ability and means to perform these functions and those listed in (a-g) are described in more detail below.
[0042] The apparatus is especially adapted to interface with a humidification spray system, either as a newly-built one or one that already exists or can be retrofitted into an existing mechanical spray system.
[0043] The apparatus can also be used with a supply of the aqueous iodine concentrate rather than employ components to generate such a concentrate from solid iodine. The apparatus can also have the capability to both generate the aqueous iodine concentrate and receive an already produced aqueous iodine concentrate for making the diluted iodine solutions with their controlled species and concentrations for use in a disinfecting application.
[0044] Preferably, the apparatus described above can further comprise peristaltic or positive displacement pumps to move a first water supply through the iodine cylinder, a peristaltic or positive displacement pump to move the iodine concentrate either generated and stored in a tank or received from an external source for blending with a second water supply to produce a known iodine disinfectant concentration to be housed in retention tanks or chambers. Electronic valves located on the retention tanks can provide the iodine disinfectant to the humidification/spray system. Peristaltic pumps or other controls can be employed to control the pH of the iodine disinfectant.
[0045] The apparatus can preferably include the following components to produce the desired disinfectant for use as desired:
A) a temperature sensor to detect the first water flow; B) a sealed insulated PVC plastic iodine cylinder with diffusers; C) a heating system to detect and control the temperature of the first water supply; D) an oxygen reduction potential meter/or a halogen analyzer test system to electronically detect the iodine solution concentration; E) a pump to blend the concentrated iodine solution into the second supply of water thereby producing a known aqueous iodine disinfectant concentration that is to be retained within or without the system; F) a pump and chemical (carbonate/bicarbonates) to adjust the pH and therefore the species of the retained iodine disinfectant; G) a typical 5 gpm water chiller/immersion chiller rod or a low watt immersion probe heating system to chill or heat the retained iodine disinfectant; H) a plumbing connection controlled by solenoid valves, for example, to the water feed supply of an existing mechanical humidification/spray device. I) a programmable controller that collects data on the operation of the system, wherein the programmable controller that can remotely access data produced by the system and includes interactive displays and built in safety limits.
[0055] The present invention targets and addresses the current problems with microbiological control within hospitals and medical establishments. The invention provides the broadest spectrum of iodine microbial control within the general disinfectant marketplace. This invention safely provides both and aerosol disinfectant to kill airborne disease and a surface disinfectant that can be applied on a continuous or intermittent basis to manage or eradicate harmful pathogens specifically bacteria and viruses.
[0056] The present invention provides for a myriad of iodine species configurations, retention times within the iodinated mist water and disinfection treatment levels, for example ranging from 0.25 ppm to 600 ppm aqueous iodine, preferably 0.25 to 100 ppm.
[0057] The present apparatus as hereinabove described may be used in other applications that do not involve a humidification or spray system. This invention provides a known broad spectrum aqueous iodine disinfectant that can be used in medical, pharmaceutical, agricultural applications, poultry and egg treatment, food processing, ice, hand washes, dental offices, and the like.
[0058] Other applications that can employ the iodine disinfectant produced by the invention include providing controlled aqueous iodine solutions for the ocean industries to control zebra mussel's migration and other ballast water microbes, micronutrient applications for human, animal and plant development, inhalation or injection of aqueous iodine for the reduction of tumors and other diseases in humans, and treatment for iodine deficiency in humans.
[0059] Accordingly, in further aspect the invention provides iodine species that are contained in an aqueous state, prepared according to the invention as hereinabove defined for use in the aforesaid applications.
BRIEF DESCRIPTION OF DRAWINGS
[0060] FIG. 1 represents a schematic flow diagram of one embodiment of the method and apparatus according to the invention.
[0061] FIG. 2 represents a flow diagram showing an alternative method and apparatus according to the invention.
[0062] FIG. 3 represents a further embodiment of the inventive method and apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0063] One embodiment of the invention is described in FIG. 1 . This Figure shows an apparatus to produce an iodine disinfectant for use in any number of applications, including a humidification/spray system. FIG. 1 also describes the methodology of producing the iodine disinfectant and the overall system is designated by the reference numeral 950 . FIG. 1 shows the embodiment wherein an iodine concentrate is made and then further modified into a number of solutions of different iodine concentrations. These different solutions are then controlled in terms of pH, etc. so that they are ready for use in an application appropriate for the particular type of iodine disinfectant prepared. Applications include a humidification/spray system of a hospital to provide a surface and aerosol disinfectant in operating rooms, post operating rooms, intensive care, trauma centers, clinics, and other areas where surface disinfection and air quality pose a health risk. Other uses of the surface and aerosol iodine disinfectant for example are cruise ships, airplanes, trains, office buildings, apartment buildings, food processing facilities, restaurants, schools, and nursing homes.
[0064] With reference to FIG. 1 , a source of water or water supply is available and designated by reference numeral 301 . Water from the water supply 301 is proportioned through a pump 400 into water heater ( 100 ). The water supply is typically a potable water or distilled. The temperature of the source water is sensed by way of a thermocouple 303 . The water is then heated in the heater 100 to approximately 80 degrees ° F. and passed through an iodine cylinder 500 to create a saturate of aqueous iodine, e.g., 250 to 300 ppm or up to 600 ppm. Reference numeral 300 shows the water flow direction from the source 301 as well as to other components of the system as detailed below.
[0065] The iodine cylinder 500 is fabricated from an iodine inert material, e.g., PVC plastic, designed with directional diffusers that enhance the dissolution of the iodine crystals. The aqueous iodine saturate is contained in a retention tank 600 . The aqueous iodine solution is transferred to a retention tank 600 and is then monitored for iodine concentration by an apparatus, e.g., an oxygen reduction potential meter or an online analyzer test system 55 .
[0066] The iodine saturate in retention tank 600 is blended with water from the water supply 301 using a pump 401 to reduce the saturate to a desired disinfectant concentration. This diluted saturate is then pumped via pump 401 to one or more of a plurality of disinfection tanks 620 B- 620 E.
[0067] A flow meter 775 is provided in conjunction with the pump 401 . The flow meter 775 enables an accurate production of a desired disinfectant by proportionately blending the source water from supply 301 and the aqueous iodine concentrate from tank 600 .
[0068] A typical pH control system, 400 representing the system and 800 representing the ability to control the pH in the tanks 620 B-E, with pumps (not shown) and pH adjustment chemicals to target pH levels, e.g., a ph of 7 or less in tank 620 B and 620 D and a pH level of 8.5 or greater in tanks 620 C and 620 E.
[0069] The disinfection tanks 620 B-E are fed using a valve 301 V, preferably a solenoid valve, and pump 401 with iodine disinfectant. For disinfection tank 620 B, the disinfectant fed to the tank 620 B is further controlled using valve 320 BL, which can also be a solenoid valve. The disinfectant being fed to tank 620 B can be cooled by a water chiller system 700 and pH adjusted to 6.5 using the pH adjustment system 400 / 800 to polarize the elemental species of iodine within the disinfectant.
[0070] Disinfection tank 620 C is loaded through another valve 320 CL with iodine disinfection, is then cooled using chiller 700 and pH adjusted using the pH system and control 400 / 800 to 8.5 to polarize the hypoiodous acid species within the disinfectant.
[0071] Disinfection tank 620 D is loaded through yet another valve 320 DL with iodine disinfectant and is then heated using a heater 100 and pH adjusted using the pH system and control 400 / 800 to 6.5 to polarize the elemental species of iodine within the iodine disinfectant.
[0072] Disinfectant tank 620 E is loaded through another valve 320 EL with iodine disinfectant and is then heated using the heater 100 and pH adjusted using the pH system and control 400 / 800 to 8.5 to polarize the hypoiodous acid species of the iodine disinfectant.
[0073] With each of the tanks 620 B to 620 E loaded with a disinfectant of specific iodine concentration and species, the system is now ready to dispense one or more of the disinfectant solutions for a desired use.
[0074] The system and method also uses an electronic controller 900 and its use in the system and method is now described. This controller 900 is programmable and receives inputs from multiple sensors (not shown) within the system. Sensors in retention tank 600 enable starting pump 400 to meter a supply of water from source 301 through heater ( 100 ) to heat the water to less than 80 degrees ° C. The water then passes through iodine cylinder 500 and produces a saturate of aqueous iodine which then fills retention tank 600 .
[0075] Level sensors (now shown) are provided in the tanks 620 B- 620 E and provide a signal to the controller to fill. Solenoid valve 301 V opens and water from supply 301 begins to flow. Flow sensor 775 sends a signal to the controller for pump 401 to proportionally blend iodine from retention tank 600 with water from supply 301 to create a pre-selected disinfection concentration of aqueous iodine to be provided to disinfection tanks 620 B-E via the valves 320 BL- 320 EL.
[0076] Once the disinfection tanks 620 B-E are filled, the controller closes solenoid valves ( 320 BL to 320 EL at the inlet of the tanks 620 B-E). Based on the particular program selected by the controller, water temperature and pH is sensed and adjusted in each tank individually.
[0077] When using the disinfectant solution for air borne or surface treatment, the disinfection tanks 620 B-E can be connected directly into the feed supply of the humidification/spray system and using solenoid valves ( 320 Bu-Eu), which are located at an outlet of the tanks 620 B-E. These valves 320 Bu-Eu are also operated by the controller ( 900 ). The controller ( 900 ) can modulate the programming of the valves ( 320 Bu-Eu) and provides for a vast variety of disinfection capabilities at the outlet 330 . This would include using just one of the tanks 620 B-E as a supply for disinfection or combining the solutions in one or more of the tanks 620 B-E as the supply for a desired disinfecting application.
[0078] As noted above, the disinfectant solution 330 can be used in any of the applications noted above as well as others that require disinfection where iodine is the appropriate disinfecting agent.
[0079] The system 950 also includes a shut off valve 325 . The shut off valve 325 isolates the outlets of the tanks. The shut off valve can also serve as a source of dilution water if the iodine solutions in the tanks 620 B-E need to be further diluted 620 B-E from the water supply. That is, the tank 600 can have a concentration of up to 600 ppm iodine and this saturate could be pumped to one or more of the tanks 620 B-E. This saturate could then be diluted by opening valve 325 and providing source water in this way.
[0080] The water source 301 can be filtered prior to its use with the inventive apparatus. Any filtering can be used, with a preferred filtering being a reverse osmosis system. The filter is designated by reference numeral 304 in FIG. 1 .
[0081] The apparatus provides a means for creating a second iodine solution in each tank, wherein the second iodine solution has a predetermined concentration of iodine and a predetermined iodine species in the tanks 620 B-E. This includes the ability to dilute the iodine concentrate, whether made or supplied from an external source, using the supply water and control the pH and temperature of the diluted solution for ultimate use in a disinfecting application, e.g., the pH control system 400 / 800 and heater 100 and chiller 700 .
[0082] The apparatus also includes means for making one or more of the second iodine solutions of a desired iodine concentration and desired iodine species from the plurality of tanks 620 B-E available for use in an application needing the desired iodine concentration and iodine species. This means includes the controller 900 and the outlet valves of the tanks 620 B-E since the controller is able to make the desired species and concentration in each of the tanks 620 B-E by temperature and pH adjustment and further control the flow of the second iodine solutions to provide one or more for desired applications, e.g., a spray/humidification system or any other application that can use one or more of the second iodine solutions).
[0083] The apparatus also includes means for creating a first iodine solution from the solid iodine, e.g., the diffuser-containing iodine cylinder adapted to receive temperature-controlled water, a tank for receiving and storing of the first iodine solution, and a system to monitor the iodine concentration in the tank.
[0084] FIG. 2 shows an alternative system and methodology of the invention and is designated by the reference numeral 960 . In this embodiment, the capability of producing the concentrated iodine solution for later dilution for tanks 620 B- 620 E is not included. Instead, the iodine concentration retention tank 600 is filled with a concentrate of aqueous by an external source. In this mode, the tank 600 and its connection to the line 601 feeding the tanks 620 B-E is made so that the tank 600 can be easily removed and replaced with another tank loaded with the desired iodine solution, e.g., a quick connect coupling.
[0085] FIG. 3 shows yet another system and method of the invention that is designated by reference numeral 970 . This embodiment puts the concentrated iodine solution making components on the back end of the tanks 620 B-E rather than upstream as shown in FIGS. 1 and 2 . Put another way, a feed water is prepared and then mixed on the fly with the iodine saturate for immediate use in a given application. Thus, the iodine saturate is proportionately blended directly into the prepared source water to produce the feed water for a humidification system or the like
[0086] In this embodiment, the iodine saturate providing means is designated by the number 750 and includes the same features as shown in FIG. 1 for making the iodine saturate from the supply water 301 . In FIG. 3 , the supply water for iodine saturate manufacture can be provided via line 715 . Also and in accordance with FIG. 2 , the ready made iodine saturate tank can be used with the appropriate pumps, etc. for supply of the saturate to the pH and temperature adjusted feed water from tanks 620 B-E.
[0087] In this embodiment, the tanks 620 B-E are controlled in terms of temperature and pH to produce to become an adjusted feed water supply. This adjusted feed water supply 340 , which is controlled using flow meter and totalizer 775 is then combined with the appropriate amount of iodine solution from the outlet 324 from the tank 600 as an output 345 , which can be delivered to a humidification/spray system. Since these humidification and spray system are well known, a detailed description of these systems is not necessary for understanding of the invention.
[0088] As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfills each and every one of the objects of the present invention as set forth above and provides a new and improved apparatus and method for supply iodine in a disinfecting solution for use in various applications needing disinfection using iodine.
[0089] Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claim. | A method and apparatus for producing aqueous iodine solutions to be used as a surface and aerosol disinfectant under continuous and dynamic flow conditions for medical applications comprises dissolving iodine into a first water flow thereby producing a concentrated aqueous iodine solution. The iodine solution is stored and then blended with a second water flow to produce a predetermined iodine disinfectant concentration of aqueous iodine. The disinfectant concentration is then stored and chemically adjusted to polarize to the species of iodine. The disinfectant concentration is then thermodynamically adjusted to maximize retention and disinfection variables. The iodine disinfectant is then ready to be used in an application requiring disinfection using iodine. | 1 |
BACKGROUND OF THE INVENTION
The instant invention relates generally to brushes and more specifically it relates to a flow-through brush fluid dispensing container.
Numerous brushes have been provided in prior art that are adapted to include bristles set in handles which are used especially for cleaning or painting. For example, U.S. Pat. No. 4,375,924 to Lemire; U.S. Pat. No. 4,863,302 to Herzfeld et al.; U.S. Pat. No. 5,294,207 to Keating et al. and Des. 282,318 to Herzfeld all are illustrative of such prior art. While these units may be suitable for the particular purpose to which they address, they would not be as suitable for the purposes of the present invention as heretofore described.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a flow-through brush fluid dispensing container that will overcome the shortcomings of the prior art devices.
Another object is to provide a flow-through brush fluid dispensing container that is a plastic squeeze bottle with a removable elongated bristle stem which applies barbecue sauce and the like through the bristle stem onto foods during the cooking of the foods and which has a long reach, so that the heat from the barbecue does not damage the bottle or burn the hands of the chef.
An additional object is to provide a flow-through brush fluid dispensing container in which the plastic squeeze bottle and the removable elongated bristle stem can be washed clean and reused again.
A further object is to provide a flow-through brush fluid dispensing container that is simple and easy to use.
A still further object is to provide a flow-through brush fluid dispensing container that is economical in cost to manufacture.
Further objects of the invention will appear as the description proceeds.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The Figures on the drawings are briefly described as follows:
FIG. 1 is a diagrammatic perspective view of the instant invention being used with an open barbecue grill;
FIG. 2 is a diagrammatic perspective view of the instant invention being used with a cooking range;
FIG. 3 is a diagrammatic perspective view of the instant invention per se with the filler cap exploded therefrom;
FIG. 4 is an enlarged end view taken in the direction of arrow 4 in FIG. 3;
FIG. 5 is an enlarged end view taken in the direction of arrow 5 in FIG. 3, illustrating the bottle being squeezed to help dispense the contents therein;
FIG. 6 is an enlarged diagrammatic side view of the components enclosed in the dotted curve indicated by arrow 6 in FIG. 3, with parts broken away and in section, showing the stem in greater detail and which may be manufactured in a variety of lengths.
FIG. 7 is an enlarged view of the components enclosed in the dotted circle indicated by arrow 7 in FIG. 3, with parts broken away and in section, showing an air release valve in a closed position; and
FIG. 8 is an enlarged view as indicated by arrow 8 in FIG. 3, with parts broken away and in section, showing the air valve being depressed in order to permit air to enter the bottle easily.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 8 illustrate a flow-through brush fluid dispensing container 10 comprising a squeeze bottle 12 for holding a liquid 14 therein. An elongated stem 16 extends from the bottle 12. A plurality of bristles 18 are disposed at a distal free end 20 of the stem 16, and receive the liquid 14 squeezed from the bottle 12 through the stem 16, so that the bristles 18 can be utilized to apply the liquid 14 onto various articles 22, such as food in an open barbecue 24 in FIG. 1 and food in a cooking range 26 in FIG. 2.
The squeeze bottle 12 consists of a flexible hollow body 28 that has a substantially flat base 30 at a first end and a hollow cylindrical neck 32 extending from a second end. A filler cap 34 is threaded into the flat base 30, so as to allow for insertion of the liquid 14 through the flat base 30 when the filler cap 34 is removed. A structure 36 that is disposed on a distal end of the hollow cylindrical neck 32 attaches the elongated stem 16 thereto in a removable manner. The elongate stem 16 is a hollow cylindrical tube 38, has the same outer diameter as the hollow cylindrical neck 32.
The attaching structure 36, shown in FIG. 6, is a small hollow cylindrical extension piece 40 that is integral with and extends from a distal end of the hollow cylindrical neck 32. The small hollow cylindrical extension piece 40 has an outer diameter substantially equal to an inner diameter of the hollow cylindrical tube 38. The hollow cylindrical tube 38 fits snugly onto the small hollow cylindrical extension piece 40 while permitting the liquid 14 to flow freely therethrough. The bristles 18 have a central channel opening 42 therethrough and extend from the hollow cylindrical tube 38, so that the liquid 14 can flow through the central channel opening 42 and saturate the bristles 18 for application onto the various articles 22.
The squeeze bottle 12 further includes a component 44 that may operate automatically or manually, so as to allow for venting air into the flexible hollow body 28, so that the liquid 14 can flow freely therefrom. The air venting component 44 is a push button air release valve 46 that is integrally formed with a bellows 56 and a valve seat 60 on the flexible hollow body 28, and when depressed by a finger 64 of a hand 48 of a person 50 holding the flexible hollow body 28 will allow air to enter therein.
The push button air release valve 46, as best seen in FIGS. 7 and 8, contains a plunger 52 extending through a wider aperture 54 in the flexible hollow body 28. A compressible cap 66 is integrally formed with a bellows 56 that has an air hole 58 therethrough. When the compressible cap 56 is pressed downwardly, as in FIG. 8, the plunger 52 will move the valve seat 60 away from the inner cooperating surface 62 of the container 28 and accordingly open the aperture 54, so as to allow air to pass through the air hole 58 and the aperture 54 into the flexible hollow body 28. The bellows serves the dual purpose of biasing the plunger outwardly, so as to maintain the valve seat in a normally closed position and also to help prevent dirt and other contaminants from entering the container.
OPERATION OF THE INVENTION
To use the flow-through brush fluid dispensing container 10, a person 50 simply attaches the hollow cylindrical tube 38 onto the hollow cylindrical extension piece 40 on the hollow cylindrical neck 32. The person 50 now grips the flexible hollow body 28 by his/her hand 48. The bottle 12 is squeezed to force some of the liquid contents 14 therein out through the brush 18 and on to the cooking food 22. Quite often, the contents 14 of a typical barbecue sauce can be reasonably viscous and thick. Accordingly when the grasp on the bottle is released the bottle will attempt to recover its undeformed original shape. It is at this point that air would normally gurgle slowly up through the sauce trapped within the neck 32 of the bottle and possibly drawing any charcoal or other food material into the contents 14 of the bottle and thus contaminating the contents of the bottle. Because of the differential of pressure created when the bottle attempts to recover its undeformed shape air will be automatically drawn in through the bellows 56 and valve seat 60. It now becomes apparent that this bellows valve arrangement has the two additional purpose of allowing the bottle to recover its shape quickly while at the same time preventing contaminates from being drawn up the neck.
Alternatively, when desirable the compressible cap 66 of the push button air release valve 46 can be pressed downwardly by the finger 64 while the bottle 12 is being held, and not squeezed, by the hand 48 and pointed toward the food 22. This allows a liquid 14 which is not viscous, but thin and quite fluid, to flow easily from the bottle 12 into the bristles 18 with a high degree of control without squeezing or deforming the bottle. The bristles 18 can now apply the liquid 14 onto the food articles 22.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention. | A flow-through brush fluid dispensing container comprising a squeeze bottle for holding a liquid therein, having a combine manual and automatic mechanism for venting air into the container. A removable elongated stem extends from the bottle for transferring the contents therein therethrough. A plurality of bristles are provided at a distal free end of the stem, for receiving the liquid squeezed from the bottle through the stem, so that the bristles can apply the liquid onto various articles and surfaces. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2013/060187 filed May 16, 2013, which designated the United States and has been published as International Publication No. WO 2014/183793 A1, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present invention relates to a method for operating a process and/or production installation. In addition, the present invention relates to an apparatus for operating a process and/or production installation.
In the planning and the operation of process and/or production installations, so-called tool chains are normally used. These consist of a number of engineering systems which are connected to one another along a predetermined operating sequence. In this context, output files are generated by the respective engineering systems which are transferred to the other engineering systems. For example, a signal list from a CAE program (CAE—Computer Aided Engineering) is used for programming control units. In this context, it is difficult to check dependences of the individual output files on one another. For example, an upper limit value is defined for the temperature measurement with a CAE tool. Later, this value is transferred, using export and import functions, to an engineering system which is used for controlling the control units. Later, this limit value can be changed by means of an engineering system or by a monitoring and control unit. By this means, inconsistencies between the data which are provided with the CAE tool and the data which are provided by the engineering system for controlling the control units can arise. In this process, the persons who operate the installation are not informed about these contradictions, however. In addition, version management is not supported in most of the engineering systems.
To solve this problem, different tools and/or processes are normally provided. Examples of this are organizational processes or engineering processes by means of which changes can be monitored. However, these special functions are usually used only in particular applications or engineering systems. For example, a so-called “upload” function is provided with the SIMATIC PCS 7 tool by means of which current parameters and values are transferred from the installation back into the associated engineering system. Usually, the operators of the installation are responsible for avoiding such inconsistencies. For the purpose of documentation and for project management, table calculation programs or text processing programs are normally used.
SUMMARY OF THE INVENTION
It is the object of the present invention to operate a process and/or production installation more reliably.
According to one aspect of the invention, the object is achieved by a method for operating a processing and/or production installation, including the provision of at least two engineering systems for respectively generating an output file which comprises an operating variable for at least one component of the process and/or production installation, the provision of a first output file by means of a first one of the engineering systems, the transmission of the first output file from the first one of the engineering systems to at least one second one of the engineering systems, the provision of a second output file by means of the at least second one of the engineering systems using the first output file and the operating of the process and/or production installation in dependence on the second output file, wherein first origin data which describe an origin of the first output file from the first one of the engineering systems and second origin data which describe an origin of the second output file from the second one of the engineering systems are provided.
The method can also be used for putting a processing and/or production installation into operation. At present, at least two engineering systems that are arranged in a predetermined operating sequence, a so-called tool chain, are used. A first output file is generated which comprises information on an operating variable of at least one component of the installation using the first engineering system. Such an operating variable can be, for example, a limit value for a temperature measurement of a component of the installation. This operating variable can be stored in a control unit of the installation. This first output file is transferred from the first engineering system to the second engineering system. The first output file is exported by the first engineering system and imported by the second engineering system. By means of the first output file, the second engineering system creates a second output file. This second output file can be used for operating the processing and/or production installation.
In addition to the first output file of the first engineering system, first origin data are provided which describe the origin of the first output file from the first engineering system. The first origin data provide information on the fact that the first output file was created with the first engineering system. In addition, second origin data are provided which describe an origin of the second output file from the second one of the engineering systems. By means of the first and second origin data, it is thus possible to track which output file comes from which engineering system. Thus, it is also possible to check which engineering system, for example, has provided or altered an operating variable.
Preferably, the second origin data are provided with second linkage data which exhibit a linkage to the first origin data. The second origin data can be provided, for example, together with the second linkage data in a common file. By means of the second linkage data, a direct link to the first origin data can be provided which specify that the first output file has been provided by the first engineering system. It is thus possible to examine the dependence between the output files in a simple manner.
In one embodiment, a timestamp and/or a version number are provided in addition to the first and the second origin data. By means of a timestamp, it is simple to track when an output file has been created by an engineering system. By means of a version number, it is possible to check in a simple manner how often an output file has already been changed. It is thus possible to discover any inconsistencies in the output files of the engineering systems.
In one embodiment, in the case of a change of the operating variable of the at least one component, the changed operating variable is transmitted from the second one to the first one of the engineering systems by means of the second linkage data. An operating variable of a component can be changed, for example, by an operating input or by an engineering system itself. In order to transfer this changed operating variable to all engineering systems, for example, an output file can be generated by the at least second engineering system which output file is transferred to the first one of the engineering systems in opposition to the direction of processing of the tool chain. The output file which is generated by the second one of the engineering systems can comprise the changed operating variable.
Preferably, an error message is generated if the changed operating variable is not transmitted from the second one to the first one of the engineering systems. By this means it is possible to ensure that the current operating variables are present in the engineering systems as basis for planning and/or controlling the installation.
In a further embodiment, the first origin files are provided in the first output file and the second origin files are provided in the second output file. Thus, the respective origin files can be transmitted to the engineering systems together with the associated output files. This makes it possible to guarantee reliably that the origin files are transmitted to the engineering systems.
As an alternative, the first and the second origin files are provided in each case in a separate file. The respective origin data can be collected in a higher-level file. This makes it possible to provide an overview of which files have been provided by which engineering system.
In a further embodiment, the first origin data are provided by the first one of the engineering systems and the second origin data are provided by the second one of the engineering systems. When generating the respective output file, the engineering system can generate the associated origin file at the same time. This variant is suitable, in particular, when the origin data are provided together with the respective output file. In a further embodiment, the first and the second origin data are provided by a separate computing facility. On this separate or higher-level computing facility, the current origin data can also be stored. Thus, a higher-level computing facility can be provided by means of which the output files and the associated origin data are managed. This makes it possible to prevent inconsistencies between the output files and the operating variables contained therein.
According to another aspect of the invention, the apparatus for operating a processing and/or production installation includes a multiplicity of engineering systems for respectively generating an output file which comprises an operating variable for at least one component of the process and/or production installation, wherein by means of a first one of the engineering systems, a first output file can be provided and transmitted from the first one of the engineering systems to at least one second one of the engineering systems, and wherein by means of the at least second one of the engineering systems, a second output file can be provided using the first output file and wherein the process and/or production installation can be operated with the apparatus in dependence on the second output file and wherein the apparatus is designed to provide first origin data which describe an origin of the first output file from the first one of the engineering systems and second origin data which describe an origin of the second output file from the second one of the engineering systems.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and developments previously described in conjunction with the method according to the invention can be transferred to the apparatus according to the invention.
The present invention will now be explained in greater detail by means of the attached drawings, in which:
FIG. 1 shows a diagrammatic representation of an apparatus for operating a process and/or production installation;
FIG. 2 shows a diagrammatic representation of the apparatus according to FIG. 1 according to a further embodiment;
FIG. 3 shows a timing schedule in which the provision of output files by engineering systems of the process and/or production installation is illustrated;
FIG. 4 shows a temporal representation according to FIG. 3 in a further embodiment;
FIG. 5 shows a diagrammatic representation of the apparatus in a further embodiment;
FIG. 6 shows a diagrammatic representation of the apparatus in a further embodiment;
FIG. 7 shows a diagrammatic representation of the apparatus in a further embodiment; and
FIG. 8 shows a diagrammatic representation for illustrating the creation of output files and origin data of the engineering systems.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The exemplary embodiments described in greater detail in the text which follows represent preferred embodiments of the present invention.
FIG. 1 shows a diagrammatic representation of an apparatus 10 for controlling a process and/or production installation. The apparatus 10 comprises at least two engineering systems. In the present exemplary embodiment, the apparatus 10 comprises three engineering systems 12 , 14 and 16 . The engineering systems 12 , 14 , 16 are arranged in succession in their process sequence in a tool chain. Each of the engineering systems 12 , 14 , 16 generates an output file which comprises information on at least one operating variable of the installation. In the present exemplary embodiment, the first one of the engineering systems 12 is a tool by means of which a pipeline and instrumentation plan of the installation can be provided. The first engineering system 12 generates a first file 20 which is transmitted to the second engineering system 14 . The second engineering system 14 is in the present case an engineering system by means of which a circuit diagram of the installation is provided. Using the first output file 20 which is provided by the first engineering system 12 , a second output file 22 is generated by the second engineering system 14 . The second output file 22 is transmitted to a third engineering system 16 . The third engineering system 16 is in the present exemplary embodiment a tool by means of which a program code for control units of the installation can be provided.
The first output file 20 comprises first origin data 30 . In the origin data 30 , an origin indication O is specified which indicates by which engineering system 12 , 14 , 16 the output file 20 has been generated. Furthermore, the origin file 30 comprises a timestamp T and a version indication V. Furthermore, an operating variable B which, in the present example, specifies a maximum value at a temperature measurement, is deposited in the origin file. In addition, the second timestamp. T 2 identifies the time of change of the operating variable B. Furthermore, the first origin file 30 comprises first linkage data 32 to the origin data of the engineering system or, respectively, origin files, from which the output file has been received. In the present case, the first linkage file 32 is empty since the first engineering system 12 has not received an output file from another engineering system. In the present case, the origin files 30 are integrated as header in a predetermined file format in the first output file 20 .
By means of the second engineering system 14 , a second output file 22 is generated by means of the first output file 20 . The second output file 22 , too, contains second origin data 34 which comprise an origin indication O, a timestamp T and a version indication V. In addition, the second origin data 34 comprise second linkage data 36 which establish a linkage to the first origin data 30 of the first output file 20 . The third output file 24 , too, comprises corresponding origin data 38 and third linkage data 40 which refer to the second origin data 34 .
In the present case, the operating variable B is now changed from 100° C. to 90° C. This change can be made, for example, by the third engineering system 16 or by a user input. The third output file 24 is transferred to a higher-level control unit 18 by means of which a change of the operating variable B can be detected. As a consequence of the change of the operating variable B, a fourth output file 26 , which is transferred to the second engineering system 14 , is generated by the third engineering system 16 . Furthermore, a fifth output file 28 , which is transferred to the first engineering system 12 , is generated by the second engineering system 14 . The fifth output file 26 comprises fifth origin data 42 and fifth linkage data 44 . The sixth output file 28 comprises sixth origin data 46 and sixth linkage data 48 . Thus, the change of the operating variable B can be transferred to all engineering systems 12 , 14 , 16 and inconsistencies can thus be avoided.
FIG. 2 shows a diagrammatic representation of the apparatus 10 in a further embodiment. In this case, the second engineering system 14 is used as a central node. In the present case, a sample 50 for a circuit diagram is supplied to the second engineering system 14 . Using this sample 50 , the second engineering system 14 can create a circuit diagram 52 in dependence on information or the output file 20 from the first engineering system 12 .
Using a higher-level control unit 18 by means of which linkages between the engineering systems 12 , 14 , 16 are deposited, for example, by means of the respective linkage data 32 , 36 , 40 , 44 , 48 , it is possible to verify inconsistencies in the output files 20 , 22 , 24 , 26 , 28 and the operating variables B.
FIG. 3 shows a timeline of the generation of the output files 20 , 22 , 24 , 26 , 28 with the engineering systems 12 , 14 , 16 according to the example of FIG. 1 . In the present example, the second engineering system 14 generates an output file which is not transmitted to the first engineering system 12 . In consequence, the operating variable B was not updated in the first engineering system 12 . By means of the higher-level control unit 18 , a corresponding warning signal is now output which provides an indication that inconsistencies can exist in the output files 20 , 22 , 24 , 26 , 28 or the operating variables B, respectively.
FIG. 4 shows a further example of a timeline of generating the output files 20 , 22 , 24 , 26 , 28 of the engineering systems 12 , 14 , 16 . In the present case, a seventh output file 20 ′ is generated by means of the first engineering system 12 which, however, is not transmitted to the second engineering system 14 . In the second engineering system 14 , the operating variable B is stored which was transferred to the second engineering system from the third engineering system 16 in consequence of the change. Using the higher-level control unit, it is possible to check, by means of the origin data of the output files, the version number V, the timestamp T and the origin indications O whether there are inconsistencies in the data. In this context, it can also be provided that, in the case of changes within the installation or during the creation of revisions, an output file is generated automatically by the respective engineering system 12 , 14 , 16 . In this context, it can also be sufficient if, instead of the complete output file, only the origin data 30 , 34 , 38 , 42 , 46 are transmitted.
For the origin data 30 , 34 , 38 , 42 , 46 , standardized headers can be used. In principle, there are two options for providing the header. On the one hand, headers can be provided in the respective output files 20 , 22 , 24 , 26 , 28 . As an alternative, the headers can be stored with the origin data 30 , 34 , 38 , 42 , 46 in a separate file. If only one file is provided, the output files and the associated header can be provided with the origin data with different file changes. The header can then be provided directly with the respective engineering system 12 , 14 , 16 or with a separate computing facility. This separate computing facility can be activated, for example, by the respective engineering system 12 , 14 , 16 . As an alternative, the separate computing facility can read out corresponding storage areas in the engineering systems 12 , 14 , 16 at predetermined times.
FIG. 5 shows a diagrammatic representation of the apparatus 10 , in which a number of data are used for the respective output files 20 , 22 , 24 , 26 , 28 , which are stored in a common storage facility. The associated header files with the origin data are also stored in the storage facility with a separate file name and a separate ending. For example, three output files 20 , 20 ′ and 20 ″ and respectively associated origin data 30 , 30 ′ and 30 ″ are generated successively in time with the first engineering system. In order to be able to differentiate between the origin data 30 , 30 ′, 30 ″, the timestamps T can be used, for example. By means of the origin indications O, it is possible to distinguish whether the files have been imported from another engineering system or have been changed by the engineering system 12 , 14 , 16 itself. By this means, it is possible to verify in a simple manner by which engineering system 12 , 14 , 16 a change has been effected. This information can be used, for example, for the management of the installation or, in the worst case, for evaluating damages in the installation. In this context, the origin data can also be designed in such a manner that it cannot be changed, for example by the operator of the installation.
Apart from origin data, an additional functionality can be provided in that, for the respective output files, a reference to the origin of the output files 20 , 22 , 24 , 26 , 28 is stored. This information can also be stored in a separate storage facility in order to avoid changes in the existing systems. Thus, the references between the individual output files 20 , 22 , 24 , 26 , 28 and the engineering systems 12 , 14 , 16 , respectively, can be identified.
FIG. 6 shows a diagrammatic representation of the apparatus 10 in a further embodiment. In this context, an importation of output files 20 into the second engineering system 14 is initiated by an administrator 54 . In this context, the first origin files 30 are initially transferred from the first engineering system 12 to the second engineering system 14 . Following this, the first output file 20 is transferred from the first engineering system 12 to the second engineering system 14 . Beginning with the output files 20 a originally stored in the second engineering system 14 , output data 22 and origin data 34 are created by the first engineering system 12 by means of the first output files 20 and the first origin data. By means of the second engineering system 14 , it is now possible to generate by means of the second origin data 34 a corresponding header which has a reference to the first origin data 30 of the first engineering system 12 . As an alternative, a second output file 22 ′ can be provided by means of the second engineering system 14 and a separate computing facility generates the origin data 34 from the second output file 22 ′.
FIG. 7 shows the apparatus 10 in a further diagrammatic representation. In this exemplary embodiment, the second engineering system 14 is designed to store timestamps T and changes. However, the second engineering system 14 is not designed to provide corresponding origin data or linkage data. In the present case, a second output file 22 ′ is generated by means of the second engineering system 14 using the first output file 20 from the first engineering system 12 . Providing the second output file 22 ′ addresses a higher-level control unit 18 . In the higher-level control unit 18 , the configuration of the engineering systems 12 , 14 , 16 is deposited. Using this information, the higher-level control unit 18 can generate origin data 34 ′. These second origin data 34 ′ also comprise linkage data 36 ′ which exhibit a linkage to the first origin data 30 of the first engineering system 12 . A project manager 56 of the installation can check by the data deposited in the higher-level control unit 18 the references between the engineering systems 12 , 14 , 16 , and the associated output files or origin data, respectively. In addition, the linkage between engineering systems 12 , 14 , 16 can be represented to the project manager 56 in a first representation 58 . As an alternative, the generation of output files of the engineering systems 12 , 14 , 16 can be represented to the project manager 56 in dependence on time t in a second graphic representation 60 .
For the creation of output files and origin data, corresponding samples can be used. This is illustrated diagrammatically in FIG. 8 . The use of samples is particularly suitable for heterogeneous engineering systems which are used, for example, for mechanical, electrical or automation fields. In the present case, corresponding samples are used for output files 62 , 64 , 66 by the engineering systems 12 , 14 , 16 . Using the samples 42 , 44 , 46 , an origin file 30 , 34 , 38 is generated in each case by means of the engineering systems. The information from the origin data 30 , 34 , is in each case used for creating corresponding samples 68 , 70 , 72 for origin data. In addition, information from the origin data 30 , 34 , 38 is supplied to a higher-level sample 74 for origin data. Thus, corresponding standards can be provided for the samples which can be used for planning and controlling the installation.
By means of the apparatus 10 described before, the dependences between the engineering systems 12 , 14 , 16 and the associated output files can be determined in a simple manner on the basis of the origin data and the linkage data. Thus, changes, for example of the operating variables B, can be tracked in a simple manner. In addition, no additional version management is needed. Furthermore, the operators of the installation are able to obtain an overview of the linkages between the engineering systems in a simple manner. | The invention relates to a method for operating a processing and/or production installation having at least two engineering systems producing a respective output file including an operating variable for at least one component of the installation. The first output file of a first engineering system is transmitted from the first engineering system to a second engineering system. A second output file is provided by a second engineering system using the first output file, and the processing and/or production installation being operated using the second output file. first origin data describing an origin of the first output file of the first engineering system, and second origin data describing an origin of the second output file from the second engineering system. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and incorporates by reference copending U.S. Provisional Application Ser. No. 60 / 433 , 927 , filed Dec. 18 , 2002 .
BACKGROUND OF THE INVENTION
SUMMARY OF THE INVENTION
[0002] This invention relates to devices for maintaining liquids contained in smooth or threaded-neck bottles and cans in a cold or warm state and more particularly, to heat-exchanging tubular devices for cooling or heating liquids in such bottles and cans. The devices include a cooling/heating tube, fitted in one embodiment with a seal near one end and containing one or more refrigerant/heating fluids such as water or an artificial liquid refrigerant, typically known as “blue ice”, as well as other liquids. In one embodiment a single refrigerant or heating liquid is contained and sealed in the tube. In other embodiments a pair of separate, but connected containers create a selected exothermic or endothermic reaction and condition when mixed on demand in the tube. The upper portion of the tube, or a tube connector extending the tube above the seal in the single-liquid first embodiment, is provided with openings which are disposed below a cap to which the tube or tube connector is attached, the cap typically having internal threads for attachment to the threaded bottle neck. In each threaded cap embodiment, a central opening or spout communicates with the openings in the tube connector or tube to facilitate drinking the liquid in the bottle when the bottle containing the tube is inverted in conventional fashion. Furthermore, the typically resilient, and/or flexible internal threads in the cap are designed to removably and threadably engage the threaded bottle or can neck to facilitate extending the cooling/heating tube inside the bottle or can and in contact with the liquid contents when the cap is threaded on the bottle or can neck. In the dual-container embodiment, when the tube is seated in the bottle or can and at least partially submerged in the liquid contained in the vessel and the cap is threaded on the bottle or can neck, the contents of the bottle or can may be maintained in a cool, cold, hot or warm state, depending upon the nature and properties of the fluids in the inserted tube containers, responsive to pressing a button at the bottom of the tube to effect mixing of the liquids in the containers. The liquid in the bottle or can may then be removed for drinking by inverting the bottle or can in conventional fashion. This inversion facilitates a flow of liquid from the bottle or can through the openings in the upper portion of the cooling tube or the tube connector and through the spout in the cap, to the user. In a preferred design the cap includes a sports valve that slides on the spout for sealing the contents of the bottle or can against spillage or leakage due to inadvertent inversion or dropping of the vessel. In a third preferred embodiment, the cooling/heating tube or the dual reservoirs or containers themselves may be inserted in a pre-formed, elongated opening or sleeve molded or otherwise provided in the bottle or can and extending from the bottom thereof, and a button is pressed to rupture a membrane dividing the contents of the containers in the tube to mix the liquids and effect either an exothermic reaction or an endothermic reaction and cool or heat the contents of the bottle or can. In this design the contents of the bottle or can are poured from the spout or neck opening in conventional fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The invention will be better understood by reference to the accompanying drawings, wherein:
[0004] FIG. 1 is a perspective view of a first preferred embodiment of the device for cooling or heating liquids of this invention, more particularly illustrating a perforated cooling or heating tube inserted in and attached to a conventional bottle for cooling or heating and drinking a liquid contained in the bottle as the bottle and tube are oriented in an inverted position;
[0005] FIG. 2 is an exploded view of the first embodiment bottle and tube combination illustrated in FIG. 1 , with the bottle in upright configuration and the cooling/heating tube extended from the bottle, more particularly illustrating a preferred cooling/heating tube structure;
[0006] FIG. 3 is an exploded view of the cooling/heating tube illustrated in FIG. 2 , more particularly illustrating the elongated cooling/heating tube, a seal joining the upper end of the tube to a tube connector fitted on an internally-threaded cap for engaging the bottle and a valve for sealing the contents of the bottle against inadvertent spillage or leakage;
[0007] FIG. 4 is a sectional view taken along line 4 - 4 of the inverted first embodiment bottle and cooling/heating tube illustrated in FIG. 1 , more particularly illustrating a typical flow path of liquid in the bottle through openings in the upper portion or tube connector of the cooling/heating tube and through the spout in the cap, to a user.
[0008] FIG. 5 is a perspective view, partially in section, of a second preferred embodiment of the cooling/heating tube of this invention, fitted with a flexible and/or resilient cap and gasket for mounting the cooling/heating tube in a bottle;
[0009] FIG. 6 is a perspective and longitudinal sectional view of the cooling/heating tube illustrated in FIG. 5 ;
[0010] FIG. 7 is a perspective and longitudinal sectional view of the bottom end of the cooling/heating tube illustrated in FIGS. 5 and 6 , more particularly illustrating the push-button actuating element;
[0011] FIG. 8 is a top perspective view of an alternative cap for connecting the cooling/heating tube to a bottle or can;
[0012] FIG. 9 is a longitudinal sectional view of the cooling/heating tube illustrated in FIGS. 5 and 6 ;
[0013] FIG. 10 is a longitudinal sectional view of the middle and lower end of the heating/cooling tube illustrated in FIG. 9 , more particularly illustrating actuation of the push-button and mixing of the liquid contents of the two containers responsive to upward movement of the push-button;
[0014] FIG. 11 is a sectional view of the bottom end of the cooling/heating tube and the push-button, more particularly illustrating a push-button clip attached to the push-button and positioned in non-engaging configuration with respect to a recess in the interior cooling/heating tube wall;
[0015] FIG. 12 is a sectional view of the bottom end of the cooling/heating tube and the push-button, more particularly illustrating the push-button clip engaging the recess in the interior cooling/heating tube wall to prevent return of the push-button to its original position in the cooling/heating tube;
[0016] FIG. 13 is an exploded view of the straw, top container neck, gasket seal and bottom container neck configuration illustrated in FIG. 9 .
[0017] FIG. 14 is a perspective view, partially in section, of another preferred embodiment of the invention wherein the internal components of the cooling/heating tube are positioned in a sleeve or cavity molded or otherwise provided in a bottle or can;
[0018] FIG. 15 is a sectional view of the tube component embodiment illustrated in FIG. 14 ;
[0019] FIG. 16 is a sectional view of the lower end of the tube component embodiment illustrated in FIGS. 14 and 15 , with a break-away cap illustrated in place over the push-button element;
[0020] FIG. 17 is a perspective, exploded and sectional view of another embodiment of the invention wherein a cooling/heating tube is inserted in a sleeve or cavity provided in a bottle or can; and
[0021] FIG. 18 is a perspective and sectional view of the cooling/heating tube provided with threads and threaded in the sleeve or cavity provided in the bottle or can.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring initially to FIGS. 1-4 of the drawings, a first preferred device for cooling or heating liquids of this invention is generally illustrated by reference numeral 1 . The device 1 is designed to removably seat in a conventional bottle 29 (or a can) having a bottle neck 30 , fitted with neck threads 31 and typically having a neck flange 32 (illustrated in phantom) for normally receiving a cap (not illustrated), threaded on the neck threads 31 . The device 1 is further characterized by an elongated cooling/heating tube 2 which may be of sufficient length to insert inside a bottle 29 of desired height and size and become at least partially submerged in the contents. The cooling/heating tube 2 is designed to receive a refrigerant/heating (heat transfer) fluid 7 ( FIG. 4 ), including water or an artificial fluid, gel or freezable refrigerant or ice substitute such as “blue ice” or methyl-cellulose product, and the like, in non-exclusive particular. The cooling/heating tube 2 is characterized by a cylindrical tube wall 6 that defines a tube bore 3 ( FIG. 3 ) having a selected diameter or cross-section which is commensurate with the diameter or cross-section of the bottle 29 , and is bounded by a closed bottom end 4 and an open top end 5 , as illustrated in FIG. 3 . The tube wall 6 is typically cylindrical and may have any desired thickness consistent with an acceptable heat transfer coefficient. However, it will be appreciated that the tube wall 6 may define an alternative configuration, as desired.
[0023] Referring again to FIGS. 2 and 3 of the drawings in this first preferred embodiment of the invention the top end 5 of the cylindrical cooling/heating tube 2 receives a tube connector 8 , typically having a cylindrically-shaped connector wall 9 that corresponds in size to the diameter of the tube wall 6 of the cooling/heating tube 2 , with the open connector bottom 11 of the tube connector 8 tightly fitted on the upper seal stopper 15 of a seal 14 . The top end of the tube connector 8 is fixed to a cap 19 , having a cap wall 20 , fitted with internal cap wall threads 21 ( FIG. 2 ). Similarly, the top end 5 of the cooling/heating tube 2 is tightly seated on the lower seal stopper 16 of the seal 14 and the connector bottom 111 and top end 5 seat tightly and hermetically against a stopper spacer 17 of larger diameter, which divides the upper seal stopper 15 and the lower seal stopper 16 of the seal 14 . In this manner the tube connector 8 is removably and hermetically connected to the cooling/heating tube 2 , such that the fluid contents of the cooling/heating tube 2 , typically a refrigerant or heating fluid 7 , ( FIG. 4 ) located inside the tube bore 3 of the cooling/heating tube 2 cannot exit the cooling/heating tube 2 . An air space 13 is typically provided in the tube bore 3 of the cooling/heating tube 2 as necessary ( FIG. 4 ), to facilitate expansion of the refrigerant/heating fluid 7 under circumstances where the refrigerant/heating fluid 7 is water or a synthetic fluid that expands as it is heated or changes from the liquid to the frozen state.
[0024] As further illustrated in FIGS. 3 and 4 of the drawings, a connector bore 12 is defined by the cylindrical or tubular connector wall 9 of the tube connector 8 , and the connector bore 12 communicates with the spout opening or bore 24 of a spout 23 , which spout opening 24 also communicates with one or more flow openings 10 , provided in the connector wall 9 of the tube connector 8 ( FIG. 4 ). Accordingly, a consumable liquid 33 contained inside the bottle 29 is able to flow downwardly in the direction of the arrows illustrated in FIG. 4 , from the inverted bottle 29 , through the flow openings 10 in the connector wall 9 of the tube connector 8 and subsequently, through the spout opening 24 of the spout 23 , to the user.
[0025] In another preferred aspect of this embodiment of the invention, a sports valve 25 slides on a valve seat 26 of the spout 23 in the cap 19 and the sports valve 25 includes a valve opening 27 , illustrated in FIG. 1 , to facilitate exit of the bottle liquid 33 from the inverted bottle 29 directly into the mouth of a user. As further illustrated in FIG. 3 a valve cap or cover 28 may be seated over the valve 25 and removably attached to the cap wall shoulder 22 of the cap wall 20 in a friction-fit, to maintain the valve opening 27 free of dust and debris. Furthermore, whether or not a sports valve 25 is utilized in connection with the inverted bottle 29 , the cap 19 , fitted with internal cap wall threads 21 in the cap wall 20 ( FIG. 2 ), is designed to thread on the bottle neck 30 of the bottle 29 by engagement of the cap wall threads 21 and the neck threads 31 , respectively. This connection seals the cap 19 on the bottle 29 and facilitates a flow of bottle liquid 33 from the interior of the bottle 29 , around the cooling/heating tube 2 , through the flow openings 10 and the spout opening 24 in the spout 23 and through the valve opening 27 , when the bottle 29 is inverted.
[0026] In an alternative embodiment, it will be recognized by those skilled in the art that the sports valve 25 can be removed and the spout opening 24 provided in the top of the cap 19 without a closure and with an optional valve cap or cover 28 ( FIG. 3 ) which typically seats over the cap wall shoulder 22 in a friction-fit to removably cover the spout opening 24 against entry of dust and debris.
[0027] In yet another aspect of this first preferred embodiment of the invention the cooling/heating tube 2 can be designed with the tube connector 8 integrally formed with the cooling/heating tube 2 and the flow openings 10 provided in the upper portion of an integral tube wall 6 of selected length and shape, with a stopper or seal 14 of suitable size tightly and hermetically fitted in the tube bore 3 of the cooling tube 2 to seal the refrigerant/heating fluid 7 inside the cooling/heating tube 2 from the flow openings 10 . Accordingly, the upper end of the tube 2 which is fitted with the flow openings 10 can be attached to the cap 19 such that the cap 19 and the cooling/heating tube 2 are removably threaded onto the bottle neck 30 of the bottle 29 by engaging the neck threads 31 and the corresponding internal cap wall threads 21 in the cap wall 20 . This facility and design eliminates the necessity of providing a separate tube connector 8 and a specially designed seal 14 , illustrated in FIG. 3 of the drawings. In this alternative design it will be further understood that a sports valve 25 may be utilized in connection with the cap 19 or may be eliminated in favor of a cap wall shoulder 22 and the provision of a removable valve cap 28 that snaps onto the cap wall shoulder 22 in a friction-fit, as described above.
[0028] The following tables illustrate the function of the device for cooling or heating liquids, as the liquid in the bottle contacts the heated, cooled or frozen device:
TABLE I 16 oz. bottle containing Gatorade out of refrigerator, with a cooling device containing ice located inside the bottle: Gatorade temperature measurements taken while bottle is in the refrigerator: Room temperature 72° F. Time 1:48 p.m. 42.6 F. (starting temperature) 1:50 p.m. 42.6 F. 1:52 p.m. 42.6 F. 1:54 p.m. 42.6 F. 1:57 p.m. 42.8 F. 2:00 p.m. 43.3 F. 2:05 p.m. 44.4 F. 2:10 p.m. 45.9 F. 2:15 p.m. 48.0 2:20 p.m. 49.3 F. 2:30 p.m. 51.3 F. 2:35 p.m. 53.1 F. 2:40 p.m. 54.0 F. (ending temperature)
[0029]
TABLE II
16 oz. bottle containing Gatorade;
cooling device containing frozen “blue ice”: Gatorade
measurements taken with bottle out
of refrigerator. Room temperature- 72° F.
TIME
1:25 p.m.
57.7 F. (starting temperature)
1:29 p.m.
52.7 F.
1:33 p.m.
51.4 F.
1:37 p.m.
51.4 F.
1:41 p.m.
52.0 F.
1:45 p.m.
52.7 F. (ending temperature)
[0030]
TABLE III
24 oz. bottle containing Gatorade;
cooling device containing frozen “blue ice”: Gatorade
measurements taken with bottle out of refrigerator
and sports valve in place. Room temperature-
86° F.
TIME
2:28 p.m.
50.4 F. (starting temperature)
2:31 p.m.
51.1 F.
2:33 p.m.
52.0 F.
2:35 p.m.
53.4 F.
2:50 p.m.
64.6 F.
2:53 p.m.
66.2 F. (ending temperature)
[0031]
TABLE IV
24 oz. bottle containing Gatorade;
cooling device containing frozen “blue ice”: Gatorade
measurements taken at room temperature- 86° F.
TIME
2:56 p.m.
67.1 F. (starting temperature)
2:59 p.m.
59.2 F.
3:00 p.m.
59.9 F.
3:18 p.m.
69.3 F.
3:21 p.m.
70.0 F. (ending temperature)
[0032] The examples illustrate the versatility and effectiveness of the device of this invention in cooling and heating liquids in bottles in the first preferred embodiment of this invention. The device 1 is simple, easy and inexpensive to construct and effective for its intended purposes.
[0033] Referring now to FIGS. 5-13 of the drawings, in a second preferred embodiment of the invention a second device for cooling or heating liquids is generally illustrated by reference numeral 40 and includes a second cooling/heating tube 41 , which is designed to fit inside a conventional bottle 29 , through the bottle neck 30 and into a bottle liquid 33 (illustrated in FIG. 4 ). The elongated second cooling/heating tube 41 encloses a top container 46 , which is positioned in inverted configuration, with a top container neck 47 extending downwardly, typically into a gasket seal 64 , as further illustrated in FIGS. 6, 9 and 10 . The top container 46 is filled with a top container liquid 50 ( FIG. 9 ) and is supported in the second cooling/heating tube 41 at a top container seat 49 . A top container stop 48 is provided near the top of the second cooling/heating tube 41 to facilitate snugly seating the top container 46 inside the second cooling/heating tube 41 , between the top container stop 48 and the top container seat 49 , as illustrated. In a preferred aspect of this embodiment of the invention a typically flexible and/or resilient gasket 42 is provided on the gasket cap 43 at the top end 5 of the second cooling/heating tube 41 , to facilitate threading the gasket threads 42 a in the flexible gasket 42 on the existing conventional neck threads 31 provided on the bottle neck 30 of the bottle 29 . A spout opening 44 a is provided in a cap spout 44 , shaped in the gasket cap 43 and the spout opening 44 a communicates with the open top end 5 of the second cooling/heating tube 41 and one or more flow apertures 45 , provided in the open top end 5 to facilitate pouring the consumable bottle liquid 33 from the bottle 29 , through the respective flow apertures 45 and the open top end 5 and from the cap pour opening 44 when the bottle 29 is inverted for drinking purposes with the second cooling/heating tube 41 in place, as heretofore described with respect to the first preferred embodiment of the invention illustrated in FIGS. 1-4 of the drawings.
[0034] A bottom container 51 is also seated in the second cooling/heating tube 41 , beneath the top container 46 , with a bottom container neck 52 facing upwardly and aligned with or slidably receiving the downwardly-extending top container neck 47 , and also typically engaging the gasket seal 64 . As illustrated in FIG. 9 , a seal 54 , which may be either wax, thin plastic, aluminum foil or the like, is compatible with the heating/cooling reagents and is typically provided in the bottom container neck 52 of the bottom container 51 to prevent the top container liquid 50 from flowing into the bottom container liquid 53 located in the bottom container 51 . While the top container neck 47 may be smaller than the bottom container neck 52 and slidably fitted therein adjacent to the seal 54 , in a preferred arrangement, a tube or straw 62 is inserted in the gasket seal 64 and extends upwardly for fixed attachment inside the top container neck 47 . The straw 62 also projects downwardly and slidably into the bottom container neck 52 adjacent to the seat 54 , to connect the top container 46 and the bottom container 51 , as further illustrated in FIG. 9 of the drawings. The straw 62 connections are typically sealed by the gasket seal 64 . The straw edge or lip 63 is positioned adjacent to the seal 54 on the straw 62 at the space 52 a ( FIG. 9 ) and is sufficiently stiff to penetrate and rupture the seal 54 , as hereinafter described. A straw ring 65 is provided on the straw 62 between the extending ends of the top container neck 47 and the bottom container neck 52 to stabilize the straw 62 in place, as illustrated in FIGS. 9 and 10 . As further illustrated in FIG. 9 , a push-button 55 is slidably seated in the bottom end 4 of the second cooling/heating tube 41 and rests against the inside bottom of the bottle 29 , for purposes which will be hereinafter described. A bottom end cap 4 a is applied in a friction-fit to the bottom end 4 of the second cooling/heating tube 41 to protect the push button 55 prior to removal and insertion of the second cooling/heating tube 41 into the bottle 29 ( FIG. 5 ).
[0035] Referring now to FIGS. 5-7 , 9 - 12 , 17 and 18 of the drawings, a push-button 55 is slidably captured in the bottom end 4 of both the second cooling/heating tube 41 and a third cooling/heating tube 67 of a third device for cooling or heating liquids 66 ( FIGS. 17 and 18 ) and in the latter case, communicates with a bottle sleeve 34 ( FIG. 17 ) that is molded or otherwise provided in the bottom of the bottle 29 . For example, as further illustrated in FIG. 17 , a bottle depression 36 typically extends from the side of the bottle 29 to the sleeve interior 34 a of the bottle sleeve 34 that receives the third cooling/heating tube 67 , to facilitate slidable upward movement of the push-button 55 , as hereinafter further described. In both embodiments a push-button gasket 56 is typically seated on the push-button 55 adjacent to a round push-button flange 57 ( FIGS. 9 and 10 ) to seat the push-button 55 in the bottom end 4 of the second cooling/heating tube 41 and the third cooling/heating tube 67 . One or more, spaced-apart push-button clips 59 are typically molded or otherwise provided in the inside wall of the second cooling/heating 41 and the third cooling/heating tube 67 , adjacent to the push-button gasket 56 of the push-button 57 ( FIGS. 11 and 12 ) and are designed to position the push-button 55 in the third cooling/heating tube 67 (as well as the second cooling/heating tube 41 ) in a desired upwardly-displaced position, as further hereinafter described. When installed, the push-button 55 engages the bottom end of the bottom container 51 in the second cooling/heating tube 41 , as further illustrated in FIGS. 9 and 10 of the drawings. The push-button 55 which is mounted in the third cooling/heating tube 67 illustrated in FIGS. 17 and 18 is typically likewise configured and seated therein.
[0036] In yet another preferred embodiment of the invention the third device for cooling or heating liquids 66 includes a third cooling/heating tube 67 which is typically provided in a preferred design with tube threads 68 ( FIG. 18 ) that engage corresponding sleeve threads 34 b provided in the bottle sleeve 34 , extending into the interior of the bottle 29 from the bottom end thereof, for accommodating the third cooling/heating tube 67 . Alternatively, it will be appreciated from a consideration of FIG. 17 of the drawings, that the third cooling/heating tube 67 can be typically inserted in a bottle sleeve 34 provided in the bottle 29 at the bottom end of the bottle 29 in a friction-fit or maintained therein by other techniques known to those skilled in the art, rather than using the tube threads 68 illustrated in FIG. 18 .
[0037] As illustrated in FIGS. 14-16 of the drawings, in still another alternative embodiment of the invention, the internal components of the third cooling/heating tube 67 can be manufactured in place inside the bottle sleeve 34 of the bottle 29 or installed therein after manufacture of the bottle 29 and bottle sleeve 34 , according to techniques known to those skilled in the art. Accordingly, the top container 46 , with a supply of top container liquid 50 and the bottom container 51 , with a supply of bottom container liquid 53 , connected as described above at a gasket seal 64 , can be inserted in or assembled in the sleeve interior 34 a of the bottle sleeve 34 , with the push-button 55 slidably captured in and protruding from the bottom end of the bottle sleeve 34 , as illustrated. Accordingly, as illustrated in FIG. 15 , the bottle depression 36 in the bottom of the bottle 29 can be shaped to terminate inwardly in a push-button seat ring 58 that engages the push-button flange 57 and captures the push-button 55 in the bottom end of the bottle sleeve 34 .
[0038] In operation, and referring again to FIGS. 5-18 of the drawings, in the embodiments detailed above regarding the second cooling/heating tube 41 and the third cooling/heating tube 67 , after the respective cooling or heating tubes ( FIGS. 5-13 , 17 and 18 ) or tube components ( FIGS. 14-16 ) are provided with caps or inserted in the corresponding bottle sleeves 34 in the bottle 29 , respectively, cooling or heating of the bottle liquid 33 in each case is effected by the following procedure: Under circumstances where the flexible gasket or cap 42 of the second cooling/heating tube 41 is tightly threaded on the bottle neck 30 pressure is exerted on the push button 55 , forcing it upwardly. If the bottom end 4 of the third cooling/heating tube 67 is covered by a break-away cap 70 , typically as illustrated in FIGS. 15 and 16 , the break-away cap 70 is initially removed from the bottom end of the bottle 29 , thus exposing the push-button 55 . The exposed push-button 55 is then pushed upwardly, thus forcing the bottom container 51 in the third cooling/heating tube 67 upwardly in each case, as illustrated in FIGS. 10-12 . Both actions force the seal 54 in the bottom container neck 56 against the straw lip 63 of the straw 62 , thus rupturing the seal 54 ( FIG. 10 ) and allowing the top container 50 liquid to flow through the straw 62 and into the bottom container liquid 53 located in the bottom container 51 , to define a heating or cooling liquid mixture 72 . The push-button 55 is typically maintained in the upward position by operation of the push-button clip or clips 59 that lie adjacent to a corresponding clip seat or seats 59 a , provided in the internal wall of the respective second and third cooling/heating tubes 41 and 67 , ( FIGS. 11 and 12 ), to facilitate a steady flow of top container liquid 50 into the bottom container liquid 53 . Mixing of the top container liquid 50 with the bottom container liquid 53 into the liquid mixture 72 ( FIG. 10 ) causes either a heating or cooling effect inside the second cooling/heating tube 41 or the third cooling/heating tube 67 , or in the bottle sleeve 34 where no tube is used, as illustrated in FIGS. 14-16 , depending upon the properties of the top container liquid 50 and bottom container liquid 53 , thus cooling or heating the consumable bottle liquid 33 in the bottle 29 . Since the bottle sleeve 34 serves the same purpose as the second and third cooling/heating tubes 41 and 67 , pressing the push button 55 operates to commingle the top container liquid 50 and bottom container liquid 53 in the same manner as described above with respect to the devices illustrated in FIGS. 5-13 and 17 - 18 . Typical cooling reagents are ammonium thiocyanate and ammonium hydroxide, although various other cooling/heating reagents can be used, according to the knowledge of those skilled in the art. Drinking of the bottle liquid 33 is then effected by inverting the bottle 29 in conventional fashion to facilitate a flow of bottle liquid 33 from the interior of the bottle 29 , through the flow apertures 45 in the gasket cap 43 and the open top end 5 , in the case of the second cooling/heating tube 41 , or directly through the bottle neck 30 of the bottle 29 , in the case of the third cooling/heating tube 67 inserted in the bottle sleeve 34 , or the sans tube embodiment illustrated in FIGS. 14-16 , all as heretofore described with respect to the first device for cooling or heating liquids 1 illustrated in FIGS. 1-5 .
[0039] While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | Heat-exchanging devices for cooling or heating liquids in a bottle or can, which include in a first embodiment, an elongated cooling or heating tube having a tube bore filled with a refrigerant/heating fluid such as water and sealed at the top, with liquid flow openings provided in the tube, or in a tube connector attached to the tube above a tube seal. The tube or tube connector is fitted with a cap having internal threads for engaging the external threads of the bottle neck of the bottle into which the cooling tube is inserted. In second and third embodiments the insertable tube contains a pair of interconnected reservoirs containing liquids that will create an exothermic or endothermic reaction when mixed. A disc separating the liquids is ruptured by button action at the base of the tube to facilitate mixing of the liquids by gravity. Access to the cooled or heated liquid in the bottle is gained in each case by inverting the bottle in conventional manner to allow a flow of liquid from the bottle through the openings in the upper portion of the tube or the tube connector and into a spout provided in the cap, for drinking purposes. In a preferred embodiment a sports valve may be provided on the spout for sealing the spout against inadvertent leakage or spillage of the contents of the bottle. | 5 |
[0001] This application is a continuation of U.S. patent application Ser. No. 10/711,959, attorney docket number BUR920040201US1, filed on Oct. 15, 2004, currently pending.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to integrated circuit design, and more particularly, to selectively scaling an integrated circuit design layout by: layer, region or cell, or a combination of these, for the purposes of increasing yield in early processes in such a way that hierarchy is preserved.
[0004] 2. Related Art
[0005] One way of modifying an existing very large scale integrated (VLSI) circuit design to increase its manufacturing yield is to spread wires and add redundant vias in order to decrease critical area and increase via reliability. However, in the early stages of a new manufacturing process, these post-layout modifications alone may not be sufficient to achieve the desired yield improvement. Another yield-enhancing modification to an existing layout is to relax the spacing and width tolerances, which can be accomplished by a geometric scaling process. A challenge arises, however, when this scaling is attempted on only certain design layers and in the presence of certain other geometric constraints or in the presence of hierarchy. For example, back-end-of-line (BEOL) layers might be chosen for scaling but without altering any device sizes, and with the requirement that the location of connections from the top-level wiring to the integrated-circuit package remain fixed.
[0006] A simple linear geometric scaling (i.e., multiplying the coordinates of every object in the design database by a fixed scaling factor) is obviously inadequate if connectivity is to be maintained between layers that are scaled and layers that are not scaled. The problem of hierarchical scaling itself is difficult to solve. One approach is addressed in co-pending U.S. patent application Ser. No. 10/438,625 (currently pending), entitled “A Practical Method for Hierarchical-Preserving Layout Optimization of Integrated Circuit Layout,” which is hereby incorporated by reference. Another approach is selective scaling, an example of which is disclosed in U.S. Pat. No. 6,756,242 to Regan. Regan, however, teaches scaling an entire design with different scaling factors in an X direction and a Y direction, which is also inadequate if connectivity is to be maintained between layers.
[0007] In semiconductor manufacturing, design layouts are completed with a set of fixed ground rules that are provided to the designers by the manufacturing organization. The ground rules describe process and lithography best estimates of what is manufacturable. The ground rules attempt to balance chip density on a wafer (aggressiveness) with what can be reliably manufactured (conservatism). During the lifetime of a technology process or a design, “learning” takes place through failure analysis on finished products and in the manufacturing line. If implemented, this learning can improve yields. For example, the ground rules may change to reflect the yield learning. Unfortunately, frequent or considerable changes cannot usually be made because implementation of any change is expensive because each requires designer involvement in modifying the design to reflect the new ground rules. More significantly, any design modification typically requires new masks, which are extremely expensive. Accordingly, design changes are historically only made very infrequently. Yield related design changes may be added if functional changes require new masks (i.e., if there are difficulties with the function or performance which require a new design iteration), or if there are significant yield issues which force a new design iteration in order to achieve cost targets.
[0008] Future manufacturing and design environments, however, provide several important aspects that may allow significant improvement of this process: First, maskless lithography has been proposed for future technologies, which if implemented will eliminate the costs of additional mask sets for a changed design. Second, improved simulation and validation capabilities may provide the ability to do more “full-up” simulations of designs because of improved algorithms, parallel processing, and system architectures. In this fashion, selective scaling may be applied in a tightly coupled feedback loop with the manufacturing line with process and yield feedback, during the life of a design. In current manufacturing and design environments, limited mask lifespans offer the opportunity for periodic layout updates during the life of a design.
[0009] In view of the foregoing, there is a need in the art to address the problems of the related art.
SUMMARY OF THE INVENTION
[0010] The invention includes systems and program products for selectively scaling an integrated circuit (IC) design by: layer, region or cell, or a combination of these. The selective scaling technique can be applied in a feedback loop with the manufacturing system with process and yield feedback, during the life of a design, to increase yield in early processes in such a way that hierarchy is preserved. The invention removes the need to involve designers in improving yield.
[0011] A first aspect of the invention is directed to a method for selectively scaling an integrated circuit design layout, the method comprising the steps of: identifying a scaling target for at least one problem object of the design layout based on manufacturing information; defining technology ground rules and methodology constraints for each problem object; determining a scaling factor for each problem object; determining which at least one of a plurality of scaling techniques is to be applied to each problem object, and scaling each problem object with a respective at least one scaling technique and scaling factor; and in the case that assembly is required, performing placement and routing to assemble the design using the scaled problem object.
[0012] A second aspect is directed to a system for selectively scaling an integrated circuit design layout, the system comprising the steps of: means for identifying a scaling target for at least one problem object of the design layout based on manufacturing information; means for defining technology ground rules and methodology constraints for each problem object; means for determining a scaling factor for each problem object; means for determining which at least one of a plurality of scaling techniques is to be applied to each problem object, and scaling each problem object with a respective at least one scaling technique and scaling factor; and means for, in the case that assembly is required, performing placement and routing to assemble the design using the scaled problem object.
[0013] A third aspect is directed to a computer program product comprising a computer useable medium having computer readable program code embodied therein for selectively scaling an integrated circuit design layout, the program product comprising: program code configured to identify a scaling target for at least one problem object of the design layout based on manufacturing information; program code configured to define technology ground rules and methodology constraints for each problem object; program code configured to determine a scaling factor for each problem object; program code configured to determine which at least one of a plurality of scaling techniques is to be applied to each problem object, and scaling each problem object with a respective at least one scaling technique and scaling factor; and program code configured to, in the case that assembly is required, perform placement and routing to assemble the design using the scaled problem object.
[0014] A fourth aspect is directed to a method for improving yield of an integrated circuit design layout during manufacturing, the method comprising the steps of: testing a manufactured design layout and identifying at least one problem object that is a problem; generating a scaling target for each problem object based on manufacturing information obtained during the testing; and feeding back the manufacturing information to a system for selective scaling of the design layout to improve yield using a scaling target for at least one problem object of the design layout based on the manufacturing information.
[0015] A fifth aspect of the invention is directed to a system for improving yield of an integrated circuit design layout during manufacturing, the system comprising: means for testing a manufactured design layout and identifying at least one problem object that is a problem; means for generating manufacturing information including a scaling target for each problem object; and means for feeding back the manufacturing information to a system for selective scaling of the design layout to improve yield using a scaling target for at least one problem object of the design layout based on the manufacturing information.
[0016] A sixth aspect of the invention is directed to a computer program product comprising a computer useable medium having computer readable program code embodied therein for improving yield of an integrated circuit design layout during manufacturing, the program product comprising: program code configured to test a manufactured design layout and identifying at least one problem object that is a problem; program code configured to generate manufacturing information including a scaling target for each problem object; and program code configured to feedback the manufacturing information to a system for selective scaling of the design layout to improve yield using a scaling target for at least one problem object of the design layout based on the manufacturing information.
[0017] The foregoing and other features of the invention will be apparent from the following more particular description of embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like elements, and wherein:
[0019] FIG. 1 shows a block diagram of a selective scaling system and a manufacturing system benefiting from the scaling system according to one embodiment of the invention.
[0020] FIG. 2 shows a flow diagram of operational methodology of the system of FIG. 1 .
[0021] FIG. 3 shows a flow diagram of operation of the manufacturing system of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0022] For purposes of organization only, the description includes the following headings: I. System Overview, II. Operational Methodology, III. Conclusion.
I. SYSTEM OVERVIEW
[0023] With reference to the accompanying drawings, FIG. 1 is a block diagram of an integrated circuit (IC) design selective scaling system 100 according to one embodiment of the invention. System 100 includes a memory 112 , a processing unit (PU) 114 , input/output devices (I/O) 116 and a bus 118 . A database 120 may also be provided for storage of data relative to processing tasks. Memory 112 includes a program product 122 that, when executed by PU 114 , comprises various functional capabilities described in further detail below. Memory 112 (and database 120 ) may comprise any known type of data storage system and/or transmission media, including magnetic media, optical media, random access memory (RAM), read only memory (ROM), a data object, etc. Moreover, memory 112 (and database 120 ) may reside at a single physical location comprising one or more types of data storage, or be distributed across a plurality of physical systems. PU 114 may likewise comprise a single processing unit, or a plurality of processing units distributed across one or more locations. I/O 116 may comprise any known type of input/output device including a network system, modem, keyboard, mouse, scanner, voice recognition system, CRT, printer, disc drives, etc. Additional components, such as cache memory, communication systems, system software, etc., may also be incorporated into system 100 . System 100 receives an IC design 200 to be legalized and outputs an improved IC design 202 . It should be recognized that system 100 may be incorporated as a part of a larger IC design system or be provided as a separate system.
[0024] As shown in FIG. 1 , program product 122 may include a scaling target identifier 124 , a constraint definer 126 , a scaling factor creator 128 , a scaling technique determinator 130 , a placement/router module 132 , an evaluator 134 and other system components 138 . Other system components 138 may include any other necessary functionality not expressly described herein.
[0025] It should be recognized that while system 100 has been illustrated as a standalone system, it may be included as part of a larger IC design system or a peripheral thereto. An IC design 200 is input to system 100 , and an improved IC design 202 is output from system 100 .
[0026] Manufacturing system 400 will be described in greater detail below.
II. OPERATIONAL METHODOLOGY
A. Overview
[0027] Co-pending U.S. patent application Ser. No. 10/438,625, entitled “A Practical Method for Hierarchical-Preserving Layout Optimization of Integrated Circuit Layout,” describes a method for scaling different layers in an integrated circuit (IC) design layout by different scaling factors without creating so-called “pull-aparts,” i.e., situations where two touching shapes on the same layer do not touch after being scaled. In this application, a method is taught on how to apply these techniques to a hierarchical design by specifying constraints for interfaces between hierarchical design levels and by showing how the placement of hierarchical elements (e.g., libraries or macros) can be specified during the scaling. Additionally, the invention allows different functional components embedded in an overall design to be scaled differently, without the necessity for disassembly and reassembly. The invention also can be used to scale by selected regions of any size up to and including an entire chip, based on any selection criteria, e.g., pattern matching, hierarchy, name, etc. The invention thus allows for: a) the scaling itself to be an optimization process—some scaling targets will be met and some not met. This allows a designer to impose and obey certain methodology constraints (such as pin locations). b) In the case where sub-circuits grow as a consequence of the scaling, the placement of the circuits is modified to preserve layout topology. c) The scaling can be applied component by component, as a design is assembled, or the scaling can be applied to the fully assembled (placed and routed) design at the end. d) A very fine degree of control is allowed over the scaling—by component, by layer, or even by geographic location.
[0028] The invention also includes a manufacturing yield improvement loop ( FIGS. 2-3 ) that extends back to the original design, without involving the original designer. This loop can be run in real time in the manufacturing environment, or it can be applied when new masks are built. The advantage of this flow is that it makes the manufacturing/design feedback loop a tighter, more focused loop than currently exists. A cost target can be set for a design, and the size of the layout (chips per wafer) versus yield can be automatically adjusted throughout the life of the design and process, in order to meet that target.
[0029] In a “maskless lithography” world, this optimization could be applied batch-to-batch in manufacturing. In a “mask” world, this optimization could be applied whenever a new mask set is needed. Given that mask lifespans are limited, a long-running design may go through multiple sets of masks.
B. Selective Scaling Methodology
[0030] Given a ground-rule correct hierarchical IC design layout and feedback from manufacturing describing known problems, the design layout is scaled by a scaling factor for each object, i.e., layer, region and/or cell-specific values.
Scaling Techniques
[0031] The selective scaling methodology may implement different scaling techniques depending on the parts to be scaled. For purposes of this invention, three different scaling techniques will be described. It should be recognized, however, that other now known or later developed scaling techniques may be implemented. The three scaling techniques include: Flat Scaling, Minimum Perturbation Compaction, and Scaling of Custom Circuitry. Since each of these scaling techniques is described in detail in other U.S. patent applications or otherwise known by those with ordinary skill in the art, details of each will not be made.
[0000] a) Flat Scaling
[0032] A flat scaling of library elements uses the technique described in U.S. patent application Ser. No. 10/10/438,625, entitled “A Practical Method for Hierarchical-Preserving Layout Optimization of Integrated Circuit Layout,” to scale the data using appropriate scale factors for different layers/regions.
[0000] b) Minimum Perturbation Compaction
[0033] For circuits with defined border methodology (e.g., RLMs, bit stacks) use, a longest-path analysis referred to as minimum perturbation (hereinafter “minpert”) compaction may be used to calculate the amount by which each sub-cell will grow. Minpert compaction is described in U.S. patent application Ser. No. 10/707,287, entitled “Circuit Area Minimization Using Scaling,” which is hereby incorporated by reference. In this technique, the placement location of each sub-cell is modified so that after expansion, their boundary shapes abut. Then, each macro circuit is scaled hierarchically.
[0000] c) Scaling of Custom Circuitry
[0034] With pure custom circuits, the macro is typically scaled in two passes. The first-pass scaling modifies shapes and transform locations. “Transform” refers to a location of a circuit in terms of an X value, a Y value, a mirror value and a rotation value. For example, a circuit may have location of X=5, Y=4, be mirrored about the X-axis and a 90° rotation value (in this example, a shape vertex at point 5, 4 would first move to 5, −4 with the mirroring, then move to 4, 5 when rotated +90 degrees). A transform location modification changes the outline of the shape, thus changing its position relative to its neighbors. In a second pass, transform locations are rounded to integer values and ground-rule fix-up is performed using the layout optimizer, i.e., to accommodate the neighboring shape requirements.
2. SELECTIVE SCALING TECHNIQUE
[0035] Turning to FIG. 2 , operational methodology of system 100 according to one embodiment of the invention will now be described. In step S 1 , based on information from manufacturing, at least one scaling target for at least one object of the design layout is identified by scaling target identifier 126 . An “object” as used herein means a layer, region and/or cell (i.e., one or more layers, one or more regions, one or more cells, or a combination of those) of the design layout. As used herein, a “cell” is any placeable part of an IC design, sometimes referred to as macros, cells, sub-cells, etc. In addition, in certain instances, an “object” may include the entire chip. This step may include manual identification of a layer, region and/or cell by, for example, a person familiar with the manufacturing process and yield issues. Alternatively, this step may be carried out by any now known or later developed automated failure analysis system that can identify a layer, region and/or unit that is causing yield issues and may be a target for scaling. In addition, step S 1 may include determining how much scaling is ideally required. “Manufacturing information” may be any information usable to identify a scaling target for an object. Manufacturing information will be described in greater detail below. Problem objects are identified regardless of whether they relate to design-related layout patterns that are known to be difficult to manufacture, or process-related defects, e.g., lines, vias, or other structures on a particular level which are not printing well.
[0036] In step S 2 , the technology ground rules are defined for each object having a scaling target. This step is required because the scaling may be applied to more than just layers. For example, spacing ground rules that apply to the object, e.g., wiring or pins, must be defined and obeyed. In addition, methodology constraints are defined. For example, cell boundaries that limit growth, pin shapes, pin position, wiring tracks, etc., are defined.
[0037] In step S 3 , a scaling factor is determined for each object having a scaling target. “Scaling factor” can be any form of changing the design now known or later developed. For example, the scaling factor may be one or more of a compensation (e.g., grow this unit by 3%), a new ground rule (e.g., change spacing for this layer by 2 nm), a scaling multiplier (e.g., decrease units on this layer by a factor of 0.011), etc.
[0038] In step S 4 , a determination is made as to which at least one of a plurality of scaling techniques is to be applied to each object. For example, for flat cells without a hierarchy (e.g., library cells), the object may be scaled using the Flat Scaling technique, i.e., the region is flattened, determine the hierarchy and scale according the Flat Scaling technique. The object may be, for example, a region having an X-Y space. It should be recognized that each object is evaluated individually in that an object may be positioned at one location which is to be scaled, and also at another location which is not to be scaled or may be scaled by another scaling factor. Another example is a cell with border methodology constraints, which may be composed of instances of sub-cells with abutting boundary shapes. In this case, the MinPert Compaction scaling technique may be appropriate. Each pure custom circuit will be scaled using the Pure Circuit scaling technique, i.e., in two passes.
[0039] In step S 5 , two different operations may occur depending on whether the above-described methodology is applied to: a) the objects and the chip re-assembled, or b) to the whole assembled circuit. In the former case, standard placement and routing technology is used to assemble the design using the scaled objects. In one embodiment, this step includes using an optimization-based hierarchical program to produce a legal layout for each object. In the latter case, the selective scaling is applied to an entire assembled circuit, i.e., the chip is the object, which eliminates the need to rerun placement and routing.
[0040] Step S 6 represents an optional step in which the new design layout is evaluated by evaluator 134 to determine whether the expected behavior is achieved. Evaluator 134 may include software and/or hardware for comparing the new design layout to the old design layout, and a simulator to implement design intent information (defined below) and check tools to verify that the expected behavior is achieved. This step may be carried out after the new design layer is virtually generated, or after a manufacturing run. The process may then repeat, as shown in FIG. 2 .
3. EXAMPLE IMPLEMENTATIONS
[0041] The following illustrative implementations are not exhaustive and, therefore, should not be considered limiting of the attached claims. In a first example, a particular library cell in a design may require scaling of certain levels. A second example includes a particular redundant via cell. For example, if a particular arrangement of vias was found to cause yield issues (perhaps due to an optical proximity correction (OPC) issue), the spacing or arrangement of this particular model could be changed in every occurrence. (OPC is a technique for improving printing of shapes, which is applied just before masks are made. OPC makes additions to or subtractions from difficult to print structures due to the optical effects and the small wavelength of light used. For example, an inside corner, like the bend in an “L,” tends to fill-in a little during printing, so those corners get little notches cut out. Outside corners like the end of a line tend to round-off, so they get a small extra bump added.) A third example includes a situation in which difficulty with only a particular metal layer (e.g., Ml) in a chip is observed. In this case, a chip-wide scaling of just that metal layer is necessary.
C. Application of Selective Scaling to Yield Learning
[0042] The above-described method can be applied to yield learning in a manufacturing system 400 on a continuous basis, or as new masks are built using the following methodology. The following methodology would occur as part of step S 1 , described above. It should be recognized that manufacturing system 400 may include similar computer-based sub-system structures (i.e., PU, I/O, busses, program products, etc.) as scaling system 100 .
[0043] Referring to FIG. 3 , in a step S 101 , a design layout is manufactured by conventional manufacturing equipment 402 . This step includes sub-step S 101 A preparing the design layout for photolithography, i.e., conventional data prep and conversion for masks or maskless data for tools. This step may include provision of design “intent” information by a designer to the manufacturing organization. This intent information is used during simulation of changes to the actual layout shapes, in order to ensure correct performance and function if small layout changes are made. For example, performance and tuning information and/or power information can be provided. In particular, a layout indicates how an IC works statically, but not how it functions dynamically, i.e., how fast or how much power is consumed in a clock cycle. Intent information may include data regarding static behavior deductions from the layout, the anticipated dynamic behavior such as performance and power. Also, noise to neighboring circuits or circuit groupings could be a piece of intent information. Circuit groupings may indicate circuits arranged so that they do not all switch simultaneously, because if they did it would cause a substantial voltage drop on a particular power bus so that some might not function correctly. In sub-step S 101 B, parts are manufactured.
[0044] In step S 102 , testing is conducted by conventional testing equipment 404 . In one embodiment, testing includes characterizing operation by obtaining data indicating how well objects or features are able to be manufactured. For example, line monitors (e.g., kerfs or special wafers) may measure the ability of the process to print embedded lines at a particular pitch. In another example, kerf structures could monitor the performance of types of via combinations for printability.
[0045] At step S 103 , manufacturing information is generated by manufacturing information generator (MI) generator 406 , and fed back to system 100 by any now known or later developed communications mechanism 408 , e.g., a network. Ml generator 406 may include any mechanism to generate the manufacturing information including, for example, mechanisms for determining when certain parameters exceed a threshold. In terms of parameters, manufacturing information may include, for example: a) Layers that should be scaled up to larger sizes or pitches because of unacceptable defects on those layers; b) Layers that can be scaled down to smaller sizes or pitches because of unexpectedly good manufacturability; c) Regions of a design that should be scaled up to a larger size in order to minimize systematic defects in these particular regions; d) Regions of a design that can be scaled down to a smaller size due to unexpectedly low defect densities in those regions; e) Cells that cannot be placed next to one another due to inappropriate interactions; and/or f) Cells that require modification to be placed next to one another to be more independent or tolerant of neighboring cells. Relative to the above described example in which line monitors measure the ability of the process to print embedded lines at a particular pitch: if the printable pitch drifts slightly, manufacturing information can be generated (next step) such that the above-described selective scaling can be applied to narrow or widen the actual pitch used in the design. The increments of change made could be very small, i.e., below that would be normally considered for ground rule changes (˜10 nm, for example). Similarly, where kerf structures monitor the performance of types of via combinations for printability, manufacturing information could indicate that changes in vias are necessary, e.g., slight enlargement or spacing changes, in response to changes in the process. The manufacturing information is fed back and applied to the current layout as manufactured using the above-described selective scaling methodology. As discussed above, the manufacturing information is used to identify scaling targets for problem objects.
[0046] This yield learning process may be particularly helpful when moving a design to a new, second fabrication facility. The second fabrication facility is likely to have very slightly different “optimum” points for some ground rule values. Over time, these points can be found, and the part numbers optimized to the separate fabrication facilities.
III. CONCLUSION
[0047] In the previous discussion, it will be understood that the method steps discussed are performed by a processor, such as PU 114 of system 100 , executing instructions of program product 122 , stored in memory. It is understood that the various devices, modules, mechanisms and systems described herein may be realized in hardware, software, or a combination of hardware and software, and may be compartmentalized other than as shown. They may be implemented by any type of computer system or other apparatus adapted for carrying out the methods described herein. A typical combination of hardware and software could be a general-purpose computer system with a computer program that, when loaded and executed, controls the computer system such that it carries out the methods described herein. Alternatively, a specific use computer, containing specialized hardware for carrying out one or more of the functional tasks of the invention could be utilized. The present invention can also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods and functions described herein, and which—when loaded in a computer system—is able to carry out these methods and functions. Computer program, software program, program, program product, or software, in the present context mean any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after the following: (a) conversion to another language, code or notation; and/or (b) reproduction in a different material form.
[0048] While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims. | The invention includes a solution for selectively scaling an integrated circuit (IC) design by: layer, region or cell, or a combination of these. The selective scaling technique can be applied in a feedback loop with the manufacturing system with process and yield feedback, during the life of a design, to increase yield in early processes in such a way that hierarchy is preserved. The invention removes the need to involve designers in improving yield. | 6 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to so-called wide mouth containers and associated neck finishes that accept tamper resistant closures.
2. Description of Prior Art
Prior art devices of this type have relied on a number of cap and neck finish combinations, see for example U.S. Pat. Nos. 3,940,004, 4,438,857, 4,625,876 and 4,691,834.
In each of the above referred to patents, caps of plastic material are shown with cooperative neck finishes. The present invention provides a wide mouth neck finish that will accept tamper resistant snap cap twist off cap configurations that are provided with a tear tab that must be released and partially removed to allow the cap to be removed from the neck finish.
SUMMARY OF THE INVENTION
A neck finish on wide mouth containers for tamper resistant closures. The neck finish provides multiple sealing configurations for engagement with the closure holding same on the container. The neck finish has an upper portion of a reduced diameter in which vertically aligned ribs and grooves are formed on its outer surface for communication and registration with a tamper resistant cap.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective elevation of a cap in use with the present invention;
FIG. 2 is a perspective elevation of the cap after removal of the tear skirt;
FIG. 3 is an enlarged vertical section of the neck finish of the invention with a portion of the cap of FIG. 1 on lines 3--3 thereof; and
FIG. 4 is an enlarged vertical section of the portion of the cap in FIG. 2 on lines 4--4 thereof positioned on a portion of the neck finish of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
By referring to FIGS. 3 and 4 of the drawings, it will be seen that a container 10 such as a blow molded polyethylene or the like plastic resin material bottle is partially illustrated with a neck finish 11 formed on a cylindrical upper end with an outer surface including an upwardly and inwardly curving section 12 with a first vertical smooth surface 13 extending thereabove. An inwardly and upwardly angled section 14 extends above said first vertical smooth surface 13. A second vertical smooth surface 15 extends inwardly thereabove, an outwardly and upwardly extending angled section 16 defines a primary sealing area. A third vertical smooth surface 17 ascends above the angled section 16 on a vertical plane with said first vertical smooth surface 13. A second inwardly and upwardly angled section 18 extends above said third vertical smooth surface 17 and is angularly inclined towards the horizontal to a greater extent than said first inwardly and upwardly angled section 14, a fourth vertical smooth surface 19 extends thereabove in the same vertical plane as the second vertical smooth surface 15 hereinbefore described. An outwardly and upwardly extending angled section 20 extends thereabove to a fifth vertical smooth surface 21 in the same vertical plane as said third vertical smooth surface 17. The fifth vertical smooth surface 21 transcends into a convex inwardly curving outer surface 22 which continues into a horizontal extending flange 23 of transverse reduced diameter at 24.
By referring to FIGS. 1-3 of the drawings, a cap 25 can be seen having a top portion 26 with a depending annular flange 27 extending from the peripheral edge thereof. An annularly outwardly offset secondary flange 28 extends from the lower portion of the annular flange 27, the Junction below an upper portion of the annular flange 27 and the secondary flange 28 comprising an outwardly and downwardly curving section 29.
An upstanding pull tab 30 can be seen in broken lines in FIG. 3 of the drawings and is integrally formed with the secondary annular flange 28 as to extend upwardly from the outwardly and downwardly curving section 29 thereof.
Referring now to FIG. 1, it will be seen that a horizontal frangible tear line 31 extends circumferentially around the depending annular flange 27 substantially above the outward and downward curving section 29 from which the secondary flange 28 depends with the exception that in the area of the depending annular flange 28 adjacent the upstanding pull tab 30. The frangible tear line 31 takes a lower position adjacent the pull tab 30 as best seen in FIG. 2 of the drawings to define a downturned secondary tab 30A. A curving frangible line 32 extends from the second end of the horizontal frangible line 31 adjacent the pull tab 30 to the lowermost edge of the annular flange 27.
It will be evident from the above description that by grasping the pull tab and moving it outwardly from the depending annular flange 27 will tear the portion of the depending annular flange 28 below the horizontal frangible tear line 31 including the secondary flange 28 from the cap 25 along the upper portion of the cap as seen in FIGS. 2 and 4 of the drawings.
The remaining portion of the cap, best seen in FIGS. 2 and 4 of the drawings is comprised of the top 26, the upper portion of the annular depending flange 27 thereon extending downwardly and the secondary tab 30A formed by the removal of the pull tab 30 with the lower portion of the secondary annular flange 28.
Referring now to FIG. 3 of the drawings, it will be seen that when the cap 25 is engaged on the neck finish 11 of the invention, that the uppermost part of the horizontally disposed inturned flange 23 is in sealing relation with the lower surface of the top portion 26 of the cap 25 with the innermost surface of the area of reduced transverse dimension at 24 abutting a depending annular sealing flange 33 which is spaced inwardly in relation to the depending annular flange 27 of the cap 25. An inturned annular rib 34 is formed on the inner surface of the annular sealing flange 33 for increased rigidity, with the lower outer surface 35 of the annular sealing flange 33 curved inwardly and downwardly to position and engage the cap 25 on the neck finish 11 of the container 10.
Still referring to FIG. 3, it will be seen that a pair of annular ribs 36 and 37 are formed on the inner surface of the depending annular flange 27 in vertically spaced relation to one another forming upper secondary sealing and lower primary sealing fastening configurations on the cap 25 and are in abutting sealing relationship to the outwardly and upwardly extending angled sections 20 and 16 respectively of the neck 11.
The fifth smooth vertical surface 21 of the neck 11 is in abutting relationship with a registering vertical smooth surface 38 formed on the inner surface of the annular depending flange 27 thereabove said annular rib 36. A continuous annular seal is thus formed between the respective vertical smooth surfaces 21 and 38 and the respective angular surface section 20 and the upper angular surface of the annular rib 36 as hereinbefore described. Given the foregoing arrangement, it will be seen that the frangible tear line 31 is positioned between said annular ribs 36 and 37 of the depending annular flange 27 as clearly indicated in FIG. 3 of the drawings and adjacent the lower portion of the secondary offset flange 28 indicating its relative position between the upper portion of the annular depending flange 27 and the lower secondary annular flange 28 in the area of the pull tab 30 as hereinbefore described.
It will occur to those skilled in the art that when the pull tab 30 is grasped and used to tear the tear skirt from the original cap structure 25, the remaining cap portions seen in FIGS. 2 and 4 of the drawings still retains two fastening and sealing configurations comprising the hereinbefore described upper portion of the annular depending flange 27 with registering fifth vertical smooth surface 21 of the neck 11 and the respective upper angular surface of the rib 36 in the outwardly and upwardly extending angle section 20.
It will thus be seen that a new and novel neck finish on a wide mouth container for use with a snap on twist off tamper indicating cap has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention, therefore | A neck finish on a wide mouth container to accept a tamper evident cap to provide multiple sealing surfaces therebetween. The neck finish having cooperating upper and lower locking ribs and grooves holding the cap in place until a majority portion of the cap is removed by tearing along a horizontal frangible line, disengaging one of the locking ribs from the neck finish. The neck finish provides multiple sealing surfaces in both vertical and horizontal alignment. | 8 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention is directed to lighting fixtures that use solid-state electronic devices as the lighting elements
[0003] 2. Related Art
[0004] Conventionally, industrial, commercial and, occasionally, residential spaces are illuminated using fluorescent tubes or high-intensity-discharge (HID) lamps. High-intensity discharge (HID) lamps include these types: mercury vapor electrical lamps, metal halide (HQI) electrical lamps, high-pressure sodium (Son) electrical lamps, low-pressure sodium (Sox) electrical lamps and less common, xenon short-arc lamps. The light-producing element of these lamp types is a well-stabilized arc discharge contained within a refractory envelope (arc tube). Whichever metal is used, the lamp produces the light once the metal is heated to a point of evaporation, forming a plasma in the arc tube. Like fluorescent lamps, HID lamps require a ballast to start and maintain their arcs.
[0005] However, fluorescent tubes and HID lamps have minimal options for varying light output. Due to their modes of operation, it is difficult and expensive, if not impossible, to moderate the amount of light emitted by a fluorescent tube or an HID lamp. Likewise, due to aging effects and the like, completely turning off and on fluorescent tubes and HID lamps on a need-for-illumination basis is generally discouraged.
SUMMARY OF THE DISCLOSED EMBODIMENTS
[0006] Solid-state light emitting electronic elements, such as, for example, LEDs, have been developed that output intense white light. Such solid-state electronic devices emit light as a function of input current. Thus, the output light intensity can be readily varied by moderating or adjusting the supplied current. Likewise, by turning on and off the supply of current, these solid-state devices can be readily turned on and off with no output delays, such as those present in conventional fluorescent tubes and HID lamps, and without aging the solid-state devices.
[0007] This invention provides a light fixture having multiple LED elements in place of conventional light sources such as fluorescent, incandescent or high intensity discharge (HID) lamps.
[0008] This invention separately provides a light fixture having multiple LED elements, a gasket, cover and sealing mechanism that seals the light fixture.
[0009] This invention separately provides a light fixture having multiple LED elements and a water resistant IP rating that allows the light fixture to be used in hostile environments.
[0010] This invention separately provides an open light fixture having multiple LED elements that replace a fluorescent strip light including the main fixture body.
[0011] This invention separately provides a retrofit kit for a standard fluorescent strip light fixture, allowing the main fixture body to stay intact while the fluorescent bulb is replaced with multiple LED elements.
[0012] This invention separately provides a retrofit kit usable to retrofit a 2×4 or a 2×2 fluorescent fixture with a removable pan that houses the LED system.
[0013] This invention separately provides a light fixture having multiple LED elements that replace a 2×4 and/or 2×2 fluorescent fixture.
[0014] This invention separately provides a light fixture having an ambient light sensor and control system that automatically adjusts a light output of the solid-state light emitting elements based on the sensed ambient light.
[0015] This invention separately provides a light fixture having an occupancy light sensor and control system that adjusts a light output of the solid-state light emitting elements based on a sensed occupancy level of a sensed area around the light fixture.
[0016] This invention separately provides a light fixture having an ambient light sensor, an occupancy light sensor and control system that adjusts a light output of the solid-state light emitting elements based on the sensed ambient light and on a sensed occupancy level of a sensed area around the light fixture.
[0017] This invention separately provides a light fixture having control system, that adjusts a light output of the solid-state light emitting elements based on a load signal indicative of an overall electric load of an area or structure that the light fixture is located in.
[0018] Unlike fluorescent or HID lamps that have minimal options for varying light output, solid-state lamps, such as LED lamps, are completely adjustable in their output allowing for a near perfect match for any lighting scenario. The number of solid-state lamps used for each fixture will be based on desired illumination levels for a particular application. Highly polished reflectors can be used to improve fixture performance as well as to help dissipate heat.
[0019] In various exemplary embodiments, the light fixture body can be constructed of a high strength fiberglass. A high-strength polycarbonate diffuser lens, continuous-poured neoprene gasket and cam-action latch system can be used to cover and seal the light fixture assembly. The fixture will have a water resistant IP rating of at least 65, allowing protection from entry of dust, bugs, rain and low pressure power washing. The incoming electrical line will also be sealed. The fixture can be surface, chain, pendant or continuous row mounted.
[0020] One or more sensor packages can be mounted to the outside and/or inside of the light fixture body. The one or more sensor packages can include an ambient light sensor, an occupancy sensor, a load sensor or any other desired sensor whose output can be used to controllably modify the output or activation state of the solid-state lamps. A control system, which can be included in the one or more sensor packages or as a separate device, inputs the output signals from the one or more sensors and modifies the light output, and/or turns on or off, the solid-state lamps. The control system can also receive a control signal from a central location that monitors a total peak energy use by the building or location in which the light fixture body is located. In response to this signal, the control system can modify the light output, and/or turn on or off, the solid-state lamps when the overall energy use rises too high or falls back down from a peak energy use period.
[0021] In various exemplary embodiments, the LED system is under-driven to allow for age compensation. Under-driving the LEDs will increase their life and reduce energy usage. That is, by under-driving the LEDs, as the LEDs age and loose output later in their life, the control system will automatically sense that loss of output and increase the driving current, and thus the light output, accordingly, which will result in consistent light levels throughout the life of the product. With the LEDs normally under-driven, that leaves extra room to increase the output later in the life of the product without having to over-drive the LEDs.
[0022] In various other exemplary embodiments, a light fixture conversion kit includes multiple solid-state light emitting elements, such as LED elements, arranged into one or more solid state lamps, such as LED lamps, that are used in place of conventional light sources, such as standard T5, T8 or T12 fluorescent tubes within the housing of a conventional fluorescent light fixture. The conversion kit can include a reflector with one or more rows of LED lamps mounted on a back side of the reflector. Each LED lamp includes a plurality of LED elements that are mounted on a heat sink. The LED elements protrude through the reflector to the polished or reflective side of the reflector. The number of LED lamps can depend on the dimensions and number of lamps present in the light fixture that the conversion kit is being used to replace. The number of LED lamps can vary widely, allowing for flexibility in replacing all types of fluorescent or HID lighting. The conversion kit may additionally have additional elements that replace the existing pan, pins and/or ballasts of the fluorescent fixture.
[0023] In various exemplary embodiments, the housing can be modified so that one or more sensor packages can be mounted to the outside of the housing and/or to the inside of the housing. The one or more sensor packages can include an ambient light sensor, an occupancy sensor, a load sensor or any other desired sensor whose output can be used to controllably modify the output or activation state of the solid-state lamps. A control system, which can be included in the one or more sensor packages or as a separate device, inputs the output signals from the one or more sensors and/or remote control signals and modifies the light output, and/or turns on or off, the solid-state lamps.
[0024] In various exemplary embodiments, installing the conversion kit is simple and easy, requiring only basic hand tools. This process involves removing the existing lamps, ballast cover and socket brackets of a fluorescent lamp fixture to be retrofitted. New spring clips and chains are then installed with the supplied self-drilling screws. Next, the conversion LED pans are connected to the socket brackets with supplied ¼ turn fasteners. Finally, the LED pan is wired and fastened to the fixture body with supplied chains.
[0025] These and other features and advantages of various exemplary embodiments of systems and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various exemplary embodiments of various devices, structures and/or methods according to this invention.
BRIEF DESCRIPTION OF DRAWINGS
[0026] Various exemplary embodiments of the systems and methods according to this invention will be described in detail, with reference to the following figures, wherein:
[0027] FIG. 1 is a first perspective view of a first exemplary embodiment of a solid-state lighting fixture according to this invention;
[0028] FIG. 2 is a second perspective view of the first exemplary embodiment of a solid-state lighting fixture according to this invention, with a transparent cover;
[0029] FIG. 3 is an exploded perspective view of the first exemplary embodiment of a solid-state lighting fixture according to this invention, showing the elements of the solid state lighting fixture, including a first exemplary embodiment of a solid-state lamp and reflector assembly;
[0030] FIG. 4 is a perspective view showing in greater detail a first exemplary embodiment of a solid-state lamp according to this invention;
[0031] FIG. 5 is a perspective view showing a second exemplary embodiment of a solid-state lamp and reflector assembly according to this invention;
[0032] FIGS. 6 and 7 are perspective views of a first exemplary embodiment of a solid-state lamp conversion kit according to this invention; and
[0033] FIG. 8 is a perspective view showing in greater detail a second exemplary embodiment of a solid-state lamp according to this invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0034] A solid-state light fixture includes multiple LED elements or other solid-state light emitting elements, in place of conventional light sources such as fluorescent, incandescent or high intensity discharge, (HID). For ease of description, the following detailed description of the following exemplary embodiments will refer primarily to LED lamps and elements. However, it should be understood that the phrases LED lamps and LED elements is intended to encompass any other known or later developed solid-state light emitting elements that can be appropriately used as disclosed herein.
[0035] The number of LED lamps used for each fixture will be based on what required levels exist for each application. Unlike fluorescent or HID that have minimal options for varying light output, the LED lamps are completely adjustable in their output allowing for a near perfect match for any lighting scenario. Highly polished reflectors are used to improve fixture performance as well as to dissipate heat.
[0036] FIGS. 1 and 2 show two perspective views of a first exemplary embodiment of a solid-state lighting fixture 100 according to this invention. FIG. 3 shows an exploded perspective view of the solid-state lighting fixture and its constituent elements. In the exemplary embodiment shown in FIGS. 1-3 , the solid-state lighting fixture 100 includes a light fixture body or housing 110 , a pair of LED lamps 120 each comprising a heat sink 122 and a plurality of LED packages 125 mounted on the heat sink 122 , a reflector 150 and a diffuser 160 . A power supply 170 and a load-shedding receiver 140 are mounted to an inside surface of the housing 110 above the LED lamps 120 and the reflector 150 , while a sensor package, including an occupancy sensor 130 and a daylight sensor 135 , is mounted to the outside of the housing 110 .
[0037] In various exemplary embodiments, the light fixture body or housing 110 is constructed of a high strength fiberglass. In various exemplary embodiments, the diffuser 160 , which can be implemented as a high-strength polycarbonate diffuser lens, a continuous-poured neoprene gasket and a cam-action latch system can be used to cover and seal the solid-state light fixture. This solid-state light fixture 100 will have a water resistant IP rating of at least 65, allowing protection from entry of dust, bugs, rain and low pressure power washing. In such exemplary embodiments, the incoming electrical line will also be sealed. It should be appreciated that the solid-state light fixture 100 can be surface, chain, pendant or continuous row mounted (lens down only).
[0038] FIG. 4 shows a first exemplary embodiment of the LED lamps 120 in greater detail. As shown in FIG. 4 , a plurality of LED packages 125 are mounted along a bottom surface of a heat sink 122 , with the LED elements 125 themselves extending away from the bottom surface of the heat sink 122 . The heat sink 122 has one or more heat dissipating fins extending from its top surface. Typically, the heat sink 122 will have a plurality of holes formed in it that allow the LED packages 125 to be mounted to the heat sink 122 and that allow the LED packages 125 to be connected to the power supply 170 .
[0039] FIG. 8 shows a second exemplary embodiment of LED lamps 220 in greater detail. As shown in FIG. 8 , in various other exemplary embodiments, the LED elements 125 of the LED lamps 220 are mounted on an electronic board 228 , such as, for example, a printed circuit board, to form a single LED assembly. This allows for all of the LED elements 125 mounted on the board 228 to be installed into and to be easily removed from a channel 224 formed in a heat sink 222 as a single unit. The channel 224 allows the board 228 with the LED elements 125 to be mounted directly to the heat sink 222 for easy installation and removal. To allow the electrical connection to be as easily installed and removed, the two halves of a quick-connect electrical connector can be provided in the wires connecting the board 228 to the power supply 170 .
[0040] In the exemplary embodiment shown in FIG. 3 , the reflector 150 is a generally flat member. However, in various other exemplary embodiments, the reflector 150 can be curved or cupped to improve the fixture efficiency. In this exemplary embodiment, the reflector 150 has two sets of linearly-arranged holes. The LED lamps 120 are mounted to the back surface of the generally flat or directional reflector 150 such that the LED elements 125 extend through the holes and illuminate a lighted side of the reflector 150 . In various exemplary embodiments, the angle of the reflector is matched to the direction that the opposing rows of LED's are facing. In such exemplary embodiments, the reflector 150 reflects the light from the LED elements 125 out of the fixture. The reflector 150 is then connected to the housing 110 using, for example, the two bosses that extend downwardly from the interior surface of the housing 110 .
[0041] FIG. 5 shows a perspective view of a second exemplary LED lamp and reflector assembly. In the exemplary embodiment shown in FIG. 5 , the reflector 250 comprises a pair of generally arcuate segments that are joined together along one edge. The generally arcuate segments can be formed, as shown in FIG. 5 , by a flat central section and two arcuate wings. Each of the flat central sections is provided with a set of linearly arranged holes that the LED elements 125 of the LED lamps 120 extend through to illuminate the concave side of the generally arcuate segments. The light output from the LED diodes 125 may be directed or bounced off the reflective panel to create a more even and less directional output.
[0042] It should be appreciate that the exemplary embodiment of a solid-state light fixture 100 shown in FIGS. 1-5 has a variety of features. For example, it can be used to replace fluorescent two-foot, four-foot and/or eight-foot T12, T8 and T5 lighting fixtures and/or metal halide and high pressure sodium, (HID) lighting fixtures. Due to its sealing features, it operates in wet environments and carries an IP rating of at least 65. Its versatile design allows for a wide range of applications. Due to using solid-state light emitting elements, each lamp has a lamp life of at least around 50,000 hours (and the life may extend to 100,000 or more hours), provides instant-on lighting, regardless of environmental temperatures, can provide color ranges from 2800K to 6000K, and works in almost any temperature. While the exemplary embodiment shown in FIGS. 1-5 has a sealed diffuser, this solid-state light fixture 100 can operate as an open fixture without the lens. As indicated above, the exemplary embodiment of a solid-state light fixture 100 shown in FIGS. 1-5 has a built in daylight sensor 135 , a built in motion sensor 130 , and an internal load shedding sensor 140 that communicates with the EMS system.
[0043] FIGS. 6 and 7 are perspective views of one exemplary embodiment of a solid-state lamp conversion kit 200 according to this invention. As shown in FIGS. 6 and 7 , the light fixture conversion kit 200 includes multiple LED lamps 120 , each comprising a plurality of LED elements 125 , in place of conventional light sources such as standard fluorescent T5, T8 or T12 tubes. The number of LED lamps 120 used for each fixture will be based on what required levels exist for each application. Unlike fluorescent lamps that have minimal options for varying light output, the LED fixtures are completely adjustable in their output allowing for a near perfect match for any lighting scenario.
[0044] In various exemplary embodiments, the conversion kit includes an LED lamp and reflector assembly comprising a highly polished aluminum reflector 150 or 250 with rows of LED lamps 125 protruding through the polished side of the reflector 150 or 250 . In the exemplary embodiment shown in FIGS. 6 and 7 , the second exemplary LED lamp and reflector assembly shown in FIG. 5 is used as the LED lamp and reflector assembly. The number of LED lamps 120 will be dependent on the light fixture the conversion kit is being used to replace and can vary widely allowing for flexibility in replacing all types of fluorescent lighting. The conversion kit can also include structural and electric elements that replace the existing pan, pins and ballasts of the fluorescent fixture. The reflector 150 or 250 can be constructed from die formed code steel or white paint aluminum and is mounted to the underside of the existing fluorescent fixture housing. The reflector 150 or 250 can be attached to the existing fluorescent fixture housing die formed spring steel and chain for quick access to the power supply. Computer assisted design can be used to create a reflector shape that provides maximum light output, uniform light distribution and rigid strength for a given application. In various exemplary embodiments, the reflector pan has a minimum of 91% reflectivity (TR)
[0045] As outlined above with respect to FIGS. 3 and 5 , in various other exemplary embodiments, the reflectors 150 and/or 250 used in a conversion kit 200 can be curved or cupped to improve the fixture efficiency, and/or the angle of the reflector can be matched to the direction that the opposing rows of LEDs are facing. In other exemplary embodiments, such reflectors 150 and/or 250 can have generally arcuate segments that are joined together along one edge. The light output from the LED packages 125 may be directed or bounced off the reflective panel to create a more even and less directional output.
[0046] In various exemplary embodiments, the housing can be modified so that one or more sensor packages can be mounted to the outside of the housing and/or to the inside of the housing. The one or more sensor packages can include an ambient light sensor 135 , an occupancy sensor 130 , a load sensor 140 or any other desired sensor whose output can be used to controllably modify the output or activation state of the solid-state lamps. A control system, which can be included in the one or more sensor packages or as a separate device, inputs the output signals from the one or more sensors and/or remote control signals and modifies the light output, and/or turns on or off, the solid-state lamps.
[0047] In various exemplary embodiments, installing the conversion kit is simple and easy, requiring only basic hand tools. This process involves removing the existing lamps, ballast cover and socket brackets of a fluorescent lamp fixture to be retrofit. New spring clips and chains are then installed with the supplied self-drilling screws. Next, the conversion LED pans are connected to the socket brackets with, for example, ¼ turn fasteners. Finally, the LED pan is wired and fastened to the fixture body with supplied chains 255 .
[0048] It should be appreciated that the exemplary embodiment of a solid-state light conversion kit 200 shown in FIGS. 6 and 7 has a variety of features. For example, it can be used to replace fluorescent two-foot, four-foot and/or eight-foot T12, T8 and T5 fluorescent tubes in existing fluorescent lighting fixtures and/or metal halide and high pressure sodium, (HID) lamps in HID lighting fixtures. Its versatile design allows for a wide range of applications. Due to using solid-state light emitting elements, each lamp has, as indicated above, a lamp life of at least 50,000 hours, provides instant-on lighting, regardless of environmental temperatures, can provide color ranges from 2800K to 6000K, and works in almost any temperature. While the existing fluorescent light fixture shown in FIGS. 1-5 does not have a sealed diffuser, the LED lamp and reflector assembly, power supply, sensor package(s) and/or load-shedding receiver can be retrofit into a sealed fluorescent or HID lighting fixture. As indicated above, the exemplary embodiment of a solid-state light conversion kit 200 shown in FIGS. 6 and 7 has a built in daylight sensor, a built in motion sensor, and an internal load shedding sensor that communicates with the EMS system.
[0049] Control of the solid state lamps in the solid state lighting fixture can be provided in four ways: 1) occupancy sensing; 2) daylight sensing; 3) load sensing; and 4) a switch. In occupancy sensing, the fixture is controlled using a built-in occupancy sensor that will allow for complete preset variable lighting levels. Full level lighting can be used when necessary but as the areas surrounding the fixture become unoccupied, the light levels will either go off completely or be reduced to a pre-determined level.
[0050] In daylight sensing, as the daylight, or other ambient light, surrounding the solid state lighting fixture reaches a pre-determined level, the daylight sensor will automatically reduce the output of the fixture by reducing the power supplied to the LED lamps. As more natural or ambient light is available, the fixture output will be reduced until, in some cases, all of the light in the space is provided by natural light and/or other light sources and the LED lamps are on stand-by until artificial or mechanical light is needed again.
[0051] In load sensing, many facilities come equipped with energy management systems (EMS) to help control equipment and avoid and lessen the affects and cost associated with high peak demand. In various exemplary embodiments, the fixture can be equipped with a sensor that will communicate with the EMS system, allowing the EMS to controllably and remotely dim the solid state lamps during times of peak load. This system may reduce or cut fixture loads in common or non-essential areas or may even reduce the main lighting depending on what levels currently exist and how low the various lighting levels are allowed to go.
[0052] Switching simply means that the solid-state lighting fixture can also be controlled by a simple switch as standard lighting sources are. An override system is in place that will allow for basic operation without use of the above mentioned controls.
[0053] While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents. | A high performance, high efficiency solid state electronic lighting device, having a sealed fixture body for use outdoors or in environments requiring IP rated sealed fixtures, uses light emitting diodes for producing light from AC current that operates on an as needed basis dependent upon occupancy, ambient light levels and facility load requirements. The high performance, high efficiency solid state electronic lighting device can also be used to replace the internal workings and reflective surfaces of a standard fluorescent fixture, a high-intensity-discharge (HID) lamp, or other arc-based lamps using light emitting diodes for producing light from AC current that operates on an as needed basis dependent upon occupancy, ambient light levels and facility load requirements. | 5 |
CROSS REFERENCE TO OTHER APPLICATIONS
This application is a continuation-in-part of application Ser. No. 491,815, filed May 5, 1983, now U.S. Pat. No. 4,545,171.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to prefabricated structures, illustratively residential dwellings, which have a prefabricated central core and are comprised of a plurality of prefabricated floor, wall and roof members that fold inwardly about the core to produce a compact partially collapsed folded structure, which is easily transportable, and fold outwardly from the core for quick and inexpensive on-site installation.
2. Background of the Invention
Over the years, the vast majority of structures, particularly residential houses, were completely constructed on-site. Specifically, once a suitable building lot has been chosen by a prospective home owner or developer, the lot was sufficiently cleared to accommodate a suitable foundation for the home. Shortly thereafter, construction proceeded through a sequence of stages. For each stage to occur, necessary materials and skilled labor were brought to the site. For example, after the foundation was laid, the shell of the house was constructed by a team of carpenters which cut to length and appropriately nailed together a requisite number of standard dimension wooden studs, illustratively 8, 10 or 12 foot sections of 2"×4" or 2"×6" studs. Thereafter, exterior wall and roof sheathing, and interior sub-floors were installed using appropriately sized plywood sheets, followed by the installation of exterior siding and roof shingles. Simultaneously therewith, the windows and the heating, electrical and plumbing systems were installed by carpenters, heating contractors, electricians and plumbers, respectively. Insulation was then added to the structure followed by the installation of all the interior walls and floors. Thereafter, the necessary appliances were put in position and connected to the appropriate electrical and plumbing systems. This, in turn, was illustratively followed by all remaining interior work such as painting, wall-papering, installation of interior trim and the like and any external landscaping.
While complete on-site construction, in a manner typified by that described above, has been the predominant form of house construction, construction costs, noteably labor, have substantially increased during the past two decades to the point where a significant number of buyers can no longer afford the price of a new house.
Consequently, various alternatives have been put forth in the art aimed at providing economically priced housing. In general, these alternatives all involve prefabricating various portions of a house at a central facility or plant by resident teams of skilled labor, transporting these portions to a building site and then performing the remaining assembly work on-site. It was generally thought that by prefabricating all or a significant portion of a house, sufficient cost savings would occur so that the purchase price of the installed prefabricated house would be advantageously less than that of a similarly sized conventionally constructed house. However, for a variety of reasons, the installation cost of each of these prefabricated prior art structures was substantial and, when added to the cost of manufacture and delivery, caused the total cost of any of these prefabricated structures to exceed that of conventional construction.
One such prior art prefabricated structure is described in U.S. Pat. No. 3,501,875 (issued to J. J. de Mailly on Mar. 24, 1970). This house is comprised of a number of rooms whose walls have been prefabricated from stressed concrete. Each room is nested inside another, to form two groups of nested rooms which are then loaded onto a flat-bed truck for the shipment to a building site. During on-site installation, a crane lifts each room from its nested group and appropriately positions it on a floor which has been attached to a suitable foundation. The rooms are then attached to each other. Thereafter, a prefabricated roof is laid in place over all the positioned rooms.
A house of this type carries a significant installation cost for the following illustrative reasons. First, since wiring and plumbing cannot be run within concrete walls, this necessitates that the rooms be electrically wired and plumbed at the time of on-site installation. In addition, nesting prevents any closets from being installed in any room until after the house has been installed on-site. Furthermore, any foundation used to support this house must be sufficiently strong to support its substantial weight and is thus usually fabricated from reinforced concrete which is quite expensive. Lastly, since a prefabricated house of the type described in the '875 patent is not self-supporting, steel columns or pillars are incorporated into the walls in order to support the weight of the roof. Unfortunately, steel columns are not standard in residential construction and hence, further increase the cost of the house.
Another approach was disclosed in U.S. Pat. No. 3,348,344 (issued to L. Tatevossian on Oct. 24, 1967). There, the prefabricated house is comprised of a pre-wired and plumbed central core surrounded on each of two sides by a number of folding rooms which share a common end wall that rides along a track. Each room contains two side walls connected at one end to a respective end wall and at the other end to the central core. Each side wall has a full-height hinge which collapses the wall with accordion-like folds. For shipping, the walls and floors are all folded inwardly towards the central core, and the roof sections of the house are folded down around the folded walls. During installation, the house is first positioned on a suitable foundation. The roof sections are first raised and the floor is then extended. Thereafter, to unfold the house, each end wall is pulled outwardly on its track from the central core and is then secured in place at the end of its travel.
While the installation cost of this folding structure is less than that associated with the structure disclosed in the '875 patent, it is still too large, for the illustrative reasons indicated below, to make the house described in the '344 patent economically viable over a similarly sized conventionally constructed house. Specifically, because of the substantial weight supported by each end wall and the large amount of friction between each end wall and the track in which it rides--particularly if dirt enters the track, a substantial amount of effort is required to fully extend each end wall away from the central core. Hence, a bulldozer or other heavy equipment must be procured, usually by renting at a fairly significant cost, for use in extending these walls away from the core. Furthermore, the accordion-like folds, in the rooms surrounding the central core, prevent any closets from being located anywhere but in the central core. Consequently, this severely limits available closet space, and thus necessitates that any additional closets be constructed on-site. In addition, this house is primarily constructed from aluminum, which is a non-standard and expensive building material. While unrelated to cost, this prefabricated house possesses an additional drawback in that it has a relatively high center of gravity, which disadvantageously makes the house, when folded, readily susceptible to tipping over.
A further approach is discussed in Italian Pat. No. 574,311 (granted to G. Desegnat et al. on Mar. 15, 1978). This patent generally discloses the idea concept of longitudinally articulating various floor and wall partitions to form a prefabricated house. The patent states that the house is entirely shop built such that, after the partitions are unfolded the house is connected to utilities, an immediately inhabitable unit is provided. The disclosure of this patent however, does not provide or suggest any specific details which one skilled in the art could use to construct a practical operable unit.
SUMMARY OF THE INVENTION
The invention relates to a prefabricated folding structure comprising at least one pre-erected central core comprising at least two oppositely arranged wall members and a floor extending between the at least two wall members, at least a first pivoting floor section, first pivoting means connecting the first pivoting floor section to the central core floor, the first pivoting means comprising means for transferring the load of the first pivoting floor section to the central core floor, at least three pivotable wall members, first means for pivotally connecting the third of the pivotable wall members to the pivoting floor section, the first pivotal connection means comprising an elongated member foldable along a predetermined crease line and capable of substantially maintaining its configuration when placed in either a folded or an unfolded condition about the crease line by a predetermined force, second means for pivotally connecting the remaining pivotal wall members to one of the central core wall members, and a plurality of beams located above the central core for stabilizing and strengthening the central core. This prefabricated folding structure is capable of forming either a compact folded structure wherein the at least one pivoting floor section and the at least three pivotable wall members are pivotally positioned inwardly about the central core so as to rest in close proximity thereto and substantially parallel to the core wall member to which the two pivotal wall members are pivotally connected, or a sturdy habitable structure wherein the at least one first pivoting floor section and the at least three pivotable wall members are pivotally positioned outwardly from the central core so as to define at least one room adjacent to the central core.
The central core may comprises at least two pair of oppositely arranged wall members having a generally rectangular configuration, with a predetermined number of these wall members utilizable as exterior walls and the remaining central core wall members being interior walls.
The first pivoting means further comprises means for reducing frictional forces during rotation of the pivoting floor section. The first pivotal connecting means conform to a predetermined position of the third pivotable wall member relative to the pivoting floor section, which position can vary from a generally parallel initial position to a predetermined final position. In a preferred arrangement, the predetermined final position of the pivotable wall member is substantially perpendicular to the pivoting floor section.
Each of the second pivotal connection means is also capable of conforming to a predetermined position of the respective remaining pivotable wall members relative to the central core wall member. This position can vary from a generally parallel initial position to a predetermined final position. Here, a preferred predetermined final position of the pivotable wall member is substantially perpendicular to the central core wall member.
The prefabricated structure according to the invention can include at least one folding interior wall member for dividing the room, a plurality of ceiling beams above the room, and means for connecting the plurality of room ceiling beams to the plurality of central core ceiling beams for horizontal support. The plurality of room ceiling beams are also attached to and at least partially supported by the third pivotable wall member.
In one embodiment, the prefabricated structure described hereinabove further comprises a flat or conventional roof installed on the structure after it is unfolded.
The invention also relates to a prefabricated folding structure comprising at least one pre-erected central core comprising at least two pair of oppositely arranged wall members and a floor extending between the wall members, at least two pivoting floor sections, first pivoting means connecting a first pivoting floor section to the central core floor and second pivoting means connecting a second pivoting floor section to the opposite end of the central core floor, the first and second pivoting means each comprising means for transferring the load of the first and second pivoting floor sections to the central core floor and means for reducing frictional forces in the first and second pivoting means during rotation of the pivoting floor sections, at least two sets of three pivotable wall members, first means for pivotally connecting each of the third of the pivotable wall members to the first and second pivoting floor sections respectively, the first pivotal connection means comprising an elongated member foldable along a predetermined crease line and capable of substantially maintaining its configuration when placed either in a folded or an unfolded condition about the crease line by a predetermined force, the folded condition corresponding to a generally parallel initial position of the third pivotal wall members relative to its respective pivotal floor section and the unfolded condition corresponding to a predetermined final position of the third pivotal wall members relative to the respective pivoting floor section, second means for pivotally connecting each of the remaining pivotal wall members of each set to each respective side of the oppositely arranged central core wall members, the second pivotal connection means capable of conforming to a predetermined position of the respective remaining pivotal wall members relative to the central core wall members, which position can vary from a generally parallel initial condition to predetermined final position, and a plurality of beams located above the central core for stabilizing and strengthening the central core. This prefabricated folding structure is also capable of forming either a compact folded structure wherein the at least two pivoting floor sections and each of the at least three pivotable wall members are pivotally positioned inwardly about each respective side of the central core so as to rest in close proximity thereto and substantially parallel to each of the at least two core wall members, or a sturdy habitable structure wherein the first and second pivoting floor sections and the pivotable wall members are pivotally positioned outwardly from the central core so as to define at least two rooms adjacent to the central core.
The prefabricated structure according to this embodiment further comprises a plurality of ceiling beams above the rooms and means for connecting each of the plurality of room ceiling beams to each end of the plurality of central core ceiling beams for partial horizontal support. Also, the plurality of room ceiling beams are also attached to and at least partially supported by at least one of the pivotable wall members.
Preferably, one pre-erected central core is used, and it includes comprising two pair of oppositely arranged wall members having a generally rectangular configuration and a floor extending between the wall members wherein a predetermined number of the central core wall members are utilizable as exterior wall members and the remaining central core wall members are interior wall members. In this arrangement, the central core contains all necessary and desired plumbing and electrical control means, and preferably includes at least a substantially prefabricated kitchen and a substantially prefabricated bathroom.
In an alternate embodiment, the prefabricated folding structure of the invention can include a plurality of prefabricated roof support trusses attached to the upper sides of one pair of oppositely arranged central core wall members and a plurality of folding roof members pivotally connected to the prefabricated roof support trusses. The plurality of folding roof members are capable of folding downwardly onto the roof trusses or folding to a position parallel to the core wall members.
In addition, the prefabricated folding structure according to the folding roof structure may comprise upper and lower folding roof sections wherein each upper section is pivotally connected at one of its ends to a corresponding lower section and to the prefabricated roof support trusses. The lower folding roof sections are at least partially supported by a pivotable wall member which is attached to a pivoting floor section.
The prefabricated folding structure of the invention can further comprise a plurality of free standing partitions which in the compact folded structure are positioned substantially parallel to and alongside at least one of the interior the central core walls, or when the folding structure has been completely unfolded, are positioned to further define a predetermined number of rooms and closets arranged adjacent to the central core. The pivotable wall members and the pivoting floor sections are configured and dimensioned to provide sufficient free space parallel to the central core walls when the structure is folded for holding non-pivotally connected building components until the structure is unfolded.
The non-pivotally connected building materials comprise free standing wall partitions and roof brace supports. Also, the central core and pivotable wall members include all necessary cable and wiring requirements.
The invention also includes a method for erecting a sturdy habitable dwelling from a prefabricated folding structure which comprises prefabricating a compact folded structure as described hereinabove, transporting the compact folded structure to a construction site, supporting the compact folded structure on at least two properly positioned central core support means, unfolding the compact folded structure by pivoting the first pivoting floor section to a horizontal position onto support means, pivoting the third pivotable wall member to a vertical position with respect to the first pivoting floor section, pivoting the other pivotable wall members, and finishing final construction details to form the sturdy habitable structure. This method further comprises adding a plurality of ceiling beams above the room and attaching these ceiling beams to the central core ceiling beams.
When the prefabricated folding structure comprises at least two adjacent rooms, the compact folded structure is unfolded by pivoting the first pivoting floor section to a horizontal position ontosupport means, pivoting the second pivoting floor section to a horizontal position onto support means, pivoting each the third pivotable wall members to a final position relative to the first and second pivoting floor sections, and pivoting the remaining pivotable wall members according to a predetermined sequence to their final positions. Preferably, the final position of the third pivotable wall members is substantially perpendicular to the pivoting floor sections. The final structural details are then completed.
The predetermined sequence of unfolding the remaining pivotable wall members preferably comprises pivoting the outermost wall member outwardly to its final position, pivoting the next outermost wall member outwardly to its final position, and repeating these pivoting stepts until all remaining wall members are pivoted outwardly to their final position. The preferred final position of the remaining pivotable wall members is a substantially perpendicular position relative to the central core wall to which it is pivotably connected. Also, this method also contemplates adding a plurality of ceiling beams above the rooms and attaching these beams to each end of the central core ceiling beams.
In order to form a multi-story structure, the invention contemplates a method which comprises prefabricating a plurality of compact folded structures as described hereinabove, transporting the compact folded structures to a construction site; supporting a first compact folded structure on at least two properly positioned central core support means, unfolding the structure by pivoting each pivoting floor sections to a horizontal position onto a support means; pivoting each third pivotable wall member to a vertical position with respect to each pivoting folded floor section, unfolding the remaining pivotable wall members, positioning a second compact folded structure above the unfolded first structure; unfolding the second compact folded structure in the same manner as the first, and finishing the final structural details to form a sturdy habitable muti-story structure.
The method further comprises repeating the positioning and unfolding steps as often as necessary to form the desired number of stories then adding a plurality of ceiling beams above the rooms and attaching these beams to the central core ceiling beams. Alternately, a flat or conventional roof can then be installed on these ceiling beams, the uppermost structure can be provided with a plurality of prefabricated support trusses attached to its central core ceiling members and a plurality of folding roof members pivotably connected to the prefabricated roof trusses as described hereinabove.
The invention also relates to the sturdy habitable structures produced according to the above-described methods.
Accordingly, an object of this invention is to provide low-cost prefabricated structures which are not only economical to manufacture but are also easy and inexpensive to install on-site, to thereby provide significant cost savings over a similarly sized conventionally constructed structure.
A particular object is to install all the necessary systems--e.g. wiring, plumbing and heating, and appliances in the structure during prefabrication.
Another particular object is to minimize the need for any heavy machinery during installation of the structure and to minimize the labor and effort required for installation.
A further particular object is to eliminate the need for any non-standard building materials, and to minimize the weight of the structure thereby eliminating the need for both internal columns and a reinforced foundation.
Lastly, another object is to incorporate as much stability as possible into the structure in order to minimize the tendency of the structure to tip-over while it is being transported.
BRIEF DESCRIPTION OF THE DRAWING
The invention may be clearly understood from a consideration of the following detailed description and accompanying drawings, wherein:
FIG. 1 is a perspective view of the outside of applicant's prefabricated folding structure shown in a completely folded shipping configuration;
FIG. 2 is a cross-sectional view of applicant's prefabricated folding structure shown in FIG. 1;
FIG. 3 is a cross-sectional view of pivot 2 shown in FIG. 2 and taken through section 3--3 of FIG. 8;
FIG. 4 is a partial cross-sectional view of one of pivots 3 shown in a folded position and taken through section 4--4 of FIG. 7;
FIG. 5 is a cross-sectional view of one of pivots 4 shown with interior wall 103 completely pivoted and taken through section 5--5 of FIG. 12;
FIG. 6 is a cross-sectional view of applicant's prefabricated folding structure, depicting the pivotal movement of upper folding roof sections 50 and 53, and lower folding roof sections 51 and 52;
FIG. 7 is a cross-sectional view of applicant's prefabricated folding structure, depicting the pivotal movement of folding floor members 61 and 62;
FIG. 8 is a cross-sectional view of applicant's prefabricated folding structure, depicting the pivotal movement of folding front and rear exterior walls 71 and 72, respectively;
FIG. 9 is a partial cross-sectional view of one of pivots 3, shown in a completely unfolded position and taken through section 9--9 of FIG. 11;
FIG. 10 is a plan elevational view of the interior of applicant's prefabricated folding structure, depicting the pivotal movement of folding exterior side walls 91, 92, 93 and 94;
FIG. 11 is a cross-sectional view of applicant's prefabricated folding structure, depicting the pivotal movement of folding ceiling sections 81 and 82 and ceiling support T-braces 86 and 87;
FIG. 12 is a plan elevational view of the interior of applicant's prefabricated folding structure, depicting the positioning of folding walls 101-104 and 108-111, and free-standing partitions 105, 106, and 107;
FIG. 13 is a cross-sectional view of applicant's prefabricated structure, shown completely unfolded;
FIG. 14 is an exterior perspective view of applicant's prefabricated structure shown completely unfolded and installed on-site;
FIG. 15 is a plan elevational view of the interior of another structure shown in a completely unfolded position which embodies the present invention and illustrates its use in structures of different shapes;
FIG. 16 is a cross-sectional view of an alternate embodiment of a single story prefabricated structure, shown completely unfolded; and
FIG. 17 is a cross-sectional view of applicant's two story prefabricated house shown completely unfolded.
In all the cross-sectional views indicated herein, which depict the folding structure in various stages of being unfolded, each cross-sectional view has been taken along a section generally similar to that shown by lines 2--2 of FIG. 10.
Also, to facilitate easy understanding, identical reference numerals are used to denote identical elements common to the figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the description that follows, the terms "beam", "stud", "plate", and "rafter" refer to support members as defined below:
(1) "beam" indicates a support member lying in a horizontal plane which has a height that is greater than its width;
(2) "stud" refers to a support member in a vertical position;
(3) "plate" refers to a flat support member (i.e.--one having a width that is greater than either the height or thickness); and
(4) "rafter" is used to indicate a stud or beam in an angled position (i.e.--in a position other than horizontal or vertical).
Although the teachings of the present invention are applicable to a wide variety of structures of different weight, size, shape and materials for a variety of diverse uses, for purposes of the following description, the present invention will be described in the context of a single-story prefabricated residential dwelling (house).
FIG. 1 shows an exterior perspective view of a single-story prefabricated folding house constructed in accordance with applicant's invention and folded into a shipping configuration. As shown, the house contains a generally rectangularly shaped prefabricated central core 5--of which only exterior core wall 21 is shown. Positioned substantially parallel to and alongside this core wall--and discussed in greater detail in conjunction with FIG. 2--are the pivotable front and rear walls and pivoting floor sections.
On the left side of the core, a plurality of studs comprising pivotable exterior side wall 71 are pivotedly connected at one end of the core wall via pivots 3, to the outer end of pivoting floor section 61 at floor joist 611. Each of these joists in the pivoting floor sections are pivotedly connected at its other end, via pivot 2, to a respective one of the floor joists, e.g. joist 411, which joists together comprise the floor of central core.
The floor of the central core is comprised of a plurality of beams positioned substantially perpendicular to the walls of the central core, at least one beam oriented parallel to the walls of the central core connected to each of the plurality of beams, and acceptable decking material attached to and substantially covering the beams.
Preferably, these beams are made of lumber or steel, and the decking material can be plywood, fiberboard or variations of these. In a particularly advantageous embodiment, the decking comprises a subflooring of plywood or the like, followed by a final floor covering of hardwood planking, carpeting, tile or linoleum, depending upon the use for that particular section of the house.
The beams of the central core floor 41, illustratively, are 2"×10" wooden joists and those of each pivoting floor section are 2"×10" wooden joists. It is also possible to use 2"×8" joists for the pivoting floor sections, rather than 2"×10", to save material costs. All the joists comprising these floor members are arranged in an approximate 16" center-to-center spacing and are staggered such that an end of each floor joist in each pivoting floor member lies adjacent to an end of a corresponding floor joist in the central core. During prefabrication, both subflooring, of illustratively 5/8" thick plywood, and final floor covering, of illustratively 1/4" hardwood planking, are nailed in place over all the joists comprising each of these floor members with exception of an area existing above pivots 2 between each pivoting floor section and the core floor. Subflooring and final flooring are installed over this area after the house has been fully unfolded, as discussed hereinbelow.
Affixed atop the central core is a ceiling member (not shown but see 40 in FIG. 2) upon which is positioned a plurality of prefabricated roof trusses--of which only truss 31 is shown. When a folding structure is used as a single story dwelling or the top floor of a multiple story dwelling, these trusses provide support for the folding roof which is comprised of lower folding roof sections 51 and 52 and upper folding roof sections 50 and 53. Each lower roof section is pivotedly connected at one of its ends to both an end of a respective upper folding roof section and to an end of each truss. In the shipping configuration as shown, the lower folding roof sections are pivotedly oriented downward to lie alongside the pivoting floor section, and the upper folding roof sections are pivotedly oriented downward to lie against each of the trusses.
These folding roof sections preferably comprise a plurality of rafters positioned substantially perpendicular to the walls of the core, at least one rafter positioned perpendicular to the plurality of rafters for connection thereto, a sheathing material connected to and substantially covering the rafters and moisture barrier means attached to the sheathing.
The moisture barrier is preferably builder felt, and a building exterior, such aluminum siding, shingles, cedar shakes, etc., is placed upon the moisture barrier and sheathing materials.
Since the weight of the folding structure is primarily supported by the walls comprising the central core, relatively little weight is borne by any of the pivoting wall, floor and ceiling members. Consequently, these pivoting members can be made fairly light in weight. Not only does this advantageously eliminate the need to use a reinforced foundation, but, in addition, this advantageously minimizes the effort required to pivotally move these members into proper position during installation of the structure. Thus, once the structure is properly positioned on its foundation, only a minimum amount of labor and no heavy machinery is needed to unfold the structure and complete the installation. These factors, coupled with the use of only inexpensive standard building materials and extensive prefabrication, advantageously permit substantial cost savings to be achieved over the cost of both prior art prefabricated structures and conventional construction.
The use of pivoting floor, wall, ceiling and roof members, which fold and unfold in a manner to be discussed in detail shortly, reduces the height and width of the folded home to specifically 11 feet 4 inches and 13 feet 8 inches, respectively. Advantageously, this greatly lowers the center of gravity of the folded home. Consequently, this ensures that the house is not susceptible to being tipped over during shipment. Hence, the house can be easily and safely transported on a flatbed truck to a suitable building site.
Once a suitable site has been appropriately excavated, a concrete foundation is laid. This foundation is provided with four points for supporting the folding structure. Two supports are located just below and outside of the core walls, and each of the two other supports is located under one of the pivoting floor sections. Thus, the two supports for the core hold the weight of the structure while the pivoting floor supports maintain the floor in the correct orientation and position i.e., parallel to and level with the core floor. A well known wood plate (not shown), which is illustratively comprised of a pair of 2"×6" studs laid one atop another, is affixed all around the top surface of this foundation. These studs and the foundation are configured and arranged so as to facilitate the unfolding of the structure. Thereafter, the folded house shown in FIG. 1 is positioned on top of the wood plate and unfolded in a manner discussed below.
FIG. 2 depicts a cross-sectional detail view of the prefabricated folding house of FIG. 1 taken through a section generally resembling 2--2 of FIG. 10. Viewed in conjunction with FIG. 1 and the interior plan view shown in FIG. 10, FIG. 2 shows that applicant's folding house is comprised of a rectangularly shaped central core 5, a plurality of folding exterior wall members--specifically folding front wall 71, folding rear wall 72 and folding side walls 91, 92, 93 and 94; and pivoting floor sections 61 and 62; folding roof 9 containing folding upper and lower roof section 50 and 53, and 51 and 52, respectively; and pivoting ceiling members 81 and 82, and lastly a plurality of prefabricated roof trusses of which only truss 31 is shown.
Specifically, central core 5 is comprised of interior core walls 22, 23, 24, 26, 27 and 28, and exterior core walls 21 and 25 all secured, illustratively, by nails to both core floor 41 and ceiling member 40. The central core is completely prefabricated and contains all piping, plumbing, and electrical control means (i.e.--circuit breaker box, etc.) for connection to external sources of supply (i.e. water, gas, electricity, etc.). Also, all necessary systems for the entire structure, e.g. heating, plumbing and electrical, and all the required appliances and plumbing fixtures are installed in the central core during prefabrication. Furthermore, any outlets that are to be located in any of the pivoting members, particularly the walls, are installed while the structure is being prefabricated.
As shown in FIG. 10, this core contains the kitchen including all its appliances; the bathroom--including the necessary plumbing fixtures, noteably a bathroom sink, tub/shower and toilet; and a closet with folding doors containing the hot water heater, washer and dryer.
Preferably, the core walls each comprise a plurality of studs and at least two plate members connected respectively to the top and bottom of the plurality of studs. Since these core walls are located within the folded structure, they are provided with gypsum board after the necessary piping, plumbing, and electrical components have been installed. An advantageous stud is a wooden 2"×4", although steel, aluminum, or other materials could be used, if desired.
Each pivoting exterior wall (front wall 71, rear wall 72 and side walls 91, 92, 93 and 94) is completely assembled during pre-fabrication. These walls would be constructed in the same manner as the core walls. One difference, however, is that these walls would each have one side facing the exterior of the building. These faces would then be covered with a sheathing, moisture barrier, and finally, the desired exterior facade.
Each wall is specifically fabricated from illustratively 2"×4"×8 foot wooden studs which are approximately spaced 16" apart on a center-to-center basis. During prefabrication, windows are installed at predetermined locations into these walls, and the exterior surface of each folding wall, i.e., that surface which faces the outside environment, is covered with standard 1/2" plywood sheathing material over which a moisture barrier along with the desired siding material, e.g. aluminum siding, asbestos shingle or other siding material, is applied. In addition, electrical outlet boxes are affixed to various studs in these walls and wired at the factory. To conform with standard building codes, all electrical wiring is placed inside each wall. Thereafter, thermal insulation is installed within each wall and illustratively 1/2" gypsum board, (also known as "dry wall" or "sheet rock") is then installed over the interior surface of each folding exterior wa1l, with an appropriately located prewired electrical outlet.
As previously discussed, means for supporting the roof and ceiling of the structure are provided above the central core. These means are located on and are supported by the common walls of the core, and preferably comprise a plurality of prefabricated truss assemblies. Each of the prefabricated trusses provide the necessary structural support for the upper and lower folding roof sections whenever they are pivoted into an open, i.e. unfolded, position. While only one truss 31 is shown in the cross-sectional view of FIG. 2, the house is illustratively comprised of a number of separate trusses, each preferably fabricated from 2"×4" rafters and mounted on a 24" center to center spacing. Any number of trusses can be used, with the particular number being predicated upon the desired spacing between trusses and the size of the structure. The spacing for the trusses (and also for the floor joists, wall studs and ceiling rafters) is often specified by local building codes and/or practice and can thus vary from that specified hereinbelow. Each truss is pivotedly attached to upper roof sections 50 and 53, and lower roof sections 51 and 52 of roof 9.
As shown in FIGS. 2 and 10, a number of structural members, including pivoting exterior side and front (and rear) walls and a pivoting floor member, are positioned during prefabrication substantially parallel to and alongside the interior core walls. Specifically, these structural members are arranged in two groups of similar members, group 7 being adjacent to interior wall 28 and the other, group 8, being adjacent to interior wall 22. In the shipping configuration shown in FIG. 2, the structural members comprising each group are positioned alongside each other and are all substantially parallel to the adjacent interior core wall 22 or 28. Group 7 is comprised of free-standing partition 105, folding exterior side wall 91, folding exterior front wall 71 and pivoting floor section 61, and also--as is apparent from FIG. 10--folding interior walls 101-104 and folding exterior side wall 94. Group 8 is comprised of similar structural members and free-standing partitions, specifically: folding exterior side walls 92 and 93, folding exterior rear wall 72, pivoting floor section 62, folding interior walls 108-112 and free standing partitions 106 and 107. It should be noted that interior walls 101 and 102 are joined together, but are provided with an open area in between for access (i.e., a doorway). The same applies to wall 103 and 104; 108 and 110; and 109 and 111.
In accordance with this feature of the invention, substantial closet space is incorporated into the folding structure through the use of the folding interior walls and free-standing partitions. When the structure is fully folded, these interior walls and partitions are initially positioned to lie alongside various interior side walls comprising the central core. Once the walls and floor members are pivoted into their properly installed positions, an enclosed area is defined around the core. Each pivoting interior wall and each free-standing partition are then pivoted or moved to a pre-determined position within this area in order to define all the rooms arranged about the core and all the closets existing therein.
Folding the Structure
The shipping configuration, shown in FIG. 2, is achieved during prefabrication by first appropriately pivoting the folding interior walls and positioning the free-standing partitions against the core walls and second folding i.e., pivotedly positioning, various structural members inwardly about the central core in the manner described below. Since the structural members comprising group 8 both pivotedly interconnect and fold in a nearly identical manner to those comprising group 7, the following sequence will be described, for the sake of brevity, with respect to only those members in group 7.
First, free-standing partition 105 is positioned, as shown in FIG. 12, alongside interior side core wall 28. This partition is preferably oriented such that its vertical edges are parallel to those of the interior core wall. In a similar fashion, folding interior walls 101-104 are pivoted and positioned, as shown in FIGS. 10 and 12, such that each lie alongside interior side core walls 26 and 27.
Thereafter, folding ceiling members 81 and 82 are each pivotedly positioned upwardly, as shown in FIG. 11, such that each folding ceiling member, e.g. ceiling member 81, lies partially within and parallel to a corresponding lower folding roof member, e.g. folding roof member 51. The rafters in each folding ceiling member are staggered with respect to those in each corresponding lower folding roof member such that when those ceiling members are folded their joints partially interleave with those in each corresponding lower roof folding section.
Next, as shown in FIG. 10, folding exterior side walls 91 and 94 are pivotedly positioned inwardly, about pivots 4, such that these walls lie alongside free-standing partitions 105 and pivoting wall 101, respectively. Then, as is evident from FIG. 8, folding exterior front wall 71, which pivots, via one of the pivots 3 about an end of pivoting floor section 61, is pivotedly positioned downward, such that it lies alongside pivoting floor section 61.
Thereafter, as shown in FIG. 7, pivoting floor section 61 is pivoted upward about pivot 2 located in the left end of core floor 41, such that folding exterior front wall 71, particularly its exterior surface, lies alongside folding exterior side wall 91 (and 94 not shown).
Now, with all the exterior folding walls folded inwardly about the core, upper folding roof section 50 and 53 are folded, as shown in FIG. 6, by being pivotedly positioned downward until each abuts against all the trusses, e.g. truss 31. Lower folding roof sections 51 and 52 are then folded by being pivotedly positioned downward and inwardly such that each lies vertically alongside folded floor members 61 and 62, respectively.
Pivots between Folding Structural Members
Pivot 2 exists between folding floor members 61 and 62 and core floor 41. This pivot is comprised of a plurality of identical pivoting assemblies, each connecting a floor joist in the central core to a corresponding floor joist in either of the folding floor members. For purposes of illustration, one such pivoting assembly, i.e. that each such existing between floor joist 611 of pivoting floor section 61 and floor joist 411 of central core floor member 41, is shown in FIG. 3.
This pivot 2 comprises pivoting means for rotation of the pivoting floor section with respect to the central core floor, means for transferring the load from the pivoting floor section to the central core floor. This pivot also includes the means for reducing frictional forces during rotation of the pivoting floor section.
The load transferring means preferably is a metal saddle strap, while the friction reducing means is a metal washer. Also, the saddle strap functions to partially reduce friction between the two support members. The pivoting means is preferably bolting means or the like.
Specifically, this pivoting assembly is comprised of bolt 11 (illustratively a 1/2" ASTM A307 bolt) secured by washers 12 and nut 13. Separate saddle straps 10 and 18, each preferably fabricated from galvanized metal 12 gauge or thicker, are each nailed to a floor joists 411 and 611 respectively, in the vicinity of the pivot. These straps provide a sliding interface against which each joist can rotate without causing any abrasion of either joist. After floor section 611 has been appropriately pivoted into its unfolded position, nut 13 is completely tightened to secure pivoting floor section 61 in position.
Pivot 3 exists between pivoting floor section 61 and folding exterior front wall 71 and between folding floor member 62 and folding exterior rear wall 72. This pivot is comprised of a plurality of identical pivoting assemblies, each connected between every joist in a pivoting floor section and every wall stud in a pivoting exterior front or rear wall. A partial cross-sectional view of one of these pivoting assemblies, i.e. that existing between floor joist 611 of folding floor member 61 and wall stud 711 of pivoting exterior front wall 71 is shown in FIG. 4.
This pivot 3 includes pivotal means connected to the pivoting floor and pivotable wall members. The pivoting means comprises an elongated member which is foldable along a predetermined crease line. This member has sufficient strength to hold its shape and requires a predetermined force to be moved or bent. This elongated member facilitates changing the position of the wall members relative to the floor from a generally parallel initial position to a predetermined final or unfolded position. Preferably, this final position has the wall members substantially perpendicular to the floor.
Also, after the wall members are rotated to the desired angle, the pivoting means is capable of retaining the wall in relative position with respect to the floor. Although the pivoting means are capable of conforming to any angle between 0 and 180 degrees, in the most advantageous embodiment, the wall is rotated 90° and the pivot maintains the wall in this position without the use of other restraining forces.
Specifically, the pivoting assembly is comprised of a metal plate 721, which is nailed to both floor joist 611 and wall stud 711 by illustratively four nails 723, sized 10 penny (10 d) common or larger. Two of these nails are driven through the plate and subfloor 612 into floor joist 611, and the remaining two are driven through the plate and gypsum board 713 into wall stud 711. Whenever exterior front wall 71 is fully pivoted upward into position, as discussed later in conjunction with FIG. 9, exterior front wall 71 is oriented perpendicular to pivoting floor section 61 and, as a result, metal plate 721 is bent by the pivoting movement of the folding wall with respect to the folding floor into an "L" shape. This plate is advantageously fabricated from galvanized steel or other material that is sufficiently thick, preferably 16 gauge or wider, such that all the plates alone can hold the wall in an upright perpendicular position and also undergo many bending and unbending operations without showing any signs of stress or fracture.
Pivot 4 includes pivotal means attached to the wall member, the core ceiling and the core floor. The pivotal means comprises means to rotate the wall member to a predetermined angle around the axis of the pivotal means. Also, the pivotal means are positioned and oriented so as to facilitate rotation of the wall member while minimizing the space between the wall member and core wall when the wall member is in an unfolded or open position.
Preferably, the pivotal means comprises two nails; one between the ceiling and wall, and the other between the floor and wall. These nails are placed slightly off center to facilitate rotation of the wall while minimizing the space between the core wall and rotated wall member.
FIG. 5 illustrates pivot 4. Interior wall 103 is pivotedly attached, as shown, to core floor 41 and ceiling member 40 by two nails 49. Each of these nails is sized preferably 16 penny (16 d) common or larger. One nail is driven through cat block 401 in its upper wall member 1033 and the other is driven through cat block 412 into lower wall member 1035. Cat block 401 is secured by nails (not shown) to two adjacent ceiling joists--of which only joist 402 is shown. Cat block 412 is secured by nails (not shown) to adjacent floor joists 411 and 412. Consequently, interior wall 103 rotatably pivots about nails 49.
FIG. 5 also shows interior wall 103 in a completely folded configuration (as shown in phantom in FIG. 12). Pivoting interior wall 103 is comprised of a sequence of illustratively standard dimension 2"×4"×8' wooden studs--of which only stud 1034 is shown--arranged with approximately 16" center to center spacing and nailed to both upper wall member 1033 and lower wall member 1035. A layer of gypsum board 1031 is affixed to each exterior side of this folding wall 1033.
Core floor 41, as shown and as previously discussed, is comprised of illustratively 2"×10" wooden floor joists--of which only floor joists 411 and 413 are shown--all arranged with an approximate 16" center-to-center spacing. Subfloor 414--illustratively 5/8" plywood sheet--is nailed to the core floor joists. Ceiling member 40 is constructed in a similar manner as is core floor 41, with the exception that gypsum board, specifically sheet 403, instead of 5/8" plywood as used in the subfloor, is nailed to the under surface of the 2"×4" ceiling beam--of which only beam 402 is shown.
When fully unfolded, interior wall 103 lies substantially perpendicular to interior core wall 27. This core wall is comprised of a sequence of 2"×4"×8' studs--of which only stud 273 is shown--arranged on an approximate 16" center to center spacing and nailed to both top wall members 271 and 272 and lower wall member 274, all of which are also illustratively 2"×4"×8' wooden studs. Gypsum board 276 is affixed to both sides of interior core wall 27.
Pivots 4 exist between core ceiling 40 and folding exterior side walls 91, 92, 93 and 94, and between core floor 41 and folding exterior side walls 91, 92, 93, and 94. All pivots connecting each folding exterior side wall to the core ceiling and core floor are identical, and would be similar to the pivot 4 illustrated in FIGS. 5. For the exterior side walls, however, the central core side walls 21, 25 are extended as shown in FIG. 10 provide enough space for the non-pivoting members, such as partition 105, "T-braces" 86, etc.
Unfolding the Structure
Having summarily described the sequence in which the pivoting walls, floor and roof members fold inwardly about the central core to form the folded structure shown in FIGS. 1 and 2, a more detailed explanation will now be given as to the manner in which all the structural members are sequentially unfolded to transform the house from its shipping, i.e., folded, configuration into a fully habitable residential dwelling. This sequence is depicted in FIGS. 6 through 8, and 10 through 12.
The first structural members to be unfolded are the roof sections. As shown in FIG. 6, upper folding roof sections 50 and 53 are pivotedly positioned upward and outward. Ridge beam 56 is preferably a 2"×6" wooden beam which runs the entire length of upper folding roof section 53 and abuts against the top edge of folding roof section 50 when both these roof sections are completely unfolded. The rafters that comprise each of these upper roof sections are 2"×4" wooden beams located on a 24" center-to-center spacing, and all the rafters comprising either of the upper roof sections are staggered with respect to those of the other. Once these upper roof sections are completely unfolded into position as shown in FIG. 6, a pair of suitably sized nails (not shown), preferably 16 penny (16 d) common or larger, are driven through the ridge beam and into each rafter comprising upper folding roof section 50 in order to fully secure both upper roof sections in position. It should be noted that all upper roof sections have been fully sheathed and shingled during prefabrication.
Next, as shown in FIG. 6, lower roof sections 51 and 52, each comprised of illustratively 2"×4" rafters are pivoted upward and outward into position. These rafters are connected by pivotal means comprising bolting means. Each pivot connecting both the upper and lower roof sections to the trusses, is comprised of a series of 1/2" bolts (not shown), each of which runs through a rafter in a lower roof section, an adjacent truss and an adjacent rafter in upper roof section. A temporary support (not shown) is then positioned under the lower end of each of these lower folding roof sections and is adjusted to an appropriate height to temporarily keep each lower roof section in its completely unfolded position. To secure the roof sections in a final position, a properly sized nut which has been threaded onto the end of each bolt is fully tightened. In addition, at least three nails, preferably 16 penny (16 d) common or larger, are then driven through each rafter in the lower roof section and into its adjacent roof truss, and likewise, three more of these nails are driven through each rafter in the upper roof section and into its adjacent roof truss. Again all lower roof sections have been fully sheathed and shingled during prefabrication.
Once the roof is completely unfolded, then as shown in FIG. 7, folding floor member 61 and 62 are pivoted into position. Specifically, both folding floor members are pivoted downward and away from the central core, thereby forming the entire floor for the dwelling.
Thereafter, as shown in FIG. 8, folding exterior front and rear walls 71 and 72 are unfolded into position. Specifically, each wall is pivoted upward and outward about pivots 3 until the upper ends of exterior front wall 71 and exterior rear wall 72 abut against all the rafters comprising lower folding roof sections 51 and 52, respectively.
As can be seen in FIG. 9 and as previously noted in conjunction with FIG. 4, the upward movement of folding exterior front wall 71 away from pivoting floor section 61 causes metal plate 721 to become "L-shaped". Whenever folding exterior front wall 71 is fully unfolded, horizontal stud 725, which exists at the bottom of this wall, lies on top of subfloor 612 of pivoting folding section member 61. In this position, exterior sheathing 714, which is illustratively 1/2" plywood sheet and which has been attached to this wall during pre-fabrication, overhangs subfloor 611 and end piece 616. This endpiece is nailed to each of the floor joists, by at least 3 nails, preferably 10 penny common or larger, which are all nailed through the sheathing and into the endpiece in the vicinity of each floor joist.
With these folding exterior front and rear walls, secured in place, folding exterior side walls 91, 92, 93, and 94, as shown in the plan view of FIG. 10, are then unfolded into position and secured in place. Specifically, each exterior wall is pivoted outwardly about pivots 4--as previously discussed and shown in FIG. 5--such that each end wall lies substantially perpendicular to the previously unfolded exterior front or rear walls. Once each folding exterior side wall is pivoted into its properly unfolded position, screw nails (not shown but well known) are driven through appropriately positioned cat blocks existing between respective adjacent ceiling rafters and floor joists into the header and lower cross-piece of each of these walls.
At the end walls of the house, the ceiling and lower roof section are pivotally joined. The pivotal means utilized for this connection comprises means for rotation of the ceiling member with respect to the roof member, and means for attaching the ceiling and roof member to the outer wall member.
At this juncture, folding ceiling members 81 and 82, as shown in FIG. 11, are unfolded into position. To accomplish this, folding ceiling members are pivoted downward such that unfolded ceiling member 81 lies on top of unfolded exterior front wall 71 and side walls 91 and 94; and unfolded ceiling member 82 lies on top of exterior front wall 72 and side walls 92 and 93, respectively.
Next, unfolded exterior front wall 71 is secured to unfolded ceiling member 81 and to lower folding roof section 51. A plurality of "L-shaped" double nailing plates (not shown but well-known) having a saddle shaped lower extension are positioned such that the saddle of each nailing plate straddles the header of folded exterior front wall 71. Each nailing plate has an upward vertically oriented section emanating from one end of the saddle, and is positioned along the header such that its vertical section abuts against one of the rafters in the lower roof section. There are as many nailing plates positioned along the header as there are rafters in this roof section. Once a plate is appropriately positioned, it is nailed to both the header--using preferably at least 6 nails sized 10 penny (10 d) common or larger, with two nails driven through the saddle of the plate into each side of the header and the remaining two nails driven through the vertically oriented section in the lower roof rafter. To further secure the unfolded exterior front wall to the lower roof section, a bolt and not assembly (not shown) preferably 1/2" diameter, which has been inserted through a pre-drilled hole existing in the vertical section in each nailing plate and into a corresponding hole in the adjacent lower roof rafter during prefabrication, is tightened. Appropriate size washers may be used with each bolt. Unfolded exterior rear wall 72 is secured to lower folding roof section 52 in a substantially identical fashion.
Since adequate support for the lower roof members is now provided by all the unfolded exterior walls, the jacks that are supporting these lower roof sections are now removed.
Additional support for folding ceiling members 81 and 82 is provided by the installation of a number of "T-braces" as shown in FIG. 11. In the illustrative embodiment shown and described herein, one T-brace, is mounted to a respective upper end of each truss and supports each ceiling member. The number of "T-braces" depends ultimately upon the number of trusses used. Each T-brace extends downward from a side of a upper end of a roof truss and lies in line with a corresponding rafter in a folding ceiling member, and provides a surface upon which the desired ceiling materials can be installed.
Since all the T-braces are approximately the same, for purposes of illustration, only T-braces 86 and 87 which run between truss 31 and folding ceiling members 81 and 82, respectively, are shown, and only T-brace 86 is discussed. T-brace 86 is comprised of an appropriate length of 2"×4" stud, e.g. stud 861, which extends downward from an appropriate, truss to a ceiling rafter, and a relatively short length of 2"×4" stud, e.g. stud 862, which is positioned perpendicularly to stud 861.
A nailing plate (not shown but well known), fabricated from galvanized 16 gauge or larger metal sheet and having a saddle at one end and a flat nailing surface at the other, can be used to secure the T-brace to the header in ceiling member 81. This plate is positioned to straddle the header such that its flat nailing surface abuts against a side surface near one end (the left end) of stud 862. The plate is then nailed to both the header and T-brace 86 using preferably 6-10 penny (10 d) common or larger sized nails; four of these nails secure the nailing plate to the header and the other two secure the nailing plate to the brace. In a similar fashion, an identical nailing plate can be used to secure the other end of this "T-brace" to a wooden crosspiece existing at the right end of core ceiling 40.
Preferably the "T-brace" can be fabricated by two 2"×4" studs oriented perpendicular to each other and merely nailed together. This method enable scrap wood to be used and is more cost effective than using nailing plates.
These "T-braces" are used to carry the ceiling loads. They are nailed to the core wall and ceiling members. Then, the weight of the roof is transferred through the "T-brace" to the other members.
Once each "T-brace" is appropriately positioned, it is then secured in position by nails, preferably 16 penny common or larger, driven through its upper end and into the adjacent truss. After all the "T-braces" have been secured, a rectangular sheet of gypsum board, e.g. sheet 863, is nailed to the lower surface of the wooden nailing plates. Each sheet is appropriately sized to both lie flush against the gypsum board previously affixed to the ceiling members during prefabrication and to completely fill in the rectangular opening occurring between the gypsum boards on the underside of each folding ceiling member and the underside of the central core ceiling. All these "T-braces" are completely fabricated during prefabrication of the house and are temporarily stored on the central core floor during shipment of the folded house to the building site.
Once the folding ceiling members have been fully unfolded and secured in position, an enclosed area is defined about this central core. Then, as shown in the plan view of FIG. 12, folding interior walls 101-104 and 108-112, and free-standing partitions 105, 106, and 107, are pivoted or moved into respective positions in this area to define both the rooms arranged about the central core and all the closets contained therein. Specifically, folding interior walls 103 and 112 pivot in the same manner as does exterior side wall 92 shown in FIG. 5 and discussed hereinabove. Once the folding interior walls are pivoted into position, then each free-standing partition is appropriately positioned in place. The folding interior walls and partitions are completely framed and covered with gypsum board during prefabrication. Once in position, each of these interior walls and partitions are secured by screw nails to the floor joists in pivoting floor sections 61 or 2, and to the rafters in ceiling members 81 and 82. Specifically these nails are driven through appropriately positioned cat blocks, existing between certain adjacent rafters in the ceiling (and between certain selected joists in the folding floor members), and into the top (and bottom) horizontal studs comprising each of these interior folding walls and partitions. Advantageously, the use of free-standing partitions, which are positioned during on-site installation, to define room sizes and closets, readily permits changing the dimensions of these rooms and closets at any time up to installation without incurring much, if any, expense. While the doors to each of the closets formed by the free-standing partitions, as well as a number of interior room doors, have all been omitted for the sake of clarity from the plan views shown in the drawing, these doors are attached, i.e. pre-hung, to corresponding pivotal walls or free-standing partitions and interior core walls during prefabrication. Advantageously, this further reduces on-site installation time and expense.
As should be readily apparent, applicant's folding prefabricated house is now completely unfolded. A cross-sectional view of it is shown in FIG. 13.
At this stage of installation, the only portion of the dwelling that remains to be enclosed is the attic. To accomplish this, a prefabricated gable end is nailed to the outermost roof rafters and ceiling beams existing at each side of the dwelling. Specifically, each of the two gable ends, of which only gable end 97 is shown in FIG. 14, is triangularly shaped and is comprised of a series of 2"×4" studs (not shown) of appropriate length and mounted apart from each other on an approximate 16" center to center spacing. A layer of sheathing (not shown), preferably 1/2" plywood, is installed over these studs during prefabrication at the factory. After the gable ends are installed on-site, appropriate siding material, e.g. aluminum or shingle, is applied to the entire side of the house including the gable ends. Applying this type of siding in the field advantageously minimizes the likelihood that any mis-alignment between the siding on the gable ends and that on the rest of the exterior side walls will be visible. If, however, cedar shingles are used for siding, then any minor mis-alignment between the siding attached to the gable ends and that attached to the rest of the exterior side walls is generally not visible. Consequently, this siding material can be applied during prefabrication to both the gable ends and to all the folding exterior side walls in order to further reduce on-site installation time and cost. The prefabricated gable ends, like the prefabricated "T-braces", are temporarily stored in the central core (more specifically by being placed on the floor of the core) while the folded house is being shipped to the building site.
The last remaining stage of installation, namely interior finishing, can now proceed. Specifically, the edges of any interior surfaces of abutting structural members are appropriately taped, spackled and sanded, in preparation for applying final wall covering, e.g. paint, or wallpaper. Thereafter, subflooring and final hardwood planking or other final flooring materials are installed in the previously unfloored areas of the house, i.e. above pivots 4. Alternatively,the entire sub-floors and final floor covering can be installed on-site. While this latter approach slightly increases installation cost, it may be necessary, depending upon the final floor covering chosen by the owner, in order to eliminate any visible gaps or joint lines from appearing in the floor. Thereafter, molding and any remaining interior trim is now installed. At this point, the dwelling has been completely constructed and only requires connection to the local utilities--e.g. electricity and sewerage--for it to be completely habitable.
An exterior perspective view of the dwelling as it stands completely installed and ready for occupancy is shown in FIG. 14.
In the illustrative embodiment described herein, heat is provided through electric baseboard. While electric heat is usually relatively expensive to operate, it is the least expensive to install. Consequently, separate electric baseboard units are installed along the interior bottom edge of various interior core walls and various folding walls. However, to minimize heating costs, a separate thermostat is installed in each room during prefabrication.
Other types of heating, ventilating, and air conditioning systems, where desired, can be substituted for electric baseboard or added in addition thereto. Any desired system can be substantially shop installed during prefabrication. In addition, the necessary cable or wiring requirements (i.e., electrical, telephone, television, etc.) can be shop installed during prefabrication.
Since the weight of a residential dwelling constructed in accordance with the teachings of the present invention is primarily supported by the walls comprising the central core, this advantageously permits all the pivoting structural members to be made relatively light. Consequently, this permits each member to be pivoted into position by a few workers without using any heavy machinery. Furthermore, the minimal weight inherent in the structure eliminates the need to incorporate any columns into the structure or to to construct the foundation from reinforced concrete. Consequently, these factors advantageously reduce installation cost.
A floor plan of one of many alternate embodiments of a folding residential dwelling embodying the principles of the present invention is depicted in FIG. 15. As is readily apparent from this figure, the exterior pivotable front walls are not limited to being co-planar when fully unfolded. As shown, the two walls making up the exterior front wall can be staggered to create a relatively large living room, for example, and also lend a pleasing appearance to the front of the dwelling. In a similar fashion, any of the other folding walls and/or core walls are also not constrained to entirely lie in a single plane but can instead by comprised of a number of staggered or otherwise non-co-planar sections. Moreover, the pivoting floor and/or ceiling member can also take on many varied non-co-planar geometries to create many diverse and architecturally pleasing layouts. Consequently, a variety of differently shaped structures, including but by no means limited to a simple rectangular layout, can be easily fabricated using the principles of the invention.
FIG. 16 illustrates a single story structure which can be provided with a flat roof or used as the first or lower floors of a multi-story structure. The single story structure or the lower floors of the multi-story structure are not provided with folding roofs or roof trusses, but instead have ceiling members 40a only in the area of the central core. Then, when such structure is to be used as a single story house, ceiling members 81a, 82a for the rooms adjacent to the central core are installed.
These members 81a, 82a shown in phantom in FIG. 16 may be pivotally connected to ceiling members 40a in the same manner as the pivoting floor sections are connected to the core floor. Alternately, these ceiling members 81a, 82a may be field installed. In either embodiment, these ceiling members are partially supported at their opposite end by a pivotable wall member.
Then, a flat or conventional roof can be constructed upon these ceiling members 40a, 81a, 82a to complete the single story structure. For multi-story, construction, the lower structures are not provided with such ceiling members 81a, 82a, since the floors of the adjacent upper structure 61, 62 become the ceiling members for the lower structure.
For multi-story fabrication, it is advantageous to use 2"×10" wooden beams 40a positioned upon the central core and to stagger the position of these beams with respect to the position of the floor joists 40 of the upper structure. Also, these beams extend slightly beyond the width of the central core 5 so as to provide enough area to pivotally connect the folding side and internal wall members. In this construction, the floor joists 40 of the upper structure will be positioned between the wooden beams 40a of the lower structure. Also, the core walls, 22, 28 are sufficiently sized to support the weight of the upper structure. Then, as mentioned above, the floor members 61, 62 of the upper structure become the ceiling members of the lower structure.
Specifically, to construct a two-story residential dwelling as shown in FIG. 17, two folding structures--an upper and a lower of the type described previously--are stacked on top of each other. The main difference between these structures is that the lower structure does not contain a roof and appears substantially as shown in FIG. 16. At the time of on-site installation, the lower structure is first appropriately positioned on the foundation supports and wood plates which forms part of the foundation, and is then completely unfolded. All the folding structural members of the lower stucture are then secured in position. As shown in FIG. 16, the lower folding structure is provided with 2"×10" ceiling beams 40a straddling the central core. As mentioned above these 2"×10" beams are positioned in a staggered configuration such that they would not be directly under the floor joists of the upper structure. Then, the upper structure, in a completely folded position, is placed above the lower structure and the floor joists of the upper structure are supported by the walls of central core of the lower structure. In this arrangement, the floor joists of the upper structure 61, 62 become the ceiling rafters of the lower structure. All the ceiling beams 40a of the lower structure thus abut against and are attached to the central core floor joists using appropriately sized nailing plates and nails. The remaining folding structural members of the upper structure are unfolded into position and secured as described hereinabove.
Appropriate openings are provided both in the ceiling of the central core of the lower structure and in the core floor member of the upper structure during their prefabrication in order to accommodate a stair case, which can be installed in the lower structure during its prefabrication. Any necessary banisters and the like are installed during the final (interior finishing) stage of on-site installation. Unless the two-story dwelling is to be a two family-house, there is little if any need to include any appliances (and/or a hot water heater) in the upper structure. Thus, the area reserved for the kitchen and closet in the central core can be converted into other usable space, e.g. a den or study.
As can be readily appreciated by those skilled in the art, multi-story structures in excess of two stories can be easily constructed in a similar manner to that described above. The number of separate folding structures that can be stacked to form the multi-story structure is essentially determined by the weight of each folding structure, and the amount of weight that can be supported by both the foundation and the walls in each folding structure--particularly the lowest in the stack.
While the pivoting structural members (walls, floors, ceiling and roof members) comprising the folding residential dwelling have been described above as folding and unfolding in a particular sequence it is readily apparent to those skilled in the art that any or all of these structural members can be readily folded and unfolded in a variety of different sequences. The particular sequence is determined by the desired volume of the folded structure and the particular materials used for the folding members and manner in which these members are constructed.
Although particular embodiments have been shown and described herein, a substantial variety of different embodiments of varying sizes and shapes and all incorporating teachings of the present invention may be devised by those skilled in the art without departing from the spirit and scope of the invention. | A prefabricated structure, illustratively a residential dwelling, having a prefabricated central core and a plurality of prefabricated floor, wall and roof members that pivotally fold inwardly about the central core to produce a compact folded structure which is easily transportable, and pivotally fold outwardly about the central core for quick and inexpensive on-site installation. Also, methods for erecting sturdy habitable structures and the sturdy habitable structures themselves. | 4 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to the transfer of a paper sheet between sections, or between elements of a section, such as the individual presses in a press section, of the papermachine on which it is being manufactured. Specifically, the present invention is a transfer belt designed both to carry a paper sheet through a portion of a papermachine, so as to eliminate open draws, wherein the paper sheet receives no support from a carrier and is susceptible to breakage, from the machine, and to release the sheet readily to another fabric or belt at some desired point.
II. Description of the Prior Art
The prior art is replete with proposals for eliminating so-called open draws from papermachines. By definition, an open draw is one in which a paper sheet passes without support from one component of a papermachine to another over a distance which is greater than the length of the cellulose fibers in the sheet. All such proposals for eliminating open draws have as their object the removal of a major cause of unscheduled machine shut-down, the breakage of the sheet at such a point where it is temporarily unsupported by a felt or other sheet carrier. When disturbances in the normally stable flow of paper stock occur, the likelihood of such breakage is quite strong where the unsupported sheet is being transferred from one point to another within the press section, or from the final press in the press section to the dryer section. At such points, the sheet usually is at least 50% water, and, as a consequence is weak and readily broken. At present, then, an open draw will place a limitation on the maximum speed at which the papermachine may be run.
The prior-art proposals for eliminating open draws include some form of transfer belt to carry and support the paper sheet between components of the papermachine. In so doing, the transfer belt may have to carry out several of the following separate functions:
a) to take the paper sheet from a press roll or press fabric (felt);
b) to carry the paper sheet into a press nip;
c) to work cooperatively with a press fabric in the press nip to de-water the paper sheet;
d) to carry the paper sheet out of the press nip;
e) to repeat functions b) through d) as necessary where the transfer belt carries the paper sheet through more than one press; and
f) to transfer the paper sheet to another fabric or belt, such as, for example, a dryer fabric.
As will be discussed below, there are specific problems associated with each of these transfer belt functions.
Transfer belts are shown in a number of issued U.S. patents. For example, U.S. Pat. No. 4,483,745 shows press arrangements which may be either the typical paired roller press or a long-nip press. In the press arrangements illustrated, the paper sheet is sandwiched between a press fabric and a looped, endless, and impermeable belt which is relatively smooth and hard, so that the paper sheet may follow the belt upon leaving the press nip without being rewet by a press fabric or other permeable belt. This arrangement utilizes the fact known to papermakers that the paper sheet will follow the surface to which it may be most strongly bonded by a thin, continuous water film, and for this reason will follow a smooth, impervious surface rather than a coarser surface when the two are separated in a papermachine.
Little detail is provided, however, on the structure of the belt itself beyond describing it as having a smooth upper surface with a smoothness and a hardness or density generally similar to a plain press roll cover. The belt surface is said to preferably have a hardness in the range of between 10 and 200 P&J (Pusey & Jones Hardness Scale). No recognition is given to the difficulty which would actually be encountered in attempting to remove a wet paper sheet from the surface of such a belt in a papermachine.
U.S. Pat. No. 4,976,821 shows another press configuration with no open draws. In the press sections described and illustrated therein, there are two successive press nips for dewatering a paper sheet, which passes in a closed draw between the nips. The paper sheet is also transferred from the last press nip of the press section to the drying section in a closed draw by a substantially non-water receiving transfer fabric. The paper sheet is removed directly from the surface of the substantially non-water receiving transfer fabric, and placed onto a dryer fabric by means of a suction roll.
In contrast to the belt shown in the '745 patent, the substantially non-water receiving transfer fabric shown in the '821 patent generally is relatively impervious, and may, for example, be a fabric produced by impregnating a press fabric with an appropriate plastic material. That is to say, it is relatively impervious when compared to an unimpregnated press fabric. As such, however, the '821 patent teaches that the fabric may still to some extent participate in the dewatering of the paper sheet in the press nip, so that the paper produced may be more symmetric in density and surface smoothness than that produced when the transfer belt is smooth and impermeable. While it is said to be easier to remove the paper sheet from the surface of such a transfer fabric, there is no recognition given to the problems actually associated with the use of a transfer fabric of this variety on a papermachine. In actual use, such a sheet transfer belt, designed to function with a low, constant porosity, will eventually meet with failure. Fine particles from the paper stock, such as cellulose fines, fillers, resins, and "stickies", rapidly fill the pores in such a belt. High-pressure water jet showering, the standard method to keep fabrics and felts clean and open on a papermachine, is not efficient on a fine-porous structure such as the one described in this '821 patent.
In general, and referring to the various functions of a transfer belt identified above, where the transfer belt removes the paper sheet from a press roll, a procedure rarely used in practice, it must overcome the strong adhesion the paper sheet will normally have for the roll, which may be very smooth. In the in-going side of a press nip, the paper is squeezed until it becomes fully saturated, at which point water will start to move out from the sheet into the water receptor, the press fabric. As a consequence, there will always be a water film, perhaps partly broken, at the interface between the roll surface and the paper sheet. This film has to be broken before the paper sheet may be reliably transferred from the roll to the transfer belt.
Where the transfer belt carries the paper sheet into a press nip, a belt having a non-air-permeable paper-side surface is generally preferred to one which is permeable. A transfer belt which may be permeable to some extent is described in the '821 patent discussed above. Others are described in U.S. Pat. Nos. 4,500,588 and 4,529,643, which will be discussed below. The disadvantage associated with the use of permeable or semi-permeable transfer belts is the risk of blowing of the paper sheet at the entrance of the press nip, as a result of air being forced out of the porous belt being compressed, or even through the transfer belt from its backside by a press roll.
In the press nip, the transfer belt must work cooperatively with a press fabric to dewater and to densify the paper sheet. As a consequence, the surface topography and compression properties of the transfer belt are critical for producing a paper sheet with a smooth, mark-free surface. Because, as is well known to those skilled in the art, even a high quality, well-broken-in press fabric may provide a very non-uniform pressure distribution in the nip, a transfer belt having a smoother and harder paper-side surface than the press fabric will provide a more uniform pressure distribution to the paper sheet being dewatered, and will impart a smoother surface to the sheet.
Further, a transfer belt with suitable compression properties can in effect lengthen the press nip to increase the time the paper sheet is exposed to pressure and to allow more time for water to leave the paper sheet under a given press load. In addition, a transfer belt with a paper side impermeable to water and air will contribute to the dryness of the paper sheet by eliminating the possibility of rewet after the press nip, as may occur when a conventional press fabric carries the paper sheet out of the nip.
Clearly, a transfer belt must be designed with the understanding that it will work cooperatively in the nip with a press fabric as a functional pair in order to provide high dewatering efficiency and high paper quality.
Referring again to the various transfer belt functions identified above, the transfer belt should carry the paper sheet out of the press nip. That is to say, more precisely, the paper sheet should adhere to the surface of the transfer belt upon exiting the nip, as opposed to following the press fabric out of the nip and then moving over to the transfer belt after the nip. Not only does the latter permit rewet while the paper sheet remains in contact with the press fabric, but the moving of the paper sheet over to the transfer belt after leaving the press nip would also constitute an open draw, the very problem the transfer belt is intended to eliminate. Such a situation can lead to blistering or some other deformation of the paper sheet. A good adhesion of the sheet to the transfer belt on the exit side of the nip is even more important in press configurations where the belt is run in the top position and the sheet is to be transferred on the underside of the belt. As before, the paper-side surface of the transfer belt should be neither water-absorbent nor waterpermeable, so that rewet of the paper sheet by the transfer belt may be avoided.
Where the transfer belt carries the paper sheet through more than one press, the stability of the transfer belt will become an important factor. The speed of consecutive presses in a press section can never be absolutely synchronized, and, normally, will increase somewhat downstream in the section. Under such conditions, the transfer belt must be able to carry the paper sheet without blowing, blistering, or drop off. In addition, the transfer belt itself must be of a durable design, capable of enduring the backside wear and high shear forces, which would attend its use through more than one press, without rapid degradation.
The final, and most critical, function of the transfer belt is to effect a correct transfer of the paper sheet to the next section of the papermachine. In many applications, this will be a transfer to the first fabric in the dryer section. It is preferred that this first fabric should be of a design suitable for both paper drying and for the closed transfer of the paper sheet.
A typical dryer fabric in the first drying position may be a woven, all-polyester monofilament fabric. Fabrics used in first drying positions normally have a low airpermeability and a smooth, fine paper side. Hence, the surface to which the transfer belt is to transfer the paper sheet may initially consist of smooth, hydrophobic monofilament knuckles.
The transfer from the transfer belt to the first dryer fabric should be carried out with as low a contact pressure as possible in order to avoid the marking of the paper sheet by the knuckles. Since the dryer fabric is air-permeable, vacuum may be used to assist the transfer of the paper sheet from the transfer belt. In order to avoid the marking of the paper sheet by the knuckles of the first dryer fabric, the vacuum level used at the transfer point must be as low as possible. It follows, then, that the transfer belt must readily release the paper sheet at the transfer point so that the vacuum level required may be kept at a minimum level.
As noted above, transfer belts of several varieties are known in the prior art. For example, in U.S. Pat. No. 5,002,638 a wet paper web is supported on a press fabric and passed through the nip between cooperating press rolls to extract water from the web. The press fabric, supporting the paper web, then travels through a span of distance and is passed around a heated dryer roll in the dryer section with the felt being interposed between the heated roll and the paper web. The press fabric is thus heated and insulates the paper web from the high temperature roll. The paper web is then separated from the press fabric and travels around the remaining dryer rolls in the dryer section, while the heated press fabric is returned to the nip into position to support the wet paper web.
The disadvantage following such an approach is considerable rewet of the paper sheet in the span between the press nip and the heated dryer roll, because the transfer belt is literally a press fabric. Further, such a transfer belt is not hard enough to replace a smooth roll surface in late presses on a publishing-grade papermachine. In short, the only reasonable application for a transfer belt of the variety shown in U.S. Pat. No. 5,002,638 is in slow machines producing heavy paper grades.
The use of modified press fabrics as transfer belts is shown in several U.S. patents. For example, U.S. Pat. No. 4,500,588 shows a conveyor felt for conveying a paper web through a press section of a paper machine. The conveyor felt is, with the exception of the surface portion of the fiber batt layer facing the web, filled with a filling material so that the felt is completely air-impermeable and has a chamois-like surface. Such a surface is, because of its fibrous character, sensitive to soiling by sticky materials, and the chamois-like structure is sensitive to wear and difficult to maintain.
In U.S. Pat. No. 4,529,643, a press felt for conveying a paper web through a press section of a papermachine is shown. It comprises a support fabric formed of a yarn structure and a fibre batt layer, formed of fibers and needled to at least one side of the support fabric. The support fabric and the fiber batt layer are filled with a filling material, preferably from the surface facing the paper with a rubber or resin emulsion, so that the press felt remains slightly air permeable.
Belts of the variety shown in these two patents have exhibited sheet drop-off upon exit from the press nip. The cause of this sheet drop-off is related to the inability of the porous surface of such a belt to permit a thin, continuous water film to form between its surface and a paper sheet in the press nip, and to maintain such a water film long enough to ensure that the paper sheet will follow the belt rather than the press fabric upon exit from the press nip. In addition, it is difficult to maintain the porosity of this variety of belt at a constant value, as material from the paper stock gradually fills the pores. High-pressure showers have not proved effective on the microporous structure of the surface of such belts, and may actually destroy the belt surface.
Finally, non-compressible, coated belts, such as those used as long nip press (LNP) belts, have also been tested for use as transfer belts. A belt of this kind is shown in Canadian Patent No. 1,188,556, and comprises a base fabric which is impregnated with a thermoplastic or thermosetting polymeric material. The belt is of uniform thickness, and has at least one smooth surface. While the belt performs in a superior manner in its intended position on a long nip press, all attempts to use it as a transfer belt have failed, as the belt could not be arranged to release a paper sheet to a dryer fabric. This is believed to result from the failure of a thin film of water between the impermeable belt and the paper sheet to break up into droplets, allowing the paper sheet to be separated from the transfer belt.
The present invention provides a long-sought solution to these difficulties in the form of a transfer belt not susceptible to the shortcomings of the prior-art transfer belts discussed above.
SUMMARY OF THE INVENTION
In view of the preceding discussion, it may be understood that a successful transfer belt must be able to carry out several different functions as it carries a paper sheet from place to place in a papermachine. Correspondingly, the behavior of the transfer belt must change in response to the conditions under which it is placed at different locations in the machine.
The most critical of these functions are: a) to remove the paper sheet from a press fabric without causing sheet instability problems; b) to cooperate with a press fabric in one or more press nips to ensure optimal dewatering and high quality of the paper sheet; and c) to transfer the paper sheet in a closed draw from one press in the press section to a sheet-receiving fabric or belt in the next press, or presses, in the press section, or to a dryer pick-up fabric in the dryer section.
The surface of the transfer belt must have a topography on a microscopic scale with a degree of roughness which decreases, or smooths out, under the levels of compression to which the belt is typically subjected in a press nip, but which restores itself after exit from a press nip, to carry out these functions. In other words, the surface topography of the transfer belt must have a pressure-responsive, recoverable degree of roughness, so that, when under compression in a press nip, the degree of roughness will decrease, thereby enabling a thin continuous water film to be formed between the transfer belt and a paper sheet to bond the paper sheet to the transfer belt upon exit from the press nip, and so that, when the original degree of roughness is recovered after exit from the nip, the paper sheet may be released by the transfer belt, perhaps with the assistance of a minimum amount of vacuum, to a permeable fabric, such as a dryer pick-up fabric. At the same time, the transfer belt must have the necessary compression and hardness properties to produce a mark-free paper.
In addition to having a surface topography with a pressure-responsive, recoverable degree of roughness, a successful transfer belt must also have an optimal combination of the following additional functional properties: 1) surface energy, which will determine the interaction of the surface of the transfer belt with water; 2) limited permeability to air or water; 3) compressional properties, both for the surface of the belt and for its structure as a whole; 4) hardness; 5) modulus; 6) durability; and 7) chemical, thermal and abrasion resistance.
The present invention is a transfer belt for a papermaking, boardmaking or similar machine having a surface topography with the requisite pressure-responsive recoverable degree of roughness, and having an optimal combination of the above-noted additional functional properties. This transfer belt has been successfully tested on a papermachine under several machine configurations and manufacturing a number of different paper grades, and has been found to carry out the critical functions identified above where prior-art attempts have failed. The pressure-responsive, recoverable degree of roughness remains a characteristic of the transfer belt throughout its entire lifetime on the papermaking or boardmaking machine so that the transfer belt will be capable of carrying out its intended function for that time.
The transfer belt of the present invention comprises a reinforcing base with a paper side and a back side, and having a polymer coating, which includes a balanced distribution having segments of at least one polymer, on the paper side. This balanced distribution takes the form of a polymeric matrix which may include both hydrophobic and hydrophilic polymer segments. The polymer coating may also include a particulate filler. The reinforcing base is designed to inhibit longitudinal and transverse deformation of the transfer belt, and may be a woven fabric, and may be endless or seamable for closing into endless form during installation on the papermachine. Further, the reinforcing base may contain textile material, and may have one or more fiber batt layers attached by needling onto its back side. By textile material is meant fibers and filaments of natural or synthetic origin, intended for the manufacturing of textiles. The back side may also be impregnated and/or coated with polymeric material.
In this regard, the back side of the transfer belt should be of a structure suitable for running against the rolls in the press section of a papermachine, and must be of a material at least as durable as that on the paper side of the belt. Textile structures, that is, fibers or filaments of natural or synthetic polymers, which have been woven, knitted, braided, entangled or bonded into a sheet-like structure, in other words, textiles, may be attached to the back side. Alternatively, a solid film, formed by coating the back side of the reinforcing base with the same polymer as is used on the paper side, may be attached to the back side of the transfer belt. This film may be made porous by including within the coating to be used on the back side of the reinforcing base a water-soluble resin, which may be dissolved after the curing of the polymer to create pores. Finally, a polymeric foam may be attached to the back side of the reinforcing base to form the back side of the transfer belt.
The transfer belt may be characterized as having a sheet-facing surface with a well-defined topography and a well-defined surface energy, such a surface being favorable for taking a paper sheet from a press roll or press fabric, and carrying it into a press nip, where it cooperates with a press fabric. The surface itself includes regions defined by the hydrophilic and hydrophobic polymer segments (or particle segments) of the polymer matrix in the coating. In the present context, surface energy may be taken to be a measure of the wettability of the surface of the transfer belt by water. The hydrophilic polymer segments of the polymer matrix have a higher surface energy than the hydrophobic polymer segments, and, by comparison, are more wettable by water. Upon exit from a press nip, the two polymer segments of the polymer matrix are believed to cooperate in playing at least a part in breaking up the water film, as water will tend to form beads on those surface regions defined by the hydrophilic polymer segments of the polymer matrix.
The transfer belt may be further characterized as having a sheet-facing surface, optimally impermeable to water and air, with a pressure-responsive microscale topography. Under pressure, the microscale degree of roughness of this surface decreases, making the surface much smoother and allowing a thin, continuous film of water to be built up between the paper sheet and that surface. Such a thin, continuous film of water provides much stronger adhesive forces between the paper sheet and transfer belt than those between the paper sheet and the press fabric, so that the paper sheet may consistently and reliably follow the transfer belt when leaving the press nip. Even where the press fabric, by reason of structural expansion, creates a light vacuum at the outgoing side of the press nip, the energy required to overcome the adhesive forces arising from the water film between the transfer belt and paper sheet is greater than that required to overcome any adhesion the paper sheet may have for the press fabric. In addition, the caliper regain of the paper sheet upon exit from a press nip is normally much slower than that of the press fabric. As a consequence, when a light vacuum arises in both the expanding press fabric and expanding paper sheet upon exit from the press nip, the latter holds its vacuum for a longer period of time and sticks to the transfer belt by virtue of the thin, continuous water film disposed therebetween. As a consequence, the paper sheet will follow the transfer belt.
Despite the strong adhesion the paper sheet has for the surface of the transfer belt at the nip exit, the material composition of the paper side of the belt and its surface characteristics provide it with the necessary release properties to successfully transfer the paper sheet to another fabric or belt. These release properties are a direct consequence of the use of an appropriate polymer coating, which may contain filler particles of a material having a different hardness than the polymeric matrix has itself, on the paper side of the transfer belt. This coating, having a surface topography with a pressure-responsive recoverable degree of roughness, ensures that the water film between the paper sheet and the transfer belt surface in the press nip will break up in the span between the press nip and the point where the paper sheet is to be transferred to another carrier, allowing the paper sheet to be released.
Although the polymer coating has been described above as being impermeable to air or water, complete impermeability is an optimal condition which will provide the transfer belt with the best function over a long period of time. A substantially impermeable belt, having a very low permeability to air and water, and having the polymer coating in accordance with the present invention, will also carry out the sheet-handling and transfer functions of the impermeable belts of the present invention. More specifically, the belt will be able to carry out these functions quite well so long as it has an air permeability of less than 20 cubic feet per square foot per minute, when measured according to the procedure set forth in "Standard Test Method for Air Permeability of Textile Fabrics", ASTM D 737-75, American Society of Testing and Materials, reapproved 1980. Such a low permeability will not adversely affect the transfer function of the present belt, and, in the course of use on a papermachine, will tend to decrease as pores in the belt become filled with paper fines and other materials.
The mechanism by which the water film is broken up during the span between the press nip and the point where the paper sheet is to be transferred to another carrier is thought to be primarily a function of the pressure-responsive microscale surface topography of the coating on the paper side of the transfer belt. In this regard, in order to break up the water film, the recovered degree of roughness of the surface topography of the transfer belt should be at least equal to the minimum caliper of the water film. Other mechanisms may be contributing to the ability of the present transfer belt to release the paper sheet at the desired time. For example, it has been proposed, as noted above, that the balanced distribution of polymer segments on the paper side of the transfer belt, each polymer segment having a different surface energy and wettability, assists the water film in breaking up into droplets, radically reducing the adhesion of the sheet to the transfer belt.
The presence of one or more particulate fillers in the polymeric coating material, which fillers themselves have different surface energies and wettabilities from the polymers, may also contribute to the breaking up of the water film, when a particulate filler is included in the coating. While individual particles in the filler have sizes falling within a range or distribution of values, larger particles, embedded in the belt surface, are thought to move out to protrude therefrom when the pressure is released upon exit from the press nip. In so doing, those larger particles would physically be able to cut through the water film. Since they too will have a different surface energies and degrees of hydrophilicity from the polymer segments of the polymer matrix of the coating, they may also cause the water to form beads thereabout. In addition, it is thought that the particulate fillers may reinforce the surface of the polymeric coating, so that its pressure-responsive, recoverable degree of roughness may not be polished away after an unduly short period of use on a papermachine.
It has also been proposed that the balanced distribution of polymer segments and one or more particulate fillers enable the surface of the transfer belt to release the paper sheet at the desired time, because the materials in the coating have different compressibilities. The slight pressure and shear placed on the belt surface in the transfer zone may cause the water film to break into droplets, thereby further reducing the adhesion of the paper sheet to the transfer belt.
As has been discussed above, the primary mechanism by which the present transfer belt releases the paper sheet at a desired point is thought to be its pressure-responsive, recoverable microscale surface topography, since the strength of the adhesive bond formed between the surfaces of the transfer belt and the paper sheet depends upon the actual interfacial contact area and surface roughness of each.
The water film between the paper sheet and transfer belt will tend to fill the low spots in the belt surface and to orientate to those regions defined by the hydrophilic polymer segments in the polymeric matrix surfaces. As the pressure distribution changes in the interface between sheet and belt during expansion after exit from the nip, the belt roughness will increase, after having been compressed to a smoother-than-normal condition in the nip. The increased roughness causes the water film to break. The work necessary to counteract the adhesion of the paper sheet to the transfer belt and to separate the two from one another depends upon surface tension, which decreases with increasing water film thickness. Where there are low spots in the surface of the transfer belt, the thickness of the water film will be increased. This reduces the adhesion of the paper sheet to the transfer belt at such locations and promotes sheet release.
It is also possible that air may be trapped in low spots on the surface of the transfer belt as the transfer belt, paper sheet and press fabric are entering the nip. As the paper sheet is compressed in the nip, the air is compressed into such low spots. In the outgoing part of the nip, this compressed air expands, exerting a pressure which helps to break the water film.
The particle filler in the coating, when included, may also contribute to the breaking up of the water film by physically acting as crack-initiating sites. This is particularly thought to be so for larger than average particles in the filler. Because the polymeric material will be resilient, particles of the filler residing on the surface of the coating will be depressed deeper thereinto by compression in the nip. Upon exiting the nip, the particles will protrude from the surface of the coating, where they begin to physically break the water film to start a de-bonding process in the interface.
It is most likely that the water film holding the paper sheet to the transfer belt is broken up in the span between the press nip and the transfer point by a combination of these mechanisms.
The polymer coating of the paper side of the transfer belt of the present invention is substantially, if not completely, impermeable to air or water, and has a surface smoothness within a certain range, different surface energies for each of its components, a hardness within a certain range and specified compression properties.
In summary, the transfer belt of the present invention is built on a supporting carrier for dimensional stability. The paper side layer may be made by coating, impregnation, film lamination, melting, sintering or deposition of a resin which through a secondary process forms a layer at least substantially impermeable to air and to water. The bottom layer, or back side, of the transfer belt can be textile, solid or porous film, or polymeric foam, or a combination of these. The paper side of the transfer belt is coated. The coating may be a homopolymer, a copolymer, a polymer blend or an interpenetrating network of polymers, and may contain a particulate filler.
A specific embodiment of the present invention will now be described in more complete detail, with reference frequently being made to the figures identified as set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first representative press arrangement including a transfer belt for eliminating an open draw in a papermachine.
FIG. 2 shows a second such press arrangement.
FIG. 3 shows a third such press arrangement.
FIG. 4 shows a cross-sectional view, taken in the cross-machine direction, of the transfer belt of the present invention.
FIGS. 5A through 5D depict on an exaggerated scale, for the purpose of illustration, the roughness of the surface of the transfer belt of the present invention at the points labelled A, B, C, and D, respectively, in FIG. 3.
FIG. 6 is a Scanning Electron Microscope (SEM) photograph showing a cross section of the particle-filled polymer coating of the transfer belt of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Representative press arrangements which include a transfer belt for eliminating an open draw in a papermachine are shown, for purposes of illustration and general background, in FIGS. 1, 2 and 3. Arrows in these figures indicate the directions of motion or rotation of the elements shown therein.
Turning first to FIG. 1, a paper sheet 1, represented by a dashed line, is being carried toward the right in the figure initially on the underside of a pick-up fabric 2, which pick-up fabric has previously taken the paper sheet 1 from a forming fabric, not shown.
The paper sheet 1 and pick-up fabric 2 proceed toward a first press nip 16 formed by a first press roll 3 and a second press roll 5. A transfer belt 4 is trained and directed around first press roll 3. In the first press nip 16, paper sheet 1, carried on the underside of pick-up fabric 2, comes into contact with the surface of transfer belt 4.
Paper sheet 1, pick-up fabric 2, and transfer belt 4 are pressed together in first press nip 16. To transfer paper sheet 1 from pick-up fabric 2 to the transfer belt 4, a certain level of pressure, such as that provided in first press nip 16, is needed to cause a water film to be formed between paper sheet 1 and transfer belt 4. Most of the water in that water film comes from the paper sheet 1, which must be pressed in first press nip 16 with a pressure sufficient to cause the boundary layer between the surfaces of transfer belt 4 and paper sheet 1 to become filled with water. This water film causes paper sheet 1 to adhere to the surface of transfer belt 4, which is smoother and harder than pick-up fabric 2. Pick-up fabric 2, trained around second press roll 5, is separated from paper sheet 1 and transfer belt 4 upon exit from first press nip 16, while transfer belt 4 carries paper sheet 1 further toward a second press nip 6 formed between a third press roll 7 and a fourth press roll 8. A press fabric 9 is trained around third press roll 7, guided by a first guide roll 13 and a second guide roll 14, and dewaters paper sheet 1 in the second press nip 6. Third press roll 7 may be grooved, as suggested by the dashed line within the circle it in FIG. 1, to provide a receptacle for water removed from the paper sheet 1 in the second press nip 6.
Upon leaving the second press nip 6, paper sheet 1 remains adhered to the surface of the transfer belt 4, whose surface is smoother than that of press fabric 9. Proceeding to the right in FIG. 1 from second press nip 6, paper sheet 1 and transfer belt 4 next reach a vacuum transfer roll 10, about which is trained a dryer fabric 11. Suction from within vacuum transfer roll 10 lifts paper sheet 1 from the transfer belt 4 to the dryer fabric 11, which carries paper sheet 1 to the first dryer cylinder 15 of the dryer section.
The transfer belt 4 proceeds onward to the right in FIG. 1 away from vacuum transfer roll 10 to a third guide roll 12, around which it is directed to further guide rolls, not shown, which return the transfer belt 4 to first press roll 3, where it may again accept paper sheet 1 from pick-up fabric
As may be observed in FIG. 1, the transfer belt 1 eliminates open draws in the press arrangement shown, most particularly the open draw between the second press nip 6 and the vacuum transfer roll 10. Most importantly, paper sheet 1 is supported at all points in its passage through the press arrangement shown by a carrier.
A somewhat more complicated press arrangement is shown in FIG. 2. There, a transfer belt 20 carries a paper sheet 21, again represented by a dashed line, through two presses, and on to a point where it is transferred to a dryer section.
More specifically, paper sheet 21 is initially being carried toward the right in the FIG. 2 on the underside of a pick-up fabric 22, which pick-up fabric 22 has previously taken paper sheet 21 from a forming fabric, not shown.
Paper sheet 21 and pick-up fabric 22 proceed together toward a first press nip 23, formed between a first press roll 24 and a second press roll 25. Transfer belt 20, trained about first guide roll 26, also proceeds toward first press nip 23, where it will receive paper sheet 21 from the underside of pick-up fabric 22, and carry paper sheet 21 onto another press. First press roll 24 and second press roll 25 may both be grooved, as suggested by the dashed lines within the circles representing these rolls in FIG. 2, to provide a receptacle for water removed in the first press nip 23 from the paper sheet 21. Second press roll 25 may be grooved for this purpose, since transfer belt 20 may be of the variety not completely impermeable to water, and therefore may participate to some extent in the dewatering of paper sheet 21.
Upon exiting from first press nip 23, paper sheet 21 adheres to the surface of transfer belt 20, as previously noted. Pick-up fabric 22 proceeds from first press nip 23, around second guide roll 27, and around further guide rolls, not shown, which together return it to the point where it accepts paper sheet 21 from a forming fabric.
Paper sheet 21 and transfer belt 20 proceed onward, to the right in FIG. 2, toward a second press nip 28, which may be and is depicted as a long press nip formed between a third press roll 29, which, too, may be grooved to provide a receptacle for water removed in the second press nip 28 from the paper sheet 21, and a long nip press arrangement 30 having a shoe 37. A press fabric 31, trained about third guide roll 32, also proceeds toward second press nip 28 to participate in the further dewatering of paper sheet 21.
Upon exiting from second press nip 28, paper sheet 21 remains adhered to the surface of transfer belt 20. Press fabric 31 proceeds from second press nip 28, around fourth guide roll 33, and around further guide rolls, not shown, which together return it to third guide roll 32, from which it will again proceed to second press nip 28.
Paper sheet 21 and transfer belt 20, proceeding to the right in FIG. 2 from second press nip 28, next reach a vacuum transfer roll 34, about which is trained a dryer fabric 35. Suction from within vacuum transfer roll 34 lifts paper sheet 21 from transfer belt 20 to the dryer fabric 35, which carries paper sheet 21 to the first dryer cylinder 38 of the dryer section.
The transfer belt 20 proceeds onward away from vacuum transfer roll 34 to a fifth guide roll 36, around which it is directed to further guide rolls, not shown, which return the transfer belt 20 to first guide roll 26, where it will again proceed on to first press nip 23.
As may again be observed in FIG. 2, the transfer belt 20 eliminates open draws in the press arrangement shown, and actually carries the paper sheet 21 through two presses to the point where it transfers the paper sheet 21 directly to dryer fabric 35. Paper sheet 21 is supported at all points in its passage though the press arrangement by a carrier.
Still another press arrangement is shown in FIG. 3. There, a paper sheet 40, again represented by a dashed line, is being carried toward the right initially on the underside of a pick-up fabric 41, which pick-up fabric 41 has previously taken the paper sheet 40 from a forming fabric, not shown.
The paper sheet 40 and pick-up fabric 41 proceed toward a first vacuum transfer roll 42, around which is trained and directed a press fabric 43. There, suction from within first suction roll 42 removes paper sheet 40 from pick-up fabric 41 and draws it onto press fabric 43. Pick-up fabric 41 then proceeds from this transfer point, toward and around a first guide roll 44, and back, by means of additional guide rolls not shown, to the point where it may again receive the paper sheet 40 from a forming fabric.
Paper sheet 40 then proceeds, carried by press fabric 43, toward a press nip 45 formed between a first press roll 46 and a second press roll 47. Second press roll 47 may be grooved, as suggested by the dashed line within the circle representing it in FIG. 3, to provide a receptacle for water removed in the press nip 45 from the paper sheet 40. A transfer belt 48 is trained around first press roll 46, and is directed through press nip 45 with paper sheet 40 and press fabric 43. In the press nip 45, the paper sheet 40 is compressed between the press fabric 43 and the transfer belt 48.
On exiting press nip 45, paper sheet 40 adheres to the surface of the transfer belt 48, whose surface is smoother than that of press fabric 43. Proceeding toward the right in the figure from press nip 45, paper sheet 40 and transfer belt 48 approach a second vacuum transfer roll 49. Press fabric 43 is directed by means of second guide roll 50, third guide roll 51 and fourth guide roll 52, back to first guide roll 42, where it may again receive paper sheet 40 from pick-up fabric 41.
At second vacuum transfer roll 49, paper sheet 40 is transferred to a dryer fabric 53, which is trained and directed thereabout. Dryer fabric 53 carries paper sheet 40 toward the first dryer cylinder 54 of the dryer section.
The transfer belt 48 proceeds onward to the right in the figure away from second vacuum transfer roll 49 to a fifth guide roll 55, around which it is directed to a sixth guide roll 56, a seventh guide roll 57, an eighth guide roll 58, and a ninth guide roll 59, which eventually return it to the first press roll 46 and to the press nip 45, where it may again accept the paper sheet 40 from the press fabric 43.
As may be observed in FIG. 3, the transfer belt 48 also eliminates open draws in the press arrangement shown, most particularly, the open draw between the press nip 45 and the second vacuum transfer roll 49. Paper sheet 40 is supported at all points in its passage through the press arrangement shown by a carrier. In addition, it should be noted that the paper sheet 40 is carried on the underside of the transfer belt 48 upon exiting from the press nip 45.
The transfer belt of the present invention may be used in any of the preceding press arrangements with results superior to those of the prior art, and may be seen in a cross section taken in the cross-machine direction in FIG. 4. The transfer belt 60 comprises a reinforcing base which is a woven base 62 having a back side 64 and a paper side 66.
The base 62 may be woven in a duplex pattern having vertically stacked weft yarns defining two layers bound together by a single system of warp yarns. In the base 62 shown in FIG. 4, warp yarns 70 lie in the cross-machine direction of the transfer belt 60. That is, the base 62 has been woven endless to produce the transfer belt 60 shown in the figure, although one may weave the base 62 in a manner permitting its being joined into endless form during the installation of the transfer belt 60 on a papermachine. In such case, the base 62 is flat woven, and its two ends provided with loops for closing into endless form with a pin seam. Alternatively, the two ends of a flat woven base 62 may be woven together forming a woven seam to place the base 62 into endless form. Again alternatively, base 62 may be woven by a modified endless weaving technique, wherein the filling yarns weave back and forth continuously between the opposite sides of the weaving loom and form the loops required for pin seaming at each side. In a base 62 woven by this last technique, the filling yarns run in the machine direction when the fabric is on a papermachine, and the loops are at each end as required. In each case, the base 62 may also be provided in a length substantially equal to the circumference of a press roll, so that a transfer belt 60 produced therewith may be used as a press roll cover through installation thereon in a sleeve-like fashion.
The machine-direction yarns of the base 62, seen in cross-section in FIG. 4, are the weft yarns during the weaving of an endless base. The top weft yarns 72 are on the paper side 66 of the transfer belt 60. In a vertically stacked one-to-one relationship with the top weft yarns 72 are the bottom weft yarns 74 on the back side 64 of the transfer belt 60. For purposes of clarity, the separations between the warp yarns 70, top weft yarns 72, and bottom weft yarns 74 have been greatly exaggerated in FIG. 4.
The yarns used to weave woven base 62, that is, the warp yarns 70, top weft yarns 72, and bottom weft yarns 74, may be monofilament yarns of a synthetic polymeric resin of one of the varieties commonly used in the weaving of fabrics for the papermaking industry, and are so depicted in FIG. 4. The yarns may be extruded from polyamide, polyimide, polyester, polyethylene terephthalate, polybutylene terephthalate, or from other synthetic polymeric resins. Monofilament yarns of the following diameters may be used in the weaving of base 62: 0.20 mm, 0.30 mm, 0.40 mm, or 0.50 mm. The base 62 should be woven in a pattern sufficiently open to ensure that the polymer coating applied to the paper side 66 may impregnate that side completely by surrounding the top weft yarns 72, so that, after curing, the polymer coating may form a mechanical interlock therewith.
Alternatively, the base 62 may be woven from multifilament yarns, plied monofilament yarns, or spun or textured yarns, produced from these resins. For example, the base 62 may include 3-, 4-, 6-, or 10-ply 8 mil (0.20 mm) plied monofilament yarns or 24-ply 0.10 mm multifilament yarns. In addition, the reinforcing base, instead of taking the form of woven base 62, may be a non-woven fiber assembly, a knitted fiber assembly, or a polymeric film. In the last case, the polymeric film may be permeable or impermeable, and may be reinforced by fibers.
The back side 64 of the base 62 may be needled with at least one layer of fibrous web 76. The needling process may be concluded with additional dry passes on both the back side 64 and the paper side 66 of the base 62. Fibrous web 76 may be needled directly into the back side 64 of the base 62, or may be needled into the paper side 66 thereof for a sufficiently long enough time to leave most of the needled fibers on the back side 64.
A textile material may be attached to the back side 64 of the woven base 62 instead of or in addition to fibrous web 76. Alternatively, a non-porous or porous polymeric film, or a polymeric foam, may be attached to the back side 64 of the woven base 62 in lieu of or in addition to fibrous web 76.
Coating 80 may be a non-organic particle-filled aqueous-based acrylic polymeric resin composition, mixed in batches of a suitable size, such as 150 kg, according to the following formulation:
______________________________________COMPONENT WEIGHT % (WET)______________________________________Acrylic polymer resin (nonionic 59.8emulsion - 45% solids)Water 7.4Ammonium hydroxide 1.0Kaolin clay 26.8Surfactant (non-ionic 0.9acetylenic diol)Polyether modified dimethyl 1.1polysiloxane copolymersolution (50% solids)(surface property enhancer)Butyl cellosolve acetate 0.7Dioctyl phthalate 1.4Melamine formaldehyde resin 0.8Amine salt of p-toluene sulfonic 0.1acid (25-28% solids)______________________________________
Ingredients were added into the polymeric resin composition in the order shown. Other additives may be used to improve processability, such as thickeners and defoamers. The kaolin clay may be omitted if a polymer coating not having a particulate filler is desired.
Alternatively, coating 80 may be a non-organic particle-filled aqueous-based polyurethane polymeric resin composition, mixed in batches of a suitable size, such as 150 kg, according to the following formulation:
______________________________________COMPONENT WEIGHT % (WET)______________________________________Aliphatic polyurethane dispersion 67.5(35% solids)Ammonium hydroxide 1.0Ethylene glycol 1.9Kaolin clay 23.6Surfactant (non-ionic 0.8acetylenic diol)Polyether modified dimethyl 0.9polysiloxane copolymersolution (50% solids)(surface property enhancer)Butyl cellosolve acetate 0.6Dioctyl phthalate 1.2Melamine formaldehyde resin 2.3Amine salt of p-toluene sulfonic 0.2acid (25-28% solids)______________________________________
Again, ingredients may be added into the polymeric resin composition in the order shown. Other additives may be used to improve processability, such as thickeners and defoamers. Again, the kaolin clay may be omitted if a polymer coating not having a particulate filler is desired.
Coating 80 may also be of a non-organic particle-filled aqueous-based polyurethane/polycarbonate polymeric resin composition.
Kaolin clay is one particulate filler which may be included in coating 80, and is represented as particles 82 in FIG. 4. The distribution of particle sizes in kaolin clay (China clay) ranges from sub-micron size to over 53 microns. In general, however, at least 75% of the particles are smaller than 10 microns, and no more than 0.05% are larger than 53 microns.
In general, individual particles 82 in the particulate filler used will have a hardness different from that of the polymer coating 80. That is to say, the particles 82 may be either harder or softer than the polymer coating 80. Where the particulate filler is kaolin clay, the particles 82 will be harder than coating 80.
In broader terms, the particulate filler may include particles of a non-organic material, polymeric material, or metal. Kaolin clay is one possible non-organic material suitable for use as the particulate filler. A metal powder may also be used for this purpose; stainless steel is but one possible example. Where the particulate filler includes particles of metal, individual particles 82 will be harder than the coating 80. On the other hand, where the particulate filler includes particles of a polymeric material, individual particles 82, depending on their composition, may be either harder or softer than the coating 80.
The mixing of the components in each of the preceding formulations to produce the polymeric resin compositions for use as coating 80 may be carried out in an industrial mixer at a mixing speed of 550 rpm. At final dry weight, after drying and curing, the filler accounts for 45% of the weight of the coating 80, when it is included. This filler content provides the coating 80 with a harder and somewhat more hydrophilic surface, where the particulate filler is kaolin clay.
Coating 80 may be applied to the base 62 by means of a blade-coating procedure, wherein the base is extended between a pair of rollers in endless form, and moved thereabout at a speed of 1.5 m/min. The blade height above the taut base 62 is gradually raised to smooth the mixture being applied to achieve greater thickness.
Initially, with the blade height set at 0.0 mm, that is, barely contacting the surface of the base 62, the base 62 moves through two coating revolutions to allow effective penetration into the base structure. Subsequently, coating 80 is applied for anywhere from 2 to 5 revolutions, while the build up layers of gradually increasing thickness. Then, optionally, one or two additional coating revolutions may be made, increasing the blade height by as much as another 0.3 mm to provide a smooth finish. The coating 80 was then carefully dried for 2 or 3 final revolutions under infrared heaters providing a temperature in the nominal range from 30° C. to 40° C. The belt 60 may then be left under tension on the coating apparatus for several additional hours, perhaps as long as overnight, until dry.
The belt 60 should then be cured to ensure that the coating 80 adequately crosslinks to provide it with a positive mechanical interlock with the base 62. This positive mechanical interlock ensures that coating 80 will not delaminate during the use of the transfer belt 60 on a papermachine.
The belt 60 may be cured on a production dryer having a hot cylinder. For half of this time, the coated belt surface may face away from the hot cylinder surface, and this may be reversed for the second half of the curing time. The cylinder temperature may be 150° C. The belt speed on the cylinder may be 1.0 m/min.
The coating 80 may be ground on the same production dryer. Sandpaper of three different grades of coarseness, 50, 100 and 400, may be used to produce belts 60 with the required topography. The grinding procedure is begun with the most coarse sandpaper (50) in order to get even and totally ground surfaces. Grinding is continued with grade 100 sandpaper and finished with grade 400 sandpaper until the desired surface topography was obtained.
After grinding, the lateral edges of transfer belt 60 may be trimmed and melted before its removal from the production dryer.
The polymer coating 80 of the finished belt 60 has a hardness in the range from Shore A 50 to Shore A 97. Individual particles 82 in the particulate filler used will have hardnesses different from, that is, either harder or softer, that of polymer coating 80.
After grinding, the surface of the polymer coating 80 of the finished belt 60 has an uncompressed roughness in the range from 2 microns to 80 microns, measured as R z -values according to ISO 4287, Part I. Specifically, R z is the ten-point height, defined in that International Standard Organization standard to be the average distance between the five highest peaks and the five deepest valleys within the sampling length measured from a line parallel to the mean line and not crossing the surface profile. When the belt 60 is in a press nip, where the linear load may typically be 100 kN/m, and more generally may fall within a range from 20 kN/m to 200 kN/m, the roughness is compressed to the range from 0 microns to 20 microns. Belt 60 has the capability of recovering its uncompressed roughness upon exit from a press nip, so that it may release a paper sheet in the intended manner. Whether compressed or uncompressed, the roughness is a measure of the amount by which the surface of the polymer coating 80 departs from absolute smoothness in a direction perpendicular thereto. Generally stated, the smoother the belt 60 becomes when compressed in the nip, the better belt 60 will work as a sheet-conveying belt, so long as it recovers its uncompressed roughness soon after exit from a press nip, as its success will be measured by its ability to permit a thin, continuous water film to be formed between its surface and that of a paper sheet in the press nip.
The back side 64 of base 62 may also be provided with a polymeric resin coating, which may be of the same composition as that provided on the paper side 66. Such a coating may be either porous or non-porous. A coating of the latter variety is required where the transfer belt of the invention is also to serve as a long nip press belt, which passes over the shoe or slot component in a long nip press. In such a case, the coating must be impermeable to prevent the oil used to lubricate the shoe, or the pressurized liquid in the slot, from contaminating the paper web. The coating must also be uniformly smooth and abrasion-resistant. A polyurethane resin composition may be used as a coating for the back side 64 where the transfer belt is also to be used as a long nip press belt.
As previously discussed, the mechanism by which the water film between a paper sheet and the transfer belt of the present invention is broken up after exit from a press nip is thought to be primarily a function of the pressure-responsive microscale surface topography of the surface of the coating on its paper side. With reference to FIGS. 5A through 5D, which depict on an exaggerated scale the roughness of the surface of the transfer belt of the present invention at the points labelled A, B, C, and D, respectively, in FIG. 3, this mechanism is shown schematically.
In FIG. 5A, a portion of the polymer coating 80 of the transfer belt as it might appear before entering a press nip, such as at point A in FIG. 3, is shown. The roughness, while greatly exaggerated for the purpose of illustration, is in the range from R z =2 microns to 80 microns. The roughness is made apparent by the numerous peaks 90 and valleys 92 disposed along the surface. In some of the valleys 92, droplets 94 of water remain from the previous passage of the transfer belt through the press nip.
FIG. 5B shows a portion of the polymer coating 80 of the transfer belt as it might appear in a press nip, such as at point B in FIG. 3. A thin, continuous water film 100 resides between a paper sheet 40 and the polymer coating 80 of the transfer belt. The paper sheet 40 is supported by a press felt 43, which accepts some of the water pressed therefrom in the press nip. The surface of polymer coating 80 is depicted as being smooth; in actuality, it would have a roughness in the nip in the range from 0 microns to 20 microns.
In FIG. 5C, which shows a portion of the polymer coating 80 of the transfer belt as it might appear at point C in FIG. 3, soon after exit from a press nip, but before reaching a transfer point, the surface of the polymer coating 0 has begun to recover its uncompressed roughness. The paper sheet 40 is still held to the underside of the transfer belt, but the thin, continuous water film 100 has begun to break up into droplets 102. As the roughness of the surface of the polymer coating 80 approaches its uncompressed value after exit from the nip, these droplets 102 will grow larger, increasing the separation between the paper sheet 40 and the polymer coating 80, and reducing the strength of the bond therebetween.
FIG. 5D shows a portion of polymer coating 80 as it might appear at point D in FIG. 3, where the paper sheet 40 is transferred to dryer fabric 53. By point D, the surface of the polymer coating 80 has fully recovered its uncompressed roughness, which, again, is in the range from R z =2 microns to 80 microns. separated from one another, in turn increasing the separation between the paper sheet 40 and the surface of the polymer coating 80, and decreasing the strength of the bond by which paper sheet 40 is held thereto. After separation, when paper sheet 40 proceeds onto the dryer section, water droplets 94 remain in some of the valleys 92 of the rough surface of the polymer coating 80.
FIG. 6 is a Scanning Electron Microscope (SEM) photograph showing a cross section of the particle-filled polymer coating of the transfer belt of the present invention. Peaks 90 and valleys 92 are clearly visible on the surface of the polymer coating 80, as well as a number of individual particles 82 of the particulate filler. Some relatively large particles 82 protrude from the surface of the coating 80. One particle 82 does so approximately every fifteen polymer peaks 90. Distances in the photograph may be measured according to the scale appearing in the lower right-hand corner thereof.
Modifications to the above would be obvious to those skilled in the art, and would not bring the press fabric so modified beyond the scope of the appended claims. | A transfer belt for eliminating an open draw between a press in a papermachine and a transfer point has a supporting base with a particle-filled polymer coating. The coating, which constitutes the paper side of the transfer belt, carries the paper sheet from a press nip in a closed draw to a transfer point without sheet flutter or drop-off. At the transfer point, the paper sheet is readily released to another sheet-conveying papermachine-clothing product. The transfer belt may carry the sheet through more than one press nip. The transfer belt surface has a pressure-responsive recoverable degree of roughness, which is made relatively smooth by compression in the press nip, allowing the thin, almost continuous water film to form between the transfer belt and the paper sheet. When leaving the press nip, the paper sheet is held to the transfer belt by the thin, almost continuous water film. Following exit from the press nip, the transfer belt surface recovers its uncompressed roughness, breaking up the water film, so that, by the time the paper sheet reaches the transfer point, it is readily released by the transfer belt to the next sheet-conveying papermachine-clothing product, which might be a felt, a belt, or a fabric. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 60/376,039, entitled “Method and Apparatus for Load Balancing and Protecting Data Traffic in an Optical Ring” filed on Apr. 26, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of communication. More specifically, the invention relates to communication networks.
2. Background of the Invention
Current networks must satisfy consumer demand for more bandwidth and a convergence of voice and data traffic. The increased demand of bandwidth by consumers combines with improved high bandwidth capacity of core networks to make edge networks a bottleneck despite the capacity of optical networks.
Multiplexing is used to deliver a variety of traffic over a single high speed broadband line. An optical standard such as Synchronous Optical Network (SONET) or Synchronous Digital Hierarchy (SDH) in conjunction with a multiplexing scheme is used to deliver various rates of traffic over a single high speed optical fiber. SONET/SDH is a transmission standard for optical networks which corresponds to the physical layer of the open standards institutes (OSI) network model. One of the protection schemes for SONET/SDH involves automatic protection switching (APS) in a bi-directional line switched ring (BLSR) architecture. BLSR utilizes linear switching to implement APS.
High speed optical rings offer large amounts of bandwidth, but the protection scheme utilizes 50% of that bandwidth. This 50% of total bandwidth for a protection channel typically goes unused while there is not a failure. It is typically unused because traffic transmitted in the protection channel would be preempted by the working TDM traffic when a failure occurs.
An alternative to unprotected preemptable traffic in a protection channel is to provide a non-preemptable unprotected traffic (NUT) channel. A NUT channel allows for an implementation that runs a unidirectional path switched ring (UPSR) over a BLSR. Unfortunately, the traffic carried in a NUT channel may be dropped if a failure occurs in the BLSR. Hence, certain customers will not purchase NUT channels.
BRIEF SUMMARY OF THE INVENTION
A method and apparatus for utilization of spanning trees in an optical ring is described. According to one aspect of the invention, a method in a network element provides for configuring multiple spanning trees in a set of one or more network elements of an optical ring, load balancing with the multiple spanning trees data traffic transmitted in unprotected data channels provisioned through the optical ring, and protecting the unprotected data channels with the multiple spanning trees.
These and other aspects of the present invention will be better described with reference to the Detailed Description and the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings:
FIG. 1A is an exemplary diagram illustrating provisioning of an unprotected data channel in an optical ring according to one embodiment of the invention.
FIG. 1B is an exemplary diagram illustrating configuration of metrics and creation of spanning trees in an optical ring according to one embodiment of the invention.
FIG. 2A is an exemplary diagram illustrating failure in an optical ring with spanning trees according to one embodiment of the invention.
FIG. 2B is an exemplary diagram illustrating active links of a newly created spanning tree in an optical ring according to one embodiment of the invention.
FIG. 3 is an exemplary diagram illustrating binding a spanning tree to VLANs according to one embodiment of the invention.
FIG. 4 is an exemplary diagram illustrating VLAN circuits and spanning trees in a optical ring according to one embodiment of the invention.
FIG. 5A is an exemplary diagram illustrating MAC address learning in an optical ring according to one embodiment of the invention.
FIG. 5B is an exemplary diagram illustrating MAC address learning in an optical ring continuing from FIG. 5A according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known circuits, structures, standards, and techniques have not been shown in detail in order not to obscure the invention.
FIGS. 1A-1B are exemplary diagrams illustrating creation of a spanning tree for an unprotected data channel in an optical ring according to one embodiment of the invention. FIG. 1A is an exemplary diagram illustrating provisioning of an unprotected data channel in an optical ring according to one embodiment of the invention. In FIG. 1A , network elements 101 A- 101 D comprise an optical ring. The optical ring illustrated in FIG. 1A is connected in the following manner: the link 111 A connects the network elements 101 A and 101 B; the link 111 B connects the network elements 101 B and 101 C; the link 111 C connects the network elements 101 C and 101 D; and a link 111 D connects the network elements 101 D and 101 A. The links illustrated in FIG. 1A are bi-directional links, but the described invention can also be applied to a uni-directional ring.
The network element 101 A includes a switching fabric 103 A and a data traffic switching medium 105 A. Edge lines 107 A- 107 C connect the network element 101 A to non-core network elements, which are not illustrated. At a time 1 , the set of subchannels 113 A and a set of sub-channels 113 B are selected. At a time 2 , the set of selected sub-channels 113 A are concatenated. Likewise, the set of selected sub-channels 113 B are concatenated. Although this illustration describes sets of subchannels, another example can involve a single subchannel that does not get concatenated. At a time 3 , the concatenated set of selected subchannels 113 A and the concatenated set of selected subchannels 113 B are aggregated and terminated on the data traffic switching medium 105 A. The same set of operations are performed for each trunk port of the optical ring of the network elements 101 C and 101 D.
The network element 101 B does not include a data traffic switching medium. Therefore, the concatenated set of selected subchannels 113 A and the concatenated selected set of subchannels 113 B are not terminated and aggregated in the network element 101 B. In the network element 101 B, the concatenated selected set of subchannels 113 A are cross connected through a switch fabric 103 B. Similarly, the concatenated set of selected subchannels 113 B are cross connected through the switch fabric 103 B.
FIG. 1B is an exemplary diagram illustrating configuration of metrics and creation of spanning trees in an optical ring according to one embodiment of the invention. In FIG. 1B , the aggregated concatenated selected set of subchannels 113 A and 113 B are illustrated as an unprotected data channel 121 A- 121 C. The unprotected data channel 121 A begins at the network element 101 A and terminates at the network element 101 C, traversing the network element 101 B. The unprotected data channel 121 B runs between the network elements 101 C and 101 D. The unprotected data channel 121 C runs between the network elements 101 D and 101 A.
In creating a spanning tree, metrics are defined for the spanning tree. Defining metrics includes assigning bridge priorities and defining path costs. At a time 1 , a bridge priority is defined for network elements 101 A, 101 C, and 101 D. The bridge priority for the network element 101 C is defined as 1. The bridge priority for the network element 101 D is defined as 3. The bridge priority for the network element 101 A is defined as 2. In this illustration, the lower number has a higher priority. At a time 2 , the path costs are defined. The path costs are shown in Table 1 below.
TABLE 1
Path Costs
LINK
PORT
PATH COSTS
101A → 101C
123A
1
101C → 101D
123G
5
101D → 101A
123J
2
101A → 101D
123K
4
101D → 101C
123H
1
101C → 101A
123E
1
Once the path costs are defined, the root bridge is determined. The root bridge is determined by the network elements 101 A, 101 C, and 101 D sending out bridge protocol data units announcing themselves as the root bridge. Upon determining that a different network element has a higher priority, a network element will identify the network element with the higher priority as the root bridge. In FIG. 1B , the network element 101 C has the highest priority. Therefore, the network element 101 C will be the root bridge. Once the root bridge is determined and the path costs are defined, root path costs are calculated. Root path cost is the sum path cost to reach the root bridge. The root path costs are calculated as shown in Table 2.
LINK
PORT
ROOT PATH COSTS
101A → 101C
123A
1
101A → 101B
123K
5
101D → 101C
123H
1
101D → 101B
123J
3
Table 2
Root Path Costs
The spanning tree that is created from defined metrics are presented by a graph 135 . The graph 135 shows the network element 101 C as root of a tree. The left branch of the tree connects the network element 101 A and the right branch of the tree connects the network element 101 B. Since the root path cost to network element 101 A through port 123 A is cheaper than the root path cost through port 123 K, the spanning tree of the network element 101 A blocks the port 123 K (discards the link 121 C and does not forward through traffic the port 123 K). The spanning tree of the network element 101 D selects port 123 H to reach the root path bridge and blocks port 123 J, which is more expensive.
FIGS. 2A-2B are exemplary diagrams illustrating protection of data traffic with spanning trees in an optical ring according to one embodiment of the invention. FIG. 2A is an exemplary diagram illustrating failure in an optical ring with spanning trees according to one embodiment of the invention. In FIG. 2A , network elements 201 A- 201 D comprise an optical ring. The optical ring is connected in the following manner: the link 205 A connects to a network element 201 D and 201 A, the link 205 B connects the network elements 201 A and 201 B, the link 205 C connects the network elements 201 B and 201 C and link 205 D connects network elements 201 C and 201 D.
In FIG. 2A , the network element 201 A has been designated as the root bridge. A spanning tree 215 in the network element 201 D forwards traffic to the port 202 A along the link 205 A to the root bridge network element 201 A. A graph 210 illustrates the spanning tree 215 . The root bridge network element 201 A forwards the traffic to a port 202 C where the traffic exits the ring. The root path costs throughout the ring are shown in Table 3 below. When the link 205 A fails, root path costs are recalculated and a new spanning tree is created at each network element throughout the ring.
LINK
PORT
ROOT PATH COSTS
1D → 1A
202A
1
1D → 1A
202K
6
1C → 1A
202J
3
1C → 1A
202H
2
1B → 1A
202E
1
1B → 1A
202G
8
Table 3
Root Path Costs
FIG. 2B is an exemplary diagram illustrating active links of a newly created spanning tree in an optical ring according to one embodiment of the invention. In FIG. 2B , the link 205 A has been discarded due to a failure. Now traffic is forwarded from the network element 201 D in accordance with a spanning tree 217 through the previously blocked port 202 K and along the previously discarded link 205 D. The root path costs used for new spanning trees at each network element are shown in Table 4 below. Based on Table 4, the network element 201 D is the only network element that creates a new spanning tree. The graph 213 illustrates the new spanning tree 217 .
TABLE 4
Root Path Costs
LINK
PORT
ROOT PATH COSTS
205D → 205A
202A
200 (default for failed link)
205D → 205A
202B
6
205C → 205A
202I
202
205C → 205A
202G
2
205B → 205A
202D
1
205B → 205A
202F
207
FIG. 3 is an exemplary diagram illustrating binding a spanning tree to VLANs according to one embodiment of the invention. In FIG. 3 , a network element 301 includes a VLAN switch 311 , edge ports 305 A- 305 C, and trunk ports 307 A- 307 B.
The edge ports 305 A- 305 C respectively connect the network element to local area networks (LANs) 303 A- 303 C. The LAN 303 A includes a host 304 A with a MAC address 7 . The LAN 303 B includes a host 304 B with a MAC address 11 . The LAN 303 C includes a host 304 C with a MAC address 5 and a host 304 D with a MAC address 9 .
At a time 1 , spanning trees 315 A- 315 B are created. At a time 2 , the spanning tree 315 A is coupled to the VLAN switch 311 and bound to the trunk port 307 A. The spanning tree 315 B is coupled to the VLAN switch 311 and bound to the trunk port 307 B. At a time 3 , a generic attribute registration protocol (GARP) virtual local area network (VLAN) registration protocol (GVRP) module 317 is enabled on the trunk port 307 A- 307 B. At a time 4 , VLANs are defined in the VLAN switch 311 . A VLAN 21 is defined as including MAC addresses 5 and 7 . A VLAN 22 is defined as including MAC addresses 9 and 11 . At a time 5 , VLAN circuits are created between the edge ports 305 A- 305 C and the VLAN switch 311 . A VLAN circuit 309 A is created from the VLAN switch 311 to the edge port 305 A for the VLAN 21 . A VLAN circuit 309 B is created from the VLAN switch 311 to the edge port 305 B for the VLAN 22 . A VLAN circuit 309 C is created for each of the VLANs 21 and 22 between the port 305 C and the VLAN switch 311 . At a time 6 , the GVRP module 317 creates a VLAN circuit between the spanning tree 315 A and an unprotected data channel 341 A on the trunk port 307 A for the VLAN 21 . The GVRP module 317 also creates a VLAN circuit between the spanning tree 315 B and an unprotected data channel 341 B on the trunk port 307 B.
FIG. 4 is an exemplary diagram illustrating VLAN circuits and spanning trees in a optical ring according to one embodiment of the invention. In FIG. 4 , an optical ring includes network elements 401 A- 401 D. The network elements 401 A- 401 D are connected with links having an unprotected data channel in the following manner: a link 403 A connects the network elements 401 A and 401 B, a link 403 B connects the network elements 401 B and 401 C, a link 403 C connects the network elements 401 A and 401 D, and a link 403 B connects the network elements 401 D and 401 A.
The network element 401 A includes a GVRP module 425 A, spanning trees 421 A- 421 B, a VLAN switch 423 A, trunk ports 409 A- 409 B, and an edge port 429 A. The trunk port 409 A connects to the link 403 A. The trunk port 409 B connects to the link 403 D. The edge port 429 A connects to a LAN 405 A.
The network element 401 B includes a GVRP module 425 B, spanning trees 421 C- 421 D, a VLAN switch 423 B, and trunk ports 409 C- 409 E. The trunk port 409 C connects the network element 401 D to the link 403 A. The trunk port 409 D connects the network element 401 C to the link 403 B. The trunk port 409 E connects the network element 401 B to another core network element in a different ring.
The network element 401 C includes a GVRP module 425 C, spanning trees 421 E- 421 F, a VLAN switch 423 C, trunk ports 409 F- 409 G, and an edge port 429 B. The edge port 429 B connects the network element 401 C to a local area network 405 C. The trunk ports 409 F connects the network element 401 C to the link 403 B. The trunk port 409 G connects the network element 401 C to the link 403 C.
The network element 401 D includes a GVRP module 425 D, spanning trees 421 G- 421 H, a VLAN switch 423 D, trunk ports 409 H- 409 I, and an edge port 429 C. The edge port 429 C connects the network element 401 D to a LAN 405 D. The trunk port 409 H connects the network element 401 D to the link 403 C. The trunk port 409 I connects the network element 401 D to the link 403 D.
In the network element 401 A, the spanning tree 421 A is bound to the trunk port 409 B and the spanning tree 421 B is bound to the trunk port 409 A. As described in FIG. 3 , the spanning tree 421 B is associated with a VLAN 21 and the spanning tree 421 A is associated with a VLAN 22 . The VLAN switch 423 A creates VLAN circuits for the VLAN 21 and 22 to the edge port 429 A. The GVRP module 425 A creates VLAN circuits on the trunk ports 409 A and 409 B for the VLANs 21 and 22 . In the network elements 401 B- 401 D, the VLANs are learned from the network element 401 A. After learning the VLANs from the network element 401 A, the network elements 401 B- 401 D will create circuits in the same fashion that the network element 401 A created VLAN circuits. Alternatively, each of the VLANs are defined in the VLAN switches 423 B- 423 D respectively on the network elements 401 B- 401 D. After defining the VLANs within the network elements 401 B- 401 D, the VLAN circuits are created as described with respect to the network element 401 A.
FIGS. 5A-5B are exemplary diagrams illustrating network elements in an optical ring learning MAC addresses for VLANs associated with different spanning trees according to one embodiment of the invention. FIG. 5A is an exemplary diagram illustrating MAC address learning in an optical ring according to one embodiment of the invention. In FIG. 5A , an optical ring is comprised of network elements 501 A- 501 D. The network elements 501 A and 501 B are connected with a link 505 A. The network elements 501 B and 501 C are connected with a link 505 B. The network elements 501 C and 501 D are connected with a link 505 C. The network elements 501 D and 501 A are connected with a link 505 D. The network element 501 A is connected with a LAN 503 A via an edge port 502 A. The LAN 503 A includes a host 506 A of a VLAN 26 with a MAC address 6 . The network element 501 A utilizes a VLAN table 513 A. At a time 1 , the host 506 A sends a packet 509 addressed to a host with a MAC address of 9 . The packet 509 is received by the edge port 502 A at the network element 501 A. At a time 2 , the spanning tree associated with the VLAN 26 forwards the packet 509 to the trunk port 504 A, since the trunk port 504 B is blocked by the spanning tree. At a time 3 , the packet 509 is received at the network element 501 B via a trunk port 504 D and forwarded out the edge port 502 B and the trunk port 504 C. At this time, the network element 501 B modifies a VLAN table 513 B to indicate the MAC address 6 and trunk port 504 D for the VLAN 26 . At a time 4 , the packet 509 is received by the network element 501 C at a trunk port 504 E. The packet 509 is forwarded out the trunk port 504 F to eventually be received by a host 506 E with a MAC address 9 . The network element 501 C modifies a VLAN table 513 C to indicate MAC address 6 and the trunk port 504 E.
FIG. 5B is an exemplary diagram illustrating MAC address learning in an optical ring continuing from FIG. 5A according to one embodiment of the invention. In FIG. 5B , the machine 506 E responds to the machine 506 A with a packet 510 . At a time 1 , the network element 501 C receives the packet 510 and modifies the VLAN table 513 C. The network element 501 C modifies the VLAN table 513 C to include an entry for VLAN 26 indicating a MAC address of 9 and the trunk port 504 F. At a time 2 , the network element 501 B receives the packet 510 on the trunk port 504 C and forwards the packet to the trunk port 504 C and the edge port 502 B. The network element 501 B modifies the VLAN table 513 B to include an entry for the VLAN 26 that indicates MAC address 9 and trunk port 504 C. At a time 3 , the network element 501 A receives the packet 510 via the trunk port 504 A and forwards it to the edge port 502 A. The network element 501 A modifies the VLAN table 513 A to include an entry for the VLAN 26 that indicates MAC address 9 and the trunk port 504 A.
The network elements described in the Figures include memories, processors, and/or ASICs. Such memories include a machine-readable medium on which is stored a set of instructions (i.e., software) embodying any one, or all, of the methodologies described herein. Software can reside, completely or at least partially, within this memory and/or within the processor and/or ASICs. For the purpose of this specification, the term “machine-readable medium” shall be taken to include any mechanism that provides (i.e., stores and/or transmits) information in a form readable by a machine (e.g., a computer). For example, a machine-readable medium includes read only memory (“ROM”), random access memory (“RAM”), magnetic disk storage media, optical storage media, flash memory devices, electrical, optical, acoustical, or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.), etc.
While the invention has been described in terms of several embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. For example, unprotected channels are described within the context of a single optical ring, but an unprotected channel may traverse multiple optical rings within an optical network. The method and apparatus of the invention can be practiced with modification and alteration within the spirit and scope of the appended claims. The description is thus to be regarded as illustrative instead of limiting on the invention. | A method and apparatus for load balancing and protecting data traffic in an optical ring is described. A method comprises configuring multiple spanning trees in a set of one or more network elements of an optical ring, load balancing with the multiple spanning trees data traffic transmitted in unprotected data channels provisioned through the optical ring, and protecting the unprotected data channels with the multiple spanning trees. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a stereo microphone unit and a stereo microphone, and more particularly, relates to a stereo microphone unit that can have smaller size compared with conventional counterparts and a stereo microphone including the same.
[0003] 2. Description of the Related Art
[0004] An XY stereo system and an MS stereo system are known as sound pickup systems of a stereo microphone. In the XY stereo system, two unidirectional microphone units are fixed to form an appropriate angle. The microphone unit directed to the left outputs L channel signal and microphone unit directed to the right outputs R channel signal. The appropriate angle is, for example, 120 degrees (see, for example Japanese Utility Model Application Publication H6-35597).
[0005] In the MS stereo system, a unidirectional microphone unit and a bidirectional microphone unit are used. A main signal M obtained from the unidirectional microphone unit and a directional signal S obtained from the bidirectional microphone unit directed to a direction orthogonal to that of the unidirectional microphone unit are fed to a matrix circuit to generate (M+S) and (M−S) signals. For example, the (M+S) signal is an L channel signal and the (M−S) signal is an R channel signal (see for example, Japanese Patent Application Publication 2002-374592).
[0006] FIG. 5 illustrates an example of a stereo microphone employing the XY stereo system. In FIG. 5 , a stereo capacitor microphone unit 100 includes a pair of left (L) channel side unidirectional microphone unit 100 L and right (R) channel side unidirectional microphone unit 100 R. In FIG. 5 , components other than the pair of unidirectional microphone units 100 L and 100 R on the left and the right side, respectively, are omitted.
[0007] As illustrated in FIG. 5 , the XY stereo system realizes more simple circuit configuration compared with that for the MS stereo system and thus is mainly employed in a low-cost stereo microphone.
[0008] In the XY stereo system, the stereo capacitor microphone units 100 L and 100 R need to be fixed with their respective directional axes DL and DR forming an appropriate angle. Therefore, a holder that holds the microphone units in an appropriate angular relationship is required. In addition, to make the range of the stereo sound variable, a mechanism is required with which the angle between the directional axes DL and DR can be changed.
[0009] Generally, two microphone units in the XY stereo system are incorporated in a single head case (windshield). Such a head case is required to have a large size and a special shape to fix the two microphone units fixed in an appropriate angular relationship.
[0010] A stereo microphone unit is known that can solve the above problems and allows an XY stereo microphone to be formed with small number of components and small size (see, for example Japanese Patent Application Publication 2008-227779). Here, two general-purpose unidirectional microphone units are fixed with their main axes forming 180 degrees. A sound insulating cover is provided over a space serving as a rear acoustic terminal between respective fixed electrodes of the left and right microphone units. Directional axes for sound pickup can be adjusted by shifting the position of the rear acoustic terminal.
[0011] A stereo microphone unit disclosed in Japanese Patent Application Publication 2008-227779 is exemplary illustrated in FIG. 6 . As illustrated in FIG. 6 , this stereo microphone unit 200 includes: general-purpose unidirectional capacitor microphone units 200 L, and 200 R being fixed with their respective main axes forming 180 degrees; and a sound insulating cover 201 provided over a space formed between respective fixed electrodes of units 200 L and 200 R. A position offset from the main axes by the sound insulating cover 201 is a rear acoustic terminal RT. Accordingly, the stereo microphone unit has directionality capable of performing stereo sound pickup with the directional axes DL and DR forming a certain angle as illustrated in FIG. 6 .
[0012] In such a stereo microphone unit disclosed in Japanese Patent Application Publication 2008-227779, an air chamber is inevitably formed between the two units (left and right) and the insulating cover. The air chamber serves not only as a rear acoustic terminal but also as a common resonator for respective rear acoustic terminals of left and right units. Therefore directional collapse occurs due to deterioration of acoustic characteristics in high frequency range and deterioration of S/N ratio.
[0013] Frequency characteristics of the stereo microphone unit 200 illustrated in FIG. 6 are exemplary depicted in FIG. 7 . In FIG. 7 , the horizontal axis represents frequency of a signal emitted from a sound source, and the vertical axis represents a gain in the stereo microphone unit 200 . FIG. 7 depicts the L channel signal of the stereo microphone unit 200 . A graph a in FIG. 7 represents a case where the sound source is at the front side in the main axis of the stereo capacitor microphone unit 200 L, that is, at the diaphragm side on the main axis of the stereo capacitor microphone unit 200 L (see FIG. 6 ). A graph b in FIG. 7 represents a case where the sound source is at the position offset by 90 degrees from the main axis of the stereo microphone unit 200 , that is, at the sound insulating cover 201 side. A graph c in FIG. 7 represents a case where the sound source is at the rear side in the main axis of the stereo capacitor microphone unit 200 L, that is, at the stereo capacitor microphone unit 200 R side. A graph d represents a case where the sound source is at the rear acoustic terminal RT.
[0014] As depicted in FIG. 7 , the stereo sound pickup is possible for a signal with frequency lower than 5 kHz because the gain in the front side in the main axis (graph a) and other gains with different sound source directions is different and sounds from left and right can be distinguished and picked up.
[0015] On the other hand, with a signal with frequency not lower than 5 kHz, resonance due to the air chamber occurs to provide a substantially omnidirectional state. When this happens, sounds from left and right cannot be distinguished, and thus, stereo sound pickup is impossible.
[0016] Such resonation can be prevented by providing an acoustic resistor in the air chamber. Unfortunately, provision of such an acoustic resistor, which has a certain amount of thickness, limits the downsizing of the stereo capacitor microphone unit as a whole.
[0017] In addition, the stereo capacitor microphone unit is likely to be affected by wind noise because each of the left and the right units has acoustic terminals respectively at the front and the back thereof. Accordingly, the stereo capacitor microphone unit needs to be improved in this point as well.
SUMMARY OF THE INVENTION
[0018] The present invention is made in view of the above problems and an object of the present invention is to provide a stereo microphone unit in which two unidirectional capacitor microphone units fixed via an insulating spacer with their main axes forming 180 degrees share a single rear acoustic terminal so that resonation is prevented from occurring and influence of wind noise is small unlike the conventional counterpart, and further more, can be formed with smaller number of components and can have a smaller size, and a stereo microphone using such a stereo microphone unit.
[0019] In accordance with an aspect of the present invention, a stereo capacitor microphone unit includes: two unidirectional microphone units integrally formed with respective fixed electrodes of the unidirectional microphone units facing each other; and an insulating spacer that is interposed between the fixed electrodes and provided with a gap formed at a portion of an outer periphery towards radial direction. The gap communicates fixed electrode rear spaces of the respective unidirectional microphone units with an external space to serve as a common rear acoustic terminal for the unidirectional microphone units.
[0020] In the above described stereo capacitor microphone unit, the gap is preferably formed at a portion around a midpoint in thickness direction of the insulating spacer with a certain length from the periphery of the insulating spacer towards a center of the insulating spacer.
[0021] In the above described stereo capacitor microphone unit, an acoustic resistor is preferably provided in the gap.
[0022] In the above described stereo capacitor microphone unit, a directional axis of each of the unidirectional microphone units is preferably offset by a certain angle from a main axis of each of the unidirectional microphone units.
[0023] In the above described stereo capacitor microphone unit, a directional axis of each of the unidirectional microphone units is offset by a certain angle from a main axis of the each of the unidirectional microphone units, and the directional axes of the unidirectional microphone units form an angle of 120 degrees at a midpoint of a main axis of the stereo capacitor microphone unit.
[0024] In accordance with another aspect of the present invention, a stereo capacitor microphone includes: a microphone, casing; and a stereo capacitor microphone unit incorporated in the microphone casing. The stereo capacitor microphone unit is the above described stereo capacitor microphone unit.
[0025] According to the present invention, the two unidirectional capacitor microphone units are fixed facing opposite directions with their main axes forming 180 degrees, the insulating spacer is provided between the rear surface sides of the fixed electrodes of respective microphone units and the gap formed at a middle portion of the insulating spacer communicates the rear air chambers of the respective fixed electrodes of the microphone units to the external space. Therefore, the two capacitor microphone units can share the single rear acoustic terminal. Accordingly, the stereo microphone unit can be obtained that has smaller size and less components as well as higher frequency characteristic by preventing the resonation from occurring and lowering the influence of sound noise, which were the problems in conventional counterparts, and the stereo microphone using such a stereo microphone unit can also be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a cross-sectional view of an embodiment of a stereo capacitor microphone unit according to the present invention;
[0027] FIG. 2 is a side view of the embodiment of the stereo capacitor microphone unit according to the present invention;
[0028] FIG. 3 is a graph exemplary depicting frequency characteristics of the stereo capacitor microphone unit according to the present invention;
[0029] FIG. 4 is a diagram exemplary depicting directionality of the stereo capacitor microphone unit according to the present invention;
[0030] FIG. 5 is a cross-sectional view of an example of a conventional stereo capacitor microphone unit;
[0031] FIG. 6 is a cross-sectional view of another example of a conventional stereo capacitor microphone unit; and
[0032] FIG. 7 is a graph exemplary depicting frequency characteristics of the conventional stereo capacitor microphone unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] An embodiment of a stereo capacitor microphone unit according to the present invention is described below with reference to some of the accompanying drawings. FIG. 1 is a cross-sectional view of a stereo capacitor microphone unit according to an embodiment of the present invention. A stereo capacitor microphone according to the present embodiment includes a stereo capacitor microphone unit 10 illustrated in FIG. 1 . As illustrated in FIG. 1 , in the stereo capacitor microphone unit 10 , two unidirectional capacitor microphone units are respectively provided at the right side and the left side of an insulating spacer 15 and the insulating spacer 15 is disposed in the center. Each of the unidirectional microphone units includes a fixed electrode 14 , a spacer (not illustrated), and a diaphragm ring 12 provided with a diaphragm 13 in a stretched state. The elements of each of the unidirectional microphones are positioned by being sandwiched between a fixing plate 11 and the insulating spacer 15 .
[0034] The insulating spacer 15 has a circular shape with a diameter larger than that of the diaphragm ring 12 .
[0035] FIG. 2 is a side view of the stereo capacitor microphone unit 10 . As illustrated in FIG. 2 , the stereo capacitor microphone unit 10 has a substantially rectangle form. The fixing plates 11 , which are substantially rectangular plate, are each provided with holes through which fixtures 112 penetrate at the four corners. The above described elements are fixed at the positions with the insulating spacer 15 disposed in the center, by fixing the fixing plates 11 with the fixtures 112 .
[0036] The fixtures 112 such as screws are inserted in respective holes in one of the fixing plates 11 and are screwed into respective screw holes in the other fixing plate 11 or into respective screw nuts provided at the holes in the other fixing plate 11 and corresponding to the fixtures 112 . Thus, inward pressing force is applied by the fixtures 112 inserted from right and left. With such a force, the diaphragm rings 12 , the diaphragms 13 , the spacer rings (not illustrated), and the fixed electrodes 14 are fixed with a certain positional relationship with the insulating spacer 15 . Multiple holes formed around the center of the fixing plate 11 serves as front acoustic terminal holes 111 . The front acoustic terminal holes 111 are covered with a mesh material such as a wire mesh to prevent foreign objects such as dust from entering therethrough.
[0037] The dotted line slightly below the center line of the fixing plate 11 illustrated in FIG. 2 represents an end portion of a later described gap provided on the insulating spacer 15 .
[0038] Returning to FIG. 1 , the diaphragm 13 may be a thin synthetic resin film having metal deposition film and the fixed electrode 14 is a metallic plate made of, for example, aluminum. Alternatively, the diaphragm 13 of a film electret type is made of an electret film, and the electret film is integrally attached to the fixed electrode 14 in a back electret system.
[0039] A circuit board (not illustrated) is disposed outside the stereo capacitor microphone unit 10 . The circuit board is provided with a field-effect transistor (FET) 17 serving as an impedance converter. The gate terminal of the FET 17 is electrically connected to the fixed electrode 14 via an intermediate electrode (not illustrated).
[0040] A part of the insulating spacer 15 is cut away from an outer peripheral towards the inner diameter direction to form a gap 152 . More specifically, the gap 152 is formed by cutting away the insulating spacer 15 at the mid point in the width direction (horizontal direction as viewed in FIG. 1 ) and from the outer peripheral portion towards the center for a certain amount.
[0041] The gap 152 includes rear air chambers 142 at portions between the insulating spacer 15 and the fixed electrode 14 and a communication hole 151 that communicates the rear air chambers 142 with the external space. Furthermore, influence of wind noise can be reduced by providing an acoustic resister 153 made of a wire body or nonwoven fabric in the gap 152 .
[0042] A sound wave from a sound source (not illustrated) entering the stereo capacitor microphone unit 10 having the above structure directly from the front acts on the front side of the diaphragm 13 via the front acoustic terminal 111 . A sound wave from the sound source entering the stereo capacitor microphone unit 10 from the gap 152 acts on the rear side of the diaphragm 13 via the communication hole 151 and the rear air chamber 142 of the fixed electrode 14 .
[0043] As illustrated in FIG. 1 , directional axes DL and DR each form a certain angle between the main axis X passing the center of the diaphragms 13 respectively at the left and the right sides, where the directional axis DL is the left directional axis of the stereo capacitor microphone unit 10 and the directional axis DR is the right directional axis of the stereo capacitor microphone unit 10 . This is because the position of the rear acoustic terminal is shifted from the main axis X due to the gap 152 . The angle of the directional axis X of the stereo capacitor microphone unit is preferably 120 degrees. The angle formed between the directional axis DL (DR) and the main axis X depends on the thickness and the depth of the gap 152 . Therefore, the angle of the directional axis X of the stereo capacitor microphone unit can be set to 120 degrees by adjusting the size of the gap 152 .
[0044] FIG. 3 is a graph exemplary depicting a frequency characteristics of the stereo capacitor microphone unit 10 according to the embodiment of the present invention. Specifically, FIG. 3 depicts output levels of the stereo capacitor microphone unit 10 corresponding to signals of various frequencies emitted from a sound source. The frequency characteristic of one of the two unidirectional capacitor microphone unit forming the stereo capacitor microphone unit 10 is depicted in FIG. 3 . In FIG. 3 , the horizontal axis represents the frequency of a signal emitted from the sound source and the vertical axis represents gain in the measured unidirectional capacitor microphone unit. A graph A in FIG. 3 represents the case where the sound source is placed on the front side in the main axis X of the microphone unit. A graph B in FIG. 3 represents the case where the sound source is placed at a position offset by 90 degrees from the main axis X and is at a portion on the upper side as viewed in FIG. 1 . A graph C in FIG. 3 represents the case where the sound source is placed on the rear side in the main axis X of the measured unidirectional capacitor microphone unit.
[0045] As illustrated in FIG. 3 , even when the frequency of the signal from the sound source is at and above 5 kHz, the frequency characteristic curves of the output of the each of the capacitor microphone units facing the left and the right sides (the graphs a and c) are separated. Accordingly, the stereo capacitor microphone unit 10 according to the embodiment of the present invention can perform stereo sound pickup without degradation in directionality due to resonance.
[0046] The stereo capacitor microphone unit 10 has directionality capable of performing stereo sound pickup as illustrated by the directional curve in FIG. 4 .
[0047] As described above, the left and the right unidirectional capacitor microphone units share the rear acoustic terminal formed by the gap 152 . The directional axes DL and DR of the left and the right unidirectional capacitor microphone units, respectively, can be offset by a certain angle from the main axis X according to the size of the gap 152 . Thus, the stereo capacitor microphone unit capable of performing stereo sound pickup can be obtained.
[0048] In the stereo capacitor microphone unit 10 according to the embodiment of the present invention, no resonance occurs due to the air chamber because the space serving as the rear acoustic terminal is extremely small. Therefore, excellent stereo sound pickup over large-bandwidth can be achieved without degradation in S/N ratio in the high frequency range. In addition, dramatic downsizing is possible because the two unidirectional capacitor microphone units share a single rear acoustic terminal.
[0049] Generally, two unidirectional capacitor microphone units have total of four acoustic terminals, i.e., one each on the left and the right side of each of the two unidirectional capacitor microphone units. The number of acoustic terminals can be reduced by sharing the rear acoustic terminal, thereby reducing wind noise.
[0050] A stereo capacitor microphone can be obtained by incorporating the stereo capacitor microphone unit according to the present invention in a microphone casing. | A stereo capacitor microphone unit includes: two unidirectional microphone units integrally formed with respective fixed electrodes of the unidirectional microphone units facing each other; and an insulating spacer that is interposed between the fixed electrodes and provided with a gap formed at a portion of an outer periphery towards radial direction. The gap communicates fixed electrode rear spaces of the respective unidirectional microphone units with an external space to serve as a common rear acoustic terminal for the unidirectional microphone units. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to removable orthodontic appliances that exert corrective forces on teeth.
2. Description of the Prior Art
Orthodontics is a specialty of dentistry which is concerned with the treatment of malpositioned teeth and the correction of improper relationships of the teeth and dental arches. It is common to utilize extra-oral orthodontic appliances to correct improperly positioned teeth. It is also common in extra-oral appliances to use some form of elastic mechanism so that a force can be applied to the teeth.
Headgear assemblies are commonly used in orthodontic treatment to apply forces to a patient's teeth to accomplish specific types of tooth movements. Such headgear assemblies typically include an inner bow, an outer bow and some type of a neck/head strap assembly. More particularly, the two ends of the inner bow are each typically inserted into a buccal tube attached to one of the upper first molars. Moreover, the outer bow is connected to the inner bow and extends at least partially about both sides of the patient's face such that the ends of the outer bow may be engaged by the neck/head strap assembly. The neck/head strap assembly is generally formed at least in part from an elastic material or other energy-storing mechanism so as to be capable of stretching and, thus, applying the desired treatment forces to each of the ends of the outer bow. These treatment forces are then typically transmitted to the upper first molars and any teeth interconnected therewith (e.g., via an arch wire and/or other appropriate connectors).
The most common type of force producing device is the coil spring. Coil springs that have been commonly used in the past are stainless steel springs. The advantage of springs as a force producing device is that they almost never require replacement during the entire length of time of usage. The disadvantage of most springs that are in common use is that they do not apply a constant force over different deflections. Deflection increases and decreases when the user speaks or moves his or her head. Therefore, when using the conventional stainless steel type of spring, the force that is applied is constantly changing. Orthodontists feel that constant force application moves the teeth more efficiently than variable forces. Furthermore, variable forces can cause pain, especially if the force significantly increases momentarily.
Moreover, to be effective, an orthodontic device must be worn over an extended period of time each day. In addition, orthodontists, in many cases, guarantee that they will be able to align a patient's teeth. For both purposes, it is desirable to record how long a patient actually wears an orthodontic device and the amount of extra-oral force exerted.
The use of removable appliances that exert corrective forces on teeth such as headgears, mono-blocks, activators, crozats, retainers, spring-loaded retainers and the like is at the discretion of the patient who most often is an adolescent. Since the appliance may be somewhat uncomfortable and inconvenient to wear, it takes considerable will power to adhere to a treatment program. It can be particularly difficult to adhere to a program for an adolescent who may not fully recognize the true value of the treatment.
The rate of corrective movement of teeth is a function both of the forces applied to the teeth and the amount of time those forces have been applied. Failure to wear an appliance for the prescribed periods results in reduced corrective movement of the teeth and, in addition, such failure can result in the use of incorrect forces in later stages of the treatment. As treatment progresses, forces are often determined in relation to the effectiveness of forces used in earlier stages. If a patient represents that the program has been fully complied with when, in fact, it has not, the orthodontist is led to believe that the forces applied earlier were insufficient to cause the desired rate of tooth movement. As a consequence, excessive forces may later be chosen which can work to the detriment of the patient.
It is an object of the present invention to provide an orthodontic care device capable of applying an extra-oral force to a patient's jaw/teeth and of recording the force applied thereto as a function of the amount of time the device is actually worn.
Another object of the invention is to provide a memory read-out unit capable of reading the force/time history recorded by said orthodontic care device and storing such history, possibly with other previously stored force/time histories, for future retrieval.
An additional object of the invention is to provide means, such as a serial or parallel port, for down-loading information stored in the memory read-out unit into a computer so that the information can be analyzed, utilizing a suitable computer program, and printed out in a convenient format for review by an orthodontist and his patients.
SUMMARY OF THE INVENTION
The above and other objects are realized by a removable orthodontic appliance including at least one force applicator operable to exert extra-oral, corrective forces on teeth. A data storage device is operably connected to store data corresponding to force applied by the force applicator. A potentiometer is operably connected to the force applicator such that a resistance across two terminals of the potentiometer depends on the force being applied by the force applicator. The potentiometer is operably connected to supply a force signal to the data storage device such that the data storage device stores data corresponding to force applied by the force applicator. The potentiometer is a slide potentiometer having a slide member that moves dependent on the force applied by the force applicator. The force applicator is a first spring and the first spring is linked to the slide member such that the slide member moves dependent on the spring position. A second spring also applies the extra-oral, corrective forces. The first spring is biased in compression for applying the extra-oral, corrective forces.
A switch is operably connected between the data storage device and the potentiometer. The switch has a state (i.e., open or closed) dependent on whether the appliance is being worn by a patient. The state of the switch allows the data storage device to record patient compliance data indicating whether a patient is wearing the appliance.
The switch is in a closed state when the appliance is being worn by a patient and the switch is in an open state when the appliance is not being worn by a patient.
The switch is a bending switch that senses whether the appliance is on a patient by sensing whether it is bent.
The present invention may alternately be described as a removable orthodontic appliance including at least one force applicator operable to exert extra-oral, corrective forces on teeth; a data storage device operably connected to store data corresponding to force applied by the force applicator. A force measurer is operably connected to the force applicator. The force measurer is operably connected to supply a force signal to the data storage device such that the data storage device stores data corresponding to force applied by the force applicator. A switch is operably connected between the data storage device and the force measurer. The switch has a state dependent on whether the appliance is being worn by a patient. The state of the switch allows the data storage device to record patient compliance data indicating whether a patient is wearing the appliance. The switch is in a closed state when the appliance is being worn by a patient and the switch is in an open state when the appliance is not being worn by a patient. The switch is a bending switch that senses whether the appliance is on a patient by sensing whether it is bent. The force applicator is a first spring and the first spring is linked to move part of the force measurer. A second spring applies the extra-oral, corrective forces. The force measurer is a slide potentiometer having a slide and the slide is the part linked to the first spring. A resistance across two terminals of the potentiometer depends on the force being applied by the first spring. The potentiometer is operably connected to supply a force signal to the data storage device such that the data storage device stores data corresponding to force applied by the first spring. The slide is linked to move with the force applicator.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention will be more readily understood when the following detailed description is considered in conjunction with the accompanying drawings wherein like characters represent like parts throughout the several views and in which:
FIG. 1 is a simplified top view of the present invention;
FIG. 2 is a simplified schematic of the present invention;
FIG. 3 is a top view, with portions broken away, of a spring housing and related parts;
FIG. 4 is a side view of a spring housing, slide potentiometer and related parts;
FIG. 5 is a side view of a spring housing, with parts in cross-section and related parts; and
FIG. 6 is a top view of parts of a slide potentiometer, with portions broken away.
DETAILED DESCRIPTION OF THE INVENTION
The orthodontic appliance 10 according to the present invention is shown in FIG. 1. A data storage device 12, which may for example be an Onset Computer Corporation (Pocasset, Mass.) data logger device sold under the StowAway trademark, is used to record the force that is applied by the appliance to the patient's teeth. The device 12 can interface with a computer (not shown) in known fashion to transfer stored data to the computer for viewing and printing.
The appliance 10 has plastic straps 14 at each end, each plastic strap having holes 16 spaced along its length. The holes 16 allow attachment of an arch wire 18 (schematically illustrated only) such that the proper force will be applied to the patient's teeth (not shown). The plastic straps 14 are movably connected via spring housings 20 and 22 to a band 24 made of nylon or other fabric. A fabric pad 26 is connected to the neckband 24 to pad or cushion the band 24 and data storage device 12 from the back of a patient's neck.
The appliance 10 is used by having the holes 16 attached to an arch wire 18 such that springs (not visible in FIG. 1) within spring housings 20 and 22 apply corrective force to the patient's teeth (not shown). The straps 16 extend from the back of a patient's neck towards the patient's mouth on opposite sides of the patient's face. Band 24 serves as a neckband at the back of a patient's neck.
Continuing to view FIG. 1, but also considering the electrical schematic of FIG. 2, the device 12 has an internal battery (not shown) and four terminals 28B, 28R, 28G and 28Y. In the preferred embodiment, the four terminals may be respectively connected to black, red, green and yellow wires. Terminal 28B is the ground, terminal 28R is a battery output from device 12 which is not connected in the present design, terminal 28G is a battery supply that powers the potentiometer, and terminal 28Y is the "input sample" line that reads the voltage output from the potentiometer into device 12. The device 12 stores a digital representation of the difference between the voltage at "input sample" terminal 28Y and ground terminal 28B. This difference is stored at regular intervals such as once per minute.
Terminal 28G is connected to the terminal 28Y via 100 K resistor 30. The side of resistor 30 that is not connected to terminal 28G is also connected to terminal 32 of a slide potentiometer 34. Terminal 36 of potentiometer is connected to terminal 28B via a bending switch 38.
The details of potentiometer 34 will be discussed below with reference to FIGS. 3 and 4. Briefly, a slide 40 varies the resistance between terminals 32 and 36 depending on the position of slide 40. In turn, slide 40 moves as a function of the corrective force that the appliance 10 is applying to the patient's teeth. Accordingly, the voltage sensed across terminals 28B and 28Y depends on the position of slide 40 and the force applied by the appliance 10.
Turning now to FIGS. 3, 4 and 5, the construction of spring housing 22 and potentiometer 34 will be discussed in detail. Spring housing 22 holds a tongue 44 of strap 14 and a coil spring 42 around the tongue 44. The spring 42 biases the strap 14 in the leftward direction in FIGS. 3 and 4 as the top and bottom of the right side of spring 42 is trapped by upper and lower pieces 22U and 22L (FIG. 5 only) of housing 22, thus trapping the left end of strap 14 in FIG. 3.
A pin 46 (FIG. 3 only) extends up from the trapped end of strap 14 through a channel 48 (see phantom lines in FIG. 1 only). The pin is attached to slide 40 such that slide 40 moves along member 50 (movement is left and right in FIG. 4) offset from housing 22 by mount offsets 52.
Note that spring housing 20 (FIG. 1 only) is constructed in the same fashion as housing 22 with the same components therein except that pin 46 and channel 48 are not needed as the slide potentiometer 34 is used at one of the two straps 14 only.
As shown in FIG. 6, one side of member 50 has two patches of resistive coating 54 and 56 respectively connected to terminals 32 and 36. The slide 40, portions of which are broken away in FIG. 6, has a connecting strip 58. The connecting strip 58 connects terminals 32 and 36 via a variable portion of coating patches 54 and 56. Therefore, the resistance between terminals 32 and 36 depends on the position of strip 58. As strip 58 is part of slide 40, the resistance varies with the movement of slide 40 and, in turn, the force applied by spring 42.
Advantageously, the bending switch 38, which may be a flex action ribbon switch 180-S as made by Tapeswitch Corporation (Farmingdale, N.Y.), is closed only when the switch is bent. As the switch 38 is in the band 24 (or between band 24 and pad 26), the switch 38 is closed when the patient is wearing the appliance 10. Conversely, when the patient is not wearing the appliance 10, the switch 38 is open.
This switch 38 allows the device 12 to differentiate between two situations. If no force is being applied because the patient is not wearing the appliance, the switch 38 is open. This records a first baseline value in device 12. When the appliance 10 is being worn, but the appliance 10 is not applying force to the patient's teeth, the switch 38 is closed. This records a second baseline such that, when force is applied by the headgear appliance 10, the force values are recorded upward from the second baseline. The use of two baselines allows all data to be recorded on a single channel recorder. The orthodontist can readily evaluate the force applied to the patient's teeth, the effect of that force, the time over which the force was applied and the patient compliance (i.e., how much the patient wore the headgear).
Although specific constructions have been presented herein, it is to be understood that these are for illustrative purposes only. Various modifications and adaptations will be apparent to those of skill in the art. For example, the potentiometer could be replaced with a magnetic (Hall effect device) or capacitance motion detector, which would be non-contact and not add frictional resistance to the movement of the strap 14. In view of possible modifications, it will be appreciated that the scope of the present invention should be determined by reference to the claims appended hereto. | A removable orthodontic appliance includes a first force applicator spring and a data storage device that stores data corresponding to the force being applied by the spring. A potentiometer serves as a force measurer to indicate the magnitude of the extra-oral corrective forces applied to the teeth of a patient. A bending switch is operable connected between the potentiometer and the data storage device. The bending switch indicates whether the appliance is on a patient by sensing whether it is bent. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The invention relates generally to mounting frames for telecom units and more particularly to a new, compact and versatile mounting frame for telecom units.
[0006] 2. Description of the Related Art
[0007] The wireless cell site equipment is changing from a few large equipment cabinets to many small cabinets and miscellaneous equipment which includes RRU (Remote Radio Unit), OBIF (Optical Basestation Interface), or PBC-02 (Power and Battery Cabinet-02). Furthermore, there are space limitations in the field of so called leased area and they restrain future growth.
[0008] There are currently available on the market frames that may be used to mount telecom units or equipment such as RRU, OBIF or PBC-02. Examples of such frames are shown in FIGS. 1 a - c. The frame in FIG. 1 a consists of two Facilities Interface Frame (FIF) racks with unistruts (i.e., long connecting brackets), which provide a horizontal plane to mount telecom equipment or units. This frame also allows equipment to be installed on the reverse side as in a back to back arrangement.
[0009] FIG. 1 - b depicts an H-Frame consisting of two vertical pipes with unistruts, which provide a horizontal plane to mount telecom equipment. This design also allows equipment to be installed on the reverse side, as in a back to back configuration. It is also possible to utilize only the unistruts and mount the RRU, OBIF, or PBC-02 directly to the wall without any vertical supports.
[0010] FIG. 1 - c shows another existing frame, a pipe mount design, consisting of an RRU, OBIF, or the like, mounted to a vertical pipe, via mounting brackets, creating a vertical plane to mount equipment. This design also allows equipment to be installed on the reverse side, as in a back to back scenario.
[0011] The problem with using any of the existing frame designs is that they are not conducive to equipment consolidation, and thus, space, which is often very expensive, is wasted. The current designs require either a high vertical space for mounting on a pole, or a large horizontal space such as when using the H-Frame design, the two FIF rack design, or the wall mounted design. In the wireless industry, when building cell sites, the carriers are required to secure leased space through a lease agreement. That leased space is what drives the need for equipment consolidation, because the space is often very small and/or very expensive. The more consolidation, the more room for growth, and this is what all the carries seek out. Thus, there is a need for a new, compact and versatile mounting frame, which allows for the telecom equipment to be consolidated into more compact and versatile, yet functional configurations that make highly efficient use of the space available to telecom companies.
[0012] The problems and the associated solutions presented in this section could be or could have been pursued, but they are not necessarily approaches that have been previously conceived or pursued. Therefore, unless otherwise indicated, it should not be assumed that any of the approaches presented in this section qualify as prior art merely by virtue of their presence in this section of the application.
BRIEF SUMMARY OF THE INVENTION
[0013] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.
[0014] In one exemplary embodiment, the new adaptable mounting frame is a four-sided frame which has one or more doors, and which is configured to permit compact and versatile mounting of telecom equipment. Thus, an advantage is that it condenses the footprint of the telecom equipment, which saves a considerable amount of economic resources. Another advantage is that this is a versatile design because, among other things, it can be mounted in the middle of the room, against a wall, indoor, outdoor, and so on, and because it can also be expanded in width, depth, and/or height. Thus, this is a versatile and compact mounting frame that solves the known problems with the prior art described above.
[0015] Again, the wireless cell site equipment is changing from a few large equipment cabinets to many small cabinets and miscellaneous equipment which includes RRU, OBIF, and PBC-02. The disclosed frame will be able to reduce the foot print of the new wireless equipment by arranging the equipment in a way which utilizes all horizontal and vertical space.
[0016] In addition, again, the space restraints in the field of so called leased area limit future growth. The disclosed frame can be built in various shapes and sizes as described below. Thus, by using the new adaptable frame, wasted or dead space is eliminated, any available space is utilized and equipment count is maximized. By fully utilizing the leased space the wireless carriers can save money by not having to expand leased area to accommodate new wireless equipment.
[0017] The above embodiment(s) and advantages, as well as other embodiments and advantages, will become apparent from the ensuing description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For exemplification purposes, and not for limitation purposes, embodiments of the invention are illustrated in the figures of the accompanying drawings, in which:
[0019] FIG. 1 a illustrates the perspective view of an existing frame design for mounting telecom units, using two Facilities Interface Frame (FIF) racks and unistruts.
[0020] FIG. 1 b illustrates the perspective view of an existing H-frame for mounting telecom units, using vertical pipes and unistruts.
[0021] FIG. 1 c illustrates the perspective view of an existing system for mounting telecom units, using vertical pipes and mounting brackets.
[0022] FIG. 2 illustrates the elevation view of the new adaptable mounting frame for telecom units, according to one embodiment.
[0023] FIG. 3 illustrates the plan view of the new adaptable mounting frame from FIG. 2 .
[0024] FIG. 4 illustrates the perspective view of a one-door version of the new adaptable mounting frame, with the door in close position, according to another embodiment.
[0025] FIG. 5 illustrates the perspective view of the one-door version of the new adaptable mounting frame from FIG. 4 , with the door in open position.
[0026] FIG. 6 illustrates the perspective view of a two-door version of the new adaptable mounting frame, with the doors in open position, according to another embodiment.
[0027] FIG. 7 illustrates the perspective view of a three-door version of the new adaptable mounting frame, with the doors in open position, according to another embodiment.
[0028] FIG. 8 illustrates the perspective view of a four-door version of the new adaptable mounting frame, with the doors in open position, according to another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] What follows is a detailed description of the preferred embodiments of the invention in which the invention may be practiced. Reference will be made to the attached drawings, and the information included in the drawings is part of this detailed description. The specific preferred embodiments of the invention, which will be described herein, are presented for exemplification purposes, and not for limitation purposes. It should be understood that structural and/or logical modifications could be made by someone of ordinary skills in the art without departing from the scope of the invention. Therefore, the scope of the invention is defined by the accompanying claims and their equivalents.
[0030] Referring now to FIGS. 2 , 3 and 4 , it is shown that the new adaptable mounting frame 400 for telecom units or equipment may be have a shape similar to that of a rectangular prism, which may be made by building a rectangular prism-like skeleton 201 , 301 , 401 , having four vertical members coupled or associated with eight horizontal members (four at the bottom and four at the top), and by removably or irremovably associating with each of the lateral faces (“lateral sides,” “sides”) of the skeleton, a panel 408 . The irremovable association, coupling or attachment may be accomplished by any standard technique known in the art such as by welding. The removable attachment may also be achieved by any standard and known techniques in the art, such as by using screws to secure the panel 408 to skeleton 401 .
[0031] As shown in FIG. 4 , the panel 408 has an open (i.e., skeleton-like, frame-like, as opposed to a panel of a cabinet) appearance itself (“open panel”), and it may be made of four exterior members, two vertical and two horizontal, and four interior and horizontal members 408 - a, and nothing in between them. As shown, two of the interior members are grouped at the bottom and two of the interior members are grouped at the top of the panel 408 . Each group of two is used for mounting telecom units or equipment 405 ( 205 and 305 in FIG. 2 and FIG. 3 , respectively) on each side of the panel 408 . Thus, each panel may accommodate four telecom units (two on each side), which means that the adaptable mounting frame 400 may accommodate a total of sixteen units. The telecom equipment or units 405 may be RRU (Remote Radio Unit), OBIF (Optical Basestation Interface), PBC-02 (Power and Battery Cabinet-02), and/or other similar equipment or units.
[0032] As shown in FIGS. 2 , 3 and 4 , the panel 408 may be attached to the skeleton 201 , 301 , 401 by using two or more known hinge mechanisms 202 , 302 , 402 and one or more locking mechanisms 204 , 304 (not shown in FIG. 4 ). It should be apparent that in this case, the panel becomes a door 203 , 403 , which may be opened (see 303 - a and 303 - b in FIG. 3 ) to access the inside of the adaptable mounting frame 400 when needed, for purposes such as mounting or demounting the telecom units 205 , 305 , 405 inside the frame 400 and/or on the other side of the door/panel. It should also be apparent that at least one door (or, alternatively, one removable panel) is needed to conveniently access the inside of the frame 400 . However, one of ordinary skills in the art would recognize that two (see FIG. 6 ), three (see FIG. 7 ) or four doors (see FIGS. 3 and 8 ) may be used, without departing from the scope and essence of the invention. One factor that has to be considered when deciding with how many doors to equip the frame 400 is the door swing clearance needed, as shown in FIG. 3 ( 303 - a, 303 - b ).
[0033] It should be understood that, alternatively, the panel 408 as well as the door 403 may be replaced, for the purpose of saving material and/or manufacturing costs for example, by two (one at the bottom and one at the top) smaller panels or doors, each comprising substantially only two (the bottom two or the top two, respectively) interior members 408 - a (with some vertical elements used at each end to connect the two respective interior members). Then, each of the smaller panel (one at the top and one at the bottom on each side of the frame 400 ) may be secured to the skeleton 401 by, for example, welding, using of screws, or by using a hinge and a locking mechanism as explained above.
[0034] It should also be apparent that each side of the frame 400 may have a combination of door and panel such as a panel on the bottom half of the side and a door on the top half of the same side.
[0035] In addition, the panel 408 may be also reduced to simply its interior/horizontal members, which may then be coupled directly with the skeleton 401 .
[0036] It should be noted that, as shown in FIG. 3 , utility cables 306 , such as but not limited to coaxial cable, fiber optics and the like, may be conveniently secured or fastened to the frame. Seismic hooks may also be added to the frame for securing cables in indoor scenarios.
[0037] It should also be understood that other modifications made be made without departing from the scope and essence of the invention. For example, instead of having a frame 400 that may accommodate, as shown, two levels of equipment units (eight units on the bottom level and eight units at the top level) the frame may be reduced in half (one level (i.e., eight units) only) or it may built such that it has three levels (twenty four units total) or even more levels.
[0038] In addition, although the emphasis herein was on a rectangular prism-like shape, the disclosed adaptable mounting frame may work equally well, as described, in a triangular prism-like configuration, when the frame would have three lateral faces (“sides”) instead of four as described above. Preferably, a triangular prism-like frame would have all three sides equal in width for an easier and more space efficient arrangement of multiple frames, on, for example, the floor of a building.
[0039] Furthermore, this new and adaptable mounting frame may have other shapes, such as hexagonal, octagonal, and so on, prism-like shapes, in order to, for example, accommodate more equipment or to fit better in the space allotted. Also, the frame can have various sizes in regards to its width, depth, and height depending on, for example, the size of the equipment to be mounted, the space requirement for leased space, building codes, or the field conditions.
[0040] The frame's 400 versatile design allows it to be used in interior or exterior spaces and, if needed, in a stackable arrangement to fill the vertical space available inside of a building or outside (e.g., on top of a building). The frame may be anchored to the ground, the roof of a building and so on, with optional mounting depending on the local building codes. Furthermore, the frame can have various sizes in regards to width, depth, and height depending on space requirement for lease space or field condition.
[0041] The frame may be made of materials such as steel, aluminum, fiber reinforced plastic (FRP), or other composite materials. The frame can be painted or finished for durability and/or camouflage to the surrounding area.
[0042] The open concept of the disclosed frame (no panels on top and bottom of the frame and nothing in between the interior members 408 - a ) makes the frame advantageous in terms of decreased weight, lower manufacturing costs and better cooling of equipment. Furthermore, it permits the mounting of multiple equipment units and to access them with ease rather than trying to pull everything out of the frame to access them. It also allow for less wind loading (when running structural calculations) since this is not a solid design like standard cabinets are.
[0043] It may be advantageous to set forth definitions of certain words and phrases used in this patent document. The term “couple” and its derivatives refer to any direct or indirect communication between two or more elements, whether or not those elements are in physical contact with one another. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.
[0044] Although specific embodiments have been illustrated and described herein for the purpose of disclosing the preferred embodiments, someone of ordinary skills in the art will easily detect alternate embodiments and/or equivalent variations, which may be capable of achieving the same results, and which may be substituted for the specific embodiments illustrated and described herein without departing from the scope of the invention. Therefore, the scope of this application is intended to cover alternate embodiments and/or equivalent variations of the specific embodiments illustrated and/or described herein. Hence, the scope of the invention is defined by the accompanying claims and their equivalents. Furthermore, each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the invention. | A prism-like frame for mounting telecom equipment made of a prism-like skeleton, which in turn is made of at least three vertical members coupled with at least six horizontal members, and at least one open panel connected to at least one lateral side of the skeleton, wherein the panel includes at least two horizontal members arranged apart from each other and away from the bottom and top of the skeleton. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from continuation-in-part patent application Ser. No. 09/374,050 filed Aug. 13, 1999, now U.S. Pat. No. 6,185,514 granted Feb. 6, 2001, which is a continuation-in-part of patent application Ser. No. 08/987,908 filed Dec. 9, 1997, now U.S. Pat. No. 5,963,914 granted Oct. 5, 1999, which is a continuation-in-part of patent application Ser. No. 08/732,675 filed Oct. 15, 1996, now U.S. Pat. No. 5,696,702 granted Dec. 9, 1997, which is a continuation-in-part of now-abandoned U.S. patent application Ser. No. 08/423,029, filed on Apr. 17, 1995 now abandoned, and all of which are incorporated by reference herein in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to systems for recording time expended in performing tasks and, more particularly, to systems for automatically recording time and work performed on a computer by monitoring file activity and by monitoring various input devices.
2. Description of the Background Art
Telecommuting refers to work being done at locations other than a central location. Telecommuters are typically knowledge workers who work primarily on tasks which require mental or intellectual activity, rather than on tasks which require physical or capital intensive work at a central location. Many Telecommuters use personal computers at their remote work site. One of the biggest obstacles to implementation of telecommuting is that managers would not be able to tell if their telecommuting employees were actually working. Another obstacle is the problem of how to measure the productivity of telecommuting employees. A manager needs to trust that a telecommuting employee is working and trust is developed through quality communications between the central site and the remotely located telecommuting worker.
Professional knowledge workers, such as computer programmers, bill their time for work done on their computers. The problem of how to monitor their time and activities on their computer, as well as how to automatically calculate the cost of these activities for accounting purposes, needs to be solved. Many invoicing systems rely on the manual inputting of the billable time and a technique is required to determine the accuracy of that billed time. In the custom software programming business, specifications often change so that more time is expended than is originally projected and a customer needs to receive accurate documentation for additional time to be billed.
A Directive issued by President Clinton on Jul. 11, 1994 on family-friendly work arrangements addressed the subject of expanding family-friendly work arrangements in the executive branch of the U. S. Government. The head of each executive department or agency was directed to establish a program to encourage and support the expansion of flexible family-friendly work arrangements, including: job sharing; career part-time employment; alternative work schedules; telecommuting and satellite work locations. All necessary steps were to be taken to support and encourage the expanded implementation of flexible work arrangements to achieve the goals of the directive.
Telecommuting would have a significant impact on reduction of air pollution. AT&T has estimated that an average employee spends 70 minutes a day commuting and generates 43 pounds of pollution a day. If two million commuters, which is less than 3% of the United States work force, telecommuted, 43,000 tons of pollution would be eliminated every day. The California's Southern Coast Air Quality Management District estimated the annual pollution from cars in 1991 to be 2,064,000 tons of pollutants.
Telecommuting provides a number of benefits. Productivity increase of 10%-20% can be expected. Turnover rates and related new employee recruitment and training costs are reduced. Management by objective rather than management by process is fostered. Specialists for a particular task can be recruited, regardless of geographic location. Organizations can be flexibly organized with faster response times and improved employee morale. Telecommuters can provide greater participation by users in their local activities. A cleaner environment and an increased ability to meet state and federal clean air and employee commuting reduction programs can be provided. The consumption of energy and dependence on fossil fuels is decreased.
Several important business economic concerns are all positively affected by telecommuting, including: maintaining or increasing productivity; decreasing office space needs; attracting or retaining critical skills among the staff; and compliance with air quality or other environmental regulations.
U. S. Pat. No. 5,305,238 dated Apr. 19, 1994, granted to Starr et al. for “Data Input Monitor and Indicator For Managing Work Pace and Rest Periods” discloses a data input monitor for use with a computer keyboard, which measures the amount of data entered into a computer and establishes rest periods based on the measured data input. This patent counts keystrokes but does not provide an indication of what work is accomplished or what projects are being worked on.
U.S. Pat. No.: 4,819,162 dated Apr. 4, 1989, granted to Webb et al. for “Time Clock System Including Scheduling Payroll and Productivity Analysis Capability” discloses a computerized time clock system, which includes a personal computer via which employee, job, and schedule records may be assembled and maintained. This system records only time-in and time-out transactions and does not provide for user-defined data collection and analysis of time expended and work accomplished.
Thus, a need exists for a technique for selectively and automatically measuring the actual amount of work done on various projects on a computer by an operator, such as a telecommuter, either at a local site or at a site on a network where the user has a number of input devices.
BRIEF SUMMARY OF THE INVENTION
It is an object of a time tracking system provided according to the invention to produce automatic documentation and unalterable proof of work done on a computer. This will allow managers to feel more comfortable with having their computer-oriented employees telecommute, resulting in economic benefits to the employer, employee, and ecological benefits from reduced vehicle usage and car emissions due to commuting. Self-employed professionals who use a computer to generate income can use this product to document their work and automatically generate invoices that accurately documents the time and work done by the computer professional.
The time tracking system according to the invention has a data analyzer which provides for the exclusion of time where there is no activity on the computer. By accurately measuring the time and work on a computer, productivity can be measured and estimates for future projects can be more accurately forecasted with reduced financial risk. The time tracking system according to the invention provides the ability to track only certain user selected files or directories.
The time tracking system provided according to the invention provides for automatic documenting of time and work performed on a computer. In the past, the tracking of worked time has been done by manual input and not on stand alone personal computers. Anyone working with a personal computer or a computer network can have an automatic, accurate, and reliable means of documenting time and work done with a personal computer. The invention permits selection of the files and directories to be monitored. Multiple customers or employers can be accommodated and all operating system calls can be stored.
The time tracking system according to the invention provides an automatic way of collecting information about computer work, categorizing it by user-definable rules, and in essence, providing proof of exactly how long someone has been working on a specified task. This provides a documentation tool beneficial to both management and workers.
The time tracking system according to the invention provides a technique for selectively and automatically measuring the actual amount of work done on each of various projects on a computer by an operator such as a telecommuter.
The data collected by the system can be encrypted to maintain the integrity of the data. Because the data is encrypted, information about reported time and work performed on the computer is accurate and cannot be altered.
The system provided according to the invention automates the documenting of time and work performed on a computer. In the past, the tracking of worked time has been done by manual input and not on stand-alone personal computers. The purpose of this invention is to measure the amount of work done on a computer. The advantage is the amount of time and work performed out of sight can be accurately and automatically documented and encrypted to prevent manipulation of recorded data. Anyone working with a personal computer can have an automatic, accurate, and reliable means of documenting their time and work done with a personal computer. For those that work with personal computers, there is now. a way of automatically documenting work performed. The system is able to select what file and directories to monitor, based on user selection. The system is also able to work with multiple customers or employers to automatically store all operating system calls.
In accordance with this and other objects of the invention, a technique is provided for measuring the amount of work done on a computer. The invention is a method and system for automatically collecting information about time and work performed on a computer and includes the following elements: data collector means for monitoring certain portions of a user's computer activity; data collector means for logging into a log file those certain portions of a user's computer activity; data analyzer means for determining, by means of user-defined rules, which portions of those certain portions of a user's computer activity constitutes work and how this work should be categorized by project and task with project; and external interface means for building the rules defining work. Work can be organized by customer, department, or any other sets and subsets.
The data collector means for monitoring certain portions of a user's computer activity includes a resident module or an operating system extension such as, for example, a TSR (terminate-and-stay-resident) module which extends the file system of the computer so that detailed records are kept of file activities. The data collector means for logging those certain portions of a user's computer activity includes an application which extends the user interface of the computer so that detailed records of user activities on external input devices, such as, for example, keyboard activity and mouse activity, are kept as a user performs work. The data collector means for logging those certain portions of a user's computer activity includes means for producing a log file which contains a chronological summary of the activities of a user. The data collector means for logging those certain portions of a user's computer activity includes means for producing the log file which contains non-automatically collected data, such as the user's comments on their work.
The data collector means for monitoring certain portions of a user's computer activity includes means for routing information about file activity to the data collection means and includes means for tabulating and writing such information to a user's disk periodically.
The system includes means for routing information about activity of various external input devices using a hardware abstraction layer which translates external activity to keyboard activity and mouse activity to the data collection means through means for filtering such activity. Using the hardware abstraction layer, the external input devices are not limited and includes voice recognition, telephone devices, remote sensors, and other known external user input devices. A filter takes information from one program, examines it, possibly changes the information, and then passes the (modified) information along to another program.
The data analyzer means includes a database and the log file captured by the data collection means. The database contains a description of which files, directories, programs, etc. on the hard disk define a task, where a task is a basic unit of work, where one or more tasks are collected in a group known as a project, and where a project defines information about the owner of the task(s), and also serves as an accumulator for all work performed.
The log file includes a series of chronologically ordered events including items selected from the group consisting of file activity such as opens, keystrokes, mouse clicks, user notes, etc., and wherein the data analyzer means include means for reading this data and sorting these activities depending upon the task descriptions.
Certain activities in the log file are categorized as belonging to a specific task. For certain tasks, a user can define certain time periods. When that certain time period has elapsed between activity, means are provided for totaling the time as a work period.
The data analyzer means includes means for updating the database with total information. The data analyzer means includes means for updating various internal data files. The data analyzer means includes means for certification of the collected data including cross-checking to detect tampering. The data analyzer means includes means for copying the log file and for creating a new empty log for further data collection.
The external interface means for building the rules defining work includes means for manually or automatically building the rules defining work. The external interface means for building the rules defining work includes means for exporting work-completed information to other, third-party, programs such as project managers, spreadsheets, etc. The external interface means for building the rules defining work includes means preparing printed reports, financial invoices, and summary information from the categorized work results. The external interface means includes a database and one or more data files, wherein the external interface means includes means for writing from the database to export data to other programs including databases, project managers, word processors, etc., and wherein the external interface means includes means for writing to the database to import data from other programs.
A method for automatically collecting information about time and work performed on a computer includes the steps of. differentiating between multiple types of external user input devices using a hardware abstraction layer of software between the external devices and a monitoring system; monitoring certain portions of a user's computer activity; logging into a log file those certain portions of a user's computer activity; determining, by means of user-defined rules, which portions of those certain portions of a user's computer activity constitutes work and how this work should be categorized by various sets and subsets, such as, for example, projects and tasks; and building the rules defining work.
The step of monitoring certain portions of a user's computer activity includes monitoring with a resident module or an operating system extension such as, for example, a TSR (terminate-and-stay-resident) module which extends the file method of the computer so that detailed records are kept of file activities including activities such as open, close, read, write, rename, etc. The step of logging those certain portions of a user's computer activity includes extending the computer's user interface so that detailed records of activity on external input devices, such as keyboard activity, mouse activity, etc. are kept as the user performs work.
The step of logging those certain portions of a user's computer activity includes providing the log file which contains a chronological summary of the user's activities. The step of logging those certain portions of a user's computer activity includes producing the log file which contains non-automatically collected data such as the user's comments on their work.
The step of monitoring certain portions of a user's computer activity includes the step of routing information about file activity to the data collection means and the steps of tabulating and writing such information to a user's disk periodically.
A system and method according to the invention includes, but is not limited to the following internet/intranet application areas: remote access, telecommuting employment; on-site employees documenting their time for payroll; accurate billing for computer-based independent professionals and consultants such as attorneys, accountants and computer consultants; determination of activity costs; estimation of time and amount billable for future projects/work; measurement of cost/benefit of new software or hardware; project management linking; accounting systems linking; tracking of activities and time used on a distributed basis; nano-business costing; resource management tool; assistance in social accounting; manufacturing systems; remote education to document study/activity time; objective tool for screening new hires; means for distributors to get into duplication, publication services and have authors trust activity count; and video conferencing consultations with automatic billing calculations.
A system according to the invention provides information about continuous activity, as determined by each segment of user activity on a particular project, or task, exceeding an idle time interval. This is in contrast to manual stop/start clock systems which start and stop a clock such that work activity is being registered even if no actual work is being performed. The invention allows a work period to lapse when there is no activity for a time greater than the idle time limit interval.
Note that in the present invention the idle time interval can be created at the time that a report is prepared. Depending on the type of activity being monitored, the idle time interval can be set to one minute or to fifteen minutes. In this sense, the system can provide project, or task, measurements after the fact, that is, when the reports are generated from the log file information. A system according to the invention allows rules to be defined ex post facto and the log file data to be analyzed in a manner that was not contemplated when the activities in the log file were initially recorded.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention:
FIG. 1 is a block diagram of a system according to the invention for automatic documentation of work and time expended by a user of a computer, wherein the system includes a software module, called a hardware abstraction layer, for detecting activity of various user input devices.
FIG. 2 is a flow chart illustrating initialization of a data collection routine which is performed by a resident module or operating system extension such as a terminate-stay resident (TSR) module which performs data collection logging file activity or logging keyboard and mouse activity for a computer system.
FIG. 3 is a flow chart illustrating a TSR Interrupt 9 routine for DOS Keyboard interrupt operation.
FIG. 4 is a flow chart illustrating a special TSR Interrupt 60 routine for a Window Interface interrupt operation.
FIG. 5 is a flow chart illustrating a special TSR Interrupt 21 routine for a file system hooking interrupt operation.
FIG. 6 is a flow chart illustrating a routine for a timer based interrupt operation in the data collection routine.
FIGS. 7A, 7 B, and 7 C illustrate a flow chart illustrating a routine for purging an event buffer to a log file in the timer based interrupt operation of FIG. 6 .
FIG. 8 is a flow chart illustrating the main program for a Windows interface routine.
FIG. 9 is a flow chart illustrating a Windows interface for a DLL keyboard filter operation.
FIG. 10 is a flow chart illustrating a DLL Windows interface to a mouse filter operation.
FIG. 11 is a flow chart illustrating a DLL Windows interface to the TSR data collection routine for the keyboard filter operation of FIG. 9 and the mouse filter operation of FIG. 10 .
FIG. 12 is a flow chart illustrating an activity data analyzer routine for a system according to the invention.
FIG. 13 is a flow chart illustrating a routine for checking active times in the analyzer routine of FIG. 12 .
FIG. 14 is an illustrative timing diagram illustrating starting, restarting, and ending of an analyzer timer for a task, according to the invention.
FIGS. 15A and 15B are illustrative timing diagrams for two tasks illustrating operation of respective analyzer timers.
FIG. 16 is a flow chart illustrating initialization of a data collection routine which is performed by a resident module or operating system extension such as a terminate-stay resident (TSR) module which performs data collection logging file activity or logging keyboard and mouse activity for a computer system, which includes a DOS and a NOS.
FIG. 17 is a flow chart illustrating a call to an external provider.
FIG. 18 is a flow chart illustrating a routine for additional results to be stored for operation.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims.
FIG. 1 illustrates a data collection and analysis system 100 for automatic analysis and documentation of work and time expended by a user of a computer according to the invention. The system is called Dragnet. The Dragnet system operates with a computer such as a personal computer using, for example, a DOS operating system running DOS application programs or a DOS operating system with a Microsoft Windows graphical user interface for running Microsoft Windows applications. Other operating system platforms can be used, as desired.
The system 100 includes a main program that gives a user a database type of interface for building up project information and task information. The main program is, for example, a Visual Basic application that provides a database for keeping the data that the work analyzer needs and that provides a simple interface for selection of work analysis criteria and for printing of reports. An important part of the system 100 is a data collector that collects the data and a work analyzer that analyzes that data that interfaces to the main program.
The system 100 uses a software module which is a hardware abstraction layer 101 , which is located between the system 100 and external devices. The system 100 has a number of input paths 101 a , 101 b , 101 c for receiving input information from the hardware abstraction layer 101 . The system 100 also has an input/output path 101 d for receiving/sending information between the hardware abstraction layer 101 and the system 100 . The system 101 is designed to usually interface with a user keyboard 102 for both DOS and for Windows applications. For Windows applications, the system 100 also interfaces with a mouse 104 . A hard disk 106 is provided for storage of a user's applications as well as for storage of the various data files provided by the system according to the invention. the data collection part of the system works with either DOS or Windows applications, while the actual data analysis part of the system works only with Windows.
The hardware abstraction layer 101 allows a wide variety of storage devices and user input devices to operate with the system 100 . The hardware abstraction layer 101 translates the activities of storage devices, typically shown as 107 , so that they can use the storage path 101 d . The hardware abstraction layer 101 translates selected activities of external selection devices, typically shown as 108 , such as remote controls or devices connected by phone lines, so that they can use the DOS or Windows keyboard input paths 101 c , 101 b . The hardware abstraction layer 101 d translates pointer device activities of pointer devices, typically shown as 109 , such as a mouse or a drawing tablet, so that they can use the Windows mouse input path 101 a.
The hardware abstraction layer 101 is equivalent to the BIOS in a PC computer. The system 100 monitors keyboard and mouse functions. The addition of the hardware abstraction layer 101 provides the capability of monitoring, i.e., detecting, activities of multiple types of input devices, such as remote controls for TV set top boxes, drawing, tablets, touch-tone keyboards, etc. The hardware abstraction layer 101 allows these and other devices to be detected directly by the system 100 . This enhances the ability of the system 100 to categorize a number of additional activities, making the activities finer-grained and providing better accumulation of various different activities. Additionally, the hardware abstraction layer 101 as makes it possible to add capability to the system 100 by providing “in the field” additions to the hardware abstraction layer 101 by downloading information for new external devices to the ROM of the system 100 . The hardware abstraction layer 101 can be thought of as being similar to a plug-in module that allows one or more new activity detectors to be inserted without affecting the remainder of the system 100 , as described herein below. In this manner, detection of activity of a new input device is provided without replacing or modification of the system 100 , that is, without having to rewrite the core programs of the system 100 .
The system 100 includes two unique software modules. The first module is resident module 110 or operating system extension such as a terminate-stay-resident (TSR) Dragnet module 110 , which includes data collection and analysis functions, which are described herein below. While described in connection with a Windows or DOS environment, the resident module or operating system extension is intended to include implementations of the invention for systems other than IBM compatible systems. The second module is a Dragnet keyboard/mouse filter module 112 . The system 100 operates in conjunction with operation of a DOS application program 114 or a Windows application program 116 . A DOS file system 118 is used. For a Windows application program 116 , a Windows graphic user interface 120 is provided.
As part of the startup for the DOS operating system, the TSR program 110 is started. The TSR program 110 hooks itself up between the DOS file system 118 and either a DOS application 114 or a Windows application program 116 . A TSR (terminate-and-stay) resident program enables a program to embed itself into the computer's memory and to remain there while DOS continues to run other programs.
In the DOS mode of operation for a DOS application program, when the DOS application program makes a request to open a file or to run a program, the request first goes through the TSR program 110 before it goes to the DOS file system 118 . When a DOS application makes a request for an operation to be performed such as, for example, a request to open a file, close a file, read data, write data, or change directories, the TSR program 110 passes that request onto the DOS system and lets the DOS system process the request. Before going back to the DOS application to give the DOS application the results, if the operation was successful, then that information is recorded by the TSR program 110 . For example, if a file is tried to be open and the file does in fact open, that event is recorded. The information is recorded into a buffer memory. A separate asynchronous routine operates at one second intervals to take the buffer information into memory and to write that information out to a file on the hard disk. Because the TSR program 110 is hooked into the DOS system at a low memory address level, the TSR program cannot open files or do read/write operations with a file while data is being collected. Those other operations are done separately when the DOS system is not doing anything else.
In a similar manner, the TSR program 110 watches every key stroke that comes in from the keyboard 102 . A keystroke comes into the TSR program 110 application so that it is possible to detect that a user is pressing keys. The only information that is necessary to know is that keyboard activity is happening. It is not necessary to know what particular keys are being operated. The actual keys are not recorded. What is recorded is the fact that, during a one-second interval, a user typed something into the keyboard. The TSR program 110 is placed between the DOS application and the DOS file system to monitor the occurrence of key strokes and to send keystroke occurrence information out to the hard disk every second.
In the Windows mode of operation for a Windows application program, the Windows system installs its own Windows keyboard driver and its own mouse driver. As a result, the hook routine that is installed to catch keystrokes at the DOS level doesn't get called when Windows is running. The Windows keyboard driver and mouse driver replace other service routines with their own service routines.
In order to monitor key strokes in the Windows mode of operation, the keyboard/mouse filter 112 is used. In general, a filter takes information from one program, examines it, possibly changes the information, and then passes the (modified) information along to another program. The keyboard/mouse filter 112 watches each keystroke and mouse click that happens while Windows is running. Similar to DOS monitoring keystrokes, the keyboard/mouse filter 112 also keeps track of the fact that a keyboard or mouse activity is happening. The keyboard/mouse filter 112 under Windows also keeps track of which file is actually being used. For example, programs like Microsoft Word or Excel can have multiple documents open. It is necessary to know which files inside Microsoft Word are actually being manipulated. Using this keyboard/mouse filter 112 , each time that there is a keystroke or a mouse click, the system 100 actually looks at which window in the top window on the screen and records that information. Using Windows requires a two-step process because of the architecture of Windows. If a Macintosh platform is used, only one step is required.
In Windows, the user types his keys and the keystrokes first go into Windows and then Windows decides which applications should get those key strokes. For Windows, the invention catches the keystrokes half way between Windows graphic environment module 120 and the Windows application 116 . The Windows graphic environment module 120 looks to see which data file the Windows application is working with before passing the keystrokes onto the Windows application. The Windows graphic environment module 120 includes the Windows keyboard and mouse drivers, the Windowing system, and everything else that makes up Windows as the operating system. The Windows application 116 sits on top of the Windows operating system and puts data into a screen window in response to user operations, such as menu selections. Erg The Windows graphic environment module 120 functions to display screen windows and takes keystrokes and sends them to the Windows application 116 . It's actually up to the application to decide that when you type “A,” it should put a character on the screen. The invention catches the input keystroke information after the Windows graphic environment module 120 gets a character and decides which screen window the character goes to. The actual Windows application then gets the character. The Windows application 116 sends file activity information over to the TSR module 110 .
Windows applications do not replace the DOS file system when they are running. Windows is actually built on top of the DOS application. When a Windows application opens a file, it still goes through the TSR module 110 . When a Windows user types a key, the keystroke information first goes through the Windows graphic environment module 120 . The remaining operations with Windows are similar to the DOS operations. The keystrokes also still have to go through the TSR program to the DOS file system 118 . Under a DOS application, the information (both the keystrokes and the file information) come directly to the TSR module 110 . Under Windows, the file information goes to the TSR module 110 directly from the Windows application 116 , but the keyboard and mouse information to the TSR module 110 come from the Windows graphic environment module 120 , and not directly from the keyboard.
FIG. 2 is a flow chart illustrating initialization of the TSR module 110 , where the TSR module 110 performs data collection by logging file activity or by logging keyboard and mouse activity for a computer system.
Block 202 indicates initialization of a third party product called Coderunner which provides a very compact run-time library for the C programming language. The library subroutines from the compiler writers for a C program are used to open and close files and to print text on the screen, etc.
Block 204 indicates that parameters are loaded into a file from a parameter file 206 . The parameters basically indicate if there are any files or directories that are not to be tracked. For example, a user might not want to keep track of an activity in a temporary directory or every time someone wants to open a font on a Windows directory. To avoid collection of voluminous and meaningless activities, a user can exclude such activities.
Block 208 indicates that the old DOS interrupt vectors are saved. Block 210 indicates that new interrupt vectors are stored in low memory. When a DOS application program wants to invoke a DOS routine, the Intel processor has a software interrupt feature so when the DOS application wants to invoke the DOS routine, DOS loads up some registers and generates an INT 21 command, which goes down to low memory and finds the address where the DOS routine is located and then jumps off to the DOS routine. The contents of that low memory location are saved. Hooking the interrupt means replacing the address of where the function is with the interrupt routine address and then calling the function.
In FIG. 2, the initialization proceeds from top to bottom without stopping and without going to any of the interrupt vectors. When it says store new interrupt vectors, it just means you're storing the addresses of these flow charts discussed in connection with FIGS. 3 4 and 5 discussed herein below. FIG. 2 . only shows initialization of the system.
Block 212 initializes a time-based scheduler routine, which is part of the Coderunner library. The time-based scheduler routine calls however often you want. It is initialized and Block 214 indicates that it is set for a one-second interrupt.
FIG. 3 is a flow chart 300 illustrating a TSR Interrupt 9 routine for DOS Keyboard interrupt operation for keyboard activity. Block 302 indicates that, when the low-level keyboard driver has a character, it generates an Interrupt 9 which is intended to go to DOS to eventually transmit that key onto the application. So we get the interrupt from the keyboard driver and set a flag saying we see a keystroke and then we call the DOS sub-routines which were supposed to get it in the first place.
Block 304 test flags to determine whether the Dragnet system is ready and whether the Dragnet system is on in order to make sure that we don't start trying to collect data through the file system interrupt before we actually have all the buffers and other items ready. When the actual work is analyzed, no data is collected and the Dragnet is off. Dragnet is turned off so we are not trying to collect data about analyzing the work because that doesn't make any sense; there's nothing there to be collected. The ready flag says that everything is set up. If Dragnet's ready and on, the Block 308 determines whether a keystroke was stored since the last interrupt. If a keystroke was stored, the routine exits. Each keystroke is not stored because users can type a number of characters per second.
Block 310 indicates that, if a keystroke has not been recorded since the last interrupt, the keystroke record in a collection buffer is stored. There is an end memory collection buffer where, when different kinds of activity happen, we put data records in this collection buffer. Every second we get a different kind of interrupt that comes in and takes however many records are in the buffer and writes them out to the disk.
The interrupt routine for the keyboard of FIG. 3 only gets called when a user actually types a key. That's where it will go after we've done the boxes marked Store New Interrupt Vectors.
FIG. 4 is a flow chart 400 illustrating a special, arbitrarily-named TSR Interrupt 60 routine for a Windows Interface interrupt operation. This routine is unique to a system according to the invention and is not something that the DOS operating system already provides. The TSR Interrupt 60 routine provides a 110 mechanism so that the Dragnet keyboard/mouse filter module 112 can communicate with the TSR module 110 in order to put data into that same buffer that gets written out to the disk once every second. Blocks 402 and 404 indicate whether Dragnet is ready and on.
When the Window keyboard/mouse filter 122 wants to store some information, it puts a code value in the register and does an Interrupt 60 . The code values are 1, 2, or 3, which indicates three different operations: Code 1 asks the TSR where the buffer is; Code 2 tells the TSR to change the address of the pointer within the buffer; and Code 3 provides a Windows Busy mechanism to make sure that the DOS TSR operation and the Windows collection do not happen simultaneously.
Block 406 tests whether a Code 1 is present. If so, Block 408 shows that the address of the buffer pointer is returned. If not, Block 410 tests whether a Code 2 is present. If so, Block 412 updates the buffer pointer for the register. If not, Block 414 tests whether Code 3 is present. If so, Block 416 sets or clears the Windows busy Flag. This ensures that, while the buffer is being filled up, a protection mechanism is provided to make sure that, while a user is putting data in the mouse keyboard filter, the one-second interrupt handler isn't trying to write the buffer contents out to the disk. This routine is called once to ‘set the flag’ and then it is called again to flag when the user is done. In that way, if a one-second interrupt comes in when the system is in the middle of processing a mouse click from Windows, the system will wait for the next second.
FIG. 5 is a flow chart 500 illustrating a special TSR Interrupt 21 (INT 21 ) routine for a file system hooking interrupt operation. An interrupt 21 is a DOS function which controls how DOS applications open files, close files. Interrupt 21 is written in Assembler code and is a true interrupt handler. The Block 502 saves the values in the registers of the processor. The Blocks 504 , 506 determine whether Dragnet is ready and on.
If so, the Block 508 determines whether a TYPE is interesting. When you do an INT 21 you pass into a register one of about 60 different codes that says what you want to do. Do you want to open a file, close a file, rename a file, etc. Those are the codes or types. We don't monitor every single type; actually we monitor about 7 or 8 different types.
We look to see if a type is something that we want; mainly if is it something that has a file name associated with it. And if it is, then we save what kind of type it is and we save the string in Block 510 (normally the file name that was associated with it). Then we go call the old INT 21 in Block 512 because we have to go to DOS and actually have DOS do the work, try to open the file, for example. Then we come back and look at the processor's carry flag in Block 514 , which is one of the processor's internal registers. If it is set that means that is the way DOS indicates that there was an error. If there was an error, we back up this pointer in Block 516 where we save the record type and string because it didn't actually work.
In other words, a typical way with a DOS system is that you have this PATH statement that specifies where the files are and it goes down through the path and tries to open each file and each directory on the path until it finds it. It is not interesting to us if it had to go through 5 different directories before it found the file. We only care when it actually found it. So if you wrote an application that just simply tried over and over and over in a loop to open files that didn't exist, we wouldn't consider that work. You are not accomplishing anything; therefore, it is not recorded as work.
FIG. 6 is a flow chart illustrating a routine for a timer-based interrupt operation in the data collection routine. Block 602 asks if DOS is busy and if DOS is busy, then Block 604 causes another one second delay. We set up the timer to interrupt us in another second and then we leave. If DOS isn't busy, Block 608 indicates that the data that was collected by the TSR is written to a disk, which is the purge event buffer file.
Block 610 indicates that the pointers are checked for initialization. If not, Block 612 sets up pointers with the values of the current data segment registers in the Intel processor. The first time that this flow chart is executed it is necessary to initialize some things because one of the segment registers inside the Intel processor changes between initialization time and actual execution time of the sub-routine. That process is done once and in Block 614 flags are reset that say we have seen a keystroke. In Block 618 a flag is set that says the pointers are ready so that the next time we come through we will take that yes path out of Block 610 . Block 620 indicates that in a second later we go back to start.
FIGS. 7A, 7 B, and 7 C illustrate a flow chart 700 for purging an event the Windows Busy flag is tested. If Windows is not busy, Block 704 decrements the Windows Busy flag. If the Windows mouse filter is doing something, then Windows is busy and we have to wait until the next second. Windows is busy means that our portion of our system that runs on Windows is busy, not the Windows operating system. If we can, then we decrement this flag which tells buffer to a log file in the timer based interrupt operation of FIG. 6 . In Block 702 Windows that we're busy so it doesn't try to do anything while we're doing this. Block 706 test if anything is in the buffer. If not, Block 708 increments the Windows busy flag and we leave. If there is something in the buffer, Block 710 indicates that the Dragnet_On flag is set to 0, or turned off in order to prevent our INT 21 's from being recorded. As we are trying to write this data to the file, we are going to be issuing INT 21 's and we don't want our INT 21 's to be recorded. Block 712 indicates that we open the activity log file 714 on the hard disk 106 . The activity log file 714 is structured for convenience as one file for each month. The current date and time are determined and the appropriate monthly activity log file 714 is opened. The routine continues as indicated by the Purge 2 continuation symbol 716 to FIG. 7 B.
In FIG. 7B, Block 720 tests whether the activity log file 714 opened. If not the routine continues, as indicated by the Purge 3 continuation symbol 722 to FIG. 7 C. The file not being open means that some error is happening, but the system is not going to crash and the routine continues on. Block 724 indicates that we go to the end of the activity log file 714 because we are appending data to the end of the activity log file 714 .
Block 726 is the start of a loop which fetches and writes activity records to a data collector. Block 726 fetches a new activity by RecType and Data. RecType indicates the type of activity such as a file opening or closing, a keystroke, etc. Data is typically the name of the file or a path when a change directory operation happens.
The loop proceeds to Block 728 which tests whether a file name which consists, for example, of 8 tildes and 3 back quotes is open. The file name is not a normal file name. If an attempt has been made to open that file, Block 730 indicates that the parameter file 206 of FIG. 2 is to be re-read. This allows changes to be made and to be read from the parameter file without having to re-boot the computer. After the parameter file is re-read, the data not actually recorded to the disk. If Block 728 does not detect the file name which causes the parameter file to be re-read, Block 732 tests whether another special file name, which is called DRAGNET ˜OFF is active. This file is activated as a way of turning Dragnet off. Code for a subsequently described work analyzer code can try to turn the Dragnet system off. And if in fact that is the case, then the Dragnet system is turned off by means of Block 734 which sets a turnOff variable to a one state. If Block 728 or Block 732 indicate that neither one of the two special file names has been opened or attempted to be opened, then Block 736 indicates that the activity data is to be written to a Dynamic Data Collection (DDC), or Dragnet Data Collection. The DDC is the same as the activity log file 714 with a different name.
Block 738 tests whether more data is in the buffer. If so, the routine loops back to Block 726 to fetch more data. Data is collected for one second. In one second, the computer could have opened and closed a number of files, received three keystrokes, and done a number of other functions so there will be a number of different records in the buffer. The loop starting with Block 726 and ending with Block 738 keeps operating until the buffer is empty.
If Block 738 finds that the buffer is empty, the routine goes through the Purge 4 continuation symbol to Block 740 of FIG. 7C, which closes the activity file. Block 742 indicates that the buffer pointers are then reset and all of the data collected is lost.
With reference to FIG. 6, Block 608 is implemented in FIGS. 7A, 7 B, and 7 C to purge the event buffer once a second to the activity log file. Blocks 610 , 614 , 618 , and 620 check if the pointers are initialized, reset the flags, and wait for another one second. The TSR module gets interrupted every one second according to the routine of FIG. 6 . The TSR module is also asynchronously interrupted using the interrupt routine of FIGS. 3, 4 , and 5 for INT 9 , INT 21 , and the special INT 60 . These synchronous and asynchronous interrupt routines get information to the TSR module.
FIG. 8 is a flow chart illustrating the main Windows interface program 800 which implements the system of FIG. 1 . The Dragnet keyboard/mouse filter 112 has two parts. It has the main Windows interface program 800 and something called dynamic link library (DLL) programs which are methods of implementing programs under Windows. The main Windows interface program 800 initializes everything. The dynamic link library (DLL) programs actually gets called in a similar kind of way when each keystroke gets hit inside Windows.
The Dragnet keyboard/mouse filter 112 works as follows: When the system, or program, according to the invention is installed for Windows, an icon for this program is put into the Windows start-up folder. When Windows starts, it automatically runs the program. This is the Drag hook indicated as element 802 in FIG. 8 . This is similar to the TSR 110 of FIG. 1 for DOS, which is started when DOS is booted. The Windows interface of FIG. 8 is started when Windows is started.
Block 804 initializes the program. Block 806 installs the keyboard filter, Block 808 installs the mouse filter, and Block 810 displays a message. Block 812 indicates that the program then loops forever. The forever loop of Block 812 means that the program just sits there and loops forever because in the process of installing the keyboard and mouse filters the extra separate subroutine library called a DLL is loaded. If the program quits, the DLL would not. If the DLL would get removed from memory, the whole system would crash. The program is a Windows program with no screen window in which the user never sees it as a window on the screen.
FIG. 9 is a flow chart illustrating a dynamic link library (DLL) routine 900 for a Windows interface for a DLL keyboard filter operation. The DLL is a Dynamic Link Library which is a way of having sub-routine libraries that get loaded when they're needed and can be shared between different applications. A DLL also is a way inside Windows that allows certain things to be done because of certain Intel addressing conventions.
Every time a user presses a key, we get called before the application that's looking for the key gets called in the same way as a DOS interrupt but not as an interrupt. When the keyboard filter 900 is invoked at point 902 , Block 904 saves the title of the last window that was looked at. This is similar to what was done with the DOS version of the present invention. If a user types a hundred keys on the same screen window, a hundred messages are not written to the activity log file. An activity log file is written under Windows only every ten seconds. The conditions for writing something to the log file from a Windows application has to be a key in a new window, or it's been ten seconds since the last key.
Block 904 saves the last Window title, we get window text as a Windows call. Block 906 gets the title of the current window and Block 908 tests whether the current window contains a valid file name to determine activity by a user. If the file name is not valid, then Block 910 calls EnumChildWindow, which is a window call which sorts through a number of screen windows on top of each other window until it finds the screen window that has the file name that is actually being used. This is done because in Windows again, when you have a multiple document application, you can either have a frame window and smaller windows inside, or you can actually blow up the inside windows so that you still only see one document at a time but you still have multiple documents open. When you do that, it puts the name of the file in the outside window. The active file name is looked for in the outside window. If it is found, we are in the particular case where the inside windows are maximized. If the name is not found, then we have to go down and search down through the “children” windows until we find which particular window we are currently working with.
After the window is found with a valid file name in it, Block 912 determines if conditions are right. The conditions are: a key down, more than ten seconds since the last key, or a different window since the last interval. If all the conditions are true, Block 914 stores a string using the INT 60 routine, as described herein below. Block 918 calls the next hook which means that we call the next person in the chain here to effectively process the keystroke. In Windows there could be multiples of these keyboard filters and we can get called after some have been processed and before all of them have been processed so we come in and do our work and pass it on to the next guy which may be the application, or it may not be; we don't care.
FIG. 10 is a flow chart illustrating a DLL Windows interface to a mouse filter operation which works exactly like the keyboard filter. We get the mouse click, we go find the title of the current window in Block 1008 , and decide whether it has a file number in it or whether we have to go searching for it and then we look for the conditions and the conditions are similar. It has to be a mouse down and either more than ten seconds, or in a different window. And if it meets those conditions, then we write the information off to the TSR buffer saying something happened. And then we call the next animal in the food chain in Block 1016 to do whatever with this mouse click that needs to be done.
FIG. 11 is a flow chart illustrating a DLL Windows interface to the TSR data collection routine for the keyboard filter operation of FIG. 9 and the mouse filter operation of FIG. 10 . This is the way in which we use the interrupt 60 to communicate. Block 1102 is called by Block 914 of FIG. 9 . Block 1104 calls the TSR to tell it to do the Get/Set Windows Busy flag routine. Block 1106 looks to see if the TSR is present in memory. If it isn't present in memory, the program exits. If the TSR routine is not started, we don't want windows to crash simply because it's not there. So there is some error protection to make sure that Windows isn't crashing. If the TSR is present, then Block 1108 looks to see whether we got the Windows Busy flag. Block 1110 provides a one second delay because if we were in that routine that we went through before where we were doing the purge event buffer routine, then we can't get it so we have to wait for a second and try again. This provides a synchronization mechanism between these two parts of the program to make sure that both people aren't trying to write into the buffer at the same time. So assuming that when we finally get done with this, and we get the flag (the windows busy flag), then Block 1112 indicates that we go call the TSR to get the address of where does the next record go into memory buffer. Because we're running in Windows, Block 1114 converts that real memory address to a virtual memory address because that is what Windows applications are expecting, virtual memory addresses. Then just like in INT 21 , for example, Block 1116 indicates that we do a store RecType and String routine which means that we store whether it's a keystroke or a mouse click and we store whether it's a name of the file on top of that window. Block 1118 indicates a TSR Update which is a third call inside the TSR that says move the pointer in the buffer just past the end of the record just entered. This is done so that the next piece of information to go into the buffer will be stored at the proper place because what was done was to get the buffer point and put the data in and how much data was put in. Block 1120 indicates that the Windows Busy flag is cleared and that the TSR can use the buffer again.
FIG. 12 is a flow chart illustrating an activity data analyzer routine 1200 for a system according to the invention. Once we get everything loaded serially into the activity log file, analysis can be done either locally or remotely. With regard to time and this system, one way to think about this is to divide your work up into various tasks and for each task have a stop watch. But for this type of stop watch, unlike a regular stop watch, you have to keep pressing the button to keep it going and if you don't press the button after a while, it will stop. These are the active times used for this invention. All the stop watches are initialized to zero. Cumulative time file are used to store the amount of time already spent. These files are updated to cumulatively track work. Block 1202 initializes the times to zero. Block 1204 loads current cumulative times from a cumulative time file 1206 .
Block 1208 gets the next activity and determines which tasks belong to that particular activity.
Block 1210 determines the owner of a particular activity. This means that if you set up so that everything inside the Jones folder belongs to Jones and everything inside the Smith folder belongs to Smith, we go read something from the activity file that says I opened up the A.B file inside the Jones folder, then the owner logic will use that information which says that everything inside the Jones folder belongs to the Jones task to determine that the owner of that particular activity is Jones.
Block 1212 checks if a job or activity is not to be counted. Not every activity that the system might do belongs to a particular task. There are activities that don't belong anywhere, for example, when the operating system reads and writes its own file. The act of opening that font file does not necessarily belong to an activity because the act of opening the font file belongs to the operating system. In an operating system such as Windows, for example, the font file will get opened once for an application like Microsoft Word, even if multiple documents are using the font. The activity of opening the font in this particular example does not belong to a particular owner, it belongs to Word. In this case, for example, this result equals No_Job?.
If there is NoJob, Block 1214 checks the active time. The stop watches do not automatically shut off. The system has to periodically look to see if they have been running too long without any activity and shut them off if the result wasn't equal to NoJob. If the result was equal to a particular job, then Block 1216 accumulates the time for that particular job. This is analogous to actors who spin plates on top of sticks. If you get some activity for user Jones, the system gives the Jones stick a little spin to keep the plate going. But if there is no continuing activity on Jones, eventually the plate will fall off the stick. Each activity is looked at to see who it belongs to and if it belongs to a certain person, then we simply give their plate another spin.
For the concept of the determined owner, what the Visual Basic application does is to provide an interface with a database where a user specifies what the names of his tasks are, like Jones and Smith. Then, what is specified is how you determine whether an activity belongs to Jones or belongs to Smith. This is implemented using string matching based upon the file names. In other words, every activity inside the Jones directory on a certain disk drive belongs to Jones. Every activity that has the word “Smith” in it, belongs to Smith no matter where it is. A variety of different criteria can be specified, using OR logic. An activity is classified if it matches a criterion that belongs to that particular task. Particular things can be excluded. Temporary files, backup files, or other things not to be tracked can be excluded in this way. For example, tracking of certain kinds of program applications like Microsoft Word and Excel but not Solitaire can be done. Two owners can both get credited for the same activity. If Smith is a graphic design project, you might watch for use of Fractal Design Painter application and credit that use to Smith. Two tasks can share the same activity.
FIG. 13 . is a flow chart illustrating a routine 1300 for checking active times in Block 1214 in the analyzer routine of FIG. 12, which is the logic for keeping the “plates spinning”. Block 1302 starts a timing loop for each job. Block 1304 calculates the difference in time between activities. Block 1306 tests if the allowable idle time is exceeded to stop that stop watch. If not, the routine loops back to Block 1302 for another job. If the idle time is exceeded, Block 1308 accumulates the job time. If it's time to stop that stop watch, then we accumulate the total time in Block 1310 and go back to do the next job. If it's not time to stop the stop watch, we go on to the next task. All tasks are looked at to determine if there's any activity. If any files are updated, Block 1312 writes the data out to the file.
An event analyzer module reads the activity log file over a particular range of days. Another module called a reports module provides an external interface to the system according to the invention. Data can be imported from other programs and project manager. Exports can be made to database project managers, etc. to provide printed reports, invoices and summary information.
The event analyzer for the time tracking system is described in the following pseudo code to function as follows:
1. For each job or task, there are four times:
a. total time (all time since last reset/billing)
b. current time (all time since last job start)
c. active time (time of last event)
d. idle time (timeout for end of job)
Total and Current time are 0 relative (i.e. they represent total hours/minutes/seconds). Active time is real-time and is used to compare with event times to determine if a job has exceeded it's idle time limit.
2. Analyzer loop:
Load all total times from file
Zero all current times
again: get next event
determine which job this event belongs to . . .
If it is NO_JOB then it is a ‘system’ event
which we can use to check active times
so we CheckActiveTimes( )
otherwise if
(old event time!=0)
currentTime[job]+=this event time_old event time
set activeTime[job]=this event time
CheckActiveTimes( ) for all other jobs to determine if idle
goto again
3. CheckActiveTimes( )
for(i=1 to # of jobs)
if this event time_old event time [i]>idle [i]
job is idle
if old event time[i] !=0
currentTime[i]=old event time+idle [i]
total time[i]+=currentTime[i]
if any totals updated then
Write totalTime file
Write a record to the job worked file
Write a record to the cumulative job file for this job
FIG. 14 is an illustrative timing diagram illustrating starting, restarting, and ending of an analyzer timer for a task, according to the invention.
An explanation of how a work computation data analyzer is as follows: For each task we keep what in electronic terms is called a “re-triggerable one-shot” monostable timer. This means that the timer can be reset from its current position to the maximum position at any time. It only expires if nothing has retriggered before the timeout value. A waveform for such a timer is shown in FIG. 14 :
At time a, the timer is started.
At time b, the first timer expires.
At time c, the timer is started.
At time d, the timer is re-started.
At time e, the timer expires.
FIGS. 15A and 15B are illustrative timing diagrams for two tasks illustrating operation of respective analyzer timers.
If one imagines each “start” as the detection of activity for a certain task then each restart is another detection of activity for that same task. Only when the timer “expires” does the work analyzer decide that work has been performed. That is when the time between the last event for this task and the current event for this task is greater than the idle time.
In the work analyzer one of these “timers” is created for each task in the user's database. When an activity is seen, the activity starts and restarts the timer. At the end of the analyzed time all the timers are assumed to have expired. A waveform form is shown in FIGS. 15A-B with a user working on two tasks:
At time f, start task 1 .
At time g, end task 1 .
At time h, start task 2 .
At time i, end task 2 .
At time j, start task 1 again.
At time k, restart task 1 .
At time 1 , start task 2 again.
At time m, restart task 2 .
At time n, end task 1 .
At time o, end task 2 .
And so forth.
The print module will contain an analyzer that attempts to correlate all information in the totalTime file, the job worked file and the cumulative job file before printing. If any of the totals don't match the report will not be printed.
In the event that the totalTime file or the cumulative job file is missing, the report can be printed but will contain a caption indicating that it is not a validated report.
Also the size and checksum for the first and last blocks of the job worked file will be calculated each time the file is opened or closed and if they don't match an entry will be written to the file indicating tampering has occurred.
A system and method according to the invention includes, but is not limited to, the following application areas: remote telecommuting employment; determination of activity costs; estimation of time and amount billable for future projects/work; measurement of cost/benefit of new software or hardware; project management linking; accounting systems linking; tracking of activities and time used on a distributed basis; nano-business costing; resource management tool; assistance in social accounting; manufacturing systems; remote education to document study/activity time; objective tool for screening new hires; means for distributors to get into duplication, publication services and have authors trust activity count; and video conferencing consultations with automatic billing calculations.
For remote telecommuting employment applications, managers and clients can know when the employees or consultants are working and can measure productivity resulting in energy savings and improved air quality caused by reductions in miles driven in polluting vehicles.
For determining activity costs such as, for example, the cost of financial reporting, accounting reconciliation, computer file maintenance, etc., linkups to accounting software provide financial statements showing monthly/YTD costs by activity.
For estimating time and amounts billable for future projects/work, a system according to the invention provides data to be exported and used in an estimating algorithm or used in statistical analysis to estimate at, for example, an 80% probability using statistical functions found with spreadsheet programs.
For measuring cost/benefit of new software or hardware, the system provides data for activity-based costing of activities and for determining benefits of new processes or products.
For project management linking, the system can automatically feed recorded actuals into project software. For accounting systems linking, data entry of timecards information can be eliminated.
For tracking of activities and time used on a distributed basis, instead of a centralized timer of services provided by mainframes, cable TV, etc., activities and time used are tracked on a distributed basis. A user knows what he is going to be charged for services when the user is hooked up to a computer. Current mainframe time tracking software tracks CPU time at one rate and does not accumulate charges based on directory/file criteria. The invention can be used in smart houses or in allocating mainframe charges to departments.
For nano-business costing applications with a multi-tasking operating system on a desktop computer and the system's ability to accumulate activities and costs in separate budgets, a computer user can simultaneously perform various types of business functions on a desktop computer and automatically have the activities documented and costs accumulated in the chosen business function, such as marketing, production, accounting, etc.
As a resource management tool, the invention helps measure time and costs of various methods of getting a job done. The system helps to objectively determine the time, cost, and resources needed to perform a task, using a computer. Given the information, a manager has useful information to determine how to allocate resources to accomplish multiple simultaneous tasks among a department or company.
To assist in social accounting, the system helps to determine what it costs to implement a government program. A system helps to determine not just the funds that are distributed to the beneficiaries, but also the staff and material costs for managing the program.
For manufacturing systems, this system with remote sensors, such as RF ID devices, is used to document production and to assign costs.
For remote education, the system is used to document study or activity time. A tutor or teacher can review a student's approach and logic in solving a problem and can address any errors. The system facilitates multimedia programming training on demand with feedback on students approach to solving assigned programming exercises.
The system is useful as an objective tool for screening new hires and for performance-based assessment testing. Managers can screen candidates for a computer oriented job by assigning a task. The system will document time and activities but does not measure quality. The system provide valuable information for a manager to make an objective hiring decision in filling the job vacancy.
Installation of the system on disk duplicating machines would allow distributors to get into duplication or publication services and have the authors trust the counts of the distributors to verify that royalty payments have included all of the distributors sales.
The system facilitates video conferencing consultations with automatic billing calculation. Clients or patients can reach their professional or doctor, regardless of their geographical location and without having to go to their office and without having to manually start and stop a clock.
The invention covers browser activity where browser programs are just application programs and are treated by the present invention like any other program. Browsers interact with files on a local machine and they also interact with files that are accessed via networks such as the internet/intranet. To extend the processes of the present invention to browsers, it is necessary to enhance the data collector to monitor traffic between a particular application and the internet/intranet in addition to the normal traffic between the application and the DOS file system.
As illustrated in FIG. 1, interaction between an application and the internet is performed by a software component known as a network operating system, NOS, 130 , which is similar in function and features to a disk operating system, DOS, 118 , as previously described in connection with the system 100 . A network 132 is illustrated. The technical methods involved in intercepting interactions or traffic between an application and the NOS are slightly different than those between an application and DOS but from a high level they appear the same (i.e., the data collector for NOS watches for file open and close, file read and file write operations just as the data collector for DOS does.
FIG. 16 illustrates a internet/intranet initialization process which is to the DOS initialization which does not actually hook an interrupt but inserts a hook of similar design. The actual running process uses the same identical code to write the collected data to the data collector or disk file. This provides a process for hooking internet/intranet traffic and is similar to the concept of hooking disk traffic. The routing of the data thus collected to a data collector file writer uses exactly the same method used to write keyboard and mouse activity to the file.
FIG. 17 is similar to FIG. 2 and further includes Block 216 which indicates the step of finding a network interface. The network connects non-file system services providers which provide interface such as, for example, telephony interfaces and e-mail provider interfaces. Block 218 indicates that old code is saved. Block 220 inserts system calls to a data collector for network activities.
FIG. 17 is analogous and similar to FIG. 5 and illustrates a network call routine 1700 for an external network provider. Block 1702 extracts information regarding the user and the provider. Block 1704 analyzes information regarding who are active current uses of the provider. Block 1706 constructs a data collection for activities. Block 1708 writes and saves the user activity data collection records. Block 1710 calls the network interface.
FIG. 18 follows Block 1710 and illustrates an additional routine 1800 which saves additional information. Decision Block 1802 determines if there is additional information to be stored. If Yes, that information is stored as illustrated by Block 1804 in the DDC file and returns to the end of the routine.
Network applications of the invention include monitoring of actual activity at a particular Worldwide Web site. Activity can also be monitors between the computer running the data collector and other computers on its network that does not go through the DOS. This activity includes video streams, audio streams, game playing, internet telephony, etc. In general, any kind of conversation (either two-way or one-way) can be monitored and tracked, such as, for example, pay-per-play or pay-per-view. Additional combinations of work done on the local computer and work performed over the network can also be monitored including file access on remote systems and remote data collectors, in which, for example, a data collector is installed on a machine in the field which sends its information over a network to another data collector for concentration at a common site.
As described above, in addition to operating system environments such as DOS, Windows, Macintosh, etc., the invention is useful with a remote server which has application accessed by a user through a network The server itself can collect user activity information. The functionality of the TSR 110 is extended to include a NOS, which is treated as another data store. A browser accesses a data file in a remote computer and uses the NOS as a two-way connection.
For server and browser application the monitoring system determines which users are active and which files or functions are being used by the user.
The foregoing descriptions of specific embodiments of the present invention have been presented for the purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A method and system for automatically collecting and for analyzing information about time and work performed on a computer includes a hardware abstraction layer for monitoring activity on various user input devices. The system also includes the following elements: a data collector for monitoring certain portions of a user's computer activity and for logging into a log file those certain portions of a user's computer activity; a data analyzer for determining by following user-defined rules showing which portions of those certain portions of a user's computer activity constitutes continuous work activities, and how this work should be categorized by project and task with project; and an external interface for building the rules defining work. The data collector includes a resident module, such as a TSR (terminate-and-stay-resident) module, which extends the file system of the computer so that detailed records are kept of file activities. The data collector also routes information about file and keyboard activity, and tabulates and writes such information to a user's disk periodically. The hardware abstraction layer is a software module which is interposed between actual physical user input devices and the data collector. | 6 |
FIELD OF THE INVENTION
The present invention relates to semiconductor devices, and more specifically, to a system and method for transfer epitaxially grown thin film material from its original substrate to a destination substrate in the form of an array of islands with selectable spacing and periodicity.
BACKGROUND OF THE INVENTION
Current state-of-the-art semiconductor device processing trends are increasingly moving towards thin film devices, flexible electronics, and sophisticated three-dimensional integration schemes, and the like. All of the aforementioned generally require device layers to be transferred from a growth substrate of one desired property (e.g., a desired lattice parameter) to an alternate substrate with other desired qualities (e.g., for integration with other devices).
Transfer of a device layer from a growth substrate to another substrate may be accomplished by several different methods such as, but not limited to: a lapping and etching process, separation by ion implantation, a laser lift-off method, and a selective etching process. All of the above have limitations which will be described below.
Semiconductor film transfer may be done by a lapping and etching process. With GaAs and InP based materials, the substrate is often removed by lapping and chemical etching after the original wafer is mounted face down on the new substrate. The waste products of this process may be recycled; however significant energy and cost go into the recycling process.
Separation by implantation is used in the Silicon on Insulator (SOI) process, whereby a thin layer of silicon is transferred to an insulating substrate for further processing. This technique has not been applied to other semiconductors or to epitaxial layers that may be damaged by ion implantation.
Laser Lift-off (LLO) has been used successfully by the GaN LED industry for separating the processed devices or the epitaxial film from the sapphire substrate that was used for the epitaxial growth. Laser lift-off may be used with GaN family of materials grown on a sapphire substrate. The substrate may be reused after laser lift-off. The typical process involves irradiating the wafer with short ultraviolet laser pulses through the transparent sapphire substrate. The interfacial GaN layer absorbs the radiation and generates localized heat that facilitates the release of the substrate. This approach, however, is not applicable to III-V substrates (on which most lasers, optoelectronic devices, and many high-speed electronic devices are grown). The reason is that the substrates are opaque to visible and UV radiation. Also no interfacial layer exists that can absorb the radiation transmittable through the substrate while preventing any heat induced damage to the active epitaxial layers.
Film transfer to flexible substrates has been demonstrated by wet chemical etching of a sacrificial layer. This process relies on selective etching of a thin sacrificial layer grown below the epitaxial film. AlAs, and AlGaAs with a high aluminum content, are convenient sacrificial layers that can be used on GaAs substrates. The film and the flexible substrate are “peeled off” of the original substrate as the sacrificial layer dissolves in the etchant. High selectivity is achieved by a dilute HF etch of these materials. The etchant does not attack the GaAs substrate. Similar sacrificial layers and etch chemistries are also available for InP. However, the epitaxial film develops microcracks when transferred to a flexible substrate, and the subsequent processing is difficult on a non-rigid surface.
Thus, a need existed to provide a system and method to overcome the above problems.
SUMMARY OF THE INVENTION
In accordance with one embodiment, a method of transferring an epitaxial film from an original substrate to a destination substrate is disclosed. The method comprises: growing an epitaxial film over a sacrificial layer on the original substrate; patterning the epitaxial film into a plurality of sections; attaching the plurality of sections to a stretchable film; removing the plurality of sections attached to the stretchable film from the original substrate; and attaching a permanent substrate to the plurality of sections.
In accordance with another embodiment, a method of transferring an epitaxial film from an original substrate to a destination substrate is disclosed. The method comprises: growing an epitaxial film grown with a sacrificial layer on the original substrate; patterning the epitaxial film into a plurality of sections; attaching the plurality of sections to a stretchable film; and attaching a permanent substrate to the plurality of sections.
A method of transferring an epitaxial film from an original substrate to a destination substrate comprises: growing an epitaxial film grown with a sacrificial layer on the original substrate; patterning the epitaxial film into a plurality of sections; attaching the plurality of sections to a stretchable film; removing the plurality of sections attached to the stretchable film from the original substrate; stretching the stretchable file to a size of a permanent substrate; attaching the plurality of sections to a temporary substrate prior; removing the stretchable tape; and attaching a permanent substrate to the plurality of sections.
The foregoing and other objectives, features, and advantages of the invention will be apparent from the following and more particular, descriptions of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A depicts a step involved in substrate lift-off wherein epitaxial film grown with a sacrificial layer;
FIG. 1B depicts a step involved in substrate lift-off wherein the epitaxial film is patterned into sections islands and attached to a stretchable film;
FIG. 1C depicts a step involved in substrate lift-off wherein the sacrificial layer is etched away and the islands are “peeled off” attached to the stretchable film;
FIG. 2A depicts a step for transferring the patterned epitaxial film wherein the tape is stretched to the size of the final substrate;
FIG. 2B depicts a step for transferring the patterned epitaxial film wherein the separated islands are attached to a temporary rigid substrate and the stretchable tape is removed;
FIG. 2C depicts a step for transferring the patterned epitaxial film wherein the islands are fused or permanently attached to the final substrate; and
FIG. 2D depicts a step for transferring the patterned epitaxial film wherein the temporary substrate is removed, precise positioning of the islands is achieved by transferring oversized sections and trimming them by etching to a smaller size using lithography. This will form compound semiconductor mesas precisely positioned for further processing on the new substrate.
Common reference numerals are used throughout the drawings and detailed description to indicate like elements.
DETAILED DESCRIPTION
The present invention relates to the transfer of epitaxially grown thin film material from its original substrate to a destination substrate in the form of an array of islands with selectable spacing and periodicity. In accordance with one embodiment, this method will make it possible for compound semiconductor devices to be processed together with silicon devices on a full size silicon wafer. The method may further allow the compound semiconductor substrate to be reused for epitaxial growth.
Referring now to FIGS. 1A-2D , a method to the transfer of epitaxially grown thin film material from its original substrate to a destination substrate will be disclosed. The method is a multi-step process wherein a patterned epitaxial film is lifted off of a base substrate, the patterned epitaxial film is then placed on a temporary substrate, a permanent substrate is then attached to the patterned epitaxial film, and the temporary substrate is then removed.
Referring now to FIGS. 1A-1C , a base substrate 10 is provided. The base substrate 10 may include any device or structure that may be formed when making a semiconductor device. The base substrate 10 may be formed of silicon, germanium, silicon germanium, or other suitable semiconductor material. The listing of the above is given as an example and should not be seen in a limiting manner.
A sacrificial layer 12 is grown on a first surface 10 A of the base substrate 10 . The sacrificial layer 12 may be comprised of a conductive metallic material, a polymer material or a combination of both a conductive metallic material and a polymer material. Examples of possible sacrificial layer materials include, but are not limited to, aluminum, copper, steel, iron, bronze, brass, polyimide, polyetherimide, fluoropolymer and alloys and combinations thereof.
Next, the epitaxial film 14 is grown on a top surface of the sacrificial layer 12 . As shown more clearly in FIG. 1B , the epitaxial film 14 is patterned. In the embodiment shown in FIG. 1B , the epitaxial film 14 is pattern and etched into a plurality of small sections 16 . Each section 16 is formed in the size of a desired compound semiconductor device to be fabricated.
A stretchable material 18 is then attached to a surface of each section 16 . The surface is generally the surface opposite of the surface of the epitaxial film 14 that is attached to the sacrificial layer 12 . The stretchable material 18 may be a stretchable tape or the like having an adhesive surface that attaches to each section 16 . The stretchable tape may be a variation of the products known in the industry as “dicing tape”. One example is Advantek DU099H™ tape which has a Polyolefin base and a UV release adhesive.
The sections 16 of the patterned epitaxial film 14 are attached to the stretchable material 18 in order to transfer the sections 16 . The stretchable material 18 allows the sections 16 to be removed from the base substrate 10 .
Referring now to FIG. 1C , as the sacrificial layer 12 is etched away, the stretchable material 18 allows the sections 16 to be “peeled off” of the base substrate 10 , wherein the sections 16 remain attached to the stretchable material 18 . An etchant fluid may be used to dissolves the sacrificial layer 12 from the base substrate 10 . Thus, stretchable material 18 and its adhesive need to be resistant to the wet etch chemistry used to remove the sacrificial layer 12 .
Referring now to FIG. 2A , once the sections 16 are released from the base substrate 10 , the stretchable material 18 is expanded. The stretchable material 18 is expanded to the size of a silicon or other semiconductor wafer on which the array of sections 16 is to be deposited.
The “dicing tape” disclosed above is capable of stretching to multiple times its original size. A linear stretchability or elongation of up to 4× is desirable. This will expand the array of sections 16 by a factor of 16. So the devices built on the epitaxial film 14 will constitute˜6% of the total area of the integrated circuit. For example, a 3″ GaAs wafer can supply the islands for a 12″ silicon wafer, and the GaAs substrate can be reused for epitaxial growth.
Even if the expansion of the stretchable material 18 is not desired, the etching of the epitaxial film 14 into a plurality of sections 18 is beneficial in reducing the micro-cracks that may develop during the separation from the base substrate 10 .
The expansion of the stretchable material 18 may create cracks in the epitaxial film 14 . In order to reduce this possibility, several steps may be taken to minimize this risk. For example, additional epitaxial material may be grown to give provide more rigidity to the epitaxial film 14 . Also, a protective layer 26 may be deposited on top of the epitaxial film 14 . The protective layer 26 may be a protective metal layer deposited on top of the epitaxial film 14 . Alternatively, the protective layer 26 may be a flexible protective layer such as a polymer deposited on top of the epitaxial film 14 . This will reduce the stress on the epitaxial film 14 during the expansion of the stretchable material 12 . Another step that may be taken to minimize this risk is to perform the expansion in multiple smaller steps by transferring the sections 16 of the epitaxial film 14 from one tape to another between each expansion. Another possibility is to remove the base substrate 10 only after the array of sections 16 has been stretched. This will not allow the original substrate to be reused for epitaxial growth, since it needs to be diced.
After the optional expansion of the stretchable material 18 , the sections 16 are attached to a temporary rigid substrate 20 . This may be accomplished by applying an adhesive 22 to the temporary rigid substrate 20 . The adhesive 22 may be an epoxy or other temporary adhesion method.
The reason for the temporary rigid substrate 20 is that typically permanent attachment or the fusion of the sections 16 to the final substrate 24 requires the application of heat and pressure which may not be suitable for the stretchable material 18 . However, if high-temperature attachment is not needed for the final application, or if the stretchable material 18 that is destroyed in high-temperature attachment can be removed by cleaning, the use of the temporary rigid substrate 20 may not be needed.
Referring now to FIG. 2B , the stretchable material 18 is then removed. In accordance with one embodiment, the removable of the stretchable material 18 may be accomplished by UV releasing of the adhesive of the stretchable material. However, it should be noted that other methods may be used without departing from the spirit and scope of the present invention.
Referring to FIG. 2C , the next step is to perform attach the sections 16 to, a final substrate 24 . In accordance with one embodiment, the sections 16 may be fused or permanently attached to the final substrate 24 .
The attachment of the epitaxial islands to the final substrate may be done by a number of different techniques depending on its end use requirements. These techniques fall into two general categories: direct bonding, and bonding with intermediate layers.
Direct bonding between silicon and III-V materials may be done by applying pressure at temperatures in the range of 400 to 650° C. Better interface quality may be achieved by lower temperature bonding using e.g. plasma assisted bonding.
Bonding with intermediate layers may be categorized into: conducting interface and non-conductive interface. Conductive interface formation normally involves the metallization of one or both surfaces and the use of various eutectics or solders. Attachment with a nonconductive interface involves an intermediate layer such as glass, or various polymers.
Commercial equipment is available with programmable pressure and temperature cycles to achieve optimal and reproducible bonding.
Next, as shown in FIG. 2D , the temporary rigid substrate 20 is removed. The sections 16 may then be trimmed by lithography prior to the full processing of the new wafer. The trimming enhances the placement accuracy of the epitaxial sections 16 and forms the mesa structures on which the compound semiconductor devices are fabricated.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. | A method of transferring an epitaxial film from an original substrate to a destination substrate comprises: growing an epitaxial film grown with a sacrificial layer on the original substrate; patterning the epitaxial film into a plurality of sections; attaching the plurality of sections to a stretchable film; removing the plurality of sections attached to the stretchable film from the original substrate; stretching the sections apart as needed; and attaching a permanent substrate to the plurality of sections; and trimming the sizes of the sections as needed for precise positioning prior to integrated circuit device fabrication. | 7 |
This is a divisional of application Ser. No. 08/096,483 filed Jul. 22, 1993, now U.S. Pat. No. 5,446,964.
FIELD OF INVENTION
The invention relates to assembling flexible line trimmers shipped in a disassembled state.
BACKGROUND OF THE INVENTION
An electrically powered trimmer includes a cutting element mounted to the drive shaft of an electric motor, a housing in which the motor is mounted and that is attached to one end of a tube, and a pair of handles at the opposite end of the tube. The cutting element is most often a length of flexible line, though it could also be a blade. The length of line extends from a line head connected to the shaft of the motor. The head is spun rapidly to flail the line against vegetation. Because the line frequently breaks, a supply of flexible line is stored on a spool in the head, the end of the line extending through an opening in the head.
An operator holds the trimmer while standing erect by grasping with one hand a main handle attached to the end the tube that extends upwardly and rearwardly from the housing. Depending on the size of the trimmer, the other hand may grasp an auxiliary handle that can be attached lower down on the tube between the main handle and the housing to provide enhanced control. A trigger located, usually, on the main handle operates a normally off switch that turns the motor on and off.
Usually, power is delivered to the motor by a 120 volt alternating current from a household outlet. A plug or "pigtail" for connection to an extension cord running from the outlet is typically located in the rear of the handle, but is sometimes located elsewhere on the trimmer. The power source alternately is a battery pack placed in the vicinity of the main handle for balance. With either power source, a power wire runs to the electric motor in the housing through the tube to the normally-off trigger switch on the rear handle.
To save space, electric, flexible line trimmers are sometimes packaged and shipped in a "knocked down" or partially disassembled state. The benefits of packing trimmers disassembled are well known and it has been done for many years. Traditionally, to knock down the trimmer, the tube that supports the handles is manufactured in two or more sections that are separated and folded over when placed in a box. In other cases, the tube may be manufactured as a single piece but not attached to the motor housing, the main handle or both to save space.
For safety, the trimmer must be "prewired," as the wire through the tube carries relatively high voltage (120 volt) alternating current. The wire is run through the tube and attached to the electric motor and the power plug and/or trigger switch on the main handle before packaging and shipment. The lower length of the tube is then attached to the housing and the upper length is attached to the rear handle. When the trimmer is taken from the box, the two pieces of the tube are pushed together and secured with bolts. One end of the tube length has a smaller diameter so that it slides into the larger diameter end of the other tube length. An electric trimmer of the general type described is disclosed in U.S. Pat. No. 4,829,675, issued May 16, 1989 to Beihoffer.
Although of considerable benefit in terms of cost of shipping and storage to those who sell trimmers, consumers find assembling a knocked down line trimmer a nuisance and inconvenience. Furthermore, final assembly is not as simple as it may appear. As pointed out in Beihoffer, an extra length of wire is necessary to allow the tube pieces to be pulled apart and folded over and to prevent the end of each piece rubbing against the wire during shipment. The extra length of wire is relatively stiff due to having a size sufficient to carry the AC current. It must be pushed into one or both tube halves, thus making assembly more difficult and tedious. Beihoffer points out that problems may result from a consumer assembling the handle portions in a rough manner or inappropriately forcing the extra wire into one or both handle halves. Furthermore, proper orientation of the upper length of tube length with the lower length is frequently overlooked by first time buyers and is not discovered until after bolts are installed to secure the tube lengths, thus causing frustration and discontent.
Retailers would, naturally, prefer to provide to customers the convenience of a fully assembled trimmer. To maintain the goodwill of their customers, some retailers are willing to assemble the trimmers when they are offered for sale or are sold. However, this may require extra trained personnel. Sometimes they do not have the personnel immediately available or must charge a fee to recover costs, thus inconveniencing the customer.
Beihoffer addresses the problem of the extra length of wire and teaches cutting notches in the ends of the tubes so that the length of the wire may be reduced. However, he provides only a partial solution. Assembly of the tube sections is still required and is inconvenient to the consumer. Thus, the demand for a solution remains.
SUMMARY OF THE INVENTION
Addressing these problems, the invention is an electric trimmer which can be pulled from a package in a knocked-down state and properly assembled in seconds without tools or the opportunity for missteps. Thus, consumers may conveniently assemble the line trimmer, without hassle and without the help of, or the expense to, retailers.
According to the invention, a prewired electric trimmer is packaged for shipment with a single elongated handle support inserted into and received by a specially adapted extended neck of a housing for an electric motor. When the trimmer is removed from the box for final assembly, the tubular handle support is pulled from the housing by a main handle located at the end of the handle support. Once the handle support is extended, it is secured so that the trimmer has convenient height to operate while standing. The handle support and the housing cooperate to maintain proper orientation of the main handle with respect to the housing.
The invention thus eliminates the inconvenience and problems associated with assembling two pieces of the tubular handle support, as well as the possibility of improper orientation. Furthermore, the wire running from the main handle to the electric motor does not interfere with final assembly.
In accordance with another aspect of the invention, the neck of the housing includes a straight guide, parallel to the handle, and a cooperating member that maintains proper orientation of the tube. The cooperating member is preferably a spring biased detent button that clicks into place when the tube is extended to an operating position, the clicking providing feedback to the consumer that the tube is properly extended.
In accordance with several other aspects of the invention, the guide includes a ramp with an abrupt end that slowly depresses the detent button as the tube is extending and then drops the button at its end, locking the tube into place and giving the customer further assurance that the tube is properly extended and in place. Arrows or other visual indicators may also be placed on the tube to indicate to the customer when the tube has been properly extended and placed in an operating position. By placing a second guide generally perpendicular to the first guide at the locking position allows the tube to be rotated to allow the cutting element of the trimmer to be used as an edger. To prevent tangling of the wire during final assembly, an extra length of wire necessary to accommodate the extension of the tube is pinned in the lower housing to take up any slack.
These and other advantages of the invention will be described with reference to a preferred embodiment illustrated by the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a fully assembled line trimmer.
FIG. 2 is a side elevational view of the line trimmer of FIG. 1 in a collapsed shipping position and with a side of the handle and the motor and handle support tube housing removed.
FIG. 3 is a side elevational view of the line trimmer of FIG. 1 in an alternate collapsed shipping position.
FIG. 4 is side view of one half of a motor and handle tube housing for the line trimmer of FIG. 1 with the handle tube in a collapsed shipping position.
FIG. 5 is a partial cross-section of the motor and handle support tube housing half of FIG. 4, taken along section line 5--5, with the handle tube shown partly in section at three locations: at a fully collapsed, shipping position; a midway position; and a fully-assembled position.
FIG. 6A is a cross section taken through the motor and handle support tube housing of the line trimmer of FIG. 1, taken along the section line 6A--6A in FIG. 1.
FIG. 6B is a cross section taken through the housing of the line trimmer of FIG. 1, taken along the section line 6B--6B in FIG. 1.
FIG. 6C is a cross section taken through the housing of the line trimmer of FIG. 1, taken along the section line 6C--6C in FIG. 1.
FIG. 6D is a cross section taken through the housing of the line trimmer of FIG. 1, taken along the section line 6D--6D in FIG. 1.
FIG. 6E is a cross section taken through the motor and handle tube housing of the line trimmer of FIG. 1, taken along the section line 6E--6E in FIG. 1.
FIG. 7 is a simplified side elevational view of half of the motor and handle support tube housing of the line trimmer of FIG. 1.
FIG. 8 is a partial cross-section of the housing half of FIG. 7 taken along section line 8--8.
FIG. 9A is a partial cross-section of an alternate embodiment of the housing half of FIG. 7 taken along section line 8--8 in FIG. 7.
FIG. 9B is a partial cross-section of an alternate embodiment for the housing half of FIG. 7 taken along section line 8--8 in FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Illustrated in FIG. 1 is a fully-assembled flexible line trimmer 100 oriented in a trimming position. While standing, an operator grasps main handle 102 and auxiliary handle 104 to maneuver a rotating head 106 in close proximity to the ground. Head 106, having a conventional design, holds a spool of flexible cutting line for supplying a length of cutting line (not shown) that is flailed against ground vegetation by the rapidly spun head. The head is spun by an alternating current electric motor that is mounted within portion 108 of an integrally formed motor and handle tube housing 110. Neck 112 of the motor and handle tube housing extends upwardly and rearwardly, generally an angle to the ground plane and toward the operator. Connected to neck 112 is a lower end of a handle support tube 114. Main handle 102 is connected to an opposite, top end of the tube 114, in a conventional manner. The position of the main handle is fixed, but it may be telescoping or rotating if desired. Auxiliary handle 104 is clamped to the tube in a conventional manner.
Power is supplied to the line trimmer by connecting an extension cord from a 120 volt wall socket to a male plug (not seen) mounted within at a distal end 116 of main handle 102. The male plug is coupled through a normally closed switch, operated by trigger 118, to the motor by a wire (not shown) that runs through the tube 114 to the motor and handle tube housing 110. Pulling trigger 118 supplies current to the motor through the wire, causing the head 106 to rotate at high speeds. Alternatively, a battery can be incorporated with the main handle to supply power to a D.C. electric motor in the power housing.
Other types of cutting elements or work producing elements may be attached to the output shaft of the motor. Also, some trimmers may be operated or controlled effectively with only one hand, permitting the auxiliary handle to be dispensed with.
Referring now to FIG. 2, when a line trimmer is packaged for shipping, it is placed in a knocked-down or collapsed condition, with the handle support tube 114 retracted within neck 112 of housing 110. In this fully retracted position, handle support tube 114 is received substantially within neck 112 of motor and handle support tube housing 110. Only enough of the tube remains for connecting handles 102 and 104. Please note that the drawing shows only side pieces 102A and 110A of, respectively, the main handle and the housing. Complementary side pieces are joined to make the handle 102 and housing 110.
During manufacture, wire 202 is run through tube 114 and connected at one end to plug 204 and switch 206 and to motor 208 at the other end. The wire is also pinned to the handle 102 and to neck 112 of housing 110 by wrapping it around several closely spaced tabs or bosses that pinch the cord when pulled. Pinning helps to prevent loosening the electrical connections with the plug and switch or with the motor. The handle is then attached to the end of the tube for shipment.
An extra length of wire 202 is pinned within housing 112, along the side of the end of the tube 114 when it is fully retracted to take up slack on the extra length of wire that is required to accommodate full extension of the tube. Pinning the extra length of wire in this manner helps to prevent interference from the wire kinking or jamming between the tube and housing when being withdrawn and to ensure placement of the tube and wire in the proper locations during assembly to avoid crimping and other problems that may occur during assembly and shipment. The pinning also accommodates retracting the tube subsequently, if desired.
Referring now to FIG. 3, further reduction in height of the trimmer for smaller package volumes can be accomplished by not attaching handle 102 to the end of tube 114 during assembly. Wire loop 302 is much shorter than wire loop 210 in FIG. 2. Length of wire 304 at the other end of the tube, near the handle, accommodates the extension of the tube and also accommodates fitting the handle over the end of the tube for final assembly. Shipping insert 306 prevents the end of tube 114 from chafing wire 202 during shipping. Note that the end of tube 114 is specially adapted to the handle so that the handle fits over and locks on the tube in a fixed, predetermined orientation with the tube.
Referring now to FIG. 4, the drawing is a simplified illustration of housing half 110. No motor or head is shown. Tube 114 is held in position within neck 112 of the housing by a series of spaced-apart reenforcing ribs 402 that are curved to receive the circular tube. The housing also includes an end stop 404 for tube 114. When tube 114 is in a fully extended position and the trimmer is being held in the operative position, ribs 406 at the end of neck 112 of the housing 110 are more closely spaced to support housing 110 on tube 114 and to distribute stress.
Referring now to FIG. 5, along the length of the side of housing 112 is a straight trough or track formed by wall 502 and a wall that runs parallel to wall 502 and which cannot be seen in this cross-section. The trough functions as a guide for a detent button 504 that extends through a hole through the wall of the tube near its end, within housing 110. Detent button 504 is biased to an extended position with spring 506. After the trimmer is unpackaged, a person pulls on the main handle 102 (FIG. 1) on the end of the tube extending from the housing 110. Detent button rides up the trough and maintains a fixed and proper orientation of the tube with respect to the housing. Ramp 508 is formed in the middle of the trough so that the detent button is slowly depressed as the tube is extended. The drawing illustrates position 510 of the detent button when the tube is fully retracted; as it is being extended, which is position 512; and at position 514 where it is fully extended.
The abrupt end of the ramp prevents the detent button from riding down the trough once extended, thus locking the tube 114 in a fully extended position. The clicking motion and sound the detent button makes when falling at the end of the ramp also provides important reassurance to a customer that the tube is fully extended and secured. Having the trimmer locked into a full extended position removes all decisions from the consumer. Knob 516 turns on a screw extending through both halves of housing 110 to tighten the neck of the housing about the tube. The trimmer is then finally assembled. Although no release is shown, it is possible to install a release mechanism to depress the detent button so that the tube may be collapsed for storage, transport or adjustability. Or, alternately, the abrupt end may be replaced with a relatively steep ramp that provides the clicking action upon extension but will depress the detent button when sufficient force is applied to the tube to collapse it.
In the fully extended position, the detent button rests in a second, semi-circular guide formed at the end of the ramp by wall 408 (which is also shown in FIG. 4) and the next adjacent of the plurality of ribs 406. This semi-circular guide allows the tube 114 to be rotated one hundred eighty degrees so that the axis of rotation of the head 106 (FIG. 1) is parallel to the ground, allowing the trimmer to be used to cut an edge.
FIGS. 6A-6D are cross-sections taken through neck 112 of housing 110, as indicated on FIG. 1, at each of the ribs 402. Handle support tube 114 rests within the circular area 602 between the curved edges of fibs 402. Guide 604, in which the detent button 504 (FIG. 5) runs, is formed between walls 502 and 606. Ramp 508 is located in the center of the guide.
Referring now to FIG. 6E, a cross-section is taken through the second, semi-circular guide 608 formed between wall 408 and the next adjacent rib 406, which is shown in FIGS. 4 and 5. Tube 114 may be rotated one hundred eighty degrees by loosening the clamping of the end of neck 112 around the tube, its rotation being limited by the detent button 504 hitting walls 502 and 610.
Referring now to FIGS. 7 and 8, housing half 112A is shown by itself, without tube 114 obstructing a view of trough 604, ramp 508 within the trough, and second guide 604.
FIGS. 9A and 9B, which are cross sections of housing half 110A taken along section line 8--8 in FIG. 7, illustrate alternate profiles for ramp 508. In FIG. 9A, the ramp is replaced with a series of knolls 902 that have slopes in each direction over which the detent button 504 (FIG. 5) rides when moving in either the retracting or extending directions along the trough 604 (FIG. 7). The handle support tube 114 (FIG. 5) is thus movable between the fully extended and fully retracted positions and thus may be collapsed once fully extended. Valleys between the knolls provide incremental or discrete positioning of the detent button 504 (FIG. 5) and feedback to the customer that proper extension of the tube has been accomplished. The height of handle 102 (FIG. 1) above the ground thus may be incrementally adjusted to the height of the user. The neck of the housing 110 is tightened around the tube 114 with knob 516 (FIG. 5) to retain the tube in the selected position. In FIG. 9B, the ramp is entirely removed to allow for a continuously, rather than incrementally, adjustable handle height. The tube 114 is held at the desired height by tightening the neck of the housing around the tube.
The foregoing embodiments are intended merely as examples of the invention. Modifications, alterations, substitutions, omissions and enhancements to the illustrated embodiments may be made without departing from the spirit and the scope of the invention as set forth in the appended claims. | A flexible line trimmer for shipping and storing in a knocked down version for reduced package sizes includes a single length of tube that is received within an extended neck portion of a motor housing. During final assembly, the tube is extended and locked into position without the need for tools. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to hydrotherapy jets.
[0003] 2. Description of the Related Art
[0004] Various hydrotherapy jets have been developed for use in spas, hot tubs, pools and bath tubs that discharge a stream of water that can be aerated through a variety of discharge nozzles. Designs of these hydrotherapy jets provide different flow characteristics that result in different massage effects being experienced by the body. Such jets have been found to produce a pleasing massage effect for many users, and have become quite popular. In the design of single or multi-use spas or tubs, it is common to use a variety of different jet nozzles to provide a variety of different massaging effects.
[0005] Early jets simply discharged a stream of warm water along the longitudinal axis of the jet body, with later jets providing aeration of the water stream. Since then numerous jets have been developed in which the direction of the stream can be adjusted. For example, U.S. Pat. No. 5,269,029 to Spears, et al. (assigned to the same assignee as the present invention) discloses a jet that provides an off axis stream of water and has an axial push-pull mechanism used to control the flow of water. The mechanism can also be rotated to rotate a stream of water around the jet axis, thus providing directional control over the stream.
[0006] Jets have also been developed having a rotating outlet or eyeball that automatically rotates in response to water flowing through the outlet. As an example, see Waterway Plastics, Inc., “1999 product catalog,” page 4, including part nos. 210-6120 and 210-6510. In these jets, the outlet can be adjusted off the jet's longitudinal axis to provide a turning moment in the eyeball in response to the water stream flow.
[0007] U.S. Pat. No. 6,178,570 to Denst et al. (assigned to the same assignee as the present invention) discloses a jet having a rotating eyeball with one or more discharge outlets that can be adjusted to vary the direction of the outlet flow stream, as well as the direction and speed of the eyeball's rotation. A high-pressure water stream flows through the outlets and, depending on the orientation of the outlets, the eyeball can rotate clockwise or counter-clockwise at different speeds.
[0008] U.S. Pat. No. 5,920,925 to Dongo (assigned to the same assignee as the present invention) discloses a jet having a rotating eyeball and a cap formed with a number of openings positioned at a common radius from the center of the cap. The jet produces a high-pressure water stream that flows through the eyeball, causing it to rotate at a high speed and discharge the jet in a circular pattern that impinges on the openings. Together, the rotational speed and the opening design produce the sensation of a number of simultaneously pulsating water streams that are directed into the spa.
[0009] Various hydrotherapy jets have been developed in the past for use with spas, hot tubs, and bath tubs that discharge an aerated stream of water through a variety of discharge nozzles. In general, such jets produce a constant flow stream that provides a good therapeutic effect. However, in an attempt to enhance the therapeutic effect, several systems have been designed that produce a pulsating flow. These systems have met with varying degrees of success as they often require additional or larger components, which increase system cost and add complexity, or generate unwanted pressure losses, thus requiring a larger pump than would otherwise be required.
[0010] One prior art approach has been to use mechanical devices to pulse water flowing to an individual jet, or a series of jets. An example of such a system is described in U.S. Pat. No. 4,320,541 to John S. Neenan. In this approach a series of mechanical blocking devices are used to intermittently block and unblock a flow stream. As a flow stream is unblocked, a pulse of water is sent to the jet and ultimately to the user. While this approach does provide a pulsating effect, blocking and unblocking of the flow stream causes abrupt pressure increases imposing a strain on spa systems. Aside from these drawbacks, such systems require additional components that add complexity, cost and weight. In addition, since the pulsation effect is generated away from the jet, the pulsed flow stream experiences a pressure loss, resulting in a decreased pulsation effect being felt at the jet exit.
[0011] In an alternate approach, rather than using mechanical devices to generate a pulsed flow, a hydraulic pumping device is used. In such a system, pulsation is produced by a distribution valve which houses a rotor that is rotated by inlet water flow, and distributes the inlet water to a series of outlets which are connected into the individual jets. The rotor is formed with a groove that sequentially aligns the water outlets to the water inlet so that each outlet is periodically connected to, and then disconnected from, the inlet. The water is supplied into each jet in a pulsating or chopping manner. Examples of this system are given in the U.S. Pat. Nos. 5,444,879 and 5,457,825 to Michael D. Holtsnider and assigned to Waterway Plastics, Inc. the assignee of the present invention.
[0012] While hydraulic systems do provide a degree of pulsation, they too suffer from many of the same problems as mechanical systems. For example, as the pulsation effect is generated away from the jet, the pulsed flow stream experiences a pressure loss which results in a reduced pulsation effect at the jet, and like the mechanical systems the additional componentry adds complexity, cost and weight to the system. Also, a larger water pump may be required to provide additional energy to rotate the rotor and to compensate for additional pressure losses.
[0013] To overcome the drawbacks associated with mechanical and hydraulic pulsed systems, pulsation systems have been designed that do not require mechanical devices or hydraulic distribution systems. Such systems generally have individual pulsation mechanisms located within the individual jets. Examples are shown in the Waterway “1997 product catalog,” page 1, deluxe and octagon series pulsating jet, and in U.S. Pat. No. 5,657,496 to Corb et al., also assigned to Waterway Plastics, Inc. The individual jets contain rotational devices commonly called eyeballs. The eyeballs have water conduits which discharge water flowing through the jet into the spa or tub. The conduits are angled to cause the eyeball to rotate and distribute the flow stream in a circular pattern. The circular distribution provides, to some degree, the sensation of a pulsed flow as the flow stream interacts with a specific point on the body in a periodic fashion. However, this is not truly a pulsed flow since the user actually experiences a continual flow stream, but in a circular pattern.
[0014] Attempts have been made to produce a jet that would produce a true pulsed flow. To this end, several designs have been developed in which pulsation is created at the jet itself. In these systems the flow stream at the jet is blocked periodically to create the sensation of a pulsed flow. See Waterway Plastics, Inc. “1997 product catalog” page 1, Standard Poly jets whirly and pulsator jets, and U.S. Pat. No. 4,508,665 to Spinnett. While both the Waterway and Spinnett Jet designs do in fact produce a pulsed flow, the pulsating is created by blocking the flow stream exiting the discharge member as it rotates past a blocking member. When the flow stream comes in contact with the blocking member the flow is temporarily interrupted or halted, thus generating a pulsed flow that is circular or spiral in nature, moving from one zone to another in a sequential manner. The blocking, however, creates an undesirable backflow into the jet, causing strain on the spa system and ultimately lowering efficiency. In addition, the Spinnett design requires multiple deflections of the flow stream as it passes through the jet, causing pressure losses and lowering the system efficiency.
SUMMARY OF THE INVENTION
[0015] The invention includes a jet, a rotating discharge member and a cap formed with a number of openings positioned at different distances from the center of the cap. The jet produces a high-pressure water stream that flows through the discharge member, causing the discharge member to rotate, and discharge the jet in a number of concentric patterns that impinge on the openings. The openings are formed in the cap so that the upstream intersection of the openings forms a series of ridges that divert the rotating water stream into the appropriate opening(s) without blocking it, or producing a backflow, and are aligned with the rotating discharge member to minimize pressure losses. Together the rotation speed and the opening design produce the sensation of a number of concentric rings each having multiple pulsating water streams that are directed into the spa or tub.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings, in which:
[0017] [0017]FIG. 1 is a simplified exploded perspective view of a pulsating hydrotherapy jet unit in accordance with the invention;
[0018] [0018]FIG. 2 is a sectional view taken along section line 2 - 2 of the double pulsating hydrotherapy jet unit of FIG. 9;
[0019] [0019]FIG. 3 is a top plan view of the discharge member used in the jet of FIG. 1;
[0020] [0020]FIG. 4 is a sectional view taken along section line 4 - 4 of the discharge member of FIG. 3;
[0021] [0021]FIG. 5 is a perspective view of a fully assembled double pulsating hydrotherapy jet unit;
[0022] [0022]FIG. 6 is a front elevation view of the cap used in the jet of FIG. 5;
[0023] [0023]FIG. 7 is a sectional view taken along section line 7 - 7 of the cap of FIG. 6;
[0024] [0024]FIG. 8 is a sectional view taken along section line 8 - 8 of the cap of FIG. 6;
[0025] [0025]FIG. 9 is a front elevation view of an assembled double pulsating hydrotherapy jet unit;
[0026] [0026]FIG. 10 is a top plan view of one embodiment of the cap used in the jet of FIG. 2;
[0027] [0027]FIG. 10 a is a bottom plan view of one embodiment of the cap used in the jet of FIG. 2
[0028] [0028]FIG. 11 is a sectional view of one embodiment of the discharge member used in the jet of FIG. 2;
[0029] [0029]FIG. 12 is an exploded perspective view of a double pulsating hydrotherapy jet unit of FIG. 9;
[0030] [0030]FIG. 13 is a perspective view of a spa/tub system using the present invention; and
[0031] [0031]FIG. 14 is a flowchart demonstrating one embodiment of the claims.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The invention, as shown in FIG. 1, relates to a low-pressure loss hydrotherapy jet system 40 that uses a single water supply 3 (not shown) and a single air intake 4 (not shown) to produce multiple concentric rings of multiple simultaneously pulsating jets in a spa bath. As shown in FIG. 1 aerated water stream 5 enters discharge member 10 , which has a major outlet conduit 17 and a minor outlet conduit 18 . Jet 5 enters discharge member 10 and splits into jets 6 and 7 , which exit discharge member 10 through minor outlet conduit 18 and major outlet conduit 17 respectively. Jets 6 and 7 discharge in concentric patterns from discharge member 10 . These concentric pattern jets 6 and 7 impinge a series of rings of openings 28 a - 28 g and 27 a - 27 g respectively molded within a stationary cap 20 . Jet 7 passing through openings 27 a - 27 g generates a ring of major pulsating jets 8 . Jet 6 passing through openings 28 a - 28 g generates a ring of minor pulsating jets 9 .
[0033] In one embodiment the upstream intersection of the openings create a ridge that diverts the rotating jet to the respective openings without generating substantial back flow. In one embodiment, when discharge member 10 receives a water supply having a pressure of at least 10 pounds per square inch (psi), discharge member 10 rotates fast enough that the user may have the sensation of major and minor jets 8 and 9 pulsating simultaneously. Simultaneous jets 9 may appear to be concentric with simultaneous jets 8 . In one embodiment discharge member 10 may rotate at speeds of at least 500 revolutions per minute (rpm). In one embodiment, the system has the added advantage that its design results in lower pressure losses.
[0034] [0034]FIG. 1 also shows discharge member 10 has a discharge member sleeve 15 that connects to inner discharge member sleeve 67 (shown in FIG. 12). Locking slot 14 on discharge member sleeve 15 allows sleeve attachment tab 66 (shown in FIG. 12) to connect inner discharge member sleeve 67 to discharge member 10 . Alignment slot 16 allows alignment of discharge member 10 to inner discharge member sleeve 67 .
[0035] As shown in FIG. 2 major outlet conduit 17 diverts aerated water stream 5 away from the longitudinal axis of water stream 5 , and forms discharge stream 7 . In one embodiment, discharge stream 7 may impart a rotational moment to discharge member 10 . Minor outlet conduit 18 also deflects aerated water stream 5 away from its longitudinal axis forming discharge stream 6 , but does not divert it as far away as major outlet conduit 17 . In one embodiment, minor discharge stream 6 may impart a rotational moment to discharge member 10 .
[0036] Channel 31 , in FIG. 2, receives water supply 3 flowing from conduit 32 through exit port 33 . Exit port 33 , whose axis is normal to that of Channel 31 , constricts the flow of water supply 3 and provides it to conduit 32 . Attached to exit port 33 , at its upstream end, is a water jet 30 that houses a venturi 34 . Jet 30 is used to produce a high-pressure water stream for the system. Venturi 34 has an upstream section 35 that tapers down to its smallest diameter at throat 36 . At throat 36 , venturi 34 expands in diameter forming an aft section 37 . Air intake 4 enters through air conduit 45 . Aft of throat 36 , in section 37 , are located a series of air openings 39 used to entrain air supply 4 to aerate the water flowing through venturi 34 . In this manner, air intake 4 is entrained into water supply 3 forming aerated water stream 5 .
[0037] In one embodiment, as shown in FIG. 2, major outlet conduit 17 diverts part of aerated water stream 5 into diverted major outlet conduit aerated water stream 7 . Diverted major outlet conduit aerated water stream 7 leaves discharge member 10 through major outlet conduit 17 . Minor outlet conduit 18 diverts part of aerated water stream 5 into diverted minor outlet conduit aerated water stream 6 . Diverted minor outlet conduit aerated water stream 6 leaves discharge member 10 through minor outlet conduit 18 . Major and minor aerated flow streams 7 and 6 exiting discharge member 10 thru major outlet conduit 17 and minor outlet conduit 18 respectively encounter openings 27 a - 27 g and 28 a - 28 g respectively. In FIG. 2, aerated water stream 5 exits discharge member 10 as major simultaneously pulsating jet 7 thru major ring opening 27 b , and minor simultaneously pulsating jet 6 thru minor ring opening 28 e.
[0038] Discharge member 10 can be seen just up stream of cap 20 . The cross section of major opening 27 b may be seen in cap 20 . A cross section of minor opening 28 e may also be seen in cap 20 . FIG. 2 shows major outlet conduit 17 lining up with major ring opening 27 b allowing major outlet conduit aerated water stream 7 to exit double pulsating hydrotherapy jet unit 40 . FIG. 2 also shows minor outlet conduit 18 aligning up with minor ring opening 28 e permitting minor outlet conduit aerated water stream 6 to exit double pulsating hydrotherapy jet unit 40 .
[0039] Washer 52 separates bearing rakes 53 and 51 in FIG. 2 from each other. Bearing rakes 53 and 51 permit discharge member 10 to rotate freely around rotational axis 11 as shown in FIG. 4. These bearing rakes 53 and 51 fit over inner bearing sleeve 54 and are attached thereto. The combination of inner bearing sleeve 54 , bearings 53 and 51 and washer 52 are then snugly fit inside outer bearing sleeve 55 as is also shown in FIG. 12. The positioning of bearing rake 51 and bearing rake 53 outside bearing sleeve 54 keeps the bearings separate from aerated water stream 5 , reducing the chance that over time these bearings might seize. Additionally, having two bearing rakes 51 and 53 reduces the wear that would be encountered by a single bearing rake, thus extending the life of the jet.
[0040] Washers 56 and 57 , as shown in FIG. 2, confine air uptake 4 entering thru air conduit 45 allowing it to aerate water stream 3 producing aerated water stream 5 . Conduit 45 has a check valve comprising check valve ball 46 and check valve ball retainer 47 . The check valve prevents water from escaping double pulsating hydrotherapy jet unit 40 back thru air conduit 45 . When water enters air conduit 45 check ball 46 is forced against check ball retainer 47 sealing the conduit closed.
[0041] As discharge member 10 rotates around its longitudinal axis, major outlet conduit 17 sweeps consecutively through major openings 27 a to 27 g . As major outlet conduit 17 sweeps through an opening 27 a - 27 g in cap 20 , diverted aerated water stream 7 passes through said opening creating a pulse of aerated water stream 8 (shown in FIG. 1).
[0042] As discharge member 10 rotates around its longitudinal axis, minor outlet conduit 18 sweeps consecutively through minor openings 28 a - 28 g . As minor outlet conduit 18 sweeps through an opening 28 a - 28 g in cap 20 , diverted aerated water stream 6 passes through said opening creating a pulse of aerated water stream 9 (shown in FIG. 1).
[0043] As may be seen in FIG. 2, in one embodiment major opening 27 b may be aligned with major outlet conduit 17 , and thus does not substantially impede the flow of water stream 7 through major outlet conduit 17 . In one embodiment, all openings 27 a - 27 g may be aligned with major outlet conduit 17 as opening 27 b is shown here. In one embodiment minor opening 28 e may be aligned with minor outlet conduit 18 , and thus opening 28 e does not interfere substantially with the flow of water out of minor outlet conduit 18 . In one embodiment, all openings 28 a - 28 g may be aligned with minor outlet conduit 18 as opening 28 e is shown here.
[0044] In one embodiment, as shown in FIG. 3 major outlet conduit 17 extends further away from the center axis 11 (shown in FIG. 4) of discharge member 10 then does minor outlet conduit 18 .
[0045] [0045]FIG. 4 shows discharge member 10 has an axis of rotation 11 that is collocated with the longitudinal axis of aerated jet 5 (shown in FIG. 2). FIG. 4 further demonstrates major outlet conduit 17 extending further away from the centerline then does minor outlet conduit 18 . In one embodiment, conduits 17 and 18 extend up and out from discharge member 10 in a manner that suggests asymmetric bunny ears.
[0046] In one embodiment discharge member 10 has a rotational axis 11 with the two linear water outlet conduits 17 and 18 passing through it. Major outlet conduit 17 has a longitudinal axis 13 that is coplanar with axis 11 . Minor outlet conduit 18 has a longitudinal axis 12 that is coplanar with axis 11 . Major outlet conduit's 17 longitudinal axis 13 , and minor outlet conduit's 18 longitudinal axis 12 are orientated at angles α and β respectively to axis 11 of discharge member 10 . In one embodiment α may be greater than 37 degrees, and β may be greater than 21 degrees. Axes 12 and 13 are further offset by an angle γ (not shown) to from a non-intersecting orientation to rotational axis 11 to provide a turning moment to discharge member 10 in response to a jet flow. Jet flows 6 and 7 exiting rotational member 10 trace out concentric patterns, as discharge member 10 rotates, which may be perceived as solid rings of water. In one embodiment angle γ may be approximately 6 degrees.
[0047] In one embodiment as shown in FIGS. 2, 3 and 4 major water outlet conduit 17 and minor water outlet conduit 18 pass through and extend downstream from discharge member 10 , and are spaced approximately 180 degrees apart from one another about axis 11 . Angles α, β and γ are set such that discharge member 10 obtains sufficient rotational speed to provide what may be perceived to be multiple continuous solid concentric bands of water. Interaction of the water bands with cap 20 ultimately may provide the user with the sensation of multiple concentric simultaneously pulsating water streams.
[0048] [0048]FIG. 5 shows double pulsating hydrotherapy jet unit 40 . Cap 20 may be placed within rotating scallop plate 49 . Scallops 49 a on rotating scallop plate 49 allow the reduction of the flow of water supply 3 to double pulsating hydrotherapy jet unit 40 by rotating discharge member carrier 55 to occlude a portion of water conduit 32 as shown in FIG. 2.
[0049] In one embodiment, as shown in FIG. 6, cap 20 contains two series of 7 cylindrical openings 27 a - 27 g and 28 a - 28 g . Cap 20 has major ring openings 27 a - 27 g arrayed around the edge of cap 20 at a common radial distance from the center, or longitudinal axis of cap 20 that coincides with longitudinal axis 11 of discharge member 10 when assembled, i.e. in a circle. Also cap 20 has arrayed around its center a circle of minor ring openings 28 a - 28 g that are arrayed at a common radial distance from the longitudinal axis of cap 20 . In one embodiment the radius of major ring openings 27 a - 27 g may be greater than the radius of minor ring openings 28 a - 28 g.
[0050] [0050]FIG. 7 shows the curve of cap 20 , and cap edge ridge 23 . Cap edge ridge 23 assists in securing cap 20 within scallop ring 49 . This cross section of cap 20 partially exposes minor ring openings 28 e and 28 g.
[0051] [0051]FIG. 8 cuts directly through the center of major opening 27 b and minor opening 28 e . This specific arrangement of openings is one embodiment of a cap for a double pulsating hydrotherapy jet unit 40 . Other embodiments will be equally effective in providing the double pulsating hydrotherapy jet effect.
[0052] [0052]FIG. 9 shows an assembled double pulsating hydrotherapy jet unit 40 showing cap 20 and rotating scallop ring 49 . Scallops 49 a can be seen around the periphery of rotating scallop ring 49 . Scallops 49 a allow better finger grip while rotating scallop ring 49 to adjust the rate of flow of water supply 3 . Major ring openings 27 a - 27 g may be seen just inside rotating scallop ring 49 . Cap 20 on which major ring openings 27 a - 27 g are placed is in fact placed over and nestled within rotating scallop plate 49 . In one embodiment, minor ring openings 28 a - 28 g may be seen nested inside and between major ring openings 27 a - 27 g.
[0053] In one embodiment, shown in FIG. 10, cap 20 may have an opening 26 in its center. Center opening 26 may be used to allow discharge of centralized water outlet conduit 19 of FIG. 11.
[0054] As is shown in FIG. 10 a , upstream of openings 27 a through 27 g at the intersection of the openings are a series of ridges 25 forming a knife like edge between the openings. The ridges divert water provided from conduit 17 into one or more of openings 27 a through 27 g . The knife like edge acts to cut the water, diverting it into the openings. The cutting action allows the water to flow into openings without producing back flow as would be the case if the surfaces were flat. Similar ridges 24 may be seen at the intersection of openings 28 a through 28 g forming a knife like edge between the openings. These ridges divert water provided from conduit 18 into one or more of bore holes 28 a through 28 g , thus reducing backflow similar to ridges 24 .
[0055] In one embodiment, as shown in FIG. 11 discharge member 10 may contain a centralized water conduit 19 coaxial with the longitudinal axis 11 of discharge member 10 . The centralized water conduit provides a continuous nonpulsating jet to the user in addition to the series of pulsating jets.
[0056] [0056]FIG. 12 demonstrates how all the individual parts of double pulsating hydrotherapy jet unit 40 relate to one another, and are assembled. Front flange 42 and gasket 41 combine with locking thread ring 48 to grasp the side of a hydrotherapy spa or tub shell 70 (shown in FIG. 13). Gasket 41 prevents leakage of water from a hydrotherapy spa or tub shell 70 . Locking thread ring 48 screws down over exterior threading 43 with interior threading 50 . Rotational movement of locking thread ring 48 towards the front of double pulsating hydrotherapy jet unit 40 compresses front flange 42 against gasket 41 and compresses gasket 41 against a wall of hydrotherapy spa or tub shell 70 . Gasket 41 is seated behind front flange 42 . Housing 44 supports stationery and rotating portions of double pulsating hydrotherapy jet unit 40 . This assembly attaches double pulsating hydrotherapy jet unit 40 to the wall of hydrotherapy jet bath.
[0057] Mechanical mount retaining ring 60 is placed into Housing 44 to hold outer bearing sleeve 55 in a fixed position. Side wall channel 33 on outer bearing sleeve 55 permits water from water channel 32 to enter the interior of double pulsating hydrotherapy jet unit 40 . Discharge member carrier outer sleeve 72 permits attachment to rotating scallop plate 49 . Locking feature 61 locks and makes secure the attachment of discharge member carrier 72 to rotating scallop plate 49 .
[0058] Inner bearing sleeve ridge 62 is used as a stop to prevent bearing rakes 53 and 51 from moving too far forward along inner bearing sleeve 54 .
[0059] Discharge member 10 slides over and encompasses inner discharge member sleeve 67 . Discharge member 10 is held in place by the interlocking of sleeve attachment tab 66 and discharge member attachment slot 14 (shown in FIG. 1). Cap 20 is attached to rotating scallop plate 49 . Cap 20 is stationery compared to, and moves with rotating scallop plate 49 . Discharge member 10 is mounted at the down stream end of venturi sleeve 30 . Venturi sleeve 30 contains aerated water stream 5 . Discharge member 10 is designed so impingement by aerated water stream 5 generates a rotational moment causing discharge member 10 to spin about its axis of rotation 11 . Located down stream of discharge member 10 is cap 20 , which diverts the water flowing from discharge member 10 to produce simultaneous pulsating jets 8 and 9 .
[0060] As shown in FIG. 13, multiple jets can be installed in a spa or tub shell 70 . In this disclosure, spa shell is defined as any bath, pool, reservoir or spa capable of containing a fluid and enabling immersive recreation or therapy. Some or all of the jets can be one of the jets described above, with the jets in this embodiment being jet 40 . The remaining jets 71 may be any other desired type, such as a variety of prior single nozzle jets. Both types of jets are connected to a water pump 78 , used to circulate the water throughout the spa system, by a series of water conduits 73 . Water from shell 70 is provided to pump 78 through the drain 77 , which is connected through return water conduit 74 to pump 78 . Water from pump 78 is provided back to shell 70 by conduits 73 , where it flows into jets 40 and 71 , as the case may be, and in turn into shell 70 , completing the loop. Additionally, an air system 79 may be included that provides air to individual jets 40 and 71 through an air conduit 80 , to aerate the water flowing through the jet. The air system 79 can be pump driven to increase the pressure of the air entering the jet 8 , or can be vacuum based with the venturis located within the jets 40 and 71 drawing air into the jets and water flow stream.
[0061] [0061]FIG. 14 shows a flow diagram of one embodiment of the claimed invention. A hydrotherapy jet discharge is provided in block 141 . A plurality of water streams is discharged in block 142 . The water streams are rotated in concentric patterns around a common axis in block 143 .
[0062] Although the present invention has been described in considerable detail with references to certain preferred configuration thereof, other versions are possible. Therefore, the spirit and scope independent claims should not limited to the preferred version contain therein. | A pulsating hydrotherapy jet is disclosed which has a jet body with a water inlet to allow water to flow into the body. The jet body discharges the water through a discharge member in more than one concentric pattern. A cap mounted on the body to receive the circular water patterns is also disclosed. The cap has a number of openings that form more than one concentric opening ring. Each of the opening rings align with a respective one of the circular water patterns to provide the sensation of a number of circular patterns of multiple pulsating jets. A system for providing a hydrotherapy jet to a reservoir of water is also disclosed. The system includes a reservoir shell capable of holding water with a number of hydrotherapy jets according to the invention that are mounted around the reservoir shell. A water pump system circulates water from the reservoir to the jets. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to a ceiling suspension system and, more particularly, to a ceiling suspension system that will position a new ceiling over an existing ceiling and with only an approximately one inch loss in ceiling height.
2. Description of the Prior Art
The fastening of runners to an existing ceiling is known in the art and cross-runners have been utilized therewith. The particularly inventive feature of the runner structure herein is the utilization of a locking means to position and hold the cross-runner in position relative to the main runner structure.
SUMMARY OF THE INVENTION
Two first or main runners are provided having a generally z cross-section. The upper flange of the runners are nailed to an existing ceiling and the lower flanges form the support for a ceiling board. At least one cross-runner of a conventional inverted T-shape is utilized and the cross-runner rests upon the horizontal flanges of the main runner. There is a notch provided in the upper end of the vertical web of the cross-runner and a projection is positioned on the nailing flange of the main runner so that the notch and projection will engage each other and hold the cross-runner in position between two main runners. The cross-runners are provided with an offset lip so that when the cross-runner lower flanges rest upon the lower flanges of the main runners, the bottom portion of the runners of both the main runner and the cross-runner are in the same plane.
The ceiling structure above permits the use of a method for positioning the cross runner in position between two main runners. A space is formed between the existing ceiling and the lower horizontal flanges of the main runners and this space is approximately one inch in size. The cross-runners are longer in length than the spacing between the ends of the flanges of two adjacent main runners. One end of a cross-runner is inserted into the space between the horizontal flanges of one main runner and the existing ceiling. This permits the other end of the cross-runner to move above the plane of the lower flange of the adjacent main runner. The cross-runner is now moved laterally so that the ends of the cross-runner may rest upon the horizontal flange of the main runners. A notch and groove locking arrangement locks the cross-runner in position so that it may not be accidentially moved laterally whereby one end of the cross-runner will drop away from the flange of the main runner.
BRIEF DFESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a crossrunner;
FIG. 2 is a perspective view of a main runner;
FIG. 3 is a perspective view of another embodiment of a main runner:
FIG. 4 is a cross-sectional view of an existing ceiling eyetem with the cross-runner and ceiling board in position;
FIG. 5 is a cross-section of an existing ceiling showing the cross-runner and ceiling board being positioned between two adjacent main runners: and
FIG. 6 is a cross-section of another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The ceiling system of the drawings comprises at least two first runners 2. Each first runner has a generally z cross-section, a vertical web 4, and, at the lower end of the vertical web, equal width horizontal flanges 8. The flanges extend either side of the vertical web perpendicular to the web. At the top of the vertical web 4 there is a single long upper horizontal flange 10 extending from one side of the vertical web perpendicular to the web. The single horizontal flange 10 is of a width greater than the width of a lower flange as measured from the vertical web 4 to the end of one portion of the horizontal flange extending to one side of the vertical web. This size difference can clearly be seen in FIG. 2. The upper flange 10 has a projection 12 near the end thereof extending therefrom in the direction towards the lower flange. The first runners or main runners are adapted to be fastened by nails 16 to the face of the an existing ceiling. As seen in FIG. 3, the existing ceiling would be primarily rafters 14 covered with some type of covering 15 which could be drywall or some other like material. The means 16 fastens the upper flange of the runner 2 to the existing ceiling with the lower flanges 8 of the first runner or main runner spaced approximately one inch from the surface of the existing ceiling and parallel to the face of the existing ceiling.
There is provided at least one cross-runner 18 which has an inverted T-shape. The cross-runner has a vertical web 20 with an upper and lower end. At the lower end of the vertical web, there is equal width horizontal flanges 22 extending either side of the vertical web parallel to the web. At the upper end of the vertical web, near each end thereof, there is positioned a notch 24. As seen in FIG. 3, a cross-runner is positioned between two adjacent first runners 26 and 28 with one end of the cross-runner resting on the lower flange of first runner 26 and the other end of the cross-runner resting on the lower flange of the adjacent first runner 28 with the notch on the right end of the cross-runner engaging the projection on the upper flange of first runner 28 whereby the projection and notch engagement holds the cross-runner in position between two adjacent runners. It can be seen in FIG. 8 also that the horizontal flanges of the first runner and naturally, the cross-runner will support the edge of a ceiling board 30. It can be seen in FIGS. 1 and 3 that the ends of the cross-runner rest on the lower flange of the first runners and that each end of the cross-runner is formed with an offset lip 32 so that the bottom of the main runner flange and the bottom of the cross-runner flange are in the eame plane.
FIG. 4 shows the method of positioning a new ceiling over an existing ceiling. On the left side of FIG. 4, there is shown a cross-runner and on the right side of FIG. 4, there is shown a ceiling board. Both are mounted in position in the same manner. The overall length of the cross-runner or ceiling board is greater than the distance between the edge of the right lower flange of runner 26 and the edge of the left lower flange of runner 28. A space exists between flange 26 and the existing ceiling and this space is approximately one inch. One end of a cross-runner or a ceiling board is inserted into this space. This provides sufficient clearance for the other end of the cross-runner or ceiling board to clear the edge of the horizontal flange of the adjacent main runner 28. Once the edge of the lower flange of runner 28 is cleared, the cross-runner or ceiling board can be moved laterally left to right and the cross-runner or ceiling board is positioned as shown in FIG. 3.
Another embodiment of the invention is shown in FIG. 5. Unequal eize bottom flanges 33, 34 are shown on runner 36. The total width of the two flangee is the same as the width of the flanges of runner 28, but the sizes of the flanges 33, 34 are about 1/3 total width and 2/3 total width while runner 28 has equal width flanges.
The unequal flange width will permit the use of the standard flat ceiling board which will have its edges rest on the flanges. However, a means must be provided to keep the board from shifting laterally and falling out of the runner system. Ceiling board 80 is held in place since part of the edge of the board contacts the edge of the flanges upon which it rests (see FIG. 3). The same is true for cross-runner 18 (offset lips 32). with the flat board 38 in place on the right side of FIG. 5, a tab 40 will engage the side of the board 38 and keep it from shifting laterally out of the runner system. The tab 40 on the left side of the board and the web of the runner on the right side of the board will retain the board 30 on the flanges of the adjacent runners 36.
The flat board 38 is positioned on the runners as per the board 30 and cross-runner 18. The left edge of the board must be raised above and pass over tab 40 for the right edge of the board to clear the edge of the flange of the right runner. | A runner system is provided to position a new ceiling over an existing ceiling and to position the new ceiling within a one inch space from the surface of the existing ceiling. A z-shaped runner is fastened to the existing ceiling and ceiling boards will rest on the horizontal flanges of the z-shaped runner. A cross-runner is also designed to rest upon the horizontal flanges of the z-shaped runner and an indentation and groove arrangement locks the cross-runners in position between the two adjacent main runners. | 4 |
DESCRIPTION
1. Technical Field
A multiple rotor turbine fan engine is constructed in modules in such a manner that, for example, the fan rotor and pitch control for the fan, low pressure compressor and the gearbox may be removed as a module. Further, the front end of the engine may be broken into several packages or modules such as the nose cone and gearbox cover, the fan drive and gearbox support, the low pressure compressor and the fan rotor and pitch control for the fan.
2. Background Art
It is general practice to make an engine in modules which are separately removable from the basic engine for ease in shipment and assembly as well as for disassembly for replacement of certain parts. The present construction goes further in making different modules and in facilitating the ease of assembly and disassembly. The present concept is intended to also permit the removal of the entire core engine as a unit with a minimum of disassembly. Many constructions require removal of more or less of the main engine cowl for access to the engine supports. The present invention contemplates removal of the core engine or any of the several modules without removal of any portion of the surrounding main cowl and the support struts remain in position while the engine or modules are removed from within the main cowl or are repositioned within the main cowl.
DISCLOSURE OF INVENTION
According to the present invention a forward section and a rearward section of an airplane gas turbine engine core are separately removable from an airplane pylon, with the corresponding forward or rearward sections remaining on the airplane pylon. In one embodiment, the forward section includes the low pressure compressor and certain assemblies forward thereof; the rearward section includes the high pressure compressor and certain assemblies rearward thereof. Separation of the forward and rearward assemblies occurs at the point of attachment of the end shaft (186) of the low pressure rotor to the low pressure shaft (18) and a circle of bolts (186) on support structure inwardly of struts (6) extending across the fan stream from a main cowl (2). The main cowl and the forward or rearward section that is not disassembled remain affixed to the airplane at a pylon (4). Removal of the forward sections from the airplane may require disassembly from the fan rotor and pitch changing mechanism, such as at bolts (154) and (146), or, alternatively, disassembly of the fan rotor and pitch changing mechanism from the support structure at a circle of bolts (49).
According to a detailed embodiment of the invention, the rear core cowl (42) for an engine is removable to permit removal of the exhaust nozzle and also provide access to the connection between the core engine and the support struts. Removal of the rear core cowl permits access to the attachments for the low pressure compressor for removal of the compressor and the parts of the engine forward of the compressor as a unit. Further, the nose cone cowl and shroud ring may be separable and moved forward to provide access to the nose cone attachment and to permit access to the fan blade mounts for removal of the individual fan blades. With suitable access to the inner module attachments, the nose cone is removable as a unit or as a pat of the larger module including the fan rotor and support, the gearbox and the low pressure compressor.
The principal feature of the detailed embodiment of the present invention is an arrangement to provide access to the core engine by removal of the core cowls that define part of the inner wall of the fan gas path within the main cowl. Another feature is an arrangement to provide access to the fan blade mounting so that the fan blades may be separately removed thereby to permit forward removal of one or more modules at the front of the engine, such as the fan rotor and pitch changing mechanism, the gearbox and drive for the fan, and the gearbox support and the low pressure compressor.
The foregoing and other objects, features and advantages of the present invention will become more apparent from the following description of preferred embodiments and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG.. 1 is a side view of a turbofan engine shown partly broken away.
FIGS. 1A, 1B and 1C are views which are partly broken away and partly in section of the forward, middle and aft sections of the engine of FIG. 1.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring first to FIG. 1, the engine is supported within a generally cylindrical main cowl 2, the later being supported from the aircraft by a pylon 4. This main cowl defines the outer wall of the path for the fan air through the device. Radial struts 6 extending inwardly from the cowl 2 engage an inner ring or sleeve 8 having axially spaced disk like flanges 10 and 11 extending inwardly therefrom and serving to support the core engine 12.
The core engine includes a multistage axial flow low pressure compressor 14 and a multistage low pressure turbine 16 connected by a low pressure shaft 18. The high pressure compressor 20 downstream of the low pressure compressor is driven from a high pressure turbine 22 being connected to the high pressure compressor 20 by a high pressure shaft 24 surrounding the low pressure shaft. Between the high pressure compressor and the high pressure turbine is a combustion chamber structure 26 where fuel is burned in the air passing through the engine in order to provide the energy to drive the turbines. The high pressure compressor, the combustion chamber and the high pressure turbine form a basic conventional structure and need not be described in detail. It will be understood that this module includes bearings for the high pressure compressor and for the high pressure turbine.
Attached to the forward end of the low pressure compressor is the gearbox structure 27 including a sun gear 28 driven from the low pressure shaft 18 and in mesh with pinions 30, only one of which is shown. The ring gear 32 surrounds the pinions gears and is connected, as will be described later, to the fan ring 34 in which the fan blades 36 are mounted. These blades extend across the fan air path and nearly into contact with the main cowl 2 near its forward end.
Mounted at the front of the gearbox structure is the nose cone structure 38 which may incorporate the engine lubricating structure as described in a copending U.S. application Ser. No. 067,340. Surrounding and enclosing the nose cone structure is a nose cone cowl 40 which defines the inner wall of the gas path to the compressor at the engine inlet.
At the rearward part of the engine, the core cowl 42 is attached to the rearward end of the inner ring 8 as by bolts 44. This core cowl defines the inner wall of the gas path for gas leaving the fan. Within the core cowl 42 is an exhaust nozzle 46 secured at its forward end to the low pressure turbine casing by bolts 48 that are accessible when the core cowl is removed. The rearward end of the core cowl engages and pilots the outer portion of the exhaust nozzle at its forward end and thus supports the rearward end of the engine.
In this disassembly the core cowl 42 is removed from its attachment of the ring 8, this being by the row of bolts 44 accessible from within the fan air path. After this core cowl 42 is removed rearwardly the nozzle 46 may be removed from its attachment to the housing. This attachment is the row of bolts 48 accessible through the space made available by rearward removal of the cowl 42.
Removal of cowl 42 also permits access to a row of bolts 49 holding the flange 11 to a flange on the outer part of the housing 50 supporting the pitch changing mechanism 52 for the fan blades. Removal of this row of bolts 49 will separate the core engine from the struts 6.
For forward removal of the core engine as a unit, the fan blades must be removed. The fan blades are individually removable to permit the low pressure compressor surrounded by the fan and its module to be removed from the front of the main cowl. As shown in FIGS. 1A and 1B, the fan blades 36 are carried by the ring 34 which is supported on a bearing 62 mounted on the housing 50 and being carried on a conical element 64 integral with and extending inwardly from the ring 34. The fan blade roots are supported in bearing 66 in radial openings 68 in the ring. These bearings engage a flange 70 on the blade root and are held in position by ring 72. The ring in turn is held in place by a split collar 73 engaging under a flange 74 on the blade root. Access to the collars 74 is possible by removal of sleeves 75 and 76 mounted on the ring 34 just under the inner ends of the airfoil portion of the blade. These sleeves may be held in position by screws not shown engaging the ring, and by removal of these screws the sleeves, which are split, may be slid out axially for access to the collars. Removal of ring 72 also permits the removal of the bearings 68, and by turning the blade so that the arm 78 on the inner end of the blade extends forwardly the blade may be moved outwardly and forwardly for removal. The arm 78 will have been previously disconnected from the actuating link 80 by removal of one connecting pin 81, this link being utilized for pitch control of the blade. Slots 82 in the element 64 permit these links to extend therethrough.
With the fan blades removed, the entire core engine with the nose cone, gearbox structure, and the fan blade mechanism all attached thereto may be moved forwardly within the main cowl and removed as a unit from the aircraft. It will be obvious that the supporting bolts 49 would have been removed in order for this forward movement of the core engine.
The actuators 208 for the pitch changing mechanism will have been unpinned from the sleeve 212, hereinafter described in detail. The slip joint 223 between the seal member 226 and the inner shroud ring 8 also later described in detail permits axial movement at this location. The engine rearwardly of the flanges 10 and 11 is smaller in diameter than these flanges so the engine may be moved forwardly out of the surrounding structure as a unit.
Alternatively for convenience, portions of the forward parts of the engines may be removed separately, for example, the nose cone structure 38 may be removed as a unit by removing a row of bolts 84 attaching the rear edge of the nose cone cowl 40 to the gearbox structure at its periphery. The bolts 84 extend through bosses 86 in the rear edge of the nose cone cowl 40 and through a cylindrical flange 88 on a housing 90 forming a part of the lubricant mechanism enclosed within the nose cone cowl. The nose cone cowl 40 has inlet ducts 92 that separate by a sliding fit 93 from a shield 94 covering the impeller 96 of the air pump. In this way, the nose cone cowl is removable by direct forward motion.
With the removal of the nose cone cowl access is possible past the air-oil cooler 98 to a row of bolts 102 that hold the housing 90 to the reduction gear housing 104 for the fan drive.
With the removal of bolts 102, the lubricating and oiling system located within the nose cone is slideable forward as a unit. This system includes the air-oil cooler 98, and the scavenge and pressure pumps in a housing 100. The drive gear 111 for the shaft 112 for the pumps is in mesh with a pinion gear 114 on a shaft 115 in bearings 116 supported by a part of the housing 90. This shaft 115 also carries the impeller 96 for the air cooling flow through the air-oil cooler. Since the air connections and lubricant connections for these several elements are not a part of the present invention they will not be described in detail.
A drive sleeve 120 splined at both ends connects with the shaft 115 to a second drive sleeve 122. The second drive sleeve 122 is splined at 124 to the low pressure compressor rotor and carries at its forward end the sun gear 28.
The gearbox housing 104 has stubs shafts 126 thereon that support the pinion gears 30 on bearing 130. These pinion gears in turn are in mesh with the sun gear 28 and a surrounding ring gear 32. This ring gear is secured by bolts 133 to a sleeve 134 forming the inner wall or shroud of the gas path and is connected through vanes 136 to the outer shroud 138. The outer shroud has a flange 140 bolted as by bolts 142 to a ring 144, the other end of which is held as by bolts 146 to a flange 148 on the fan blade ring 34. The strut, consisting of the shrouds 134, 138 and the vanes 136, is mounted on the reduction gear housing 104 on bearing 150.
Access to bolts 142 and 146 is possible by removal of a shroud ring 152 forming the leading end of the inner wall of the fan gas path. The shroud ring is held in position by bolts 154 extending through cooperating cylindrical flanges 156 and 158 on the ring 144 and the shroud ring. Shroud ring 152 is piloted at its forward end by a sliding fit 160 with the shroud ring 138.
With the removal of bolts 141, connecting the gearbox housing 104 to the support structure 108, and also bolts 142 and 146, the reduction gear mechanism may be removed as a unit. The separation is possible at the drive mechanism since the splines 124 on the rearward end of the sleeve 122 have a sliding relation to the cooperating splines 164 on the low pressure compressor rotor shaft 186.
As a further breakdown, the engine may be separated between the low pressure compressor and high pressure compressor such that the entire portion of the engine forward of the inner immediate strut or case 165 between the low pressure compressor and high pressure compressor is separable as a complete unit. The housing 50 is connected to the case 165 that extends inwardly rearwardly of the low pressure compressor case 166 and is bolted thereto and to the housing 50 by bolts 168. These bolts hold the inner edge of the housing 50 to a flange 170 on the intermediate case 165 to a flange 172 on the low pressure compressor case 166 and to a flange 173 on the inner race for the bearing 62 at the inner end of the conical element 64.
The intermediate case 165 has inner and outer shrouds 176 and 178 connected by struts 180 that cross the gas path from the low pressure to the high pressure compressors. From the forward end of this intermediate case a flange 182 thereon supports a conical element 183 for the support of a bearing 184 mounted on a shaft 186 at the end of the low pressure compressor rotor. This bearing and the adjacent seal 188 also on the shaft have a sliding fit with the outer bearing race 190 and a cylindrical seal flange 192 at the inner edge of a ring 193 attached to the element 183 to permit axial disengagement at this point. The end of the shaft 186 also carries another seal 194 engaging with a flange 196 on the forward end of the high pressure compressor shaft 195 and is axially separable.
The end shaft 186 of the low pressure rotor is splined as at 198 to the drive shaft 18 extending forward from the low pressure turbine and is held thereon by a threaded clamping ring 202. Access to this clamping ring is possible by a suitable wrench extending rearwardly from the front end of the engine. To make this possible, the end cap 204 on the front end of the impeller shaft 115 is threaded as at 126 thereon for removal. With the removal of this cap a wrench may reach the ring 202 for removing it.
One further step is necessary to divide the engine between the low pressure and high pressure compressor. The pitch of the fan blade is controlled from a plurality of actuators 208, the actuating stems 210 of which are attached to a axially slideable sleeve 212 positioned in a guide 214 in the housing 50. The sleeve 212 carries a thrust bearing 216 connected it to a surrounding sleeve 218 in a guide ring 220 supported by the fan ring 34. The thrust bearing insures that the sleeves 212 and 218 will move axially in unison but with rotation permitted between them since the sleeve 212 is not rotatable and the sleeve 218 rotates with the fan ring. The sleeve 218 is connected by the links 80, above described, to the arms 78 on the individual fan blades. When the blades are to be removed or attached to the links 80, the actuators 208 are caused to move the ring 218 forward for access to the forward end of the rings through the space made accessible by removal of the sleeve 144. The actuators 208 are secured by pins 224 to suitable bosses 224a on the flange 10 carried by the strut 6.
To separate the actuator 208 from the sleeve 212, in separating the engine at the point between the two compressors, the actuators are caused to move the sleeve 212 as far to the rear as possible. Since the links 80 are now free of the blade arms, the sleeve 212 may move to the right beyond the position shown in the drawing giving access to the pins 225 that hold the stems 210 to the sleeve 212. These pins are accessible from in back of the flange 10, the core cowl 42 having previously been removed.
In this way, once the nose cone cowl 40 and the end cap 204 are removed, the ring 202 may be undone. Following that, the removal of the bolts 49 and 168 will permit the engine to be taken apart at the downstream end of the low pressure compressor. The inner shroud 8 from the strut 6 has a sliding connection 223 with a seal carrying member 226 surrounding the actuating mechanism for the blade pitch changing mechanism. This member has an end flange 227 by which it is secured by the same bolts 49 that hold the housing 50 to the flange 11 of the strut 6.
As a forward part of the engine is moved forward to separate the engine at the downstream end of the low pressure compressor, the inner shroud 229 on the last row of vanes 231 in the low pressure compressor separates from a piloting notch 230 on the intermediate housing 165, as the end of the low pressure compressor rotor 186 with the seal 188 and bearing 184 thereon, pulls forward from the surrounding ring 193 and flange 192, and the spline connection 198 permits the shaft 186 to slide from the end of the drive shaft 18.
With this arrangement the high pressure compressor shaft 195 is still supported in place at its upstream end to hold the high pressure compressor rotor in position. To accomplish this, a bearing 232 is supported in a ring 234 which is mounted on an inner flange 236 on the inner shroud 176 for the intermediate strut.
The support structure 108 for the bearing 110 is bolted at its outer end to a flange 234 on the inner shroud 236 of the support strut 238. The inner shroud 236 and an outer shroud 240 are interconnected by strut 238 extending across the gas path for air entering the low pressure compressor. The outer shroud has a flange 244 connected to a flange 246 on the low pressure compressor case.
It will be understood that the individual modules of the forward section of the engine may be separated from one another after this forward section has been removed as a unit. Once the nose cone cowl and nose cone with its enclosed structure are removed the gearbox structure may be removed as a unit. This is possible since with the removal of bolts 141, the housing 104 is free to move and the pinion gears on the housing are free to move axially on the ring gear. The bearing 150 is axially slideable on the outer bearing race 248 and an adjacent seal 250 on the housing is free to slide axially on its cooperating surface 252 on the inner shroud 134. The ring gear, the bearing, the race 248 and surface 252 are stepped in dimension so that the bearing and seal will both pass through the ring gear.
Once the forward module is removed from the core engine, the fan blade ring 34 and the pitch changing mechanism may be removed rearwardly as a unit from its surrounding relationship to the low pressure compressor. The removal of the bolts 146 releases the fan ring, and since the bolts 49 and 168 have been already removed, the housing 50 and conical structure 64 together with the ring 34 and the pitch changing mechanism will be removed rearwardly as a unit. This then leaves the low pressure compressor a module by itself and may be overhauled as desired or as required under the circumstances.
One further possible modular separation is the removal of the low pressure compressor, and the parts forwardly thereof from the remainder of the installation leaving the fan and the pitch changing mechanism still with the support structure. By removal of the bolts 168 and the disconnection of the fan ring 34 from the gearbox by removal of the drive sleeve 144, the fan ring and the pitch changing mechanism may remain with the low pressure compressor removed forwardly from within the supporting fan ring structure 50.
It should be understood that the invention is not limited to the particular embodiments shown and described herein, but that various changes and modifications may be made without departing from the spirit and scope of this novel concept as defined by the following claims. | A gas turbine fan engine with improved maintainability features is disclosed. Forward and rearward sections of the core of the engine are joined one to the other, and each are independently separable from the pylon on which the engine is mounted without the necessity of removing the other from the airplane. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a U.S. continuation patent application of, and claims priority under 35 U.S.C. §120 to, U.S. nonprovisional patent application Ser. No. 12/228,071 (the “'071 Application”), which '071 Application was converted to a non-provisional patent application from U.S. provisional patent application Ser. No. 61/030,219 (the “'219 Application”), which '219 Application was filed Feb. 20, 2008, and which '071 Application published on Aug. 20, 2009 as US 2009/0205218 A1. All of the above-mentioned patents, patent applications, and patent application publications are incorporated by reference herein.
COPYRIGHT STATEMENT
[0002] All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.
BACKGROUND OF THE INVENTION
[0003] The present invention generally relates to a vessel for dispensing steam or moisture into a clothes drying environment, and particularly to a vessel for dispensing steam or moisture to a batch of clothes that has been left in a clothes dryer for a period of time following termination of the drying cycle.
[0004] For many families and individuals, the task of washing and drying clothing, towels, and other articles is ongoing. Quite often, as one batch of clothing articles is completed, another is ready to begin. Even with the aid of advanced washing machines and clothes dryers, washing and drying clothing articles can become an obligation that quickly fills an entire day. Washing and drying cycles for conventional washing machines and clothes dryers can have varied lengths, depending on the size of the batch of clothing articles to be washed and dried. Inevitably, busy families and individuals can lose track of the status of a batch of clothing articles during one of these cycles. As a result, it is not at all uncommon for a batch of clothing articles to sit unattended in a washing machine or clothes dryer following termination of the corresponding cycle.
[0005] In particular, with respect to the drying component of the overall process, a batch of clothing articles that is left unattended following termination of the drying cycle can become wrinkled, matted, or clumped together if left for a prolonged period of time. When this occurs, individual clothing articles may be virtually unusable without being refreshed. In order to refresh the batch of clothing articles following termination of the drying cycle, individuals may consider restarting the drying cycle so as to “fluff” the batch of clothing articles before removal from the clothes dryer. However, such attempts to refresh often do not assist with the removal of wrinkles from individual articles because the batch of clothing articles is already dry. As such, a need exists for a device or method that is capable of refreshing a batch of clothing articles that has been left in a clothes dryer for a period of time following termination of the drying cycle.
[0006] Conventional drying aids, such as dryer sheets and dryer balls, are intended for use in connection with a batch of clothing articles at the beginning of the drying cycle when the clothing articles are still wet from the washing cycle. Dryer sheets typically assist with softening the underlying fabric of the clothing articles and may reduce static between individual clothing articles during the drying cycle. Dryer balls typically facilitate greater air flow between clothing articles during the drying cycle, thereby enhancing the drying process by increasing air circulation in the clothes dryer. However, these conventional drying aids are unable to assist in refreshing or removing wrinkles from a batch of clothing articles that is already dry.
[0007] Therefore, a need exists for improvement in the field of drying aids for conventional clothes dryers, and particularly in connection with refreshing a batch of clothing articles that has been left in a clothes dryer for a period of time following termination of the drying cycle. This, and other needs, is addressed by one or more aspects of the present invention.
SUMMARY OF THE INVENTION
[0008] The present invention includes many aspects and features. Moreover, while many aspects and features relate to, and are described in, the context of dispensing vessels for clothes dryers, the present invention is not limited to use only in connection with dispensing vessels for clothes dryers, as will become apparent from the following summaries and detailed descriptions of aspects, features, and one or more embodiments of the present invention.
[0009] Accordingly, one aspect of the present invention relates to a dispensing vessel for introducing moisture to a clothes drying environment. An exemplary such dispensing vessel includes a core and a cover substantially surrounding the core. In this aspect of the invention, the core is comprised of a sponge-like material for at least temporarily retaining a moistening substance within the core. Additionally, the cover has at least one opening extending through to the core for permitting the release of moisture to the clothes drying environment. As used herein, the term “moisture” may refer to liquids, gases, or combinations thereof.
[0010] In a feature of this aspect of the invention, the dispensing vessel may further include one or more protuberances. Furthermore, each of the one or more protuberances may have a flattened tip.
[0011] Another aspect of the invention relates to a method of using a dispensing vessel for introducing moisture to a clothes drying environment, wherein the dispensing vessel includes a core and a cover substantially surrounding the core. An exemplary such method includes introducing a moistening substance to the core of the dispensing vessel, placing the dispensing vessel in a clothes dryer with a batch of clothing articles, and configuring the clothes dryer to operate at a heat setting. Moisture is released from the core of the dispensing vessel to the clothes drying environment via at least one opening in the cover of the dispensing vessel. As used herein, the phrase “clothing articles” may refer to clothing, towels, accessory garments, or related articles.
[0012] In addition to the aforementioned aspects and features of the present invention, it should be noted that the present invention further encompasses the various possible combinations of such aspects and features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] One or more preferred embodiments of the present invention now will be described in detail with reference to the accompanying drawings, wherein the same elements are referred to with the same reference numerals, and wherein,
[0014] FIG. 1 is a perspective representation of an embodiment of a dispensing vessel in accordance with one or more aspects of the present invention; and
[0015] FIGS. 2-7 are perspective representations of another embodiment of a dispensing vessel in accordance with one or more aspects of the present invention.
DETAILED DESCRIPTION
[0016] As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (“Ordinary Artisan”) that the present invention has broad utility and application. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the present invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure of the present invention. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.
[0017] Accordingly, while the present invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present invention, and is made merely for the purposes of providing a full and enabling disclosure of the present invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded the present invention, which scope is to be defined by the claims and the equivalents thereof It is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.
[0018] Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection afforded the present invention is to be defined by the appended claims rather than the description set forth herein.
[0019] Additionally, it is important to note that each term used herein refers to that which the Ordinary Artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the Ordinary Artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the Ordinary Artisan should prevail.
[0020] Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. Thus, reference to “a picnic basket having an apple” describes “a picnic basket having at least one apple” as well as “a picnic basket having apples.” In contrast, reference to “a picnic basket having a single apple” describes “a picnic basket having only one apple.”
[0021] When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Thus, reference to “a picnic basket having cheese or crackers” describes “a picnic basket having cheese without crackers”, “a picnic basket having crackers without cheese”, and “a picnic basket having both cheese and crackers.” Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.” Thus, reference to “a picnic basket having cheese and crackers” describes “a picnic basket having cheese, wherein the picnic basket further has crackers,” as well as describes “a picnic basket having crackers, wherein the picnic basket further has cheese.”
[0022] As used herein, the specific term “moisture” may refer to liquids, gases, or combinations thereof Additionally, as used herein, the specific phrase “clothing articles” may refer to clothing, towels, accessory garments, or related articles.
[0023] Referring now to the drawings, one or more preferred embodiments of the present invention are next described. The following description of one or more preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its implementations, or uses.
[0024] Turning now to FIG. 1 , an embodiment of a dispensing vessel 10 in accordance with one or more aspects of the present invention is shown. The dispensing vessel 10 includes a core 12 and a cover 14 . The core 12 is preferably composed of a sponge-like material that is capable of absorbing and at least temporarily retaining a moistening substance. The cover 14 substantially surrounds the core 12 and includes at least one opening 16 that extends through to the core 12 of the dispensing vessel 10 . As will be explained in greater detail below, when the dispensing vessel 10 is in use in a clothes drying environment, moisture is permitted to pass from the core 12 to the clothes drying environment via the at least one opening 16 .
[0025] As shown in FIG. 1 , the cover 14 of the dispensing vessel 10 may have a generally spherical shape, thereby providing the dispensing vessel 10 itself with a generally spherical shape. Although a spherical shape is shown, other shapes are also contemplated, such as an oblong shape or a cube shape. The cover 14 of the dispensing vessel 10 may be composed of any material that might be preferred. Advantageously, the cover 14 may be composed of a durable material that is capable of withstanding the high heat typically associated with conventional clothes dryers, such as a durable plastic or rubber material. The cover 14 may also be configured to have a rigid or semi-rigid character. The core 12 may be composed of any material that provides the ability to retain a moistening substance at least temporarily, such as a sponge or sponge-like material.
[0026] As further shown in FIG. 1 , the dispensing vessel 10 may include a fill opening 22 to provide an entry portal through which a moistening substance may be added to the core 12 . The fill opening 22 may be any particular size as might be preferred. Advantageously, the fill opening 22 is sufficiently large so as to permit the core 12 of the dispensing vessel 10 to be removed or replaced. Removal or replacement of the core 12 may become necessary following repeated usage of the dispensing vessel or if the material comprising the core 12 becomes soiled or worn. A cap or lid (not shown) may also be included so as to provide a means of selectively sealing the fill opening 22 after the moistening substance is added to the core 12 . The moistening substance may be any particular substance that can be added to the core 12 in order to provide moisture. Preferably, the moistening substance is a liquid that may be poured into the dispensing vessel 10 through the fill opening 22 to the core 12 . As the dispensing vessel 10 is filled, the sponge-like material of the core 12 absorbs and at least temporarily retains the moistening substance. Additives may be included in the moistening substance to convey desired properties thereto as might be preferred. For instance, a scented substance may be added to the moisturizing substance so as to add a desired scent.
[0027] As further shown in FIG. 1 , at least one opening 16 may be arranged on the cover 14 , that extends through to the core 12 of the dispensing vessel 10 . While any number of openings 16 may be incorporated in the dispensing vessel 10 , FIG. 1 depicts a plurality of openings 16 spaced along the cover 14 at relatively even intervals. The size of the at least one opening 16 may vary. Preferably, the size of the at least one opening 16 is not so large as to permit immediate spillage of the moistening substance from the core 12 . Advantageously, it is also within the scope of the present invention not to include openings 16 opposite of the fill opening 22 . In this regard, the moistening substance added to the core 12 through the fill opening 22 is less likely to seep out of the dispensing vessel 10 prior to use.
[0028] In a method of use of the dispensing vessel 10 , a moistening substance may be introduced to the core 12 through the fill opening 22 . If a cap or lid is present, the cap or lid may be affixed to the cover 14 so as to seal the fill opening 22 , thereby helping to prevent spillage of the moistening substance. The moistening substance is absorbed and at least temporarily retained by the sponge-like material of the core 12 . Optionally, an additive may be included in the moistening substance or added to the core 12 separately in order to provide the moistening substance with a desired property, such as a specific scent. The filled dispensing vessel 10 may then be placed in a clothes dryer with a batch of clothing articles. In a preferred aspect of the method, the batch of clothing articles has previously completed a drying cycle in the clothes dryer and has been left in the clothes dryer for a period of time following termination of the drying cycle, after which time the batch of clothing articles may have become wrinkled, matted, or clumped together.
[0029] Following placement of the filled dispensing vessel 10 in the clothes dryer, the clothes dryer is configured to a drying cycle with a heat setting. During the drying cycle, moisture is released from the core 12 of the dispensing vessel 10 to the clothes drying environment through the at least one opening 16 in the cover 14 of the dispensing vessel 10 . Moisture from the dispensing vessel 10 thereby assists with the removal of wrinkles from individual articles in the batch of clothing articles. Additionally, if a scented additive is included with the moistening substance, the dispensing vessel may simultaneously impart the desired scent to the batch of clothing articles in the clothes dryer, which may further refresh the batch of clothing articles. In a preferred aspect of the method, a high level of heat from the drying cycle of the clothes dryer may facilitate moisture being released from the dispensing vessel 10 as steam, which may enhance the removal of wrinkles. Additionally, a plurality of dispensing vessels 10 may be used simultaneously in connection with a large batch of clothing articles.
[0030] The dispensing vessel 10 may thus be used to provide moisture to the clothes drying environment. Use of the dispensing vessel 10 may assist with the removal of wrinkles from a batch of clothing articles and otherwise refresh the batch of clothing articles following termination of the drying cycle.
[0031] Turning now to FIGS. 2-7 , another embodiment of a dispensing vessel 110 in accordance with one or more aspects of the present invention is shown. The dispensing vessel 110 may include one or more protuberances 18 . The one or more protuberances may be formed as an integral component of the cover 14 , as specifically set forth in FIGS. 2-7 , or the one or more protuberances may be attached to the cover 14 as separate, individual components. As separate components, individual protuberances may be replaced as needed if damage occurs or if differently shaped protuberances are desired. As with the cover 14 , the composition of the protuberances 18 may vary. Advantageously, the one or more protuberances 18 are each composed of a durable material that is capable of withstanding the high heat typically associated with conventional clothes dryers, such as a durable plastic or rubber material. Preferably, the one or more protuberances 18 are composed of the same material as the cover 14 .
[0032] The one or more protuberances 18 may be shaped so as to facilitate air flow between clothing articles in a clothes drying environment, such as a conventional clothes dryer. As shown in FIGS. 2-7 , the one or more protuberances 18 may be generally evenly spaced on the cover 14 of the dispensing vessel 10 . During use of the dispensing vessel 110 in a clothes dryer, the one or more protuberances 18 help to lift and separate individual clothing articles, thereby assisting with airflow between and among individual clothing articles in the clothes drying environment. Enhancing the airflow in the clothes drying environment permits moisture released from the dispensing vessel to be dispersed more evenly in a batch of clothing articles, which thereby enhances the effectiveness of the dispensing vessel 110 in removing wrinkles from individual clothing articles.
[0033] As shown in FIGS. 2-7 , each of the one or more protuberances 18 may be shaped as a chunky knob that extends outwardly away from the cover 14 with a flattened tip 20 at an end thereof The chunky shape and the flattened tip 20 of the one or more protuberances 18 may enhance lifting and separating of individual clothing articles in a batch of clothing articles. In particular, the chunky shape and flattened tip 20 may loosen a matted or clumped batch of clothing articles that may have been left in the clothes dryer for a lengthy period of time following termination of an initial drying cycle. During use of the dispensing vessel 110 , the flattened tip 20 of the one or more protuberances 18 impacts and bangs into individual clothing articles to loosen and separate a matted or clumped batch of clothing articles, which thereby provides enhanced airflow to the clothes drying environment.
[0034] Other shapes, quantities, and arrangements of the one or more protuberances 18 are contemplated. For instance, at least some of the one or more protuberances 18 may have a generally conical shape. Selection of the shape, quantity, and arrangement of the one or more protuberances 18 may vary on the basis of the type or quantity of individual clothing articles to be refreshed. It is also within the scope of the present invention for some of the protuberances to a have a different shape than other protuberances of a single dispensing vessel 110 .
[0035] As shown in FIGS. 2-7 , which depict the one or more protuberances 18 as being integral with the cover 14 , some of the one or more protuberances 18 may have an opening 17 that extends through to the core 12 of the dispensing vessel 110 . During use of the dispensing vessel 110 , moisture may be released from the core 12 of the dispensing vessel 10 to the clothes drying environment through the openings 16 in the cover 14 and the openings 17 in the one or more protuberances 18 . Moisture from the dispensing vessel 10 thereby assists with the removal of wrinkles from individual articles in the batch of clothing articles. It is further contemplated that the dispensing vessel 110 may have openings 16 in the cover 14 without having openings 17 in the one or more protuberances 18 , and vice versa. Further, as specifically shown in FIGS. 6-7 , it is also within the scope of the present invention not to include openings 16 , 17 opposite of the fill opening 22 . In this regard, the moistening substance added to the core 12 through the fill opening 22 is less likely to seep out of the dispensing vessel 10 prior to use. Further still, if the protuberances are attachable to the cover 14 as separate, individual components, some of the protuberances may include an opening that extends through the protuberance. The openings of these protuberances may be aligned with one or more of the openings 16 of the cover 14 so as to establish a channel through which moisture may be released from the core 12 into the clothes drying environment.
[0036] Based on the foregoing description, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions 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 one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | A dispensing vessel for introducing moisture to a clothes drying environment includes a core and a cover substantially surrounding the core. The core is comprised of a sponge-like material for retaining a moistening substance within the core, and the cover has at least one opening extending through to the core for permitting the release of moisture to the clothes drying environment. | 3 |
FIELD OF THE INVENTION
The present invention relates to supported polycrystalline diamond compacts (PDCs) made under high temperature, high pressure (HT/HP) processing conditions, and more particularly to supported PDC compacts having non-planar interfaces between the PDC layer and the cemented carbide support layer. The object of the present invention is to provide a PDC cutter with improved resistance to cracking during installation.
BACKGROUND OF THE INVENTION
Abrasive compacts are used extensively in cutting, milling, grinding, drilling and other abrasive operations. The abrasive compacts typically consist of polycrystalline diamond or cubic boron nitride particles bonded into a coherent hard conglomerate. The abrasive particle content of abrasive compacts is high and there is an extensive amount of direct particle-to-particle bonding. Abrasive compacts are made under elevated temperature and pressure conditions at which the abrasive particle, be it polycrystalline diamond or cubic boron nitride, is crystallographically stable.
Abrasive compacts tend to be brittle and, in use, they are frequently supported by being bonded to a cemented carbide substrate. Such supported abrasive compacts are known in the art as composite abrasive compacts. The composite abrasive compact may be used as such in the working surface of an abrasive tool. Alternatively, particularly in drilling and mining operations, it has been found advantageous to bond the composite abrasive compact to an elongated cemented carbide pin to produce what is known as a stud cutter. The stud cutter is then mounted in the working surface of a drill bit or a mining pick.
Fabrication of the composite is typically achieved by placing a cemented carbide substrate into the container of a press. A mixture of diamond grains or diamond grains and catalyst binder is placed atop the substrate and compressed under HT/HP conditions. In so doing, metal binder migrates from the substrate and "sweeps" through the diamond grains to promote a sintering of the diamond grains. As a result, the diamond grains become bonded to each other to form a diamond layer, and that diamond layer is bonded to the substrate along a conventionally planar interface. The metal binder occupies the space between the diamond grains with little or no porosity in the sintered compact. Methods for making diamond compacts and composite compacts are more fully described in U.S.Pat. Nos. 3,141,746 ('746); 3,745,623('623); 3,609,818 ('818); 3,850,591 ('591); 4,394,170 ('170); 4,403,015 ('015); 4,794,326 ('326); and 4,954,139 ('139), the disclosures of which are expressly incorporated herein by reference.
A composite formed in the above-described manner may be subject to a number of shortcomings. For example, the coefficients of thermal expansion and elastic constants of cemented carbide and diamond are different. Thus, during heating or cooling of the PDC, thermally induced stresses occur at the interface between the diamond layer and the cemented carbide substrate. The magnitude of these stresses is dependent on the applied pressure, the temperature of zero stress and the disparity in thermal expansion coefficients and elastic constants.
Another potential shortcoming which should be considered relates to the creation of internal stresses within the diamond layer which can result in a fracturing of that layer. Such stresses also result from the presence of the cemented carbide substrate and are distributed according to the size, geometry and physical properties of the cemented carbide substrate and the polycrystalline diamond layer.
European Patent Application No. 0133 386 suggests PDC in which the polycrystalline diamond body is completely free of metal binders and is to be mounted directly on a metal support. However, the mounting of a diamond body directly on metal presents significant problems relating to the inability of the metal to provide sufficient support for the diamond body. The European Patent Application further suggests the use of spaced ribs on the bottom surface of the diamond layer which are to be embedded in the metal support.
According to the European Patent Application, the irregularities can be formed in the diamond body after the diamond body has been formed, e.g., by laser or electronic discharge treatment, or during the formation of the diamond body in a press, e.g., by the use of a mold having irregularities. As regards the latter, it is further suggested that a suitable mold could be formed of cemented carbide; in such case, however, metal binder would migrate from the mold and into the diamond body, contrary to the stated goal of providing a metal free diamond layer. The reference proposes to mitigate this problem by immersing the thus-formed diamond/carbide composite in an acid bath which would dissolve the carbide mold and leach all metal binder from the diamond body. There would thus result a diamond body containing no metal binder and which would be mounted directly on a metal support. Notwithstanding any advantages which may result from such a structure, significant disadvantages still remain, as explained below.
In sum, the European Patent Application proposes to eliminate the problems associated with the presence of a cemented carbide substrate and the presence of metal binder in the diamond layer by completely eliminating the cemented carbide substrate and the metal binder. However, even though the absence of metal binder renders the diamond layer more thermally stable, it also renders the diamond layer less impact resistant. That is, the diamond layer is more likely to be chipped by hard impacts, a characteristic which presents serious problems during the drilling of hard substances such as rock.
It will also be appreciated that the direct mounting of a diamond body on a metal support will not, in itself, alleviate the previously noted problem involving the creation of stresses at the interface between the diamond and metal, which problem results from the very large disparity in the coefficients of thermal expansion between diamond and metal. For example, the thermal expansion coefficient of diamond is about 45×10 7 cm/cm/° C. as compared to a coefficient of 150-200×10 7 cm/cm/° C. for steel. Thus, very substantial thermally induced stresses occur in the cutter.
Recently, various PDC structures have been proposed in which the diamond/carbide interface contains a number of ridges, grooves or other indentations aimed at reducing the susceptibility of the diamond/carbide interface to mechanical and thermal stresses. In U.S. Pat. No. 4,784,023 ('023), a PDC includes an interface having a number of alternating grooves and ridges, the top and bottom of which are substantially parallel with the compact surface and the sides of which are substantially perpendicular the compact surface.
U.S. Pat. No. 4,972,637 ('637) provides a PDC having an interface containing discrete, spaced recesses extending into the cemented carbide layer, the recesses containing abrasive material (e.g., diamond) and being arranged in a series of rows, each recess being staggered relative to its nearest neighbor in an adjacent row. It is asserted in the '637 patent that as wear reaches the diamond/carbide interface, the recesses, filled with diamond, wear less rapidly than the cemented carbide and act, in effect, as cutting ridges or projections. When the PDC is mounted on a stud cutter, as shown in FIG. 5 of the '637 patent, the wear plane 38 exposes carbide regions 42 which wear much more rapidly than the diamond material in the recesses 18. As a consequence, depressions develop in these regions between the diamond filled recesses. The '637 patent asserts that these depressed regions, which expose additional edges of diamond material, enhance the cutting action of the PDC cutter.
U.S. Pat. No. 5,007,207 ('207) presents an alternative PDC structure having a number of recesses in the carbide layer, each filled with diamond, which make up a spiral or concentric circular pattern, looking down at the disc shaped compact. Thus, the structure in the '207 patent differs from the structure in the '637 patent in that, rather than employing a large number of discrete recesses, the structure of the '207 patent uses one or a few elongated recesses which make up a spiral or concentric circular pattern. FIG. 5 in the '207 patent shows the wear plane which develops when the PDC is mounted and used on a stud cutter. As with the '637 patent, the wear process creates depressions in the carbide material between the diamond filled recesses. Like the '207 patent, the '637 patent also asserts that these depressions which develop during the wear process enhance cutting action. In addition to enhancing cutting action, non-planer interfaces have also been presented in U.S. Pat. Nos. 5,484,330 ('330), 5,494,477 ('477) and 5,486,137 ('137) which reduce the susceptibility to cutter failure by have having favorable residual stresses in critical areas during cutting.
Whereas the aforementioned patents assert a desirable cutting action in the rock and also favorable residual stresses in during cutting, it is also highly desirable to minimize the diamond layer's susceptibility to fracture during installation into the drill bit.
SUMMARY OF THE INVENTION
The present invention relates to supported polycrystalline diamond compacts made under HT/HP processing conditions, and more particularly to supported PDCs having improved shear strength and impact resistance properties.
In PDCs, the interface between the tungsten carbide (WC) and the polycrystalline diamond (PCD) can have a wide variety of surface geometries. It has been found that WC protrusions (See FIG. 1) into the PCD layer can often cause cracking of the PCD layer during the brazing of the cutter onto the bit. This cracking is caused by the thermal mismatch of the WC and the PCD. By providing WC protrusions with a low Cobalt (Co) content, cracking of the PDC can be avoided or greatly mitigated during brazing.
A protrusion is defined as a volume of carbide that protrudes into the PCD layer and is surrounded on its top and sides by PCD. Examples of this would be local regions of WC that exist as bumps, dimples, blocks, saw-tooth shapes, sinusoid shapes, etc., that protrude into the PCD layer. Another example is grooves in the PCD layer (at the WC-PCD interface) filled with WC which run completely across the cutter. Many surface interface geometries are preferred between the WC substrate and the PCD abrasive layer on a cutter design.
Cracking of the abrasive layer may occur due to: (1) in-process stresses, (2) residual stresses, (3) thermal stresses which occur during the heating of the cutter installation (brazing). (Cutters are made using a HT/HP process.) The subject of this disclosure is to address cracking due to (2) and (3).
Most PDC cutters are manufactured with a one piece WC support which is fitted into a refractory metal container which contains the abrasive un-sintered diamond feed. The object of this invention is to provide a PCD cutter with improved resistance to cracking during installation by decreasing the Co level in the WC protrusion into the PCD layer.
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, 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
The detailed description below describes the preferred embodiments of the invention and is intended to be read in conjunction with the following set of drawings.
FIG. 1 is a cross-sectional view of a PDC cutter showing WC protrusions with lower Co content than the WC substrate.
FIG. 2a shows finite element model results at 700 C. where the WC protrusions have normal Co content.
FIG. 2b shows finite element model results at 700 C. where the WC protrusions have low Co content.
FIG. 3a shows a process for making a PDC cutter in accordance with the present invention using a grooved WC disc with a low Co content to form the WC protrusions.
FIG. 3b shows a process for making a PDC cutter in accordance with the present invention using WC balls with low Co content to form the WC protrusions.
FIG. 3c shows a process for making a PDC cutter in accordance with the present invention using WC bars with low Co content to form the WC protrusions.
FIG. 4a is a low magnification Scanning Electron Microscope (SEM) photomicrograph that shows interpenetrating protrusions of WC and PCD, wherein the PCD is the dark material at the top of the photomicrograph.
FIG. 4b is a high magnification SEM photo-micrograph of a portion of FIG. 4a, taken from the corner of one of the WC protrusions, which shows the WC with depleted Co content.
FIG. 4c is a high magnification SEM photo-micrograph of portion of FIG. 4a, taken in the center of the WC protrusion, which shows the WC with greater Co content than at the edge of the protrusion as shown in FIG. 4b.
FIG. 4d is a high magnification SEM photo-micrograph of portion of FIG. 4a, taken in the center of the WC substrate, which shows the WC with greater Co content than in the protrusions as shown in FIG. 4b and 4c.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Polycrystalline diamond compacts (PDCs) consist of a polycrystalline diamond layer (PCD layer) bonded to a carbide substrate. The bond between the PCD layer and the carbide support is formed at high temperature, high pressure (HT/HP) conditions. Subsequent reduction of the pressure and temperature to ambient conditions results in stress development in both the PCD layer and carbide support due to differences in the thermal expansion and the compressibility properties of the bonded layers. The differential thermal expansion and differential compressibility have opposite effects of stress development as the temperature and pressure are reduced; the differential thermal expansion tending to cause compression in the PCD layer and tension in the carbide support on temperature reduction whereas the differential compressibility tends to cause tension in the PCD layer and compression in the carbide support.
Finite element analysis (FEA) of stress development and strain gage measurements confirm that the differential thermal expansion effect dominates resulting in generally compressive residual stresses (Note: there are localized zones of tension stresses present) in the PCD layer.
Upon heating a cutter, the diamond stress state will change from being in general compression to general tension. This "flip" in residual stresses occur below 700° C. range. The "flip" temperature increases with decreased bonding pressure (i.e. the pressure where the cutter temperature reaches the Co freezing point and bonding occurs).
Above the WC protrusions into the PCD layer there are high compressive stresses in the adjacent PCD layer at room temperature and pressure conditions. These stresses flip to tensions when the PDC cutter is heated in a brazing cycle and they can be mitigated in two ways:
(1) increase the "flip" temperature by decreasing the pressure at which the freezing occurs; or
(2) reduce the Co content in the local region of the protrusion such that the protrusion's thermal expansion is closer to that of the PCD layer.
This second method is the subject of the present invention. Shown in FIG. 1 is a cross-sectional view of a PDC cutter comprising WC substrate 14 of normal Co content and WC protrusions 12 into the PCD layer 10 with low Co content. In this invention it is preferred that protrusions 12 have a Co content of 6% plus or minus 3%. This will be considered low Co content WC. The major WC substrate material 14 will have Co content of 13% plus or minus 3%. This will be considered normal Co content WC. The normal Co content WC substrate 14 is desirable for impact resistance and tension strength. The lower Co content WC is desirable only in the zone of protrusions 12.
FIG. 2a and 2b show finite element model results supporting that method (2) above does mitigate stresses at brazing temperatures. In FIG. 2a, WC protrusions 22 comprised normal Co content, and, in FIG. 2b, WC protrusions 22 comprised low Co content. As indicated in each figure, the finite element model results show that, at a brazing temperature of 700° C., maximum stress 20 was reduced by 26% through the reduction of the Co content in WC protrusions 22.
A number of methods for achieving the desired result of low Co content WC protrusions would be immediately apparent to those of skill in the art. Some of these are described below.
One method involves placing separate pieces of WC into the HT/HP process and assembling into the desired geometry. The WC protrusions into the PCD layer comprise low Co content WC while the rest of the substrate comprises normal Co content WC. FIGS. 3a, 3b and 3c show some embodiments of this concept.
Each figure shows the separate pieces to be combined for use in the HT/HP process and assembled into the desired geometry. A preferred embodiment of the present invention comprises PCD feed 32, WC substrate 34 with normal Co content, and any one of the following: 1) WC grooved disc 36 with low Co content, 2) WC balls 38 with low Co content or 3) WC bars 40 with low Co content, combined in refractory metal cup 30 as demonstrated in FIG. 3a, 3b and 3c, respectively. These figures represent only a few of the embodiments of the present invention.
Another method involves having a WC manufacturer supply a graduated Co content WC substrate in which the WC manufacturer provides integral WC substrates which have low Co content protrusions and the rest essentially normal Co content. It is important that it be noted that the decreased Co content is only desired in the protrusions.
Yet another method, and the most preferred method of the present invention, consists of controlling the removal of Co from the WC protrusions during sintering of the PDC cutter. During sintering of the PDC cutter, Co contained in the WC melts and sweeps into the PCD layer. Preferential removal of Co from the WC protrusion during sweep of Co from the WC substrate into the PCD layer would result in a WC protrusion with a lower thermal expansion, the object of the present invention. The amount of preferential Co removal can be controlled by altering the geometry of the WC protrusions and the volume fraction ratio of WC protrusions (into the PCD layer) to PCD protrusions (into the WC substrate).
FIGS. 4a-d are low (4a) and high (4b,c & d) magnification Scanning Electron Microscope (SEM) photomicrographs that demonstrate the removal of Co from the region of the WC substrate adjacent to the PCD layer, with the removal being dependant on the geometry of the protrusions. FIG. 4a is a low magnification SEM photomicrograph that shows penetrating protrusions 66 of WC 60 into PCD layer 50, with PCD layer 50 being the dark material at the top of the photomicrograph and WC substrate 60 being the light material at the bottom. FIG. 4a shows the WC-PCD interface 52 at a low magnification and serves as a reference to the specific source locations of FIGS. 4b, c and d. The positions of the magnified areas shown in FIG. 4b, c and d are indicated on FIG. 4a by three squares 70, 80 and 90, respectively, drawn on the SEM photograph in FIG. 4a.
In FIGS. 4b, c and d, high magnification SEM photomicrographs of specific portions of FIG. 4a are shown. FIG. 4b, taken from the corner of one of the WC protrusions 66, shows depleted Co 64 in WC substrate 60 as compared to the Co content in FIG. 4c which was taken from the center of the protrusion 66. FIG. 4c, taken from the center of one of the protrusions 66, shows depleted Co 64 in WC substrate 60 as compared to the Co content in FIG. 4d which was taken in the center of WC substrate 60 a distance from WC-diamond interface 52.
The depleted Co 64 in the protrusion 66, as shown in FIG. 4b and c, will result in a desirably lower average thermal expansion for the WC protrusion 66. These SEM micrographs clearly show that if the surface area of WC protrusion 66 is high compared to the volume of WC protrusion 66, then a lower average content of Co 64 and a lower average thermal expansion coefficient for the protrusion 66 will result. As depicted by the SEM photomicrographs, FIGS. 4b, c and d, it is clear that the Co content of the WC substrate is depleted more in the areas closer to the WC-PCD interface 52.
Therefore, the specific geometry of the WC protrusions 66 effect the "sweep" of the Co 64 in the WC substrate into the PCD layer 50. The higher the area to volume ratio of the WC protrusion 66, the greater the Co depletion will be, and the lower the average thermal expansion coefficient for the protrusion 66. This will result in an improved match between the WC substrate 60 and the PCD layer 50, thereby enhancing the performance through improved residual stress at the WC-PCD interface 52.
The present invention is valuable as an improved way to manufacture PDC cutters with unique properties. The WC-PCD interface geometry of the present invention provides a better match between the WC substrate and the PCD layer. The primary advantage of this interface geometry being enhanced performance and less installation and/or brazing breakage due to improved residual stress at the WC-PCD interface.
While the present invention has been described with reference to one or more preferred embodiments, such embodiments are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims. Further, 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. | A supported polycrystalline compact (PC) cutter made under high temperature, high pressure (HT/HP) processing conditions having non-planar interfaces between the PC layer and a cemented carbide support layer. The carbide PC interface geometry is such that one or more protrusions extend from the support layer into the PC layer. The protrusions have a low cobalt metal binder content of about 3-9% by weight. The low cobalt metal binder content in the protrusions results in enhanced performance and improved resistance to cracking during installation and/or to brazing breakage. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of pending U.S. Ser. No. 10/596,060, filed May 26, 2006, now abandoned, which is incorporated by reference in its entirety. Applicant claims, under 35 USC §119, the benefit of priority of the filing date of a Patent Cooperation Treaty patent application, Application No. PCT/FR2004/003003, filed on Nov. 24, 2004, which is incorporated herein by reference, wherein Patent Cooperation Treaty patent application, Application No. PCT/FR2004/03003 was not published under PCT Article 21(2) in English. Applicant also claims, under 35 USC §119, the benefit of priority of the filing date of a French patent application, Serial Number FR 03 14001, filed on Nov. 28, 2003, which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to aluminium alloy strips, possibly cladded on one or two faces with a brazing alloy and intended for the production of brazed parts, particularly heat exchangers for automobiles or buildings, and more particularly parts assembled by fluxless brazing under a controlled atmosphere.
STATE OF THE ART
The most frequently used process for the assembly of automobile heat exchangers is brazing. This is based on the use of a cladded strip composed of a so-called “core” alloy coated on one or two faces with a so-called “brazing” alloy, at least for one of the components to be assembled. This so-called “brazing” alloy is characterised by a liquid temperature about 30° C. less than the solidus temperature of the core alloy. By applying an appropriate heat treatment, it is possible to melt only the cladding, which then wets the surfaces in contact allowing good assembly after the assembly has cooled.
There are three different brazing techniques presently available:
The most widespread is brazing under a controlled nitrogen atmosphere, after coating parts to be assembled with a non-corrosive “flux”, the most frequently used being the Nocolok® flux. This product, designed to dissolve the surface oxide layer on aluminium and consequently to increase the wettability of the surfaces, is of the potassium fluoro-aluminate type. A number of problems arise when it is used. Obviously, the product has an intrinsic cost; its deposition requires special installations that frequently prevent complete automation of exchanger production lines; finally an effluent treatment must be arranged.
Another older technique but one still used particularly in North America is vacuum brazing. This process makes it necessary to use cladding that contains magnesium; this element is segregated on the surface and vaporises in the vacuum, capturing residual traces of oxygen. It thus avoids the oxide layer, initially broken by differential expansion, from reforming. No flux is necessary, but vacuum-creating installations are very complicated and associated maintenance costs are very high. For these economic reasons, existing lines are progressively being abandoned and replaced by Nocolok® lines.
Finally, a third process used more marginally, consists of depositing a nickel layer instead of the flux. Brazing is then done under nitrogen. The energy released during the brazing cycle by the creation of Al—Ni phases on the cladding surface is sufficient to break the oxide layer.
The main problem consists of performing the brazing operation on existing Nocolok® lines, since these are the most widespread and the most economic, without the use of flux or any other complex surface preparation and without causing degradation of the final properties of exchangers that will be assembled using this technique.
The solution that has been developed most widely in this field is an adaptation of the nickel deposition brazing process. Although increasingly simplified deposition techniques have been found and used, for example as described in patent application WO 02/07928 (Corus), they never provide more than a partial solution to the problem. The manufacturer of exchangers, or of aluminium strips if the operation is carried out by this manufacturer, must always add on specific installations for surface preparation before brazing and must continue to manage effluents, this time generated by nickel plating baths. Furthermore, although progress has been made in terms of resistance to corrosion as mentioned in patent application WO 02/060639 (Corus), the indicated performances do not always reach the performances claimed for Nocolok® brazed products (for example see patent application WO 02/40729 by Pechiney Rhenalu).
Other solutions are related to adaptation of the cladding alloy and/or atmospheric conditions in brazing furnaces, as for example in U.S. Pat. No. 3,811,177 (VAW) that mentions the addition of the Bi, Sr, Ba or Sb elements into brazing alloys to modify its surface tension. The effect of bismuth on the surface tension is also mentioned in patent EP 0004096 (Ford). More recently, the advantage of adding sodium, possibly accompanied by potassium or bismuth, is mentioned in application WO 01/98019 by Kaiser Aluminium. Finally in EP 1306207 (Sky Aluminium), the brazing that contains Mg and Bi is covered with a thin layer formed of an aluminium alloy that will remain solid when it begins to melt; it will only break later during the brazing cycle, releasing liquid cladding that then wets its upper surface. Oxidation of the liquid brazing alloy is avoided by working under an atmosphere for a short period. The oxide present on the thin layer is broken when it is surrounded by liquid.
BRIEF SUMMARY OF THE INVENTION
The purpose of the invention is to enable production by fluxless brazing of parts made of aluminium alloy under good economic conditions, and particularly using the same equipment as is used for brazing with flux under a controlled atmosphere.
The purpose of the invention is an aluminium alloy strip or sheet containing 0.01 to 0.5% of yttrium and/or 0.05 to 0.5% of bismuth, coated on at least one face with a brazing alloy. The coating may be a layer cladded by co-rolling, for example an aluminium alloy containing 4 to 15% of silicon. It may also be a layer comprising particles of a brazing alloy, particularly particles of Al—Si alloy, possibly coated in a resin.
Another purpose of the invention is a brazed part, particularly a heat exchanger made using an aluminium alloy strip or sheet containing 0.01 to 0.5% of yttrium and/or 0.05 to 0.5% of bismuth.
DESCRIPTION OF THE FIGURES.
FIG. 1 a and 1 b show a top and side view respectively of V test pieces used in the examples to evaluate the brazability.
FIG. 2 shows the definition of the width of the brazed joint used in the brazability test described in the examples.
DESCRIPTION OF THE INVENTION
Unlike the techniques mentioned above, the invention is designed to modify the composition of the core alloy, such that brazing can take place without any deposition, under standard controlled atmosphere conditions, and that can be achieved without modifying the brazing installations used at equipment manufacturers.
Surprisingly, the addition of some elements in the core, such as yttrium at a content of 0.05% or bismuth at a content of about 0.15%, can result in a very satisfactory quality of brazed joints for fluxless brazing under nitrogen.
The method is applicable to all types of aluminium alloys containing at least 80% by weight of aluminium, and particularly alloys for which the composition satisfies the following conditions (% by weight) before the addition of elements specifically intended to enable fluxless brazing:
Si<1.0; Fe<1.0; Cu<1.0; Mn<2.0; Mg<3.0; Zn<6.0; Ti<0.3; Zr<0.3; Cr<0.3; Hf<0.6; V<0.3; Ni<2.0; Co<2.0; In<0.3; other elements<0.05 each and 0.15 total; remainder aluminium.
The sheet or strip may be cladded by co-rolling on one or two faces with a brazing aluminium alloy, usually an alloy containing 4 to 15% of silicon. The brazing alloy may contain other additives such as copper, magnesium or zinc. It may also contain elements designed to modify the surface tension of the alloy, such as Ag, Be, Bi, Ce, La, Pb, Pd, Sb, Y or mischmetal, in other words a mixture of unseparated rare earth metals. In the case in which the brazing alloy is cladded on a single face, the other face may be coated by a sacrificial alloy, usually of the Al—Zn type, in a manner commonly known and intended to improve the resistance of the core alloy to corrosion.
The brazing alloy may also be deposited in the form of particles, particularly Al—Si particles, for example as described in patent EP 0565568 (Alcan International). For brazing under a controlled atmosphere, the brazing alloy particles are usually associated with flux particles, particularly flux based on fluorides such as potassium fluoro-aluminate, and a binder such as a polymer resin. One particular advantage of the invention in this case is to avoid the presence of flux in the coating.
The alloy sheet with the addition of bismuth and/or yttrium may also be used uncoated when it is associated with another sheet coated with a brazing alloy for the production of the brazed part.
EXAMPLES
Example 1
Four plates of core alloys with the following compositions were cast:
ALLOY SI FE CU MN MG TI Y BI CA M 0.40 0.22 0.63 0.57 0.47 0.08 — — — M + Y 0.39 0.24 0.61 0.57 0.47 0.09 0.06 — — M + BI 0.39 0.22 0.62 0.59 0.49 0.09 — 0.15 — M + 0.40 0.22 0.63 0.57 0.47 0.08 — — 0.05 CA
together with a 4047 cladding alloy plate (Al-12% Si). Assemblies were made from these plates such that the thickness of the cladding alloy represents 10% of the total thickness. These assemblies were hot rolled and then cold rolled so as to produce 0.3 mm thick cladded strips. These strips were then subjected to a restoration treatment for 10 h at 260° C.
The test piece illustrated in FIG. 1 was used to evaluate the brazability of these materials. The “V” is composed of a 0.3 mm thick bare strip made of a 3003 alloy in the H24 temper. A 15-minute degreasing treatment at 250° C. was applied to the metal to be brazed. No other surface preparation was used and in particular no flux was deposited. Brazing is done in a double-wall glass furnace in which it is possible to view movements of liquid brazing alloy and the formation of joints during the treatment. The thermal cycle is composed of a temperature rise phase up to 610° C. at a rate of approximately 20° C/min, holding for 2 minutes at 610° C., and then lowering at a rate of about 30° C/minute. The complete process is done under continuous nitrogen scavenging, at a rate of 8 1/min.
The results are marked A to E at the following scale:
Mark
A
B
C
D
E
Joint length formed as a
100%
90%
75%
50%
0%
percent of the total length
The results are given in table 1:
TABLE 1
Core
Cladding
Brazability
M
4047
E
M + Y
4047
A
M + Bi
4047
A
M + Ca
4047
E
The improvement in the brazability obtained due to the addition of Y or Bi to the core alloy can be seen.
Example 2
Two plates with the following compositions were cast in the same way:
Alloy Si Fe Cu Mn Mg Ti Y N 0.17 0.18 0.64 1.37 — 0.08 — N + Y 0.19 0.17 0.67 1.32 — 0.09 0.06
together with a 4045 cladding alloy plate (Al-10% Si). The transformation procedure and the tests carried out are exactly the same as for example 1.
The results are given in table 2:
TABLE 2
Core
Cladding
Brazability
N
4045
E
N + Y
4045
A
It can be seen that the addition of yttrium to alloy N significantly improves the brazability.
Example 3
Two plates with the following compositions were cast in the same way:
Alloy Si Fe Cu Mn Mg Ti Y P 0.15 0.35 0.1 0.1 0.8 0.125 — P + Y 0.15 0.35 0.1 0.1 0.8 0.125 0.06
together with a 4045 cladding alloy plate (Al-10% Si). The transformation procedure and the tests carried out are exactly the same as for example 1.
The results are given in table 3:
TABLE 3
Core
Cladding
Brazability
P
045
E
P + Y
4045
A
It can be seen that the addition of yttrium to alloy P significantly improves the brazability. | The invention relates to a strip or sheet of aluminium alloy, comprising at least 80% by weight of aluminium and 0.01 to 0.5% yttrium and/or 0.05 to 0.5% bismuth, coated on at least one face with a brazing alloy. Said sheets and strips are used for the production of pieces by non-flux brazing. | 1 |
FIELD OF THE INVENTION
A process is disclosed for decreasing the amount of sulfur in hydrocarbon streams.
BACKGROUND OF THE INVENTION
Environmentally driven regulatory standards for motor gasoline (mogas) sulfur levels will result in the widespread production of 120 ppm S mogas by the year 2004 and 30 ppm by 2006. In many cases, these sulfur levels will be achieved by hydrotreating naphtha produced from Fluid Catalytic Cracking (cat naphtha), which is the largest contributor to sulfur in the mogas pool. As a result, techniques are required that reduce the sulfur in cat naphthas without reducing beneficial properties such as octane.
Conventional fixed bed hydrotreating can reduce the sulfur level of cracked naphthas to very low levels, however, such hydrotreating also results in severe octane loss due to extensive reduction of the olefin content. Selective hydrotreating processes such as SCANfining have recently been developed to avoid massive olefin saturation and octane loss. Unfortunately, in such processes, the liberated H 2 S reacts with retained olefins forming mercaptan sulfur by reversion. Such processes can be conducted at severities which produce product within sulfur regulations, however, significant octane loss also occurs.
Several methods exist for removal of sulfur from hydrocarbon streams. For example, U.S. Pat. No. 3,876,532; U.S. Pat. No. 4,149,965; U.S. Pat. No. 5,423,975; and U.S. Pat. No. 5,826,373 each teach hydrotreating methods using deactivated or spent catalyst. U.S. Pat. No. 5,885,440 teaches cooling of a hydrocrackate prior to hydrotreating. U.S. Pat. No. 3,338,819 teaches hydrotreatment of a hydrocrackate over a granular catalyst bed at substantially the same conditions as used to produce the hydrocrackate.
U.S. Pat. Nos. 5,510,016; 5,308,471; 5,399,258; 5,346,609; 5,409,596; and 5,413,697 each teach hydrodesulfurization followed by treatment over an acidic catalyst to restore octane.
What is needed in the art is a process which produces sulfur levels within regulatory amounts and which minimizes loss of product octane.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 depicts a typical SCANfining process.
FIG. 2 depicts one possible embodiment of the invention. The typical SCANfining process flow scheme is included for convenience, however, all that is required in the instant invention is that the stream being treated be previously hydrodesulfurized. Hence, the Figure depicts a previously hydrodesulfurized (SCANfined) feedstream ( 7 ) containing mercaptan sulfur entering a three phase reactor ( 18 ) with a fixed catalyst bed along with a stripping gas ( 8 ) and hydrogen sulfide and gas exiting at ( 10 ) and desulfurized product at ( 9 ).
FIG. 3 depicts one possible embodiment again where the SCANfining step is included merely for convenience. A previously hydrodesulfurized feedstream ( 7 ) and stripping gas ( 21 ) enter three phase reactor ( 19 ). The product from the reactor ( 19 ) then undergoes a depressurization step ( 17 ) and enters a stripper ( 18 ) where gases ( 10 ) and product ( 9 ) are recovered. In this scheme, it is possible to utilize a much smaller three phase reactor and provide additional stripping of hydrogen sulfide, if necessary, in a subsequent step. Such a flow scheme would be beneficial when carrying out the invention in a concurrent flow reactor.
SUMMARY OF THE INVENTION
A method for decreasing sulfur levels in a mercaptan sulfur containing hydrocarbon feedstream comprising the steps of passing said mercaptan sulfur containing hydrocarbon feedstream over a fixed bed catalyst in a three phase, gas, liquid, solid, system in the presence of a stripping gas, for a time and at a temperature and pressure sufficient to decompose at least a portion of said mercaptans to produce olefins, H 2 S, as an off gas, and a hydrocarbon product stream having decreased levels of mercaptan sulfur and to disengage said hydrocarbon product stream having decreased amounts of mercaptan sulfur from said H 2 S and said stripping gas and wherein when said stripping gas is hydrogen, said fixed catalyst bed comprises (a) a non-reducible metal oxide or (b) a Group VIIIB metal promoted Group VIB catalyst, and wherein when said stripping gas is an inert gas, said fixed bed catalyst comprises a Group VIIIB metal promoted Group VIB catalyst.
As used herein, non-reducible metal oxides are metal oxides that will not reduce to the zero valent metal and water in flowing hydrogen at temperatures below 400° C. and include mixed metal oxides.
As used herein, inert gas, means a gas that is unreactive with unsaturated organics and organosulfur species in the mercaptan sulfur containing feed. The inert gas merely facilitates removal of the H 2 S gas produced.
DETAILED DESCRIPTION OF THE INVENTION
An aspect of the invention includes removing mercaptan sulfur from a mercaptan sulfur containing hydrocarbon stream in a three-phase system in the presence of a stripping gas over a mixed metal oxide catalyst.
Thus, a sulfur containing hydrocarbon stream, preferably a previously hydrodesulfurized hydrocarbon stream which still contains an amount of mercaptan sulfur, is passed to a three phase system containing a fixed bed catalyst. The system will be a three-phase system with the catalyst bed located in the hottest zone. The skilled artisan can readily identify the hottest zone for location of the catalyst bed, through, for example, use of thermocouples to read temperature throughout the reactor. The fixed catalyst bed will typically reside at the bottom of the reactor system. Typically, a tray for catalyst is present in such systems and the catalyst will be located in the tray provided.
The mercaptan sulfur containing hydrocarbon stream is reacted over the fixed catalyst bed, in the presence of a stripping gas, to produce H 2 S gas and olefins from said sulfur containing hydrocarbon stream. The stripping gas facilitates the disengagement of the hydrocarbon product stream, which will contain the produced olefins, having decreased levels of mercaptan sulfur from the H 2 S gas and allows the gases to be removed as off gases from the three phase system.
Any suitable three-phase systems can be employed in the instant invention. For example, a stripper having a fixed catalyst bed in the hottest zone can be employed to accomplish the sulfur removal described herein. Additionally, a fixed bed reactor, such as the one depicted in FIG. 3, where the temperature is maintained below the dew point of the hydrocarbon mixture contained within the reactor, so that a substantial portion of the hydrocarbon feed is maintained in the liquid phase may be utilized. Other systems known to the skilled artisan may also be employed. Preferably, in such a system, the temperature will be maintained at least about 5°, preferably at least about 10° C. below the dew point. Furthermore, the temperature should remain above about 200, preferably above about 250° C. By substantial portion is meant at least about 20%. In operating the invention in this manner, a further stripping step to remove hydrogen sulfide may be employed as shown in FIG. 3 .
The invention accomplishes the sulfur removal without any significant change in octane of the hydrocarbon stream being acted upon. By significant is meant, no more than about 0.5 number modification in octane number.
The catalyst utilizable for the fixed bed catalyst, when hydrogen is the stripping gas is a non-reducible metal oxide or mixed metal oxide. Non-reducible metal oxides are defined as metal oxides that will not reduce to the zero valent metal and water in flowing hydrogen at temperatures below 400° C. Non-limiting examples of such oxides include γ-Al 2 O 3 , SiO 2 , SiO 2 —Al 2 O 3 , and MgO and mixtures thereof. If hydrogen is utilized as the stripping gas in the process γ-Al 2 O 3 is the preferred catalytic material. Preferably, the catalysts will be sulfided catalysts.
If the stripping gas utilized is an inert gas or hydrogen, the catalyst is a supported group VIIIB metal promoted group VIB catalyst and the inert gas is a non-hydrogenating inert gas. Catalyst examples include, supported and bulk cobalt and nickel promoted molybdenum sulfide catalysts well known in the art, specifically a supported cobalt promoted molybdenum sulfide. Examples of a non-hydrogenating inert gases include nitrogen, helium, argon, methane, natural gas, lighter hydrocarbons in the liquid that are volatilized upon heating (light ends) and mixtures thereof. Light ends are defined as hydrocarbons that have boiling points below the temperature of the reactor.
When hydrogen is utilized as the stripping gas with a hydrogenating catalyst such as CoMoS it is preferred that the amount of stripping hydrogen be minimized. This can be accomplished by minimizing the treat rate of hydrogen. The hydrogen treat rate should be 25-1000 SCF/B (4.5 m 3 /m 3 to 180 m 3 /m 3 ), more preferably 25-500 SCF/B (4.5 m 3 /m 3 to 90 m 3 /m 3 ), most preferably 25-250 SCF/B (4.5 m 3 /m 3 to 45 m 3 /m 3 ). The hydrogen utilized, can be supplied as part of a gas stream comprising hydrogen, e.g. from a powerformer off gas, thereby leading to a completely integrated refinery process. Notably, the hydrogen stripping gas should contain no more than ½ mole percent of H 2 S One skilled in the art will readily recognize that the amount of hydrogen utilized with the Group VIIIB promoted Group VIB catalysts must be controlled to prevent a significant loss of octane. However, by utilizing a hydrogen stream, both mercaptan and thiophenic sulfur can be removed from the hydrocarbon feedstream being acted upon.
Thus, an example of one embodiment of the invention where the mercaptan sulfur containing feedstream is a hydrodesulfurized (SCANfined) feedstream is depicted in the FIG. 2 . Olefinic naphtha (Stream 1 ), such as catalytic cracked and steam cracked naphtha are mixed with hydrogen (Stream 2 ) and reacted in a selective naphtha hydrofining reactor (Reactor 12 ). The organic sulfur compounds in the olefinic naphtha feed are predominantly thiophenes. The vapor product of the selective naphtha (Stream 3 ) contains significantly lower levels of thiophenic sulfur and hydrogen sulfide but still contains significant quantities of olefins and mercaptan sulfur. The mercaptans in Stream 3 are produced through reaction of product hydrogen sulfide with feed olefins. Stream 3 is then cooled in Heat Exchanger 13 such that the C5+ fraction is liquefied in Separation Drum 14 . The overhead sour gas stream (Stream 5 ) which contains unreacted hydrogen and the majority of the product hydrogen sulfide is sent to Scrubber vessel 15 where hydrogen sulfide is removed to produce a sweet hydrogen stream (Stream 6 ). Stream 6 is compressed in Compressor 16 to the operating pressure of the Reactor 12 where it is utilized for the hydroprocessing reaction. The liquid product (Stream 7 ) from Separation Drum 14 , contains lower levels of organo sulfur, both as thiophenes and mercaptans, in addition to olefins, paraffins, aromatics, and dissolved hydrogen sulfide. Though, in a typical process, this stream would be depressurized through a pressure relief (number 17 in FIG. 1) and sent to a stripper ( 18 ), the depressurization step is omitted in the embodiment of the process shown in FIG. 2 process. In stripper 18 stream 7 is contacted with an inert gas over a fixed bed catalyst to produce hydrogen sulfide, which exits with the inert gas in stream 10 . The stripper reactor may be filled with catalyst coated packings, but it is preferred that the catalyst be loaded onto bubble trays in order to maximize residence time in the reaction zone of the stripper.
Another embodiment of this invention would be the use of a three-phase fixed bed reactor shown as Reactor 19 in FIG. 3 . In this process the liquefied desulirized naphtha (Stream 7 ) is reacted with a hydrogen or non-hydrogenating stripping gas in a fixed bed reactor containing catalyst. The temperature of this reactor is maintained at a temperature below the dew point of the feed mixture. The product of this reactor (Stream 20 ) is depressurized (Pressure let down 17 ) followed by removal of dissolved hydrogen sulfide here in a stripper 18 . Alternatively, a flash drum could be used in place of the stripper, for example.
The three phase reactor system of the invention (in the example above, a stripper) is operated at pressures of at least about 115 psi (791 kPa), more preferably greater than 150 psi (1034 kPa), and most preferably greater than 200 psi such that the temperature of bottom of the vessel where the catalyst bed will be located is established by the boiling point of the heaviest components in the feed at the pressure of the vessel. The higher the pressure the higher the temperature of the catalyst zone. It is preferred that the catalyst zone temperature be above 200° C., more preferably above 225° C. and most preferably above 250° C. Preferably, the temperature will not exceed 400° C. The amount of stripping gas added should not exceed the amount that would increase the dew point of the reactor to a temperature below that of the desired operating temperature. The gas flow rates would typically be 25 to 750 SCF/B (4.5 to 139 m 3 /m 3 ), more preferably 25 to 500 SCF/B (4.5 to 90 m 3 /m 3 ). The conditions selected favor mercaptan destruction kinetics and thermodynamics.
In a preferred embodiment, the three-phase reactor system is operated in a concurrent or counter current fashion with the countercurrent fashion being preferred. In counter current mode the liquid and gas move in opposite directions of each other. Typically liquid is injected in the top or middle of the vessel and flows downward exiting the bottom of the vessel. Gas is injected in the bottom of the reactor and moves upward through the liquid phase, thereby stripping dissolved gaseous components, exiting through the top of the vessel.
Because the selective removal or conversion of mercaptans from a previously hydrodesulfurized hydrocarbon stream is readily accomplished by the instant invention, it is possible to operate the HDS unit to achieve a higher total sulfur level, thereby preserving feed olefins and octane and then perform the method of the invention to remove the mercaptans affording an integrated process for producing a high quality product. Hence, less severe HDS conditions can be employed when an HDS step is coupled with the process herein described since the mercaptans from the HDS process can be readily decreased or removed in the process.
For example, an intermediate cat naphtha can be hydroprocessed to 60 wppm total sulfur where approximately 45 wppm sulfur is mercaptan sulfur. This first product would not meet the future 30 wppm sulfur specification. This product would then be treated with the method of sulfur removal described herein as the mercaptan sulfur containing feedstream in a three phase reactor with a fixed bed catalyst where the sulfur level would be reduced to approximately 20 wppm total sulfur, meeting environmental specifications. By not hydroprocessing the intermediate cat naphtha directly to 20 wppm sulfur, olefin saturation will be less than is obtained from hydroprocessing to 20 wppm directly. Thus, considerable octane is preserved affording an economical and regulatory acceptable product.
If it is desired to hydrodesulfurize the sulfur containing feedstream prior to passing it to the three-phase reactor with fixed bed catalyst described herein, any hydrodesulfurization process known in the art can be utilized.
Preferably, the feedstream to the three phase reactor will have less than 30 ppm of non-mercaptan sulfur, more preferably the feedstream will have less than 30 ppm non-mercaptan sulfur and greater than 30 ppm of mercaptan sulfur. Any hydrodesulfurization step capable of producing such feedstreams can be conducted prior to the three phase reactor process herein described and the resultant product sent to the three-phase reactor.
If it is desired to hydrodesulfurize the mercaptan sulfur containing hydrocarbon feedstream to produce increased quantities of mercaptans and retain olefins prior to the treatment herein, any technique known in the art can be utilized. For example, the hydrotreated hydrocarbon stream can be hydrodesulfurized to produce a sulfur containing hydrocarbon stream which contains non-mercaptan sulfur at a level below the mogas specification as well as significant amounts of mercaptan sulfur. Generally, such processing conditions will fall within the following ranges: 475-600° F. (246-316° C.), 150-500 psig (1136-3548 kPa) total pressure, 100-300 psig (791-2170 kPa) hydrogen partial pressure, 1000-2500 SCF/B hydrogen treat gas, and 1-10 LHSV.
The preferred hydroprocessing step to be utilized if prior HDS is desired, is SCANfining. However, other selective cat naphtha hydrodesulfurization processes such as those taught by Mitsubishi (see U.S. Pat. Nos. 5,853,570 and 5,906,730) can likewise be utilized herein. SCANFINING is described in National Petroleum Refiners Association paper # AM-99-31 titled “Selective Cat Naphtha Hydrofining with Minimal Octane Loss” and U.S. Pat. Nos. 5,985,136 and 6,013,598 herein incorporated by reference. Selective cat naphtha HDS is also described in U.S. Pat. Nos. 4,243,519 and 4,131,537.
Typical SCANfining conditions include one and two stage processes for hydrodesulfurizing a naphtha feedstock comprising reacting said feedstock in a first reaction stage under hydrodesulfurization conditions in contact with a catalyst comprised of about 1 to 10 wt. % MoO 3 ; and about 0.1 to 5 wt. % CoO; and a Co/Mo atomic ratio of about 0.1 to 1.0; and a median pore diameter of about 60 [Angstrom] to 200 [Angstrom]; and a MoO 3 surface concentration in g MoO 3 /m 2 of about 0.5×10 −4 to 3×10 −4 ; and an average particle size diameter of less than about 2.0 mm; and, optionally, passing the reaction product of the first stage to a second stage, also operated under hydrodesulfurization conditions, and in contact with a catalyst comprised of at least one Group VIII metal selected from the group consisting of Co and Ni, and at least one Group VI metal selected from the group consisting of Mo and W, more preferably Mo, on an inorganic oxide support material such as alumina
The SCANFINING reactor can be run at sufficient conditions such that the difference between the total organic sulfur (determined by x-ray adsorption) and the mercaptan sulfur (determined by potentiometric test ASTM3227) is at or below the desired (target) specification (typically 30 ppm for non-mercaptan sulfur). This stream is then sent to the three-phase system described herein for mercaptan removal.
The three phase system method described herein is particularly capable of removing ≧C 5 + mercaptan sulfur.
The product from the instant process is suitable for blending to make motor gasoline that meets sulfur specifications of ≦30 ppm range.
The following examples, which are meant to be illustrative and not limiting, illustrate the potential benefit of the invention, by showing specific cases in which a selective hydrofining process has been operated to produce varying levels of total and mercaptan sulfur. By reference to these cases, it should be apparent that coupling such selective hydrotreating with a subsequent mercaptan removal technology will result in improved ability to produce low sulfur products with reduced losses of olefins and octane.
The following example is illustrative and not meant to be limiting.
EXAMPLE 1
A flow through catalytic test was conducted to test catalytic materials and stripping gases for a catalytic stripping reactor. A fixed bed reactor was loaded with either 5 cc of a commercial γ-Al 2 O 3 or a commercial cobalt promoted molybdenum sulfide hydrotreating catalyst (CoMoS). The cobalt promoted molybdenum catalyst was pre-sulfided with hydrogen sulfide. A previously hydrotreated intermediate cat naphtha feed was reacted over these two catalysts at 260° C., 235 psia pressure (1620 kPa), 2.0 LHSV, and with 675 SCF/B (122 m 3 /m 3 ) of either hydrogen or nitrogen. These conditions were chosen to mimic those in the bottom of a high pressure-stripping reactor. The hydrotreated intermediate cat naphtha had a total sulfur of 60 wppm and mercaptan sulfur content of 43 wppm, and a bromine number of 20. As can be seen in the table below, alumina with hydrogen as the stripping gas results in 56% conversion of the mercaptan sulfur with no saturation of the olefins. When nitrogen is used as the stripping gas alumina rapidly deactivates and almost no conversion is observed. The CoMoS catalyst with hydrogen removes almost all the sulfur including some of the non-mercaptan sulfur, but undesirable saturation of the olefins is observed. When nitrogen is used as the stripping gas CoMoS removes approximately 95% of the mercaptan sulfur and no undesired olefin saturation is observed. CoMoS showed no apparent deactivation with nitrogen as the stripping gas.
TABLE
Catalyst
γ-Al 2 O 3
γ-Al 2 O 3
CoMoS
CoMoS
Stripping Gas
H 2
N 2
H 2
N 2
wppm Sulfur
36
53
5
20
(XRF)
Bromine Number
18.5
18.8
12.8
18.7 | A process for reducing the amount of mercaptan sulfur in a petroleum stream without significantly changing its octane value. The process comprising a three-phase system wherein the petroleum stream to be treated is passed through a fixed bed of catalyst in the presence of a stripping gas. The stripping gas can be either hydrogen containing gas or an method wherein the composition of the catalyst utilized varies according to the stripping gas. | 2 |
The present application is based on and claims priority of Japanese patent application No. 2012-147403 filed on Jun. 29, 2012, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to an image pickup lens to be mounted on imaging devices adopting relatively small and thin solid-state imaging elements such as CCD sensors or C-MOS sensors mounted on portable terminals such as cellular phones and smartphones or PDAs (Personal Digital Assistants).
Description of the Related Art
Recently, most portable terminals such as cellular phones and smartphones, PDAs and other devices are readily equipped with a camera function. With the aim to enhance the portability and usability of these devices, further downsizing and thinning of the devices have been considered, and at the same time, the improvement of the camera function corresponding to increased number of pixels has also been considered. In response to this trend, further downsizing and increase in the number of pixels are realized in imaging elements adopted in the imaging devices mounted to such devices. Furthermore, the image pickup lenses disposed in these imaging devices are required to not only have high resolving power to correspond to the increased number of pixels but also realize downsizing and thinning. Moreover, there are strong demands for an image pickup lens having a bright lens system and a wide angle of field capable of taking an image of an object from a wide area, and corresponding to the highly dense imaging elements.
In the prior art, a large number of image pickup lenses having a three-lens configuration capable of correcting aberrations to a certain level and preferable from viewpoints of size and costs had been adopted as image pickup lenses mounted on the above-listed devices, but along with the increase in the number of pixels of the imaging elements, image pickup lenses adopting a four-lens configuration realizing a higher performance than the three-lens configuration are becoming popular. Recently, however, along with the further increase in the number of pixels of imaging devices, devices having a camera function with pixels exceeding far beyond 5 megapixels are provided. In response to such trend of increase in the number of pixels, image pickup lenses having a five-lens configuration capable of realizing even higher resolution and higher performance than the four-lens configuration have been proposed.
For example, Japanese Patent Laid-Open No. 2007-264180 (Patent Document 1) discloses an image pickup lens having, in order from an object side, a positive first lens having a convex object-side surface, a negative second lens having a meniscus shape with a concave surface facing an image side, a positive third lens having a meniscus shape with a convex surface facing the image side, a negative fourth lens having both surfaces formed as aspherical surfaces and having the image-side surface concaved near an optical axis, and a positive or a negative fifth lens having both surfaces formed as aspherical surfaces.
Further, Japanese Patent Laid-Open No. 2011-085733 (Patent Document 2) discloses an image pickup lens system having, in order from an object side, a first lens group including a first lens having a convex shape on the object side, a second lens group including a second lens having a concave shape on an imaging side, a third lens group including a third lens having a meniscus shape and a concave surface arranged on the object side, a fourth lens group including a fourth lens having a meniscus shape and a concave surface arranged on the object side, and a fifth lens group including a fifth lens having a meniscus shape that has an aspherical surface with an inflection point arranged on the object side.
According to the image pickup lens disclosed in Patent Document 1, a high-performance image pickup lens system having a five-lens configuration capable of effectively correcting axial chromatic aberration and chromatic aberration of magnification and responding to the increase in the number of pixels is realized by optimizing the materials of the lenses and the surface shapes of the lenses. However, the total track length of the lens system is approximately 8 mm, which still leaves a problem in applying the lens to devices requiring further thinning. Further, since the F-value of the lens is approximately 2.8 and the angle of field is approximately 32°, it cannot be said that the disclosed lens provides a sufficiently bright lens system or a wide angle of field that is required in recent lens systems.
The image pickup lens disclosed in Patent Document 2 realizes a high resolving power and a total track length of approximately 6 mm, which realizes relative downsizing and thinning in a lens system. However, the F-value of the lens is approximately 2.8 and the angle of field is approximately 32°, which means that the image pickup lens described in Patent Document 2 cannot sufficiently satisfy the specifications (high resolution, downsizing, thinning, bright lens system, and wide angle of field) required in recent lens systems.
SUMMARY OF THE INVENTION
The present invention aims at solving the above-mentioned problems of the prior art, by providing an image pickup lens adopting a five-lens configuration capable of realizing downsizing and thinning, with high resolution, small F-value and wide angle of field.
The term downsizing and thinning mentioned above refers to the level of downsizing that satisfies TTL/(2IH)<1.0, when a maximum image height of the image being formed via the image pickup lens is denoted as IH, and a distance on an optical axis from the surface of the image pickup lens arranged closest to the object side to the image pickup plane is denoted as total track length TTL. For example, the level of downsizing refers to a level where the total track length of the image pickup lens is shorter than a diagonal length of an effective image pickup plane of the imaging element.
As for the F-value, the number should be as bright as approximately F2.6 or smaller, and the angle of field should be as wide as 70° or greater in total angle of field.
The image pickup lens according to the present invention is composed of five lenses for a solid-state imaging element, and having, in order from an object side to an image side, an aperture stop, a first lens having a positive refractive power with a convex surface facing the object side, a second lens having a negative refractive power with a concave surface facing the image side, a third lens having a positive refractive power with a convex surface facing the image side, a fourth lens having a negative refractive power and having both surfaces formed as aspherical surfaces with a concave surface facing the object side near an optical axis, and a fifth lens having a negative refractive power of a meniscus shape having both surfaces formed as aspherical surfaces with a concave surface facing the image side near the optical axis, wherein the fifth lens is designed so that the negative refractive power weakens as the distance from the optical axis increases. In addition to the above configuration, the following conditional expression (1) is satisfied:
0.55 <f 1 /f< 1.0 (1)
where f represents a focal length of an overall optical system of the image pickup lens, and f 1 represents a focal length of the first lens.
According to the image pickup lens mentioned above having a five-lens configuration, when the first lens, the second lens and the third lens are considered as a front group, and the fourth lens and the fifth lens are considered as a rear group, the configuration is similar to a so-called telephoto lens type where the front group has a positive refractive power as a whole and the rear group has a negative refractive power as a whole. By adopting such configuration and having the image-side surface of the fifth lens formed as concave surface, it becomes possible to shorten the total track length easily. Moreover, by having both surfaces of the fourth and fifth lenses formed as appropriate aspherical shapes, it becomes possible to realize the effects of correcting various aberrations and suppressing the angle of rays incident on the imaging elements.
Conditional expression (1) defines the ratio of the focal length of the first lens to the focal length of the overall image pickup lens system within an appropriate range, which is a condition for shortening the total track length, suppressing the occurrence of various off-axis aberrations, and enabling satisfactory correction of aberration. If the value exceeds the upper limit of conditional expression (1), the positive power of the first lens with respect to the power of the overall image pickup lens system becomes too weak, so that it is advantageous in reducing the fabrication error sensitivity of the lens, but disadvantageous in shortening the total track length, and therefore, downsizing and thinning become difficult to achieve. On the other hand, if the value is below the lower limit of conditional expression (1), the positive power of the first lens with respect to the power of the overall image pickup lens system becomes too strong, so that the correction of astigmatism and field curvature becomes especially difficult. Further, it is not preferable since the fabrication error sensitivity of the lens becomes high, and the accuracy of assembly is deteriorated.
Further, the image pickup lens according to the present invention preferably satisfies the following conditional expressions (2) through (6):
50<ν1<70 (2)
ν2<35 (3)
50<ν3<70 (4)
50<ν4<70 (5)
50<ν5<70 (6)
where ν 1 represents an Abbe number of the first lens, ν 2 represents an Abbe number of the second lens, ν 3 represents an Abbe number of the third lens, ν 4 represents an Abbe number of the fourth lens, and ν 5 represents an Abbe number of the fifth lens.
Conditional expressions (2) through (6) define the range of the Abbe number of the respective lens materials, which are conditions for preferably correcting the axial chromatic aberration and chromatic aberration of magnification. According to conditional expressions (2) through (6), the second lens is formed of a high-dispersion material, and the first, third, fourth and fifth lenses are formed of a low-dispersion material. Since the Abbe numbers of four out of five lenses are set to a value greater than 50, it becomes possible to more preferably correct axial chromatic aberration and chromatic aberration of magnification. Further, it is not preferable to use a material having an Abbe number that exceeds 70, since the lens material becomes too expensive and reduction of cost becomes difficult.
A generally-known method for correcting chromatic aberration is to combine a high-dispersion material with a low-dispersion material. In the case of an image pickup lens having a five-lens configuration, chromatic aberration can be corrected by alternately arranging a lens having a positive power formed of a low-dispersion material and a lens having a negative power formed of a high-dispersion material. However, when such method of correction is adopted, there is a restriction in the correction of chromatic aberration when further thinning is made. That is, according to a lens configuration where chromatic aberration is corrected by alternately arranging a high-dispersion material and a low-dispersion material, when the total track length is gradually shortened, the chromatic aberration of magnification changes from a correction insufficient state (where shorter wavelengths increase in the negative direction with respect to the reference wavelength) to a correction excessive state (where shorter wavelengths increase in the positive direction with respect to the reference wavelength) mainly in the off-axis rays from the low image-height area toward the high image-height area, and it becomes difficult to correct chromatic aberration of magnification satisfactorily throughout the overall image pickup plane. According to the present invention satisfying conditional expressions (2) to (6), the image pickup lens can realize both thinning and satisfactory correction of chromatic aberration of magnification, while overcoming the problems of insufficient correction and excessive correction of chromatic aberration of magnification.
Further, the image pickup lens according to the present invention preferably satisfies the following conditional expression (7):
−1.6 <f 2 /f<− 0.7 (7)
where f 2 represents a focal length of the second lens.
Conditional expression (7) defines a ratio of the focal length of the second lens with respect to the focal length of the overall image pickup lens system within an appropriate range, which is a condition for shortening the total track length while suppressing the occurrence of various axial and off-axis aberrations. When the value exceeds the upper limit of conditional expression (7), the negative power of the second lens with respect to the power of the overall image pickup lens system becomes too strong, and the correction of axial and off-axis chromatic aberration becomes excessive (where the chromatic aberration of short wavelengths increases in the positive direction with respect to the chromatic aberration of reference wavelength). Further, since the image-formation surface is curved toward the image side, it becomes difficult to achieve a good image formation performance. Even further, since the curvature radius of the image-side surface of the second lens becomes too small, total reflection of off-axis rays may cause stray light, which may lead to the occurrence of ghosts or flares. On the other hand, if the value is below the lower limit of conditional expression (7), the negative power of the second lens with respect to the power of the overall image pickup lens system becomes too weak, which may be advantageous in shortening the total track length, but the correction of axial and off-axis chromatic aberration becomes insufficient (where the chromatic aberration of short wavelengths increases in the negative direction with respect to the chromatic aberration of reference wavelength). Further, since the image-formation surface is curved toward the object side, it also becomes difficult to achieve a good image formation performance.
The image pickup lens according to the present invention preferably satisfies the following conditional expression (8):
1.05 <f 12 /f< 1.60 (8)
where f 12 represents a composite focal length of the first and second lenses.
Conditional expression (8) defines the ratio of the composite focal length of the first and second lenses to the focal length of the overall image pickup lens system within an appropriate range, which is a condition for ensuring back focus and enabling a preferable correction of aberration while shortening the total track length and widening the angle of field. If the value exceeds the upper limit of conditional expression (8), the positive composite power of the first and second lenses with respect to the power of the overall image pickup lens system becomes too weak, so that the focal length becomes long, and it becomes difficult to achieve the shortening of the total track length and widening of the angle of field. On the other hand, if the value is below the lower limit of conditional expression (8), the positive composite power of the first and second lenses with respect to the power of the overall image pickup lens system becomes too strong, so that the focal length becomes short, which is advantageous in realizing a wide angle of field, but is difficult to ensure back focus. If the negative power of the fourth and fifth lenses is increased to ensure back focus, astigmatism mainly occurs off-axis, so that it becomes difficult to achieve satisfactory image formation performance. Further, if the curvature radius of the lens is reduced in order to achieve a large power, the fabrication error sensitivity becomes unfavorably high. The problems described above can be overcome by defining the positive composite power of the first and second lenses to the range defined in conditional expression (8).
Further, according to the image pickup lens of the present invention, it is preferable that the object-side surface of the fourth lens have an aspherical shape in which a negative power weakens toward the periphery, and the image-side surface thereof have an aspherical shape in which a positive power weakens toward the periphery. By adopting such aspherical shape in the fourth lens which is arranged distant from the aperture stop, the optical length of the rays passing through the fourth lens can be controlled. As a result, various aberrations of the respective image heights, mainly the astigmatism, can be corrected satisfactorily.
Further, the image pickup lens according to the present invention preferably satisfies the following conditional expression (9):
1.7<ν1/ν2<2.7 (9)
where ν 1 represents an Abbe number of the first lens, and ν 2 represents an Abbe number of the second lens.
Conditional expression (9) defines a condition for further suppressing the chromatic aberration of magnification and the axial chromatic aberration.
Further, the image pickup lens according to the present invention preferably satisfies the following conditional expression (10):
−0.80 <f 1 /f 2<−0.45 (10)
where f1 represents a focal length of the first lens, and f 2 represents a focal length of the second lens.
Conditional expression (10) defines the ratio of the focal length of the first lens to the focal length of the second lens within an appropriate range, which is a condition for controlling chromatic aberration, spherical aberration and coma aberration within a preferable range while realizing downsizing and widening of angle of field of the image pickup lens. If the value exceeds the upper limit of conditional expression (10), the negative power of the second lens with respect to the positive power of the first lens becomes relatively weak, so that it is advantageous in downsizing the image pickup lens, but the correction of axial chromatic aberration and off-axis chromatic aberration of magnification becomes insufficient (where the shorter wavelengths increase in the negative direction with respect to the reference wavelength), and it also becomes difficult to achieve a satisfactory image formation performance. On the other hand, if the value is below the lower limit of conditional expression (10), the negative power of the second lens with respect to the positive power of the first lens becomes relatively strong, so that the correction of off-axis chromatic aberration of magnification becomes excessive (where the shorter wavelengths increase in the positive direction with respect to the reference wavelength). Further, coma aberration increases with respect to the off-axis beam. Therefore, it becomes difficult to achieve a satisfactory image formation performance. When these aberrations are corrected by the lenses arranged subsequent to the second lens, the total track length is elongated and downsizing becomes difficult to achieve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a general configuration of an image pickup lens according to Embodiment 1;
FIG. 2 is a view showing a spherical aberration, an astigmatism and a distortion of the image pickup lens according to Embodiment 1;
FIG. 3 is a view showing a general configuration of an image pickup lens according to Embodiment 2;
FIG. 4 is a view showing a spherical aberration, an astigmatism and a distortion of the image pickup lens according to Embodiment 2;
FIG. 5 is a view showing a general configuration of an image pickup lens according to Embodiment 3;
FIG. 6 is a view showing a spherical aberration, an astigmatism and a distortion of the image pickup lens according to Embodiment 3;
FIG. 7 is a view showing a general configuration of an image pickup lens according to Embodiment 4;
FIG. 8 is a view showing a spherical aberration, an astigmatism and a distortion of the image pickup lens according to Embodiment 4;
FIG. 9 is a view showing a general configuration of an image pickup lens according to Embodiment 5;
FIG. 10 is a view showing a spherical aberration, an astigmatism and a distortion of the image pickup lens according to Embodiment 5;
FIG. 11 is a view showing a general configuration of an image pickup lens according to Embodiment 6; and
FIG. 12 is a view showing a spherical aberration, an astigmatism and a distortion of the image pickup lens according to Embodiment 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, preferred embodiments of the present invention will be described in detail with reference to the drawings.
FIGS. 1, 3, 5, 7, 9 and 11 , respectively, are general configuration diagrams of the image pickup lenses according to Embodiments 1 through 6 of the present embodiment. The basic lens configuration is the same in all embodiments, so that an explanation is given on the image pickup lens configuration of the present embodiment with reference to the general configuration diagram of Embodiment 1.
As shown in FIG. 1 , an image pickup lens of the present embodiment is composed of, in order from an object side to an image side, a first lens L 1 having a positive refractive power, a second lens L 2 having a negative refractive power, a third lens L 3 having a positive refractive power, a fourth lens L 4 having a negative refractive power, and a fifth lens L 5 having a negative refractive power. An aperture stop ST is arranged on the object side of the first lens L 1 . A filter IR is arranged between the fifth lens L 5 and an image plane IM. The filter IR can be omitted. The value having the filter removed from the lens configuration is adopted when computing the total track length of the image pickup lens.
In the image pickup lens having the above-mentioned five-lens configuration, the first lens L 1 is a biconvex lens with both an object-side surface r 1 and an image-side surface r 2 being a convex surface, the second lens L 2 is a meniscus lens with an object-side surface r 3 being a convex surface and an image-side surface r 4 being a concave surface, the third lens L 3 is a meniscus lens with an object-side surface r 5 being a concave surface and an image-side surface r 6 being a convex surface, the fourth lens L 4 is a meniscus lens with an object-side surface r 7 being a concave surface and an image-side surface r 8 being a convex surface near an optical axis X, and the fifth lens L 5 is a meniscus lens with an object-side surface r 9 being a convex surface and an image-side surface r 10 being a concave surface near the optical axis X.
The object-side surface r 3 of the second lens L 2 is a lens surface having a weak refractive power with respect to the focal length of the second lens L 2 , and the curvature radius thereof is relatively large. The shape of the object-side surface r 3 of the second lens L 2 is not restricted to a convex surface, and can be a concave surface. The second lens L 2 according to Embodiment 3 of the present embodiment shows an example of a biconcave lens where the object-side surface r 3 and the image-side surface r 4 of the second lens L 2 are both concave surfaces.
The above-described configuration is similar to a so-called telephoto type lens, when the first lens L 1 , the second lens L 2 and the third lens L 3 out of the five lenses L 1 through L 5 are considered as a front group and the fourth lens L 4 and the fifth lens L 5 are considered as a rear group, wherein the front group has a positive refractive power as a whole and the rear group has a negative refractive power as a whole, and in addition to this power configuration, by having the image-side surface r 10 of the fifth lens L 5 formed as a concave surface, it becomes possible to shorten the total track length. Moreover, by having both surfaces of the fourth lens L 4 and the fifth lens L 5 formed as appropriate aspheric shapes, it becomes possible to achieve the effects of correcting various aberrations and restraining the angle of rays incident on the imaging elements.
Further, according further to the present embodiment, all the image pickup lenses are formed of plastic materials. In all the preferred embodiments, the first lens L 1 , the third lens L 3 , the fourth lens L 4 and the fifth lens L 5 are formed of olefinic plastic material, and the second lens L 2 is formed of polycarbonate plastic material.
By using plastic material for all the lenses, it becomes possible to realize stable mass production and facilitate cost reduction. Further, since the first lens L 1 , the third lens L 3 , the fourth lens L 4 and the fifth lens L 5 are formed of the same material, they can be fabricated easily.
The image pickup lens according to the present invention satisfies the following conditional expressions.
0.55 <f 1 /f< 1.0 (1)
50<ν1<70 (2)
ν2<35 (3)
50<ν3<70 (4)
50<ν4<70 (5)
50<ν5<70 (6)
−1.6 <f 2 /f<− 0.7 (7)
1.05 <f 12 /f< 1.60 (8)
1.7<ν1/ν2<2.7 (9)
−0.80 <f 1 /f 2<−0.45 (10)
where
f: focal length of the overall optical system of the image pickup lens f 1 : focal length of the first lens f 2 : focal length of the second lens f 12 : composite focal length of the first and second lenses ν 1 : Abbe number of the first lens ν 2 : Abbe number of the second lens ν 3 : Abbe number of the third lens ν 4 : Abbe number of the fourth lens ν 5 : Abbe number of the fifth lens
In the present embodiment, all lens surfaces are formed as aspherical surfaces. The aspherical shape adopted in these lens surfaces is represented by the following expression, when an axis in the optical axis direction is denoted as Z, a height in a direction orthogonal to the optical axis is denoted as H, a conic constant is denoted as k, and aspherical coefficients are denoted as A 4 , A 6 , A 8 , A 10 , A 12 , A 4 and A 16 .
Z
=
H
2
R
1
+
1
-
(
k
+
1
)
H
2
R
2
+
A
4
H
4
+
A
6
H
6
+
A
8
H
8
+
A
10
H
10
+
A
12
H
12
+
A
14
H
14
+
A
16
H
16
Expression
1
Next, preferred embodiments of the image pickup lens according to the present embodiment are shown. In each embodiment, f represents a focal length of the overall image pickup lens system, Fno represents an F-number, ω represents a half angle of field, and IH represents a maximum image height. Further, i represents a surface number counted from the object side, r represents a curvature radius, d represents a distance between lens surfaces on the optical axis (surface distance), Nd represents a refractive index with respect to a d-ray (reference wavelength), and νd represents an Abbe number with respect to the d-ray. Aspherical surfaces are shown with a sign * (asterisk) after the surface number i.
Embodiment 1
Basic lens data are shown in Table 1 below.
TABLE 1
Embodiment 1
Unit mm
f = 3.810
Fno = 2.52
ω(°) = 35.78
IH = 2.791
Surface Data
Refractive Index
Abbe Number
Surface No. i
Curvature Radius r
Surface Distance d
Nd
νd
(Object Surface)
Infinity
Infinity
1 (Stop)
Infinity
−0.145
2*
1.654
0.549
1.5351
56.12
3*
−6.619
0.025
4*
12.424
0.300
1.6355
23.91
5*
2.211
0.474
6*
−10.440
0.416
1.5351
56.12
7*
−3.131
0.137
8*
−1.432
0.354
1.5351
56.12
9*
−1.588
0.237
10*
2.324
0.897
1.5351
56.12
11*
1.386
0.300
12
Infinity
0.3
1.5168
64.20
13
Infinity
0.680
Image Plane
Infinity
Aspherical Surface Data
2nd Surface
3rd Surface
4th Surface
5th Surface
6th Surface
k
−1.802E+00
1.351E+01
0.000E+00
1.732E+00
2.721E+00
A4
2.749E−02
8.503E−02
3.580E−02
−5.643E−02
−1.233E−01
A6
1.542E−02
−2.531E−01
−3.023E−02
2.019E−01
−2.662E−02
A8
−4.323E−02
2.421E−01
−1.422E−01
−3.714E−01
1.753E−01
A10
−3.872E−02
−1.266E−01
3.071E−01
3.347E−01
−6.943E−02
A12
−8.698E−03
6.959E−03
−1.103E−01
−7.921E−02
−3.900E−02
A14
0.000E+00
0.000E+00
0.000E+00
0.000E+00
−1.200E−04
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
7th Surface
8th Surface
9th Surface
10th Surface
11th Surface
k
0.000E+00
−7.532E+00
−7.834E+00
0.000E+00
−2.882E+00
A4
−5.166E−02
9.012E−02
−6.513E−02
−2.554E−01
−1.410E−01
A6
−5.871E−02
−2.566E−02
1.526E−01
6.449E−02
6.493E−02
A8
1.167E−01
−7.473E−02
−1.634E−01
−4.635E−03
−2.209E−02
A10
−3.459E−02
7.815E−02
8.855E−02
5.666E−05
4.791E−03
A12
−8.978E−05
−2.090E−02
−1.828E−02
−5.779E−05
−5.930E−04
A14
−1.079E−04
1.201E−07
5.355E−04
−1.643E−08
3.281E−05
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
−2.714E−07
The image pickup lens according to Embodiment 1 satisfies all conditional expressions (1) through (10), as shown in Table 7.
FIG. 2 shows a spherical aberration (mm), an astigmatism (mm), and a distortion (%) of the image pickup lens according to Embodiment 1. The spherical aberration diagram illustrates the amount of aberration with respect to the respective wavelengths of F-ray (486 nm), d-ray (588 nm) and C-ray (656 nm). Further, the astigmatism diagram illustrates the respective amounts of aberration on a sagittal image surface S and a tangential image surface T (the same applies to FIGS. 4, 6, 8, 10 and 12 ). As shown in FIG. 2 , it can be seen that the respective aberrations are satisfactorily corrected.
Further, the total track length TTL is as short as 4.56 mm and the ratio thereof to the maximum image height IH (TTL/2IH) is 0.82, so that downsizing is realized even in a five-lens configuration. Moreover, the F-value is as bright as 2.52, and the half angle of field is approximately 35.8°, so that a relatively wide angle of field is realized.
Embodiment 2
Basic lens data are shown in Table 2 below.
TABLE 2
Embodiment 2
Unit mm
f = 3.805
Fno = 2.38
ω(°) = 35.98
IH = 2.791
Surface Data
Refractive Index
Abbe Number
Surface No. i
Curvature Radius r
Surface Distance d
Nd
νd
(Object Surface)
Infinity
Infinity
1 (Stop)
Infinity
−0.145
2*
1.558
0.556
1.5346
56.16
3*
−5.369
0.025
4*
25.731
0.300
1.6142
25.58
5*
2.176
0.497
6*
−9.466
0.421
1.5346
56.16
7*
−3.551
0.138
8*
−1.410
0.346
1.5346
56.16
9*
−1.562
0.227
10*
2.353
0.870
1.5346
56.16
11*
1.409
0.300
12
Infinity
0.300
1.5168
64.20
13
Infinity
0.617
Image Plane
Infinity
Aspherical Surface Data
2nd Surface
3rd Surface
4th Surface
5th Surface
6th Surface
k
−1.722E+00
1.350E+01
0.000E+00
1.798E+00
3.100E+01
A4
2.965E−02
8.554E−02
3.886E−02
−5.670E−02
−1.286E−01
A6
1.582E−02
−2.568E−01
−2.433E−02
2.089E−01
−3.491E−02
A8
−5.394E−02
2.280E−01
−1.416E−01
−3.519E−01
1.679E−01
A10
−6.862E−02
−1.582E−01
2.921E−01
3.496E−01
−7.333E−02
A12
−2.789E−02
−4.843E−02
−1.547E−01
−1.287E−01
−3.876E−02
A14
0.000E+00
0.000E+00
0.000E+00
0.000E+00
6.334E−03
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
7th Surface
8th Surface
9th Surface
10th Surface
11th Surface
k
0.000E+00
−7.470E+00
−8.088E+00
0.000E+00
−3.037E+00
A4
−4.742E−02
8.928E−02
−6.639E−02
−2.545E−01
−1.433E−01
A6
−5.618E−02
−2.505E−02
1.509E−01
6.471E−02
6.448E−02
A8
1.171E−01
−7.410E−02
−1.640E−01
−4.636E−03
−2.213E−02
A10
−3.447E−02
7.819E−02
8.832E−02
4.273E−05
4.791E−03
A12
4.966E−04
−2.114E−02
−1.837E−02
−6.427E−05
−5.928E−04
A14
7.383E−04
−2.128E−04
4.789E−04
−2.449E−06
3.283E−05
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
−2.766E−07
The image pickup lens according to Embodiment 2 satisfies all conditional expressions (1) through (10), as shown in Table 7.
FIG. 4 shows a spherical aberration (mm), an astigmatism (mm), and a distortion (%) of the image pickup lens according to Embodiment 2. As shown in FIG. 4 , it can be seen that the respective aberrations are satisfactorily corrected.
Further, the total track length TTL is as short as 4.48 mm and the ratio thereof to the maximum image height IH (TTL/2IH) is 0.80, so that downsizing is realized even in a five-lens configuration. Moreover, the F-value is as bright as 2.38, and the half angle of field is approximately 36.0°, so that a relatively wide angle of field is achieved.
Embodiment 3
Basic lens data are shown in Table 3 below.
TABLE 3
Embodiment 3
Unit mm
f = 3.894
Fno = 2.58
ω(°) = 35.30
IH = 2.791
Surface Data
Refractive Index
Abbe Number
Surface No. i
Curvature Radius r
Surface Distance d
Nd
νd
(Object Surface)
Infinity
Infinity
1 (Stop)
Infinity
−0.145
2*
1.644
0.559
1.5441
15.98
3*
−4.408
0.025
4*
−12.995
0.300
1.5837
30.13
5*
2.092
0.476
6*
−100.000
0.422
1.5441
55.98
7*
−3.312
0.157
8*
−1.383
0.324
1.5441
56.98
9*
−1.555
0.234
10*
2.286
0.872
1.5441
55.98
11*
1.405
0.300
12
Infinity
0.3
1.5168
64.20
13
Infinity
0.796
Image Plane
Infinity
Aspherical Surface Data
2nd Surface
3rd Surface
4th Surface
5th Surface
6th Surface
k
−1.829E+00
1.841E+01
0.000E+00
2.083E+00
0.000E+00
A4
2.742E−02
9.983E−02
3.710E−02
−5.179E−02
−1.049E−01
A6
1.508E−02
−2.726E−01
−2.474E−02
2.326E−01
−2.892E−02
A8
−6.244E−02
2.116E−01
−1.994E−01
−3.869E−01
1.664E−01
A10
−7.095E−02
−1.273E−01
1.627E−01
2.928E−01
−7.478E−02
A12
−3.371E−02
−8.438E−02
−2.463E−02
−1.143E−01
−3.460E−02
A14
0.000E+00
0.000E+00
0.000E+00
0.000E+00
1.437E−02
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
7th Surface
8th Surface
9th Surface
10th Surface
11th Surface
k
0.000E+00
−6.274E+00
−7.114E+00
0.000E+00
−2.675E+00
A4
−5.744E−02
8.790E−02
−6.626E−02
−2.589E−01
−1.454E−01
A6
−6.743E−02
−2.471E−02
1.513E−01
6.441E−02
6.661E−02
A8
1.115E−01
−7.413E−02
−1.642E−01
−4.409E−03
−2.207E−02
A10
−3.441E−02
7.843E−02
8.818E−02
1.314E−04
4.771E−03
A12
1.717E−03
−2.070E−02
−1.837E−02
−5.543E−05
−5.951E−04
A14
1.073E−03
1.684E−04
5.565E−04
−1.046E−05
3.303E−05
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
−1.381E−07
The image pickup lens according to Embodiment 3 satisfies all conditional expressions (1) through (10), as shown in Table 7.
FIG. 6 shows a spherical aberration (mm), an astigmatism (mm), and a distortion (%) of the image pickup lens according to Embodiment 3. As shown in FIG. 6 , it can be seen that the respective aberrations are satisfactorily corrected.
Further, the total track length TTL is as short as 4.65 mm and the ratio thereof to the maximum image height IH (TTL/2IH) is 0.83, so that downsizing is realized even in a five-lens configuration. Moreover, the F-value is as bright as 2.58, and the half angle of field is approximately 35.3°, so that a relatively wide angle of field is achieved.
Embodiment 4
Basic lens data are shown in Table 4 below.
TABLE 4
Embodiment 4
Unit mm
f = 3.830
Fno = 2.34
ω(°) = 35.58
IH = 2.791
Surface Data
Refractive Index
Abbe Number
Surface No. i
Curvature Radius r
Surface Distance d
Nd
νd
(Object Surface)
Infinity
Infinity
1 (Stop)
Infinity
−0.145
2*
1.643
0.559
1.5441
55.98
3*
−10.528
0.025
4*
6.987
0.300
1.6355
23.91
5*
2.022
0.476
6*
−9.746
0.422
1.5441
55.98
7*
−2.990
0.157
8*
−1.273
0.324
1.5441
55.98
9*
−1.434
0.234
10*
2.417
0.890
1.5441
55.98
11*
1.493
0.300
12
Infinity
0.3
1.5168
64.20
13
Infinity
0.708
Image Plane
Infinity
Aspherical Surface Data
2nd Surface
3rd Surface
4th Surface
5th Surface
6th Surface
k
−1.761E+00
9.900E+01
0.000E+00
2.006E+00
−8.958E+00
A4
2.686E−02
6.502E−02
3.011E−02
−4.847E−02
−1.317E−01
A6
2.299E−02
−2.721E−01
−4.555E−02
2.204E−01
−2.418E−02
A8
−7.311E−02
2.035E−01
−1.602E−01
−4.034E−01
1.716E−01
A10
−8.653E−02
−1.121E−01
2.693E−01
3.051E−01
−8.039E−02
A12
7.550E−02
8.868E−02
−1.523E−02
−3.165E−02
−4.690E−02
A14
0.000E+00
0.000E+00
0.000E+00
0.000E+00
2.336E−02
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
7th Surface
8th Surface
9th Surface
10th Surface
11th Surface
k
0.000E+00
−5.397E+00
−6.045E+00
0.000E+00
−2.659E+00
A4
−6.512E−02
8.454E−02
−7.363E−02
−2.501E−01
−1.452E−01
A6
−6.219E−02
−2.477E−02
1.556E−01
6.296E−02
6.529E−02
A8
1.107E−01
−7.272E−02
−1.627E−01
−4.865E−03
−2.205E−02
A10
−3.653E−02
7.916E−02
8.814E−02
8.702E−05
4.782E−03
A12
1.414E−03
−2.062E−02
−1.840E−02
−4.462E−05
−5.934E−04
A14
2.051E−03
−2.242E−05
5.937E−04
−2.153E−07
3.308E−05
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
−2.681E−07
The image pickup lens according to Embodiment 4 satisfies all conditional expressions (1) through (10), as shown in Table 7.
FIG. 8 shows a spherical aberration (mm), an astigmatism (mm), and a distortion (%) of the image pickup lens according to Embodiment 4. As shown in FIG. 8 , it can be seen that the respective aberrations are satisfactorily corrected.
Further, the total track length TTL is as short as 4.59 mm and the ratio thereof to the maximum image height IH (TTL/2IH) is 0.82, so that downsizing is realized even in a five-lens configuration. Moreover, the F-value is as bright as 2.34, and the half angle of field is approximately 35.6°, so that a relatively wide angle of field is achieved.
Embodiment 5
Basic lens data are shown in Table 5 below.
TABLE 5
Embodiment 5
Unit mm
f = 3.809
Fno = 2.52
ω(°) = 35.83
IH = 2.791
Surface Data
Refractive Index
Abbe Number
Surface No. i
Curvature Radius r
Surface Distance d
Nd
νd
(Object surface)
Infinity
Infinity
1 (Stop)
Infinity
−0.145
2*
1.760
0.788
1.5251
56.27
3*
−11.342
0.025
4*
5.761
0.300
1.6319
23.42
5*
2.232
0.374
6*
−10.505
0.533
1.5251
56.27
7*
−2.504
0.106
8*
−1.473
0.383
1.5251
56.27
9*
−1.664
0.282
10*
2.861
0.892
1.5251
56.27
11*
1.341
0.300
12
Infinity
0.3
1.5168
64.20
13
Infinity
0.516
Image Plane
Infinity
Aspherical Surface Data
2nd Surface
3rd Surface
4th Surface
5th Surface
6th Surface
k
−1.917E+00
8.985E+01
0.000E+00
1.271E+00
7.682E+01
A4
2.696E−02
7.364E−02
1.870E−02
−6.518E−02
−1.238E−01
A6
2.790E−02
−2.672E−01
−5.450E−02
2.086E−01
−1.338E−02
A8
−4.667E−02
2.408E−01
−1.626E−01
−3.682E−01
1.788E−01
A10
−4.163E−02
−8.438E−02
2.888E−01
3.351E−01
−7.091E−02
A12
6.953E−02
2.854E−02
−8.292E−02
−9.850E−02
−3.139E−02
A14
0.000E+00
0.000E+00
0.000E+00
0.000E+00
3.007E−02
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
7th Surface
8th Surface
9th Surface
10th Surface
11th Surface
k
0.000E+00
−5.419E+00
−6.814E+00
0.000E+00
−2.845E+00
A4
−5.451E−02
8.161E−02
−5.883E−02
−2.531E−01
−1.395E−01
A6
−6.699E−02
−2.447E−02
1.519E−01
6.637E−02
6.530E−02
A8
1.128E−01
−7.460E−02
−1.655E−01
−4.082E−03
−2.218E−02
A10
−3.368E−02
7.670E−02
8.726E−02
1.532E−04
4.781E−03
A12
2.421E−03
−2.239E−02
−1.865E−02
−5.775E−05
−5.903E−04
A14
1.885E−03
−9.529E−04
7.439E−04
−1.313E−05
3.336E−05
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
−3.589E−07
The image pickup lens according to Embodiment 5 satisfies all conditional expressions (1) through (10), as shown in Table 7.
FIG. 10 shows a spherical aberration (mm), an astigmatism (mm), and a distortion (%) of the image pickup lens according to Embodiment 5. As shown in FIG. 10 , it can be seen that the respective aberrations are satisfactorily corrected.
Further, the total track length TTL is as short as 4.69 mm and the ratio thereof to the maximum image height IH (TTL/2IH) is 0.84, so that downsizing is realized even in a five-lens configuration. Moreover, the F-value is as bright as 2.52, and the half angle of field is approximately 35.8°, so that a relatively wide angle of field is achieved.
Embodiment 6
Basic lens data are shown in Table 6 below.
TABLE 6
Embodiment 6
Unit mm
f = 3.822
Fno = 2.53
ω(°) = 35.71
IH = 2.791
Surface Data
Refractive Index
Abbe Number
Surface No. i
Curvature Radius r
Surface Distance d
Nd
νd
(Object Surface)
Infinity
Infinity
1 (Stop)
Infinity
−0.145
2*
1.533
0.550
1.5251
56.27
3*
−5.177
0.025
4*
48.409
0.300
1.6142
25.58
5*
2.251
0.484
6*
−10.434
0.431
1.5251
56.27
7*
−3.504
0.120
8*
−1.397
0.347
1.5251
56.27
9*
−1.558
0.227
10*
2.373
0.871
1.5251
56.27
11*
1.406
0.300
12
Infinity
0.3
1.5168
64.20
13
Infinity
0.652
Image Plane
Infinity
Aspherical Surface Data
2nd Surface
3rd Surface
4th Surface
5th Surface
6th Surface
k
−1.684E+00
1.396E+01
0.000E+00
1.954E+00
3.631E+01
A4
3.047E−02
8.522E−02
3.763E−02
−5.319E−02
−1.312E−01
A6
1.551E−02
−2.567E−01
−2.761E−02
2.112E−01
−3.502E−02
A8
−4.998E−02
2.217E−01
−1.429E−01
−3.525E−01
1.689E−01
A10
−6.136E−02
−1.726E−01
2.928E−01
3.538E−01
−7.447E−02
A12
−6.908E−02
−5.786E−02
−1.442E−01
−9.963E−02
−3.928E−02
A14
0.000E+00
0.000E+00
0.000E+00
0.000E+00
1.025E−02
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
7th Surface
8th Surface
9th Surface
10th Surface
11th Surface
k
0.000E+00
−7.396E+00
−8.090E+00
0.000E+00
−2.923E+00
A4
−4.673E−02
8.896E−02
−6.682E−02
−2.552E−01
−1.425E−01
A6
−5.638E−02
−2.485E−02
1.501E−01
6.431E−02
6.444E−02
A8
1.171E−01
−7.404E−02
−1.643E−01
−4.729E−03
−2.211E−02
A10
−3.440E−02
7.842E−02
8.830E−02
3.142E−05
4.792E−03
A12
4.136E−04
−2.094E−02
−1.837E−02
−6.341E−05
−5.929E−04
A14
5.085E−04
−1.782E−04
4.846E−04
−1.386E−06
3.279E−05
A16
0.000E+00
0.000E+00
0.000E+00
0.000E+00
−2.846E−07
The image pickup lens according to Embodiment 6 satisfies all conditional expressions (1) through (10), as shown in Table 7.
FIG. 12 shows a spherical aberration (mm), an astigmatism (mm), and a distortion (%) of the image pickup lens according to Embodiment 6. As shown in FIG. 12 , it can be seen that the respective aberrations are satisfactorily corrected.
Further, the total track length TTL is as short as 4.49 mm and the ratio thereof to the maximum image height IH (TTL/2IH) is 0.80, so that downsizing is realized even in a five-lens configuration. Moreover, the F-value is as bright as 2.53, and the half angle of field is approximately 35.7°, so that a relatively wide angle of field is achieved.
According to the image pickup lens of the embodiments of the present invention, the total track length TTL is 5 mm or smaller and the ratio of the total track length TTL to the maximum image height IH (TTL/2IH) is 0.85 or smaller, so that superior downsizing is achieved even in a five-lens configuration. Further, various aberrations are corrected satisfactorily, the F-value is as bright as approximately 2.5, and the angle of field is approximately 72°, so that an image having a relatively wide angle of field can be taken.
Table 7 shows the values of the respective conditional expressions (1) through (10) according to Embodiments 1 through 6.
TABLE 7
Embodiment 1
Embodiment 2
Embodiment 3
Embodiment 4
Embodiment 5
Embodiment 6
f1
2.532
2.315
2.265
2.643
2.950
2.309
f2
−4.282
−3.852
−3.041
−4.543
−5.896
−3.817
f12
4.726
4.340
5.580
4.792
4.655
4.375
Conditional Expression (1)
0.66
0.61
0.58
0.69
0.77
0.60
0.55 < f1/f < 1.0
Conditional Expression (2)
56.12
56.16
55.98
55.98
56.27
56.27
50 < ν1 < 70
Conditional Expression (3)
23.91
25.58
30.13
23.91
23.42
25.58
ν2 < 35
Conditional Expression (4)
56.12
56.16
55.98
55.98
56.27
56.27
50 < ν3 < 70
Conditional Expression (5)
56.12
56.16
55.98
55.98
56.27
56.27
50 < ν4 < 70
Conditional Expression (6)
56.12
56.16
55.98
55.98
56.27
56.27
50 < ν5 < 70
Conditional Expression (7)
−1.12
−1.01
−0.78
−1.19
−1.55
−1.00
−1.6 < f2/f < −0.7
Conditional Expression (8)
1.24
1.14
1.43
1.25
1.22
1.14
1.05 < f12/f < 1.60
Conditional Expression (9)
2.35
2.20
1.86
2.34
2.40
2.20
1.7 < ν1/ν2 < 2.7
Conditional Expression (10)
−0.59
−0.60
−0.74
−0.58
−0.50
−0.60
−0.80 < f1/f2 < −0.45
INDUSTRIAL APPLICABILITY
The image pickup lens having a five-lens configuration according to the respective embodiments of the present invention can be applied preferably to image pickup optical systems mounted on portable terminals such as cellular phones and smartphones, PDAs (Personal Digital Assistants) and so on where thinning is advanced and the number of pixels is increased in recent years. According to the image pickup lens of the present invention, the performance can be improved while realizing downsizing and wider angle of field in the image pickup optical system.
The effects of the present invention are as follows.
The present invention enables to provide an image pickup lens capable of realizing downsizing and thinning, which has a high resolution, a small F-value and a relatively wide angle of field. | An image pickup lens includes an aperture stop, a first lens with positive refractive power having a convex object-side surface, a second lens with negative refractive power having a concave image-side surface, a third lens with positive refractive power having a convex image-side surface, a fourth lens with negative refractive power as a double-sided aspheric lens having a concave object-side surface, and a fifth lens with negative refractive power of a meniscus shape as a double-sided aspheric lens having a concave image-side surface, wherein the fifth lens is designed so that the negative refractive power weakens as the distance from the optical axis increases, and wherein the following conditional expression (1) is satisfied:
0.55< f 1/ f <1.0 (1)
where f represents a focal length of an overall image pickup lens, and f 1 represents a focal length of the first lens. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of Provisional Patent Application Ser. No. 60/591,164, filed 2004 Jul. 26.
SEQUENCE LISTING
[0002] Non-Applicable.
BACKGROUND
[0003] 1. Field of Invention
[0004] This invention relates to an aerodynamic means that mitigate wind generated vortices and uplift loads on the roof perimeter area of a building, in a simple, effective, and economical way, applicable for both new constructions and retrofits of existing buildings.
[0005] 2. Discussion of Prior Art
[0006] The previous and present roof construction practices normally lead to a roof perimeter configuration that tends to generate corner-edge vortex and subjects the roof perimeter area to severe uplift and high risk of wind damage. Structural methods have been used to mitigate the risk of wind damage. For example, builders may use stronger fasteners or smaller spacing between fasteners for roof cover and deck in the roof edge and corner area, and use “hurricane straps” in lieu of toenails to tie down the roof framing to the wall structure. Some aerodynamic methods have been recommended. Banks et. al. described in U.S. Pat. No. 6,601,348 (2003) various types of wind spoilers raised above the roof plane that function to mitigate edge vortex formation. However, the apparatus is rather complicated in shape and structure, and is susceptible to wind damage itself because the raised structure subjects itself to accelerated airflow across the roof edge. In U.S. Pat. No. 4,005,557 (1977), Kramer et. al. described conceptual designs for a roof wind spoiler system used strictly near roof corners. The limited breadth of the apparatus impedes its effectiveness and causes higher wind loads along the neighboring segments of roof perimeter, which the apparatus does not extend to. Its design is also only suitable for flat roofs. Ponder disclosed in U.S. Pat. No. 5,918,423 (1999) a wind spoiler ridge cap that is designed for protecting roof ridges, while this present invention deals primarily with roof perimeters. The structure disclosed herein is continuous along a roof edge or at least substantially extends from the roof corners towards the middle part of a roof edge. The designs are suitable for both sloped and flat roofs. The examples given hereafter are particularly suitable for roofs that have roof cover extending outwardly beyond the roof deck boundary and subjecting itself to accelerated upward flow deflected by the wall directly below.
[0007] In U.S. Pat. No. 6,606,828 of this applicant et al., a series of roof edge configurations are recommended for use to mitigate vortex and high uplift in flat-roof perimeter areas, where the concept is one of coordinated exterior curvature design for a roof edge system. The present invention discloses a distinct roof edge apparatus that utilizes overhung plates that preferably have face perforation and/or outer edge serration.
SUMMARY OF THE INVENTION
[0008] This invention discloses an aerodynamic means that mitigate wind generated vortices and uplift loads on the roof perimeter area of a building, in a simple, effective, and economical way, applicable for both new constructions and retrofits of existing buildings. This is achieved by using an elongated device generally having an angle-like cross-section and being attached along a roof edge. The elongated device, which can be formed from sheet materials, is generally positioned in such a way that the open side of the angle faces outwardly and downwardly, with one side of the angle generally vertical and the other side generally horizontal. The generally vertical side is normally attached to an existing fascia or bargeboard, while the generally horizontal side extends and overhangs outwardly. The overhung portion is preferably made air-permeable and/or has a zigzag outer edge. The permeability provides a pressure equalizing effect while the outer edge serration provides a flow disorganizing effect, each of which prevents or interrupts the vortex from formation along a roof perimeter. Such a roof edge device is generally referred to as roof edge windscreen in this application. The specific configurations recommended herein pertinent to this invention are primarily applicable for edges of gable, hip, gambrel, mono-slope and flat roofs where no perimeter draining device, such as gutter, or edge flashing is installed. It is prudent that modifications be made according to the spirit and principles of the present invention when other types of roofs or roof edge constructions are encountered.
OBJECTS AND ADVANTAGES
[0009] Accordingly, several objects and advantages of the present invention are:
to provide roof edge devices which shield roof edge details from upward airflow, wind-driven rain and wind pressure; to provide roof edge devices which suppress edge vortex formation and reduce wind loads on roofing materials, roof decks and framing in the roof perimeter areas; to provide roof edge devices which reduce wind uplift loads generally on a building structure that are transferred from the roof; to provide roof edge devices which reduce vortex scouring of roofing materials, such as asphalt shingles, roofing tiles, paver etc, and prevent them from becoming wind-borne missiles injuring people and damaging adjacent building envelopes during severe wind events; to provide roof edge devices which stabilize wind flow over the roof and minimize cyclic loads on roof components resulting from recurring winds, reducing the chances of damage due to material fatigue; to provide roof edge devices which prevent rainwater from being driven sideward and upward by wind turbulence and pressed through the gaps between roofing material and roof deck, and into the inner space of the roof assembly, during wind/rain events; to provide roof edge devices which possess the desired aerodynamic performance while maintaining an aesthetic and waterproofing functionality under both extreme and recurring weather conditions.
[0017] Further objects or advantages are to provide roof edge devices which protect a roof edge from wind and rain damage, and which are still among the simplest, most effective and reliable, and inexpensive to manufacture and convenient to install. These and still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A schematically illustrates the cross-sectional view of one of the preferred basic configurations formed with sheet material, as being installed on an overhung gable end of a roof as an example.
[0019] FIG. 1B shows a similar configuration as being installed on a non-overhung gable roof edge as an example.
[0020] FIGS. 1C and 1D are isometric views showing examples of face perforation and edge serration.
[0021] FIGS. 2 and 3 schematically illustrate alternative cross-sectional shapes for the screen portion of the roof edge windscreen.
[0022] FIG. 4 exemplifies a configuration for roof edges with wrapped-down roof covering.
[0023] FIG. 5 illustrates an example of configurations for eave edges where significant rainwater run-off is expected.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] A roof edge windscreen is generally an elongated assembly that is disposed longitudinally in parallel with, and attached to, a roof edge. FIG. 1A shows a cross-section view for one of the preferred configurations of the present invention, a roof edge windscreen 110 being installed on a gable-end overhang 10 of a roof structure. A typical roof overhang is a portion of a roof structure that extends substantially outwards beyond the outer surface 21 of a supporting wall 20 of a building. The gable-end overhang 10 , along with such associated components as roof covering 11 , deck 12 , rafter 13 , fascia board 14 , soffit board 15 , lateral framing member 16 , and aesthetic trim members 31 and 32 , are prior arts. They are included here merely for illustration of their relationships with the roof edge windscreen 110 that is the subject matter of this invention. The apparatus can also be used for non-overhung roof perimeters, for example, on a non-overhung gable-end 17 as depicted in FIG. 1B . Moreover, although many of the embodiments in this application are exemplified with gable edges, the present invention is applicable on other types of roof edges. Specific examples include, but not limited to, gable, hip, gambrel, mono-slope, and flat roof edges. For roof edges where certain rainwater runoff is expected, such as the eave edges of gable and hip roofs, this invention is also applicable where roof edge windscreens will replace rainwater-draining devices such as gutters as described later in this application.
[0025] The roof edge windscreen 110 , exemplified here as made of sheet material, consists of a screen portion 111 , an intermediate channel portion formed by segments 113 a and 113 b , and lower mounting portions 115 a and 115 b , along with an optional drip edge 117 , adjoining consecutively. As exemplified in FIGS. 1C and 1D , the screen portion 111 preferably has face perforation 112 ( FIG. 1C ) or outer edge serration 114 , or has both ( FIG. 1D ).
[0026] Herein the perforation 112 is made with a plurality of through-holes on the sheet material. The specific layout, number, shapes and sizes of the distributed through-holes are not of primary significance, as long as the overall porosity resulting from the face perforation is in a preferred range approximately between 25% and 75% to provide desired air-permeability. This helps equalizing pressures on the opposite sides of the screen and suppresses the forcing mechanism for vortex formation along the edge. In FIG. 1D , in addition to perforation, edge serration is made with a zigzag or wavy outer edge of the screen portion 111 , which disorganizes the flow shear layer over the edge and prevents vorticity embedded in the shear layer from forming a concentrated vortex. While larger sizes are preferred for the projections and notches to provide deeper serration or indentation, their specific layout, number and shapes are not of critical significance. Square, semi-circular and semi-elliptic shapes etc., for example, in addition to the triangular shape shown herein, are all permissible without compromising the functionality described herein. It is also allowable that the perforations, projections and notches have varying shapes and sizes in the same assembly. The choices may be made in combination with aesthetic considerations.
[0027] Thus the function of face perforation and edge serration is to disrupt the formation of the roof edge vortex that would otherwise cause severe uplift loads and scouring on the roof surface. As illustrated in FIGS. 1A and 1B , the screen portion 111 is disposed with its inner side in close proximity to the outer edge 19 of the roof covering 11 and is extended generally outwardly. Various modifications to the configuration of the screen portion 111 shown in FIGS. 1A and 1B are permissible. For example, as illustrated in FIG. 2 , the screen portion 211 , or its outer segment, may curve outwardly and upwardly for roof edges where no significant rainwater runoff is expected, to the extent that such configurations are not expected to cause debris clogging and accumulation along the roof edge. As illustrated in FIG. 3 , the screen portion 311 , or its outer segment, may also curve outwardly and downwardly. Furthermore, as an option for serrated edge configuration, the sawtooth-like elements or projections can bend alternatively upwardly and downwardly. These alternatives may be considered in conjunction with the aesthetic aspect of a building.
[0028] The intermediate channel portion is formed by a generally vertical segment 113 a and a generally inward and upward extending segment 113 b that adjoin the screen portion 111 and the mounting portion 115 a respectively, as illustrated in each of the preceding figures. The channel portion formed by segments 113 a and 113 b serves as both a draining device and a protection from upward flow and pressure for the underside of the overhung portion 18 of the roof covering 11 . Optional draining holes (not shown) can be used near the lower edge of the channel portion where segments 113 a and 113 b meet.
[0029] The roof edge windscreen 110 may be mounted on and secured to a roof edge with any appropriate means that does not negatively affect the functionality of the screen portion 111 or that of the intermediate channel portion formed by 113 a and 113 b described herein. A simple example is already illustrated in the preceding figures, i.e. FIGS. 1, 2 and 3 . The mounting portions 115 a and 115 b are collectively conformed to the existing configuration of the roof edge and are attached to the side of the roof edge using fasteners 130 . Adequate aesthetic finishes and watertight sealing on the fasteners may be desired. Optional space washers (not shown) can also be placed between a mounting plate portion 115 a , or 115 b , and the trim member 31 , or fascia board 14 , at the location where a fastener is placed, to maintain a small gap for venting out moisture residing therein. In fact, any suitable mechanisms of similar functions may be used for mounting and securing the roof edge windscreen 110 onto a roof edge. The drip edge 117 is also optional.
[0030] The roof edge windscreen has at least three functions. The first is to suppress vortex over a roof edge. High uplifts and strong scouring that result from wind-induced edge vortex above the roof, are prime causes for wind damage to roof components. Secondly, it shields the underside of the protruding portion 18 of the roof covering 11 , such as an array of asphalt shingles or wood shakes, from upward flow and pressure that tend to peel the roof covering 11 upwards and away from other parts of the roof edge assembly 10 . The third function is to prevent upward flow-driven rain from being pressured into the roof structure through the unsealed gaps between the roof covering 11 and the roof components beneath it.
[0031] FIG. 4 provides an example for a modified roof edge windscreen 410 being installed on a roof edge where the roof covering 49 wraps downwards, most often seen with metal roof coverings, such as metal tiles, metal shakes and metal panels, as well as clay tiles in some instances.
[0032] FIG. 5 illustrates a roof edge windscreen 510 being used on an eave edge of a sloped roof where a draining device such as a gutter system is not being used. An outwardly and downwardly extending screen portion 511 is preferred to allow rainwater to shed off the eave, and drain partly through the distributed perforation and partly off the outer edge of the roof edge windscreen 510 . This is in fact a better draining scheme than allowing roof rainwater cascade down directly from the eave edge, which erodes sods, soils or aggregates around a building perimeter.
[0033] FIG. 6 shows an alternative, simpler configuration of roof edge windscreen 610 being used on an eave edge of a sloped roof where a draining device such as a gutter system is not being used. Herein the screen portion 611 extends inwardly, closely below the outmost portion of the roof cover 68 . This configuration has similar functions to the one depicted in FIG. 5 .
[0034] A roof edge windscreen provides protection against wind and rain damage for a broad variety of roof constructions whenever the apparatus and its geometric relationship with the roof perimeter are configured in accordance with the spirit of this invention, as exemplified herein in the specification and governed in the appended claims.
[0000] Installation and Operation
[0035] An embodiment of this invention is a passive flow control device for roof edges. Once installed properly, it stays functioning in such a way that it mitigates vortex formation at a roof edge and reduces uplifts and vortex scouring on the roof perimeter area, whenever the wind blows towards a building bearing atop such roof edge devices, and requires no active operational intervention.
CONCLUSION, RAMIFICATIONS, AND SCOPE
[0036] It is apparent that roof edge windscreens of this invention provide advantageous devices for mitigating roof edge vortex and roof uplift, and are still among the simplest, most effective and reliable, inexpensive to manufacture and convenient to install.
[0037] Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Various changes, modifications, variations can be made therein without departing from the spirit of the invention. Roof edge windscreens can be made of any reasonably durable material with any appropriate means of fabrication as long as a configuration according to the spirit of this invention is accomplished to support the described working mechanism and to provide the associated functionality. Various surface portions of a roof edge windscreen may also bear such surface details as corrugation or steps of adequate sizes, as opposed to perfectly smooth surfaces. Any appropriate conventional or new mounting method can be used to secure a roof edge windscreen to a roof perimeter without departing from the spirit of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | An assembly attached to the roof perimeter to mitigate wind-generated vortices and uplift loads on the roof perimeter area of a building, applicable for both new constructions and retrofits of existing buildings. The assembly comprises an overhung screen portion preferably having face perforation and outer edge serration for equalizing pressure and disorganizing shear layer vorticity, and thus disrupting vortex formation. A roof edge windscreen is generally mounted onto an existing fascia or bargeboard. As an option appropriate for new constructions, it can also be mounted directly onto a framing member in place of fascia or bargeboard. | 4 |
RELATED APPLICATIONS
There are currently no applications co-pending with the present application.
FIELD OF THE INVENTION
The presently disclosed subject matter is directed towards electrician fish tapes. More specifically, the present invention relates to fish tapes having motor-driven rewinding mechanisms.
BACKGROUND OF THE INVENTION
Having the proper tools is critical to a job that is well done. Those who perform physical labor can readily attest that the proper tools can save time and money, produce a higher quality job, increase safety, and reduce damage to equipment and to the job site.
Each field of work has its own specialty tools that perform specialized tasks. Electricians and their helpers often face the specialized but common task of pulling wires or cables through conduits, wall cavities, ceiling cavities, and the like. To do so electricians often employ a fish tape (sometimes called a draw wire or draw tape). A fish tape is a thin, flattened, relatively rigid, continuous steel band that can be pushed and guided (fished) through conduits, wall cavities, ceiling cavities, and the like. Once the end of the fish tape is through, wires or cables are attached to the exposed end. The fish tape is then pulled back through the conduits, wall cavities, ceiling cavities and the like along with the attached wires or cables. When the ends of the wires or cable are exposed they are removed from the fish tape and electrically connected. This process can be repeated as many times are required.
Fish tapes work very well and have been successfully used around the world for many decades. The are tough, rugged, long lasting, easy to use, relatively low in cost, are capable of being used by one person (albeit two (2) people make most jobs much easier). Furthermore, as almost all fish tapes are stored coiled on a reel, hundreds of feet of fish tape can be easily carried and used by unwinding the fish tape from the reel. But, therein lies probably the biggest problem with fish tape. After the fish tape is used and the wire or cable has been pulled there can be literally hundreds of feet of a continuous steel band lying around.
Re-spooling hundreds of feet of fish tape can be both tiring and time consuming. Do it several times a day and your arms and hands can hurt and you lose valuable productive time. Therefore, a need exists for a technique that enables easy and quick rewinding of fish tapes onto reels. Beneficially, such rewinding can be done at reasonable cost by a single person.
SUMMARY OF THE INVENTION
The principles of the present invention provide for a mechanism that can easily and quickly rewind a fish tape onto a reel. Beneficially, those principles can be implemented at reasonable cost and in a manner that enables a single person to rewind the fish tape.
A powered fish tape in accord with the principles of the present invention has an annular hollow hub with an inner perimeter that is formed by a centrally-located, disc-shaped rotating member. The hub includes an opening into its interior. An elongated tape connects at one (1) end to the rotating member and also passes out of the opening. A cross-member attaches to the rotating member such that the rotating member rotates when the cross-member rotates. The cross-member includes a centrally located cross-member driver with a shaft. A motor is coupled to a chuck. A flex drive extension with a coupler driver at one (1) end and a socket at the other is configured such that when the coupler driver rotates the socket also rotates. The chuck connects to the coupler driver while the socket connects to the shaft. When the motor turns the chuck turns the flex drive extension which turns the cross-member which causes the tape to wind onto the rotating member.
Preferably the powered fish tape including a handle that is integrally molded with the hub. The handle beneficially includes a handle grip and a trigger that locks the tape in position. Usefully, at least part of the motor is inside the handle. In practice the motor will be battery-powered. For convenience the battery should form part of an outer surface of the handle. A switch can selectively electrically connect the battery to the motor. The elongated tape should be a thin, flattened, relatively rigid, continuous steel band. The flex drive extension should be removable and of the type that has a rotatable flexible steel cable. To assist a user handle the flex drive a socket grip should be located adjacent the socket.
To reduce operational problems a clutch adjustment preferably couples the motor to the chuck. The clutch adjustment should be used to control the maximum torque that can be applied to the cross member. A plurality of fasteners that pass through apertures can be used to attach the rotating member to the cross-member. While other shapes are possible a square coupler driver is useful. The powered fish tape can further include a battery charger.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings in which like elements are identified with like symbols and in which:
FIG. 1 is a perspective view of a powered fish tape 10 that is in accord with the principles of the present invention;
FIG. 2 is an exploded perspective view of a housing 20 of the powered fish tape 10 depicted in FIG. 1 ;
FIG. 3 is another perspective view of the housing 20 shown in FIG. 2 ;
FIG. 4 is a side, partially broken-away view of the housing 20 shown in FIGS. 2 and 3 ; and,
FIG. 5 is a perspective view of a coupler 40 used in the powered fish tape shown in FIG. 1 .
DESCRIPTIVE KEY
10 powered fish tape
20 housing
21 hub
22 rotating member
23 cross-member
24 cross-member driver
25 fasteners
26 handle
27 handle grip
28 trigger
29 battery
30 switch
31 opening
32 steel tape
33 motor
34 clutch adjustment
35 chuck
36 cross-member aperture
37 reel aperture
38 electrical contacts
40 coupler
41 coupler driver
42 flex drive extension
43 socket
44 socket grip
50 charger
51 power cord
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The preferred embodiment of present invention is herein depicted using FIGS. 1 through 5 . Those principles provide for a powered fish tape 10 that assists electricians or similar professionals in routing electrical wire through conduit, cavities, or other openings. The powered fish tape 10 is similar to common electrician fish tapes, yet includes enhanced features that make the powered fish tape 10 easier and faster to use.
FIG. 1 presents a perspective view of a preferred embodiment powered fish tape 10 . The powered fish tape 10 has a housing 20 comprising a hollow annular hub 21 and a handle 26 . The housing 20 enables a user to handle, use, wind, and unwind an elongated steel tape 32 . The powered fish tape 10 also comprises an attachable coupler 40 that is used for rewinding the steel tape 32 using a motor 33 (see FIG. 4 ). The powered fish tape 10 is used in a conventional manner to unwind the steel tape 32 and to fish it into a desired location. The motor 33 and coupler 40 can then be used to re-wind the steel tape 32 .
Refer now as required to FIG. 2 , an exploded perspective view of the housing 20 ; to FIG. 3 another perspective view of the housing 20 ; and to FIG. 4 a side, partially broken-away view of the housing 20 . The housing 20 includes the hollow annular hub 21 that forms a space for storing the steel tape 32 . The hub 21 is beneficially fabricated from a durable plastic. The hub 21 includes both a centrally-located, disc-shaped rotating member 22 that forms its inner perimeter and an opening 31 that enables access to the hub interior. A length of steel tape 32 , preferably made from spring steel or a similar material, is wound (coiled) around and connected at one (1) end to the rotating member 22 . The other end of the steel tape extends from the opening 31 . The steel tape 32 can be unwound and re-wound through the opening 31 from and onto the rotating member 22 .
A cross-member 23 is attached to the rotating member 22 to enable connecting the rotating member 22 to the coupler 40 . The cross-member 23 is preferably fabricated from a durable metal, yet other materials may be utilized without limiting the scope of the invention. The cross-member 23 is beneficially attached to the rotating member 22 by inserting fasteners 25 through cross-member apertures 36 and into reel apertures 37 . The rotating member 22 rotates when the cross-member 23 rotates. A side surface of the cross-member 23 includes a cross-member driver 24 which is comprised of a rectangular shaft which engages a socket 43 (see FIG. 5 ) of the coupler 40 . This enables rotating motion to be applied to the rotating member 22 and to the cross-member 23 as is subsequently described.
The handle 26 is beneficially integrally molded with the hub 21 . The handle 26 provides gripping surfaces that enable easy handling of the powered fish tape 10 . The handle 26 includes an intermediately positioned ergonomic handle grip 27 that is used for grasping and holding the housing 20 . An underside surface of the handle 26 includes a protruding trigger 28 which locks or secures the steel tape 32 in position. An upper portion of the handle 26 includes a rechargeable battery 29 that provides current through a switch 30 to the motor 33 . The battery 29 is recharged as needed with a charger 50 (see FIG. 1 ). The charger 50 includes a power cord 51 which enables the charger 50 to be inserted into a common household circuit. The battery 29 beneficially slides into place to engage the upper surface of the handle 26 and secures via a snap fit to engage a pair of electrical contacts 38 . This helps maintain a contoured outer profile of the handle 26 . The contacts 38 electrically interconnect the battery 29 to the switch 30 and to the motor 33 .
An upper surface of the handle 26 includes a switch 30 which selectively activates and deactivates the motor 33 . The switch 30 is depicted as a toggle switch, yet other devices may also be used. The switch 30 is electrically interconnected by electrical wire 39 to the motor 33 and to the contacts 38 . The motor 33 is beneficially housed within the handle 26 and provides the powered fish tape 10 with a force to rotate the cross-member 23 . The motor 33 is preferably a 12-volt direct current (DC) electric motor. The motor 33 connects to a clutch adjustment 34 that enables a user to adjust the maximum torque that can be applied to the cross-member 23 . The clutch adjustment 34 includes a chuck 35 that engages and secures a coupler driver 41 (see FIG. 5 ) of the coupler 40 . The chuck 35 utilizes common methods to retain sockets upon ratchet devices such as a spring-loaded ball bearing; hog ring connector; or the like.
FIG. 5 presents a perspective view of the coupler 40 which is used to rotate the cross-member 23 . The coupler 40 includes the coupler driver 41 , a flex drive extension 42 , and a socket 43 . The coupler driver 41 inserts into the chuck 35 as abovementioned. The coupler driver 41 is depicted as a common square driver, yet it is known that other drivers also may be used. The coupler driver 41 is integral to one (1) end of the flex drive extension 42 . The flex drive extension 42 is beneficially of the type comprised of an inner flexible steel cable that rotates inside an outer shell. The coupler 40 extends from the chuck 35 to the cross-member driver 24 . Opposing the coupler driver 41 is a socket 43 which accepts the cross-member driver 24 on the cross-member 23 . Encompassing the socket 43 is a rubberized ergonomic socket grip 44 which a user grasps during use. When the chuck 35 is turned by the motor 33 the flex drive shaft causes the cross-member 23 , and thus the rotating member 22 to turn. That causes the steel tape 32 to wind onto the rotating member 22 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the powered fish tape 10 it would be installed as indicated in FIG. 1 .
The method of installing and utilizing the powered fish tape 10 may be achieved by performing the following steps: acquiring the powered fish tape 10 ; charging the battery 29 with the charger 50 as needed; engaging the battery 29 onto the handle 26 ; unwinding a desired length of fishing tape 32 ; engaging the coupler device 41 into the chuck 35 and engaging the socket 43 to the cross member driver 24 ; and, activating the motor 33 with the switch 30 as needed to rotate the rotating member 22 and wind the fishing tape 32 .
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention. | Taught is a powered fish tape having an integrated electric rewinding mechanism that winds a tape onto a rotating reel using an electric motor. A cross-member is mounted to the rotating reel. A flexible shaft and a mechanical clutch couple the cross-member to the electric motor. The powered fish tape is beneficially powered by a rechargeable battery. | 1 |
FIELD OF THE INVENTION
The present invention generally relates to a steam distributor for applying steam to a web such as a paper sheet that is moving along its side wherein steam is discharged through a plurality of perforations in a screen. By varying the output area of the perforations, optimal steam velocity can be attained to achieve the desired steam absorption into the web and/or achieve efficient moisture removal.
BACKGROUND OF THE INVENTION
The steam heating of a paper sheet is widely practiced in papermaking. The increase in sheet temperature that results provides increased drainage rates for the water thus reducing the amount of water to be evaporated in the drier section. Water drainage is improved by the application of steam principally because heating of the sheet reduces the viscosity of the water, thus increasing the ability of the water to flow. Most of the heat transfer takes place when the steam condenses in the sheet. The condensation of the steam transforms the latent heat of the steam to sensible heat in the water contained by the sheet.
A particular advantage of steam heating of the paper sheet is that the amount of steam applied may be varied across the width of the sheet along the cross machine direction so that the cross machine moisture profile of the sheet may be modified. This is usually carried out to ensure that the moisture profile at the reel is uniform. Moisture measurement devices are well known in the papermaking art that can sense the moisture profile of a sheet of paper. If such an apparatus is scanned over the paper sheet, downstream of a steam distributor, then after measuring the water profile in the sheet, steam can be applied in varying amounts on a selective basis across the sheet, thus achieving the required uniform moisture profile at the reel.
A typical steam distributor is divided into compartments with laterally spaced-apart baffle plates that are covered with a partially perforated cover. Actuators supply steam to the compartments. By regulating the supply of steam into each compartment, it was possible to a limited extent to control the moisture profile of the sheet. Nevertheless, even with these improvements, the velocity of the steam passing through the perforated cover varies only with the actuator flow rates so ideal steam velocity cannot be achieved for different flow rates.
SUMMARY OF THE INVENTION
The present invention is based in part on the development of a steam distributor that includes a front screen that is equipped with steam perforations wherein the output area of at least some of the perforations can be adjusted to enable active control of the steam jet velocity. With respect to paper manufacturing, steam velocity affects penetration depth, boundary layer penetration, and response shape, especially the response width of the steam that is applied to the sheet. Excessive steam velocity causes sheet breakage whereas slowly delivered steam yields poor efficiency. With the present invention, the steam velocity can be controlled independently of steam flow to optimize efficiency and thereby avoid sheet upsets.
Accordingly, in one aspect, the invention is directed to an apparatus to distribute steam that includes:
a steam distribution header;
a housing defining a steam discharge chamber that is in fluid communication with the steam distribution header;
a front screen that covers the steam discharge chamber and which has a plurality of perforations through which steam exits;
means for varying the size of at least one of the perforations through which steam exits; and
means for regulating the flow of steam from the steam distribution header into the steam discharge chamber.
In another aspect, the invention is directed to a method of distributing steam along a length of continuously moving sheet which includes the steps of:
(a) positioning an apparatus having a leading edge and a trailing edge relative to the moving sheet, wherein the apparatus includes:
(i) a steam distribution header; (ii) a housing defining a steam discharge chamber that is in fluid communication with the steam distribution header; and (iii) a front screen that covers the steam discharge chamber and which has a plurality of perforations through which jets of steam exit;
(b) regulating the flow of steam from the steam distribution header into the steam discharge chamber to establish a predetermined, steam flow rate through the plurality of perforations;
(c) adjusting the velocities of the Jets of steam to desired levels at the predetermined steam flow rate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a steam distribution apparatus;
FIG. 2A is a perspective view of the compartments in the steam distributor apparatus;
FIG. 2B is enlarged, partial view of the front screen panel;
FIG. 2C is a partial front view of the compartments formed by stationary baffles or dividers;
FIG. 3 shows a pair of separated plates that form a front screen when they are combined;
FIG. 4A shows the cross sectional view of a screen consisting of two plates with apertures that are form perforations through which steam flows;
FIGS. 4B and 4C show the front views of the screen consisting of two plates with apertures wherein the apertures are fully and partially aligned, respectively;
FIGS. 5A and 5B show the front views of a screen consisting of two plates with apertures of different sizes at two different alignment positions:
FIG. 6 is a cross sectional view of a compartment;
FIG. 7A is another perspective view of a compartment; and
FIG. 7B illustrates an actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the overall assembly of a steam distribution apparatus or steam box 10 which includes an elongated housing 12 that is enclosed by end plates located at opposite ends. The length of the apparatus typically corresponds to the width of the sheet or web to which steam is to be applied. For papermaking operations the length can range, for instance, up to about 30 feet (9.1 meters). An external source of steam is connected to the steam distribution apparatus 10 and excess steam in the form of condensate is removed through a drain 16 which is located on the side of end plate 14 . The contour of the front screen panel or plate 18 preferably matches the external shape of the product to which steam is being supplied. The concave-shaped curvature of front screen panel 18 is particularly suited for apply steam to a roll of material. The front screen panel can also have a planar configuration to match the straight run of a moving sheet.
As further described herein, front screen panel 18 has steam outlets or perforations (not shown) that are formed thereon. The perforations are arranged so that exiting steam expands and impacts the surface of adjacent moving sheet to form a desired pattern (or response shape) of condensate. In one embodiment, the response shape is uniform along the width (or cross direction) of the moving sheet. With the present invention, the steam velocity can be optimized independent of the steam how rate.
The steam distributor apparatus 10 is preferably separated into a plurality of steam discharge chambers or compartments along its length. By regulating the amount of steam that passes through each compartment, it is possible to control the level of condensate that is applied along the cross direction of the moving sheet. For example, the amount of steam that enters into the individual chambers can be controlled in response to variations in measured properties of the sheet along its cross direction. Furthermore, the perimeter(s) of one or more of the compartments that define that steam profiling zone for the steam application can also be modified. This permits control of the steam profile along the cross direction as well. The invention is illustrated in an apparatus with multiple steam discharge chambers or compartments. The partitions or baffle panels that are laterally spaced apart create corresponding profiling zones that are covered by a perforated screen plate through which steam passes. It is understood however that the invention can be implemented with a steam distributor having a single discharge chamber.
FIG. 2A shows a partially disassembled exposed portion of the housing 30 of the steam distributor apparatus. The housing 30 encloses a steam distribution header 36 which is connected to at least one source of steam (not shown). Header 36 runs the length of the steam distribution apparatus. The header 36 is flanked by an interior wall 60 and an exterior wall 62 . The inner enclosure 34 shields the pneumatic actuators 32 with a removable cover that is secured by the hand tightened screws 64 . A plurality of baffles or partition panels 40 , that are laterally spaced apart, are secured to the exterior wall 62 thereby creating a number of steam discharge chambers or compartments once the front screen panel segment 31 is secured to the forward part of the housing. As further described herein, screen panel segment 31 comprises an interior plate 130 that is coupled to exterior plate 120 that faces a moving web.
In this embodiment, the middle of front screen segment 31 of front screen panel 18 ( FIG. 1 ) is fully populated with outlets 20 , which as shown in FIG. 2B . Outlets 20 are preferably circular but it is understood that the individual outlets can have non-circular configurations. The number and size of the outlets are designed to achieve the desired steam flow rate and velocity. The size of the outlets 20 should be sufficiently small to minimize the amount of fibers and other debris from the sheet of material being heated that enters into the discharge chambers. Nevertheless, in operation, as steam is applied through the perforations 20 onto a moving sheet of paper, for instance, the middle of front screen segment 31 can come into contact with the sheet. In this regard, it is may be preferred to avoid excessive blank areas on the middle of front screen segment since there may be a tendency for debris to accumulate in areas on the panel that are not populated with outlets. As is apparent, the number of front screen panel segments 31 required to cover a steam distribution apparatus will depend on the total cross directional length of the steam distribution apparatus and the cross directional length of each panel segment 31 .
Each pneumatic actuator 32 is operatively connected to a pipe 42 which has an inlet end located within the header 36 and an outlet end that is located in a discharge chamber. In this embodiment, the inlet end of the pipe 42 is partially covered by a sleeve 44 . A piston is attached to the actuator 32 by a connecting rod to regulate the inlet into pipe 42 and thus control the steam flow between the header 36 and the control chamber.
As shown in FIG. 2C , a plurality of oblique-oriented baffles 40 , which are not aligned with the machine direction of movement of the traveling sheet (not shown), form a plurality of steam discharge compartments 66 along the cross direction or width of the steam distribution, apparatus 10 ( FIG. 1 ). While baffles 40 are illustrated as being planar, it understood that they can be curved or other non-planar configuration. The perimeter(s) of discharge compartments 66 define a series of trapezoidal-shaped profiling zones 22 through which steam from outlets 68 passes as it travels toward the steam perforations 20 ( FIG. 2B ). In this arrangement, adjacent trapezoidal-shaped profiling zones are inverted with respect to each other. The profiling zones 22 can exhibit other shapes depending on the configuration of partition panels 40 . Where adjacent panels 40 are vertical and parallel, the profiling zones are rectangular.
FIG. 3 illustrates the front screen 31 ( FIG. 1 ) when dissembled into an exterior plate 120 and an interior plate 130 . (Only a few of the perforations in front screen 31 are represented.) The exterior plate 120 has a plurality of apertures 124 , 126 , 128 that form a pattern of apertures as shown on the front surface 122 . Similarly, the interior plate 130 has a plurality of corresponding apertures 134 , 136 , 138 that form a pattern of apertures as shown on the front surface 132 . The dimensions and curvature of exterior plate 120 match that of interior plate 130 so that when the two plates are slidably fitted together, they form front screen 31 ( FIG. 1 ). In this embodiment, the size of the circular apertures in both plates 120 and 130 are the same; moreover, the pattern of the apertures in plate 120 is also aligned with the pattern of the apertures in plate 130 . Thus, for example, apertures 124 , 126 and 128 of exterior plate 120 are directly above apertures 134 , 136 and 138 , respectively, when exterior plate 120 and interior plate 130 are assembled to form the front screen 31 . The configurations and positions of the apertures in the plates can be varied as desired in order to achieve optimum steam velocities. For example, while the cross sectional area of the apertures is preferably circular the area can be rectangular or other polygonal shape. In the case where the cross sectional area is circular, its diameter typically ranges from 0.0625 to 0.25 inches (1.59 to 6.35 mm) and preferably from 0.0625 to 0.125 in. (1.59 to 3.18 mm). Regardless of the geometry, the cross sectional area of each aperture typically ranges from 0.003 to 0.05 sq. in. (1.94 to 32.3 sq. mm) and preferably from 0.003 to 0.012 sq. in. (1.94 to 7.74 sq. mm.) The thickness of the exterior plate 120 is preferably the same as that of interior plate 130 ; the thickness of each plate typically range from about 0.0313 to 0.125 in. (0.795 to 3.175 mm) and preferably from about 0.0625 to 0.125 in. (0.795 mm to 3.175 mm).
FIGS. 4A and 4B depict a partial cross sectional and front view of screen 31 ( FIG. 1 ) that is formed by pressing exterior plate 120 against interior plate 130 . The apertures in exterior plate 120 are fully aligned to those of interior plate 130 and, as an illustration, apertures 152 , 154 , 156 and 158 are located along one side of exterior plate 120 and are aligned with corresponding apertures 162 , 164 , 166 , and 168 , respectively on one side of interior plate 130 . In this configuration, apertures 152 and 162 form perforation 142 , apertures 154 and 164 form perforation 144 , apertures 156 and 166 form perforation 146 , and apertures 158 and 168 form perforation 148 on screen plate 31 . In the fully aligned arrangement shown in FIG. 4B , the output area of the perforation is the highest which means that for a given steam flow rate into a discharge chanter, the steam jet velocity is at the lowest.
Lateral movement of exterior plate 120 relative to interior plate 130 shifts the positions of the apertures in exterior plate 120 relative to those in exterior plate 130 so as to reduce the size of the perforations in the screen plate as shown in FIG. 4C . For example, aperture 152 partially covers aperture 162 so that the area of perforation 142 A is smaller than that of perforation 144 ( FIG. 4B ) when aperture 152 is fully aligned with corresponding aperture 162 . In this fashion, the cross sectional area of each perforation (such as perforations 142 A, 144 A, 146 A and 148 A) in the screen plate 31 is adjusted to the same degree. Lateral movement of exterior plate 120 relative to interior plate 130 can be accomplished by moving one or both plates. As shown in FIGS. 4B and 4C , in this embodiment, the exterior plate 120 is connected to a precision manual or motorized displacement device 108 . Suitable manual devices include screw mechanisms and suitable motorized devices include linear actuators. As further described herein, the effect of partially reducing the output area is to increase the steam jet velocity for a given steam volumetric flow into the discharge chamber.
FIGS. 5A and 5B illustrate an embodiment of a screen plate 190 that includes exterior plate 180 and a lower interior plate 170 where the sizes of the apertures vary. Only three rows of perforations on the screen plate 190 are illustrated. In this construction, the circular apertures in the interior plate 170 all have the same diameter whereas the circular apertures in the first and third rows of exterior plate 180 are three times larger while the remaining apertures in the exterior have the same diameter as the apertures in the interior plate 170 . As shown in FIG. 5A , when the apertures in the two plates are fully aligned, the output area of each screen plate perforation is restricted only by the size of the smaller interior apertures. In the top and third row of perforations, the larger apertures of the exterior plate 180 (such as aperture 182 ) are aligned with the smaller apertures in the interior plate 170 such as aperture 172 ). Thus, the output area for steam flow for perforation 182 is the same as the area of aperture 172 . In the second row, because the size of the apertures in both plates is the same, the output area of the perforation 194 will also be the same. For this design, shifting of the exterior plate 180 relative to interior plate 170 effects the output areas of the first and second row perforations different than the output areas of the middle row perforations. For example, as shown in FIG. 5B , when the exterior plate 180 is moved a distance equal to the diameter of the smaller interior plate 170 , the top row perforations retain the same output areas because the larger aperture 172 is sufficiently large to still fully expose the underlying smaller aperture 162 . In contrast, the output areas of middle row perforations is effectively eliminated since the aperture 182 in the exterior plate and the aperture 172 in the interior plate are not align at all. The effect is to increase the jet velocity through the top and lower row perforations if the steam volumetric flow is the same, but no steam flows through the middle perforations as they are closed. As is apparently, if the exterior plate 180 is moved a distance of less than the diameter of the smaller interior plate 170 , the output areas of the middle low perforations would be reduced thereby increasing the jet velocities in all of the perforations.
As is apparent, the shape, dimensions and arrangement of the apertures in the movable exterior and interior plates can be selected to create the desired steam output areas for the perforations in a screen that is formed. Indeed, while the screen plate is usually formed with two plates with apertures, additional plates can be used to provide additional features to the screen plate. Once the exterior and interior plates are slidably engaged, lateral movement of one or both plates changes the output area so as to modify the steam jet velocities of the steam exiting the perforations of the screen and impinging on the moving web.
In operation of the steam box as shown in FIGS. 6 and 7A , high pressure steam that is supplied to the header 36 is drawn into the pipe 42 through the annular opening between the pipe 42 and the sleeve 44 . The amount of steam drawn is controlled by the actuator 32 which is connected to a pneumatic supply 35 which tunes or regulates the actuator by pressurizing a diaphragm that is on top of a piston that is located inside the actuator 32 . The piston is connected to a measuring plug that moves inside the sleeve 44 to control the amount of steam that goes into each discharge chamber. Steam from the pipe 42 initially enters into a discharge chamber 66 through the pipe outlet 68 . The high velocity steam is dispersed within the discharge chamber 66 before exiting through the perforations of the from panel screen segment 31 and contacting a continuous moving sheet 33 located in front of the perforations. Preferably, a target plate 92 is positioned to disperse the high velocity steam uniformly throughout the discharge chamber 66 before the steam permeates through the perforations in the screen plate 31 . In this fashion, there is uniform steam distribution from the leading edge 104 to the trailing edge 106 of the steam distribution apparatus as the sheet of material moves across the screen plate 31 in the machine direction. The speed at which moving sheet 33 determines the boundary layer velocity (or cross flow velocity), which is the velocity of the gaseous fluid flowing adjacent the moving sheet. Condensate that forms on the bottom of the discharge chamber 66 seeps through a drain hole and out through a condensate drain 38 .
With respect to paper manufacturing, the desired or ideal steam velocity depends on, among other things, furnish (or paper pulp) composition, machine speed, and machine configuration. Steam velocities that are too low or excessively high degrade steam shower performance which result in reduced production, wasted steam and fiber build up in the steambox that in turn leads to sheet breaks, steam cloud, dripping and other problems. With the present invention, the steam jet velocity can be optimized to accommodate different paper production rates, paper grades and other criteria. Referring to FIG. 6 , optimizing the jet velocity can takes into account various factors including, for example: (i) the distance (H) between screen 31 (equipped with the perforations) and moving sheet 33 , (ii) output area (B) of the perforations; and (iii) boundary layer velocity. Typically, the H is between 0.125 to 0.5 in. (3.18 to 12.7 mm) and the boundary layer velocity is 300 to 7000 ft./sec. (91.4 to 2,134 m/sec.) For a particular paper production rate and grade, once H and the boundary layer velocity are established, the steam jet velocity can be optimized by adjusting the output area of the perforations. The jet velocity should range from 50 to 150 ft./sec. (15 to 45.7 m/sec.).
By monitoring and controlling the steam flow into each of the discharge chambers, the steam profile that is injected onto the sheet along its cross direction can be continuously and independently regulated. The steam profile as measured along the length of the steam distribution apparatus can be uniform or non-uniform so that the sheet or web of material can be exposed to a steam curtain having different steam velocities in the cross direction. Adjustment to the output areas of the perforations can be made in response to cross direction sensors, such as moisture profile sensors, located upstream and/or downstream of the steam distributor.
As shown in FIG. 2A , the front screen panel segment 31 has a concaved exterior contour. A backing bar 98 is secured to the lower end of the laterally spaced baffles 40 . The front screen panel segment 31 can be welded onto a portion of the backing bar 98 as well as onto the baffles 40 . In this fashion, the front screen panel segment 31 forms the front perforated wall of the steam discharge chambers. The front of the backing bar 98 also defines a series of dowel pins 84 that helps align the cleanout bar 48 as it is secured with screws 50 to the body of the steam distribution apparatus. When it is necessary to clean the steam discharge chambers between the baffles 40 , it is only necessary to remove the cleaning bar 48 to gain access to the discharge chambers through access slots that are located at the lower end of each discharge chamber.
The foregoing has described the principles, preferred embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed. Thus, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing, from the scope of the present invention as defined by the following claims. | A steam distributor includes a front screen equipped with steam perforations wherein the output area of at least some of the perforations can be adjusted to enable active control of the steam jet velocity. The steam velocity can be controlled independently of steam flow. The front screen is includes (i) a first plate that has a first set of apertures and (ii) a second plate that has a second set of apertures, wherein the second plate covers the first plate, and wherein the means fir varying the size of at least one of the perforations moves the first plate, the second plate, or both the first and the second plates in order to change the position of the first set of apertures relative to the second set of apertures. | 3 |
TECHNICAL FIELD
The embodiments described below relate generally to electronic circuits, and more particularly, to power distribution in a multi-power-source, multi-domain, integrated circuit.
BACKGROUND
Logic control signals generated by the power-up reset signals of various power supplies are commonly used to determine the power-up sequence logic in an integrated circuit device. However, during power-up of an integrated circuit device that has multi-power domains, there is no sequencing control by the integrated circuit device over the external power supplies, and the traditional methods cannot control the sequencing of power supplies within functional blocks where specific power-up sequences are required.
The transitional instability of the power level of different power supplies during the power-up process is an important issue during the power-up process. Conventional level shifters can be used to transfer logic signals among various power levels when power supplies are stable; however, during power-up mode, not all power supplies are stable. In most cases, during power-up process, some power supplies become stable while others either continue to ramp up or remain inactivated. Specially designed level shifting circuits are needed to handle the power-up processes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example of a power-up sequence control circuit, in accordance with an embodiment of the invention.
FIG. 2 illustrates a power-switch, which is an element of the power-up sequence control circuit of FIG. 1 , in accordance with an embodiment of the invention.
FIG. 3 illustrates a power-switch controller, which is an element of the power-up sequence control circuit of FIG. 1 , in accordance with another embodiment of the invention.
FIG. 4 illustrates a power-switch controller, in accordance with yet another embodiment of the invention.
FIG. 5 illustrates a power-switch controller, in accordance with yet another embodiment of the invention.
DETAILED DESCRIPTION
Various embodiments of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail, so as to avoid unnecessarily obscuring the relevant description of the various embodiments.
The terminology used in the description presented below is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.
The described embodiments illustrate the use of self-controlled power switches to control the power supplied by different power supplies to various functional blocks of an integrated circuit device. The required power-up sequence within a functional block is controlled by a set of power switches. When the power levels (voltages) of different power supplies are not the same, it is often required for a signal from a lower power supply level to control the power switches that control the higher power levels.
Another issue concerning the power-up process is the potential instability of the power being supplied during the power-up transition period of a power supply. When power supplies are stable, conventional level shifters may be used to transfer logic signals among various power levels; however, during power-up mode, not all power supplies are stable. In fact in most cases some power supplies become stable while others either continue to ramp up or remain inactivated. Therefore, especially designed level shifting circuits are needed to handle the power-up processes.
In circumstances where a power-up sequence is required, since not all power supplies may be stable or activated, the power switches must be controlled by the power-up sequence, rather than by a fixed logic that is only suitable for stable power levels. In these cases the controls to the power switches are designed to be self-timed and self-adjusted to satisfy the required power-up sequences.
FIG. 1 illustrates an example of a power-up sequence control circuit 100 , in accordance with an embodiment of the invention. In this example, there are three power supplies for the integrated circuit device, and the power levels of these power supplies are different. Power 1 , Power 2 , and Power 3 represent these three power supplies.
Power 3 has the highest power level (voltage), Power 2 has a power level lower than Power 3 but higher than Power 1 , and Power 1 has the lowest power level. During the power-up stage, Power 3 is the first to be stable, while Power 2 and Power 1 will be ramping up to stable levels. It is also required that Power 2 goes to the corresponding functional blocks after Power 1 is stable, regardless of the order in which they become stable. By controlling the power switch 110 located between Power 2 and the functional blocks supplied by Power 2 , the switch controller 112 regulates the required sequencing of Power 1 and Power 2 .
FIG. 2 is a schematic diagram of the power switch 110 , which consists of a PMOS transistor 210 whose body is connected to Power 2 , and whose gate is controlled by the switch controller 112 . There is also an NMOS transistor 212 serving as a leakage device when the power switch is not turned on. This leakage device discharges the Internal Power 2 Supply when the switch M 1 is turned off, so that the Internal Power 2 Supply is not in a floating state.
FIG. 3 is a schematic diagram of the power switch controller 112 . The power switch controller 112 has three parts:
1-Power 1 detection circuit (M 2 , M 7 , M 1 , M 5 , M 6 ) 2-Power 1 detection trigger circuit (M 3 , M 8 ) 3-Power 1 signal to Power 3 signal level shifting circuit (M 3 , M 8 , INV 1 , INV 2 )
Transistors M 1 , M 5 , M 6 generate a bias voltage for M 7 to limit its current. The gate of transistor M 2 is tied to ground (GND) so that it becomes conducting as soon as Power 1 is above V t (the device threshold turn-on voltage). M 3 is a weak PMOS device and M 8 is turned on only if Power 1 is high enough to offset the biased current sink by M 7 .
When Power 3 is on and Power 1 is off, the output of the circuit (Switch_en_b) is high (Power 3 level) because M 3 is on and M 8 is fully off.
When Power 1 starts to ramp up, M 2 starts conducting. When the voltage level at point A reaches V t of M 8 , M 8 starts conducting, and the Voltage level at point B starts to drop. In this situation the output Switch_en_b changes from high to low.
FIG. 4 is a schematic diagram of another power switch controller 112 , where:
M 4 is the feedback for the switch on lock-up (because M 3 is a weak pull-up device, it is sensitive to noise. M 4 reduces the noise sensitivity by providing a latch-like structure, especially when the Power 1 is not ready.); D 1 is the diode for preset state (D 1 provides a discharge path for the gate of M 8 to turn off M 8 when Power 1 is off so that the control circuit can return back to the preset state.); and C 1 is to reduce noise (in an integrated device, there are noise generated by other circuits. C 1 reduces the M 8 gate sensitivity to such noise.).
FIG. 5 is a schematic diagram of an alternative power switch controller 112 , where M 9 and M 10 are feedbacks for turning off bias and detection circuit static currents. M 9 and M 10 are for power management. When Power 1 is off, M 9 and M 10 are turned on so that the control circuit is ready to operate. After Power is up and stable, M 9 and M 10 are turned off so that the DC current I 1 and I 2 are eliminated, thus reducing the power consumption of the control circuit.
Conclusion
Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof.
Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.
The above detailed description of embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above. 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.
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.
Changes can be made to the invention in light of the above Detailed Description. While the above description describes certain embodiments of the invention, and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Details of the compensation system described above may vary considerably in its implementation details, while still being encompassed by the invention disclosed herein.
As noted above, 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 under the claims.
While certain aspects of the invention are presented below in certain claim forms, the inventors contemplate the various aspects of the invention in any number of claim forms. Accordingly, the inventors reserve the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention | Methods and apparatus are disclosed for controlling power distribution during transitory power-up period of multi-domain electronic circuits that are supplied by multiple power supplies. The power distribution is controlled by self-regulating power control circuits that operate based on power-up sequencing requirements. Described embodiments of the invention illustrate examples of power-switch and power-switch controller circuits used as elements of the power control circuitry. | 6 |
[0001] This application is a Continuation-in-Part of U.S. application Ser. No. 10/347,489 (now U.S. Pat. No. 6,860,074), having been filed on Jan. 21, 2003, which in turn is a Continuation-in-Part of U.S. application Ser. No. 09/986,414, having been filed on Nov. 8, 2001, each of which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention is a joint cover assembly that includes a molding, similar to a transition molding between two separate parts, such as a T-Molding, for covering a gap that may be formed between adjacent panels in a generally planar surface, such as between two adjacent flooring or wall or ceiling materials; or between a floor and a hard surface or carpet, or even a riser and a runner in a step (or a series of steps).
[0004] 2. Background of the Invention
[0005] Wood or laminate flooring has become increasingly popular. As such, many different types of this flooring have been developed. Generally, this type of flooring is assembled by providing a plurality of similar panels. The differing types of panels that have developed, of course, may have differing depths and thicknesses. The same is true when a laminate floor abuts another hard surface, such as a vinyl, tile or laminate surface, a ceramic surface, or other surface, such as natural wood flooring. Thus, when laminate panels having different thicknesses or different floor covering materials are placed adjacent to a laminate floor, transition moldings are often used to create a transition between the same.
[0006] Additionally, one may desire to install floor panels adjacent to an area with different types of material. For example, one may desire to have one type of flooring in a kitchen (e.g., laminate flooring or ceramic tile), and a different appearance in an adjacent living room (e.g., linoleum or carpeting), and an entirely different look in an adjacent bath. Therefore, it has become necessary to develop a type of molding or floorstrip that could be used as a transition from one type of flooring to another.
[0007] A problem is encountered, however, when flooring materials that are dissimilar in shape or texture are used. For example, when a hard floor is placed adjacent a carpet, problems are encountered with conventional edge moldings placed therebetween. Such problems include difficulty in covering the gap that may be formed between the floorings having different height or thickness.
[0008] Moreover, for purposes of reducing cost, it is important to be able to have a molding that is versatile, having the ability to cover gaps between relatively coplanar surfaces, as well as surfaces of differing thicknesses.
[0009] It would also be of benefit to reduce the number of molding profiles that need to be kept in inventory by a seller or installer of laminate flooring. Thus, the invention also provides a method by which the number of moldings can be reduced while still providing all the functions necessary of transition moldings.
SUMMARY OF THE INVENTION
[0010] The invention is a joint cover assembly for covering a gap between edges of adjacent floor elements, such as panels, although it may also be used as a transition between a laminate panel and another type of flooring, e.g., carpet, linoleum, ceramic, wood, etc. The assembly includes a body having a foot positioned along a longitudinal axis, and a first arm extending generally perpendicularly from the foot. The assembly may include a second arm also extending generally perpendicular to the foot. A tab may additionally be provided on either the first or second arms, displaced from the foot, extending perpendicularly from the arm.
[0011] The outward-facing surface of the assembly may be formed as a single, unitary, monolithic surface that covers both the first and second arms. This outward-facing surface may be treated, for example, with a laminate or a paper, such as a decor, impregnated with a resin, in order to increase its aesthetic value, or blend, to match or contrast with the panels. Preferably, the outward facing surface has incorporated therein a material to increase its abrasion resistance, such as hard particles of silica, alumina, diamond, silicon nitride, aluminum oxide, and similar hard particles.
[0012] The assembly is preferably provided with a securing means to prevent the assembly from moving once assembled. In one embodiment, the securing means is a clamp, designed to grab the foot. Preferably, the clamp includes a groove into which the foot is inserted. In a preferred embodiment, the clamp or rail may joined directly to a subsurface below the floor element, such as a subfloor, by any conventional means, such as a nail, screw or adhesive.
[0013] A shim may also be placed between the foot and the subfloor. In one embodiment, the shim may be positioned on the underside of the clamp; however, if a clamp is not used, the shim may be positioned between the foot and the subfloor. The shim may be adhered to either the foot or subfloor using an adhesive or a conventional fastener, e.g., nail or screw.
[0014] The assembly may also include a leveling block positioned between the first arm and the adjacent panel. The leveling block generally has an upper surface that engages the arm, and a bottom that abuts against the adjacent panel. In a preferred embodiment, the leveling block has a channel formed in an upper surface, configured to receive the tab on the arm. The particular size of leveling block is chosen, conforming essentially to the difference in thicknesses between the first and second panels. The exposed surfaces of the leveling block is typically formed from a variety of materials, such as a carpet, laminate flooring, ceramic or wood tile, linoleum, turf, paper, natural wood or veneer, vinyl, wood, ceramic or composite finish, or any type of covering, while the interior of the leveling block is generally formed from wood, fiberboard, such as high density fiberboard (HDF) or medium density fiberboard (MDF), plastics, or other structural material, such as metals or composites, at least over a portion of the surface thereof may be covered with a foil, a plastic, a paper, a decor or a laminate to match or contrast with the first and second arms. The leveling block additionally facilitates the use of floor coverings having varying thicknesses when covering a subfloor. The leveling block helps the molding not only cover the gap, but provide a smoother transition from one surface to another.
[0015] Alternatively, the tab may be positioned to slidingly engage the edge of a panel when no leveling block is used. A lip may additionally be positioned on the tab in order to slidingly engage a protuberance, adjacent an upper edge of the clamp, in order to retain the assembly in its installed position.
[0016] The tab is preferably shaped as to provide forces to maintain the assembly in the installed position. Thus, typically the tab may be frustum-shaped, with its narrow edge closest to the arm and the wider edge furthest from the arm. Additionally, the tab may be lobe shaped, having a bulbous end furthest from the arm. Of course, any suitable shape is sufficient, as long as the tab can provide enough resistive forces to hinder removal of the installed assembly. By forming a corresponding channel in the leveling block (or in the upper surface of the flooring element), the tab can help to secure the assembly in place.
[0017] The assembly may additionally be used to cover gaps between tongue-and-groove type panels, such as glueless laminate floor panels. In addition to the uses mentioned above, the tab may also be designed to mate with a corresponding channel in the panel, the edge of one of the flooring elements, or may actually fit within a grooved edge. In order to better accommodate this type of gap, a second tab may be positioned to depend from the second panel engaging surface.
[0018] An adhesive, such as a glue, a microballoon adhesive, contact adhesive, or chemically activated adhesive including a water-activated adhesive, may be positioned on the tab, the foot, and the arms. Of course, such an adhesive is not necessary, but may enhance or supplement the snap-type fit of the assembly into the gap between the floor elements. Additionally, the adhesive may assist in creating a more air-tight or moisture-tight joint.
[0019] The assembly may be used in other non-coplanar areas, such as the edge between a wall and a floor, or even on stairs. For example, the assembly may include the first and second arms, and foot as described above, but instead of transitioning between two floor elements placed in the same plane, may form the joint between the horizontal and vertical surfaces of a single stair element.
[0020] The inventive assembly may be used for positioning between adjacent tongue-and-groove panels; in this regard, the assembly functions as a transition molding, which provides a cover for edges of dissimilar surfaces. For example, when installing floors into a home, the assembly could be used to provide an edge between a hallway and a bedroom, between a kitchen and living or bathroom, or any areas where distinct flooring is desired. Additionally, the assembly may be incorporated into differing types of flooring, such as wood, tile, linoleum, carpet, or turf.
[0021] The invention also is drawn to an inventive method for covering a gap between adjacent panels of a generally planar surface. The method includes multiple steps, including, inter alia, placing the foot in the gap, pressing the respective arms in contact with the respective floor elements, and configuring at least one of the tab and the foot to cooperate to retain the assembly in the gap after the assembly has been installed.
[0022] Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exploded view of an embodiment of the joint cover assembly in accordance with the invention;
[0024] FIGS. 1A and 1B are alternate embodiments for the molding of the invention;
[0025] FIG. 2 is a perspective view of a second embodiment of the joint cover assembly in accordance with the invention;
[0026] FIGS. 3 and 3 A are comparative perspective views of embodiments of the leveling block;
[0027] FIG. 4 is perspective view of an additional embodiment of the joint cover assembly in accordance with the invention;
[0028] FIGS. 5 and 5 A are comparative perspective views of embodiments of the leveling block;
[0029] FIGS. 6-16 show comparative cross-sectional views of various embodiments of the molding portion of the joint cover assembly;
[0030] FIG. 17 depicts an embodiment of the assembly of the invention for use with stairs;
[0031] FIG. 18 shows a second embodiment of the assembly for use with stairs;
[0032] FIG. 19 is a side view of a generic element, which may be broken into the components of the invention; and
[0033] FIGS. 20-81 are various modifications of molding of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] FIG. 1 shows an exploded view of the various parts of the inventive joint cover assembly 10 . The assembly 10 includes a T-shaped molding 11 , having a foot 16 formed so that it can fit in a gap 20 between adjacent floor elements 24 , 25 . FIG. 1 demonstrates a typical use, in which the gap 20 is formed adjacent an edge 27 of a floor element 24 . Although FIG. 1 depicts all of the floor elements 24 to be conventional tongue-and-groove type floor panels (having a groove 27 positioned adjacent to the gap 20 ), this is merely one of any number of embodiments. For example, floor elements 24 , 25 need not be the same type of floor element. Specifically, the floor elements 24 can be any type of flooring designed to be used as a floor or placed over a subfloor 22 , e.g., tile, linoleum, laminate flooring, concrete slab, parquet, vinyl, turf, composite or hardwood. As is known, laminate floors are not attached to the subfloor 22 , but are considered “floating floors”.
[0035] The molding 11 is provided with a first arm 12 and a second arm 14 extending in a single plane generally perpendicular to the foot 16 . Preferably, the foot 16 , first arm 12 , and the second arm 14 form a general T-shape, with the arms 12 and 14 forming the upper structure and the foot 16 forming the lower structure. Although the foot 16 is shown as being positioned at a central axis of the molding 11 , such is only a preferred embodiment. In other words, it is within the scope of the invention to vary the position of the foot 16 with respect to the first and second arms 12 , 14 . For example, the foot 16 may be placed at the midpoint, or anywhere in between.
[0036] The molding 11 , as well as any of the other components used in the invention, may be formed of any suitable, sturdy material, such as wood, polymer, or even a wood/polymer composite. Due to the growing popularity of wood and laminate flooring and wood wall paneling, however, a natural or simulated wood-grain appearance may be provided as the outward facing surface 34 of the molding 11 . The outward facing surface 34 may be a conventional laminate, such as a high pressure laminate (HPL), direct laminate (DL) or a post-formed laminate (as described in U.S. application Ser. No. 08/817,391, herein incorporated by reference in its entirety); a foil; a print, such as a photograph or a digitally generated image; or a liquid coating including, for example, aluminum oxide. Thus, in the event natural wood or wood veneer is not selected as the material, the appearance of wood may be simulated by coating the outer surface 34 with a laminate having a decor sheet that simulates wood. Alternatively, the decor can simulate stone, brick, inlays, or even fantasy patterns. Preferably, the outward facing surface 34 extends completely across the upper face of the molding, and optionally under surface 36 and 38 of arms 12 and 14 , respectively.
[0037] The core structure of components of the invention, including the center of the molding 11 , that is in contact with the outward facing surface 34 is formed from a core material. Typical core materials include wood based products, such as high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, strandboard, and solid wood; plastic-based products, such as polyvinyl chloride (PVC), thermal plastics or mixtures of plastic and other products; and metals, such as aluminum, stainless steel, or copper. The various components of the invention are preferably constructed in accordance with the methods disclosed by U.S. application Ser. No. 08/817,391, as well as U.S. application Ser. No. 10/319,820, filed Dec. 16, 2002, each of which is herein incorporated by reference in its entirety.
[0038] A securing means, such as a metal clamp 26 , may be coupled to the subfloor 22 within the gap 20 formed between the two floor elements 24 . The clamp may be coupled to the subfloor 22 by fasteners, such as screws or any conventional coupling method, such as nails or glue. The clamp 26 and the foot 16 are preferably cooperatively formed so that the foot 16 can slide within the clamp 26 without being removed. For example, the clamp 26 may be provided with in-turned ends 30 designed to grab the outer surface of the foot 16 . Typically, the foot 16 has a dove-tail shape, having the shorter parallel edge joined to the arms 12 and 14 ; and the clamp 26 is a wire element having a corresponding shape as to mate with the foot 16 and hold it in place. Additionally, the securing element may take the form of an inverted T-element 50 ( FIG. 1A ), configured to mate with a corresponding groove 52 in an end of foot 16 , such that friction between the T-element 50 and the groove 52 secures the molding 11 in place, or, in the alternative, the end of the foot 16 may be provided with a narrowed section, designed to mate with a groove in the securing element. Finally, each of the T-element 50 , mating section of the foot 16 and/or various grooves, may be provided with notched or barbed edges 55 to simultaneously assist in mating and resist disassembly ( FIG. 1B ). However, in an alternative embodiment, the securing element can be eliminated because the molding 11 can be affixed to one of the floor elements 24 , 25 , by, for example, an adhesive. Preferably, however, the molding 11 is not secured to both floor elements 24 , 25 , as to permit a degree of relative movement, or floating, between the floor elements 24 , 25 .
[0039] The clamp 26 may additionally be formed of a sturdy, yet pliable material that will outwardly deform as the foot 16 is inserted, but will retain the foot 16 therein. Such materials include, but are not limited to, plastic, wood/polymer composites, wood, and polymers.
[0040] A tab 18 is shown as extending downwardly from the first arm 12 . As shown in FIG. 1 , the tab 18 extends downward, or away from an outward facing surface 34 of the molding, and runs generally parallel to the foot 16 . As shown in FIG. 1 , the tab 18 may also be in the shape of a dove-tail with a shorter edge adjacent to the first arm 12 ; however, other suitable shapes are possible. The shape of the outwardly facing surface 34 of the molding 11 is shown as being convex in some of the Figures (e.g., FIGS. 1A, 1B and 7 ), and substantially planar in others (e.g., FIGS. 1, 2 , 4 , and 6 ). When the outwardly facing surface 34 is substantially planar, the edges of the molding 11 may either be upright or at an angle, typically angling away from the foot 16 . However, the relative positions of the tongue/groove may also be reversed.
[0041] The assembly may further include a leveling block 40 . When flooring elements 24 and 25 are of differing heights, the leveling block 40 is positioned between either the first arm 12 or the second arm 14 and the subfloor 22 . Preferably, the size of the leveling block 40 is selected to correspond essentially to the difference in heights of the two flooring elements 24 and 25 . For example, if one flooring element 24 is a ceramic tile, having a thickness of 2″ and the second flooring element 25 is linoleum, having a thickness of ¼″, the leveling block 40 would typically have a thickness of 1¾″ to bridge the difference and be placed between arm 12 and the other flooring element 25. Without the leveling block 40, a significant space would exist between the second flooring element 25 and the molding 11, allowing for moisture and dirt to accumulate. While the difference in heights of the flooring elements 24, 25 is generally caused by a difference in thickness between the two flooring elements 24, 25, the present invention may also be used to “flatten out” an uneven subfloor 22. In addition, a shim may be placed under the track to adjust for differences in floor thickness. In a preferred embodiment, the leveling block is provided with a channel 42 designed to receive the tab 18.
[0042] Even though the assembly 10 may function without any type of glue or adhesive, an alternate embodiment includes the placement of adhesive 31 on the molding 11 . The adhesive may be placed on molding 11 at the factory (for example, pre-glued). Alternatively, the glue may be applied while the floor elements 24 , 25 are being assembled. As shown in FIG. 6 , the adhesive 31 may be provided as a strip-type adhesive, but any type of adhesive, such as glue, chemical or chemically-activated adhesive, water-activated adhesive, contact cements, microballoon adhesive may be used. Additionally, while the embodiment in FIG. 6 shows a single adhesive strip 31 attached to the arm 12 , the adhesive 31 may be attached to the tab 18 , foot 16 , and/or any location where two pieces of the assembly are joined. Preferably, adhesive 31 is only applied to one of the arms 12 , 14 in order to allow or accommodate some slight relative movement that may occur during changes of temperature, for example. This relative movement is known in the flooring art as “float”. Allowing float may also eliminate unneeded material stresses as well, thereby reducing warping or deterioration of the material surface. Typical adhesives used in the invention include a fresh adhesive, such as PERGO GLUE (available from Perstorp AB of Perstorp, Sweden), water activated dry glue, dry glue (needing no activation) or an adhesive strip with a peel off protector of paper.
[0043] FIG. 2 shows a typical embodiment of the assembly 10 in an installed condition, wherein the floor elements 24 and 25 are of differing thicknesses (H and H′ respectively). Of course, the element 24 may be of any type of covering, such as carpet, turf, tile, linoleum or the like. As shown in FIG. 3 , the leveling block 40 typically includes a substantially flat bottom 46 , and a top 45 having a channel 42 , and an inner surface 44 . The top 45 of the leveling block 40 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 46 abuts floor element 25 . Typically, the channel 42 is shaped as to firmly hold the tab 18 . The inner surface 44 of the leveling block 40 need not abut the foot, as generally, a small amount of clearance is provided between the clamp 26 or foot 16 and the inner surface 44 of the leveling block. However, the inner surface 44 may be configured to contact either of the clamp 26 or foot 16 .
[0044] The leveling block 40 may be made of a composite, pliable material that is also resilient. For example, the tab 18 may be formed to be slightly larger than the opening of the channel 42 , thereby forcing the channel 42 to outwardly deform in order to accommodate the tab 18 , and therefore snap-fit together.
[0045] As shown in FIG. 3 , the outer surface 47 of the leveling block 40 is generally treated to match or blend with the outer surface 34 of the molding or the floor element 24 , 25 in order to improve aesthetics.
[0046] FIG. 3A shows an alternate embodiment of a leveling block 40 ′. An outer surface 47 ′ of this embodiment is configured generally perpendicular to an upper surface 44 ′ and a lower surface 46 ′ of the leveling block 40 ′. This alternate configuration of the outer surface 47 ′ not only provides a different appearance, it also has been shown to be preferred when softer surfaces, such as carpet or turf, are positioned beneath the lower surface 46 ′ of the leveling block 40 ′.
[0047] FIG. 4 shows yet another alternate embodiment of the leveling block 140 . The leveling block 140 includes a bottom 146 , and a top 145 and an inner surface 144 . The top 145 of the leveling block 140 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 146 abuts floor element 25 . This leveling block 140 is positioned between a first arm 112 of the molding 111 and the flooring element 125 . In this embodiment of the assembly 110 , the tab 118 engages the inner surface 144 of the leveling block 140 .
[0048] FIG. 5 shows an embodiment of a leveling block 140 that may be used in the assembly shown in FIG. 4 . Specifically, the leveling block 140 in FIG. 5 has a solid, uninterrupted upper surface 145 , without the need for a channel because the tab ( 118 , as in FIG. 4 ) will engage the inner surface 144 of the leveling block instead of the top surface 145 .
[0049] FIG. 5A shows an additional shape of a leveling block 140 ′ that can be incorporated into the assembly shown in FIG. 4 . Leveling block 140 ′ has a front surface 146 ′ that will be generally perpendicular to a floor 122 (as shown in FIG. 4 ) when the leveling block 140 ′ is installed. This perpendicular configuration of the front surface 147 ′ not only provides a different appearance, it has also been found to be preferred with softer surfaces, such as carpet or turf. FIG. 6 shows an underside view of the molding 11 . In particular, the first under surface 36 of the first arm 12 , and the second under surface 38 of the second arm 14 are shown. In one embodiment, under surface 36 is provided with the adhesive 31 positioned to adhere to a surface of a floor element 24 , 25 or leveling block 40 , 40 ′, 140 , 140 ′.
[0050] FIGS. 7-15 show various cross-sectional views of the molding 11 . These figures show comparative configurations for the arms 12 , 14 , the tab 18 , and the shape of molding 11 .
[0051] In FIG. 7 , the tab 18 is selected to be an outward-facing hook having a barb facing away from the foot 16 , while the upper surface of the molding has a convex curvature. This particular selection for the tab 18 may be used to engage an edge or groove of an adjacent floor element 24 , 25 , or, in the alternative, an adjacent leveling block 40 . Additionally, a shim 48 may be positioned between the foot 16 and the subfloor 22 . The shim 48 is generally a pliable and flexible, yet durable, material. The shim 48 may be used in place of, or in combination with, clamp 26 .
[0052] FIGS. 8-15 show cross-sections of other shapes for the molding 11 . The configurations of the moldings are very similar, except for the shape of the tab 18 . The differing tabs have been assigned decimal numbers beginning with 18 , for clarity purposes. A tab 18 . 1 ( FIG. 8 ) is a bulbous shape, having its rounded end furthest from the arm 12 . A tab 18 . 2 ( FIG. 9 ) is provided with a hook-shape with a point facing the foot 16 . In the embodiment shown in FIG. 10 , a tab 18 . 3 is in the shape of a dove-tail, similar to the shape of the tab 18 shown in FIG. 2 .
[0053] The purpose of the various-shaped tabs ( 18 - 18 . 8 ) is multi-fold. Primarily, the tab 18 serves to engage the channel 42 of the leveling block 40 , which is used when covering of differing thickness is used. Alternatively, the respective tab ( 18 - 18 . 8 ) may engage an edge of a panel, carpet, turf, or other type of floor covering. As shown herein, the respective tab ( 18 - 18 . 8 ) may even be configured to engage a leveling block.
[0054] It is additionally considered within the scope of the invention to eliminate the tab. In such an embodiment, preferably, the molding 11 includes an adhesive on the under surface 36 , 38 of one of the arms 12 , 14 .
[0055] With respect to FIG. 16 , the invention may also be used when the floor elements are not co-planar. For example, one embodiment includes a stair nose attachment 210 that can be attached to the same molding 11 , as described above. As used herein, a stair nose attachment is a component capable of mating with the molding 11 so as to conceal, protect or otherwise cover a joint forming a single stair. Typically, the molding 11 is provided atop the first floor element 24 on the horizontal, or run 220 of the stair, such that the stair nose attachment 210 bridges the joint between the first floor element 24 and the second floor element 25 , forming the vertical section of the stair, or rise 230 . As a result, the invention can be used to cover and protect joints between flooring elements on stairs. While in a preferred embodiment, the floor elements covering the rise 220 and run 230 are the same type of flooring material, the flooring elements need not be of the same construction.
[0056] The stair nose attachment 210 may include a tab receiving groove 212 , permitting connection of the stair nose attachment 210 to the molding 11 . Because the tab receiving groove 212 in the stair nose attachment 210 is preferably shaped according to the shape of the tab 18 of the molding 11 , the stair nose attachment 210 may be attached to the molding 11 by, for example, snapping or sliding.
[0057] However, in other embodiments, the tab on the under surface 36 is eliminated. While the tabs and corresponding grooves may be eliminated, it is nevertheless considered within the scope of the invention to utilize an adhesive, as described herein. Alternatively, the stair nose attachment 210 may include a tab 218 to mate with a corresponding groove 219 on the foot 16 of the molding 11 ( FIG. 17 ), or vice-versa.
[0058] Additionally, an adhesive, as described herein, may be applied to any component in order to secure the connection between the molding 11 and the stair nose attachment 210 . Although FIG. 16 shows tab 18 (and, accordingly, the tab receiving groove 212 ) as having a dove-tail shape, it is considered within the scope of the invention to vary the particular shape of the tab 18 and tab receiving groove 212 . For example, the shapes may be bulbous, or slide tongue to matching groove, or any other configuration described herein.
[0059] It is also possible to form the molding 11 , leveling block 40 and stair nose attachment 210 from the same element, as shown in FIG. 18 . Specifically, a generic element, indicated at 300 can be milled, sawed or otherwise constructed with a variety of “break away” sections 300 A, 300 B, and 300 C. When one or more break away sections 300 A, 300 B, 300 C are removed, by for example, scoring and snapping, cutting, sawing or simply bending, the individual pieces can result. Preferably, the generic element 300 is formed as a unitary structure which is then scored as to provide stress-points to allow the removal of the break-away sections. While not required by the present invention, typically, the removal of the break away sections 300 A, 300 B, 300 C requires a significant amount of physical force or labor, as the remaining structure must maintain its structural integrity. Alternatively, removal of the break-away sections 300 A, 300 B, 300 C may require the use of a specialized tool.
[0060] By designing the generic element 300 in accordance with the invention. An installer can manipulate the generic element 300 to produce any needed component. For example, removing sections 300 B and 300 C would produce a typical stair nose attachment 210 , while removing sections 300 A and 300 C would produce a typical molding 11 . Due to this construction, it is possible to manufacture the generic elements to be purchased and appropriately broken down by the installer. Similarly, when removing sections 300 A and 300 C to form the molding 11 , section 300 A can be used as a leveling block as described herein.
[0061] By allowing an end user to purchase the generic element 300 instead of separate components, the retailers and/or distributors may accordingly reduce their inventory requirements. For example, typically over one-hundred different design patterns for the outwardly facing surface 34 of the molding 11 (as well as for the leveling block 40 and stair nose attachment 210 ) are produced. By allowing for the inventory to include only the generic elements of the invention, the total number of components retained can be reduced from three per design to one per design. Similarly, the installer only need purchase the generic elements 300 , rather than three individual components.
[0062] FIGS. 20-53 depict alternate embodiments for the leveling block (or other pieces) and the molding 11 .
[0063] FIG. 20 shows a general representation of the molding with a track 101 and shim 102 , below the molding 11 . Preferably, the track 101 is metal, and the shim 102 is plastic. However, it is within the scope of the invention to form either of these pieces out of either material. Additionally, other materials may be used, such as materials which flex, but return to their original configuration when pressure is applied and then released. In one embodiment, a track 101 , formed of metal, is fastened to a subfloor with screws. For thicker laminate flooring, the shim 102 may be snapped to the underside of the track before it is fastened to the subfloor. Use of the shim 102 offers a height adjustment for multiple thicknesses of laminate, or other flooring. Thus, where the height of a surface below the molding 11 requires the molding to be raised, the shim 102 can be used to provide the necessary spacing. However, it must be noted that, although FIG. 20 shows the shim 102 being used, such is an optional element, as the shim 102 may be used with each of the shapes and designs of moldings 11 disclosed herein, or similarly, eliminated from each embodiment, as required by the particular circumstances.
[0064] The embodiment of FIG. 21 has a leg of the molding 11 extended. Herein, there is a choice of height adjusting shims, which, in addition to the snap-on shim 102 , may additionally include a second shim 103 , formed of any material, such as wood, plastic, fiberboard, stone, metal, etc., that can be attached via any method to either the molding or the subsurface, such as with an adhesive, or screw. Typically, the extended leg of the T-molding is fastened to a subfloor with a silicone sealant, acting as an adhesive. Such a construction permits easy and quick installation, especially avoiding the need to drill holes and insert plugs for screws when installing over a concrete subfloor. The shim 102 can be attached to the underside of the extended leg of the T-molding to provide the appropriate height adjustment.
[0065] FIGS. 20 and 21 additionally represent the double and reversed tongue-and-groove configuration that functions to fasten a foot, hard surface reducer or carpet/end molding to the T-molding. In this configuration the tongue that extends from the underside of the T-molding is placed so that it falls within the expansion space of the installed flooring transition. This configuration does not require the removal of this tongue in order to install the T-molding part as a T-molding only. Should the laminate floor expand, the pressure will be sufficient to shear off this tongue on the underside of the molding, and the floor can move freely as if there were no extended tongue present in the expansion space.
[0066] Preferably, the shim 102 is a metal or plastic structure, having a pair of grabbing flanges 102 a for the purpose of clamping onto, for example, the track 101 . The grabbing flanges 102 a typically form an acute angle with respect to the remainder of the shim 102 , such that when the molding 11 is inserted into the shim 102 , the grabbing flanges 102 a are forced outward, and the grabbing flanges 102 a function to hold the molding 11 in place.
[0067] In a preferred embodiment, the molding 11 and a second member, such as a reducer, leveling block, stair nose, or any other molding attachment, are joined by one or more tongue-and-groove joints. For example, the second member can be provided with a tongue and the molding 11 is provided with a matching groove. As shown in FIGS. 25 and 26 , the tongue, which may be located on the second member, may be shaped as a dove-tail or a “half dove-tail,” wherein only one of the two sides defines an angle other than ninety degrees. Such a tongue may extend over any potion of the mating surface, such as small amount ( FIG. 25 ), approximately half ( FIG. 26 ), or even substantially the entire mating surface.
[0068] Typically, the tongue-and-groove are not simply rectangular in shape, but are provided with elements which tend to hold the pieces together. For example, as shown in FIGS. 20, 21 , 25 , 28 , and 29 , the tongue may have, on at least one side, a tapered surface, resembling a dovetail, such that the pieces cannot simply dissociate without manipulation.
[0069] In the embodiments of FIGS. 20 and 21 , the reducer has on its mating surface, one tongue and one groove, while the molding 11 has the matching groove and tongue. In FIG. 21 a , the extended leg of the T-molding allows the T to be adhered to the sub-floor with construction adhesive or tapes or other adhesives. A shim can be placed on the bottom of the extended leg of the T-molding to raise the height, either a snap-on type of shim or a simple rectangular piece of material which can be adhered onto the bottom of the foot and then the assembly is adhered to the floor.
[0070] FIGS. 22 through 27 can represent either installation method, with a track or with an extended leg on the T-molding for, T-molding, hard surface reducer, carpet/end molding and stair nosing.
[0071] In the embodiments of FIGS. 22 and 23 , the pieces are provided with a horizontal flange 111 and the molding 11 has a similarly shaped groove. In FIG. 22 , the groove is not provided with any locking elements, while in FIG. 23 , the groove is provided with a locking flange 121 , which joins with a locking groove 112 on the second member to hold the pieces together. Although not specifically shown, it is within the scope of the invention to swap the location of the tongue/groove, such that the tongue is on the molding 11 , and the groove is positioned on the second member. Similarly, there may be any number of matching tongues/grooves, and each piece may have any combination of tongues and grooves. Similarly, as shown in FIG. 27 , the tongue and groove need not be positioned adjacent to the underside of one of the arms of the molding 11 , and a gap 114 may be provided in the second member to allow for greater movement between the second member and the first member without permitting dissociation. This gap may be a break-away feature.
[0072] In FIG. 22 , a recess lateral slot is present on the underside of the T-molding, as well as a groove in the leg of the T-molding. The recessed slot and raised platform of the top of each foot hinders lateral movement of the foot and the tongue and groove stabilize the foot against the top of the T-molding.
[0073] In FIG. 23 , there is a tongue and groove with a snap-fit ridge or tab at the end of the groove or in the tongue of the leg of the T-molding. There is also shown a corresponding groove in the underside of the tongue of each foot that snaps into the tab.
[0074] In the embodiment of FIG. 24 , the locking element 110 is a downwardly facing flange, sized and shaped to mate with the locking groove 112 on the second member. When the pieces are connected, the locking element 110 and locking groove 112 function to resist separation of the pieces in a horizontal direction. Although not shown, the locking element 110 and locking groove 112 , as shown in FIG. 24 , may be combined with any of the structures as shown in any of the other embodiments disclosed herein in order to assist in maintaining a secure connection between the elements.
[0075] In one embodiment, the extension 114 is affixed to the subfloor, by a means for securing. The securing means may be, for example, a mechanical fastener or a chemical fastener through, for example, boss 134 . As used herein, a mechanical fastener is any device which joins the elements with, e.g., pressure, and includes, but is not limited to, a nail, screw, staple, claw, clamp, barb, cant hook, clapper, crook, fang, grapnel, grappler, hook, manus, nail, nipper, paw, pincer, retractile, spur, talon, tentacle, unguis, ungula, brad, nail, point, push pin, and tack. Additionally, a chemical fastener is a component, such as a sealant or adhesive, and includes tapes, glues and epoxies. This extension 114 may also attach to the track.
[0076] The embodiments shown in FIGS. 28-35 each have an extension 120 of the second member which extends below the foot of the molding. In such embodiments, typically, the second member is a stair molding and is secured to the subfloor. The T-molding is then attached to the second member, as the T-molding does not contact the subfloor. However, it is considered within the scope of the invention to additionally provide an extension bracket (not shown) for securing the T-molding to the subfloor. As shown in FIGS. 28, 29 and 35 , the second member may include a recess 124 into which the foot of the T-molding is inserted, or in the alternative, a depression 126 ( FIGS. 30, 33 and 34 ).
[0077] Additionally, the second member may have a wedge 128 ( FIGS. 31 and 32 ) to secure the T-molding in place. The foot of the T-molding may either be angled into position to bypass the uppermost section of the wedge 128 , or the wedge may be formed such that it deflects under pressure and snaps back after the foot of the T-molding is properly positioned. Again, the embodiments of FIGS. 28-35 may be combined with one or more of the tongue and groove configurations as shown or described in connection with FIGS. 20-27 .
[0078] The second member, shown as a stair nosing, in FIGS. 28-35 may be installed using construction adhesives, specialized tapes (such as simple double-sided tapes), silicone or other sealants (such as epoxies or glues) or mechanical fasteners (such as screws or nails).
[0079] The embodiments of FIGS. 36-42 can be installed using a track 101 , similar to the embodiments shown in FIGS. 20-27 . In particular, either one or both of the T-molding and second member (shown as a stair nose) may be secured with the track 101 . The members can also be fastened to the track 101 after a construction adhesive or sealant/adhesive has been applied into the track and/or additional mechanical fasteners may be used to assist in fixing the second member to the subfloor (or tread, as necessary).
[0080] FIG. 43 demonstrates an extended face for a stair nose. Therein, the extended face is sufficient in breadth to cover the edge of common stair treads, thus eliminating the need to place a separate piece of flooring on the edge of stair treads or to cover the edge of a subfloor when stepping down from a floating floor installation to a lower level floor. However, stair noses may also be installed using the method described in connection with FIG. 21 , above, without the need of a track 101 , when the T-molding has an extended leg.
[0081] The embodiments of FIGS. 44-53 allow installation of the multipurpose flooring transition using only adhesives, tapes or sealants, as no track 101 is required. The additional surface area beneath the transition is increased adding additional adhesion area for strength in bonding the transition to the subfloor. This installation method also removed the need for a track, screws and/or plugs (although they are certainly not prohibited), and additionally allows for faster installation over subfloors formed from, fore example, wood based products or concrete.
[0082] FIGS. 44 and 45 show two assembled members held together with glue before fastening to the subfloor. Such members may also be installed by other methods described herein.
[0083] FIGS. 46-49 depict two members joined together with a snap-fit, such that no glue is necessary. Such members may also be installed by another other method described herein. Although FIGS. 46-49 show a particular location for various snap-fitting elements, i.e., tongue and groove, it is certainly within the scope of this invention to increase the size, shape, location and number of the tongues and grooves as necessary. For example, FIG. 30 depicts one groove on either side of the foot of the T-molding and corresponding tongues on the second member. However, additional tongues/grooves may be located on the bottom of the foot or even on the underside of the arm. Additionally, the second member may include both tongues and grooves, combining the showings of FIGS. 46 and 47 with FIGS. 47 and 49 .
[0084] FIG. 50 represents a shim, which can be made from waste cuttings of the core material during the manufacture of the transition. This shim may be used to elevate the foot of the assembly to accommodate a thicker flooring material.
[0085] FIG. 51 shows an additional embodiment wherein the second member is a stair molding. The pieces, i.e., the T-molding and the stair molding, can be held together with glue before fastening to the subfloor, or by any other installation method described herein.
[0086] In FIG. 52 , an additional T-molding is shown that can snap-fit, i.e., without the need for glue, and FIG. 53 shows a corresponding track or structure to be incorporated into a second member. Specifically, the second member piece of FIG. 53 includes a plurality of alternating tongues and grooves, such that the foot of the T-molding, also having alternating tongues and grooves, form a snap action that functions to hold the T-molding firmly. Additionally, this design permits the elimination of the shim 102 , as the foot of the T-molding need not be completely seated in the second member. In other words, because the T-molding can be secured to the second member with a gap or space remaining between the bottom of the foot 130 and the inner-most part of the second member 130 , height variations can be accounted for without the need for an additional part.
[0087] FIGS. 54-66 show an alternate embodiment of the invention. Specifically, as shown in FIG. 64 , a single reversible molding element 1001 has an outer face 1005 , which extends over a front face 1007 and a rear face 1009 . This outer surface 1005 is the same on both the front face 1007 and the rear face 1009 , and preferably includes a laminate, but may also be of a foil. While the outer surface 1005 may be limited to only the front face 1007 and the rear face 1009 , the outer surface 1005 may extend across any additional surfaces as well. Due to the novel construction of the reversible molding element 1001 , the versatility of the invention can be greatly increased.
[0088] An example of the versatility of the reversible molding element 1001 is specifically shown in FIGS. 55 and 56 ., wherein the significant distinction between FIGS. 55 and 56 is the orientation of the reversible molding element 1001 . In FIG. 55 , the reversible molding element 1001 has its front face 1007 facing outward, while in FIG. 56 , the opposite, or rear face 1009 facing outward. As a result, when the front face 1007 is oriented outward, reversible molding element 1001 functions as a hard surface reducer. In contrast, when reversible molding element 1001 is reversed, and the rear face 1009 is oriented outward, the reversible molding element 1001 functions as an end molding. Thus, when the T-molding is put together in a single package with the reversible molding element 1001 , the combination can be used as either a hard surface reducer or an end molding, in contrast to other systems which require three independent pieces.
[0089] When using two parts instead of three, maximum use of materials is accomplished, making the invention more economical to produce and, as a result, more economically sound. This new configuration of two pieces allows a third piece to be introduced, also reversible, that broadens the use of the pieces to include a increased range of flooring thicknesses found in such products as hardwood and other finished flooring that could not be previously accommodated. An additional option that increases the range of use of the invention is to permit it to transition to a broader range of flooring thicknesses by adding a second reversible part that is higher (thicker) than the first reversible part.
[0090] In FIG. 54 , there is a tongue/groove connection in the attachable parts, for example, on the underside of the T-molding. However, it is within the scope of the invention to reverse the position of each of the tongue and groove. This figure shows the reversible molding element 1001 in a configuration with the track and shim, as optionally used in the other embodiments discussed herein.
[0091] In FIG. 57 the underside of the T-molding does not have a tongue or groove. It does, however, have a notch or shoulder, which holds the other molding piece, such as the reversible molding element 1001 , from moving laterally toward the track. The reversible molding element 1001 , preferably, is smooth, without a groove or tab on the surface which comes into contact with the underside of the T-molding. The underside of the reversible molding element 1001 preferably has a groove to accommodate an extension from the track that stabilizes the lateral movement of the reversible molding element, preventing movement away from the track. In order to hold the element 1001 in place, the track can be provided with a gripping flange 1010 , which may be formed as a break-away section on the remainder of the track, such that when the gripping flange 1010 is not to be used, it can be easily removed to have the track in a different configuration.
[0092] FIG. 58 shows both a groove and stabilizing notch on the underside of the T-molding, with a tab on the reversible molding element 1001 .
[0093] FIG. 59 shows an extendable track extension 1012 , which may be one piece or with break-away elements, and may also act as a shim to raise the track. When used as one piece, the raised tab, on the extension that affixes to the underside of the reversible molding element 1001 , can slide beneath the finished flooring when the track is used to hold a T-molding or the height of the tab can be the equivalent to the height of underlayments used in the floating floor application, and will not interfere with the floating floor, because the extension is no higher than the foam underlayment commonly used in such installations, the apparatus does not interfere with the floating floor. When used with the break-away feature, the extension can be removed and the remaining part can be used as a shim to raise the track to accommodate a thicker floor. The track may be joinable with a tongue/groove connection system to prevent relative movement. FIGS. 60 and 62 show a similar attachable extension using thinner material and a different attachment configuration.
[0094] In FIG. 61 , the underside of the T-molding does not have either a tongue or groove. It does, however, has a notch or shoulder that holds the reversible molding element from moving laterally toward the track. The reversible molding element may also be smooth, i.e., no tongue or groove, on the surface that comes into contact with the underside of the T-molding. These parts can be assembled with any type of glue or adhesive, such as fresh glue, pre-applied glue, encapsulated glue, reactive adhesives, contact adhesives or adhesive tapes.
[0095] In FIG. 63 , the T-molding has a milled groove 1012 . The top of, for example, the reversible molding element also has a groove 1014 . To complete assembly, a loose double-sided tongue 1016 can be pressed into the groove 1012 as the reversible molding element 1001 is attached to the tongue 1016 . The tongue 1016 can be pressure fit or glued into one or both of the grooves 1012 , 1014 .
[0096] The two different sizes of elements 1001 of FIGS. 65 and 66 allow for accommodation of a wide range of thicknesses.
[0097] In FIG. 67 a , there is a groove and stabilizing notch on the underside of the T-molding, and a tab on the reversible molding element 1001 (not shown). Here, the T-molding can accommodate either reversible parts (such as those shown in FIGS. 65 and 66 ), and a shim can be used with an extension (which can be broken away or folded under the shim) to increase its thickness to raise the track and accommodate thicker flooring. FIG. 67 b shows the break-away shim extension with tabs that can snap to the underside of the shim.
[0098] FIGS. 68-80 utilize the reversible concept with aluminum or other metals or composites. Generally all of the same features of the previously described materials can be used with these elements. These structures may additionally be covered, at least in part, by a décor layer (which may be, optionally directly, digitally printed and coated or a sheet which can be subsequently coated), such as a foil or other laminate structure.
[0099] FIG. 69 shows two grooves in the T-molding and two matching tongues on the second or reversible molding element. Again, the location of the tongue/groove of any embodiment described herein can be swapped without detracting from the invention.
[0100] FIG. 70 shows a T-molding with one single foot and a track to accommodate this foot, similar to FIGS. 1A and 1B .
[0101] FIG. 71 shows a T-molding and a reversible molding element with grooves that can accommodate a clip 1020 that joins the two parts together. The clip has a similar function as the double-tongue of FIG. 63 .
[0102] FIG. 72 shows a reversible molding element with a tab on the top and groove on the underside to accommodate a track extension and aid the prevention of lateral movement, similar to that which is shown in FIG. 57 .
[0103] In FIG. 73 , the T-molding is provided with serrated grooves 1022 which match similar grooves 1024 on the reversible molding element. These grooves may be serrated “inwards” to hinder pulling-out of the reversible molding element, or inwards, to hinder the reversible molding element from being pushed inward, i.e., toward the foot of the T-molding. Alternate embodiments which differ from the traditional tongue/groove connection are shown in FIGS. 75 and 76 . The T-molding can have a notch or shoulder and the reversible molding element can have a corresponding tongue to prevent lateral movement away from the track. The pieces may also be smooth and held together with an adhesive, as described elsewhere herein, or may be held together using only the track extension.
[0104] In FIG. 74 , the track is shown with an extension as a break-away section, similar to that which is shown in FIGS. 60 and 62 .
[0105] FIGS. 77-80 show a metal or composite stair nose attachment in accordance with the invention.
[0106] In FIG. 77 , the stair nose is attached to a T-molding, which need not be formed from an aluminum. This structure may be from HDF, MDF, plastic, or other metal or composite materials. Such composites can include combinations of wood based and plastic resin composites. Hidden fasteners, which are not visible form the surface of either element can be used to secure the elements to the subfloor. There can also be a track to hold the elements in place.
[0107] In FIG. 78 , the stair nose is a separate piece apart from the T and the track. It can be fastened to the subfloor or stair tread with screws through apertures 1030 integrated into the structure of the stair nose. The separate track can be secured to the subfloor also with separate screws. Additionally, the same screws may be used to affix the track and the stair nose. The T-molding can be attached to the stair nose by the tongue and groove and can be held to the subfloor or stair tread by the track.
[0108] FIGS. 79 and 80 show the stair nose and track as one piece. While the track and stair nose can be separately formed, and joined, for example, by a tongue/groove system, they can also be formed and sold as a single unit.
[0109] FIG. 81 shows a modification of the T-molding of the invention. Specifically, it is possible to remove one of the arms or members from the T-molding to create a an end molding or carpet reducer. This T-molding 1801 can be in accordance with any of the embodiments described herein. For example, the T-molding 18801 may be formed from HDF, MDF, metal or composite, and optionally provided with a decor layer, which may be printed or otherwise provided directly on the surface. Additionally, the removable section may be pre-fabricated as a frangible section, as is shown and described in accordance with FIG. 19 . A kit, such as a single package, may also be provided which includes at least two of the individual parts described herein.
[0110] It should be apparent that embodiments other than those specifically described above may come within the spirit and scope of the present invention. Hence, the present invention is not limited by the above description. | The invention is a joint cover assembly for covering a gap adjacent an edge of a panel that covers a sub-surface, and a method of covering such a gap. The assembly includes a molding having a foot, a first arm, and a second arm. The foot is positioned along a longitudinal axis, and the first arm extends generally perpendicularly from the foot. The second arm extends generally perpendicularly from the foot. A tab depends generally perpendicularly from the first panel engaging surface. At least one of the tab and the foot engage the edge in order to tightly fit within the gap. The method includes the steps of placing the foot in the gap, pressing the respective panel engaging surfaces into contact with respective panels, and configuring at least one of the tab and the foot to cooperate to retain the molding in the gap when the assembly is in an installed condition. | 4 |
This is a continuation of application Ser. No. 585,297, filed June 9, 1975, abandoned.
BACKGROUND OF THE INVENTION
This invention relates to extrusion tooling and especially to punches used for extruding the main body of a conventional tin plated steel can.
The can manufacturing industry has been using punches made of cemented tungsten carbide for such extrusion. These punches are relatively expensive and have been found to have a limited useful life. Limited punch life is due to pitting in the highly polished punch surface.
Pitting occurs during use of the punches where it is caused by etching or leaching of the binder in the tungsten carbide. Carbide grades used in the punches generally contain either cobalt or nickel binders. The cobalt or nickel at the punch surface is leached or etched during the extrusion process by the coolant used to keep the extrusion temperatures down. Cobalt is generally leached at a faster rate than nickel. Also, certain reactive inclusions on the surface of the punch may be attacked by the coolant. The surface pits gradually accumulate tin from the cans, most probably by alloying of the liquid tin phase with the binder phase of a tungsten carbide. The build-up eventually extends beyond the punch surface, making removal of the can difficult and impairing the qualify of the finished can by scoring the surface when the can is removed. On occasion the can will not be cleanly removed leaving all or a portion of the can adhering to the punch causing major damage to the tooling and machine on the next cycle.
The pitting and resultant build-up usually becomes excessive when between 200,000 and 400,000 cans have been produced. In some cases build-up becomes excessive after as few as 30,000 cans. At that point, the punch is removed to be repolished. The repolishing removes the tin build-up but does not remove the pits. After several repolishing operations a punch may be undersize or so severely pitted that it must be discarded.
The pitting problem is also encountered in the manufacture of the punches prior to use. Pits here can be caused by inclusions in the metal which fall or are knocked out of the surface during finishing operations. Pits can also result from incomplete densification in pressing and sintering operations. Inherent surface porosity of the sintered carbide material has made it necessary to hot isostatically press most punches after sintering and before finish grinding to assure that required surface conditions can be achieved. Even with hot isostatic pressing, it is not uncommon for a significant percentage of punches to be rejected for production use due to surface pitting.
In some can manufacturing operations steel punches are used to extrude tin plated steel cans in which case the leaching or etching of a binder causing pitting is not involved. However, under the heat developed in the extruding operation metal transfer occurs between the steel of the cans and the punch causing a gradual welded build-up of can steel on the punch which in turn causes galling and frequent requirements for punch refinishing.
SUMMARY OF THE INVENTION
According to this invention, punches and optionally other elements of extrusion tooling such as die rings, are coated with a thin layer of titanium nitride or a nitride of another material selected from the group consisting of tantalum, columbium, hafnium and silicon. This coating serves as a barrier to protect the cemented carbide binder from etching or leaching, and in addition, has been found to provide greater lubricity for ease of can removal after extrusion. Also, this coating may be used to reclaim rejected or otherwise unusable pitted punches as the coating will fill in or coat the pits. The coating may further serve to increase the size of otherwise undersize punches.
In the case of steel punches, the nitride coating is inert and does not chemically react or weld with the can steel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Extrusion punches used in the manufacture of two-piece tin-plated steel beverage cans are generally cylindrical in shape, 2 to 3 inches in diameter and 5 to 8 inches in length. The lead end of the punches is tapered slightly and slightly varying diameter may be used along the length of the punch.
The punch body is manufactured from tungsten carbide in a conventional manner by green pressing carbide powder into a preform billet, machining the billet to form the punch and then sintering the punch in a furnace. The sintered punch is then hot isostatically pressed. In accordance with the present invention, the outside surface of the punch is then ground slightly undersize (preferably 0.0004 inch in diameter) to allow for the application of the coating.
A coating of titanium nitride is applied to the outside surface of the punch body by a suitable conventional process, such as chemical vapor deposition, sputtering or ion plating. The titanium nitride coating is metallurgically bonded to the body surface and is chemically compatible while having desirable thermal expansion properties. More importantly, it is not possible to form solid inclusions in the coating due to the nature of the coating process used in applying the nitride. This is not the case with a refractory carbide coating such as titanium carbide, or tungsten carbide, because in depositing the carbide, a hydrocarbon is used and it is possible that free carbon can be deposited as an inclusion as the hydrocarbon undergoes pyrolysis. With titanium nitride, the coating is finer grained and free of solid inclusions. The coating is preferably applied to provide a film thickness in the order of 0.0004 to 0.0006 inch. The metallurgically bonded film coating of the present invention is specifically directed and limited to a coating which may be conventionally applied by chemical vapor deposition, sputtering, ion plating or suitable equivalent process. After the coating is applied, the punch is ground and polished with the thickness of the coating after finishing being in the order of 0.00015 to 0.0003 inch with a 0.0002 inch uniform coating being preferred.
The advantages of the titanium nitride coated punches include elimination of etching or leaching of the binder phase, protection of the surface from corrosion, elimination of problems associated with surface inclusions, surprising remarkably increased punch life, reduced frictional force between can and punch during extrusion as well as during can removal, and maintenance of punch body strength. In addition, extrusion press down time is minimized and the expense of multiple repolishing operations is greatly reduced. A test punch, according to this invention, has already produced over 1,000,000 cans (more than double the normal maximum) in a test operation without showing any signs of surface pitting. It has never been removed from the machine for re-working. The test punch has a sintered tungsten carbide body (with cobalt binder) and a 0.0002 inch thick coating of titanium nitride. All cans have been easily removed from the punch by normal means and there has been no scoring of the cans.
Punches according to this invention can be used in other extrusion processes where pitting occurs and there is a material affinity between the punch and the extruded product or the coolant fluid. Also, other extrusion tooling, such as the die pieces or rings used in conjunction with the punches in the can extrusion process, can also be made according to the invention with a thin coating of titanium nitride. In certain circumstances, the coating may eliminate the need for hot isostatic pressing to eliminate porosity and make possible the use of punches with a reduced allowance of stock for finish grind due to a reduction in the criticality of surface finish when the coating is used.
While a titanium nitride coating is preferred for commercial economic reasons, substitution of a nitride of another material from the aforementioned group may be resorted to with similar results.
In the case of steel punches, a somewhat thinner coating as low as 0.0001 inch may suffice preferably applied by sputtering or ion plating to avoid adverse surface heating effects of chemical vapor deposition. | A punch used for extruding tin plated cans consisting of a cemented tungsten carbide punch body coated with a thin layer of titanium nitride. | 1 |
The present invention relates generally to fabric decoration using ink jet spraying apparatus and processes and, more particularly, to accommodating the operating mode of the apparatus to the characteristics of the fabric to contribute to achieving more effective decoration of the fabric.
EXAMPLES OF THE PRIOR ART
Decorating fabric preparatory to manufacture into garments, and other end uses is achieved by dying, roller printing and, currently by the technique, now of choice which uses ink jet spraying apparatus described and illustrated in many prior patents, two such exemplary patents being U.S. Pat. No. 5,687,197 for “Ink-Jet Printing Cloth, Ink-Jet Printing Process And Production Process Of Print” issued to Aoki on Feb. 2, 1999 and U.S. Pat. No. 5,847,739 for “Cloth Feeding Drum For Ink-Jet Printing” issued to Kanaya et al. on Dec. 8, 1998. The noteworthy decorative results apparently warrant the use of jet spraying despite its intricacies, as perhaps best expressed in the '739 patent at col. 1, in lines 49-52 that “In order to accurately form line and delicate patterns with ink jet printing, the distance between the ink jet nozzle and the cloth surface must be kept constant while the nozzle head is moving along the width of the cloth, and the cloth printing surface must be substantially flat.”
If an unsatisfactory decorative pattern is produced, the effort, even by those well versed in the art, is to seek correction in the parameters above noted, namely in adjustments in the distance between the ink jet nozzle and the cloth surface, or in the tracking of the nozzle head and so on. Even with such adjustments however, inexplicable unsatisfactory decorative results still persist, and the solution remains elusive.
Broadly, it is an object of the present invention to minimize unsatisfactory decorative results by not limiting corrective techniques to operating parameters of the apparatus, as is now done and is a major shortcoming of the prior art.
More particularly, it is an object of the present invention to achieve a synergism of the jet spraying apparatus and of the fabric being decorated which minimizes the heretofore inexplicable unsatisfactory decorative results, all as will be better understood as the description proceeds.
The description of the invention which follows, together with the accompany ing drawings should not be construed as limiting the invention to the example shown and described, because those skilled in the art to which this invention appertains will be able to devise other forms thereof within the ambit of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 is a plan view of an ink jet fabric-printing apparatus;
FIG. 2 is a side elevational view projected from FIG. 1;
FIG. 3 a is a first sectional view taken along line 3 — 3 of FIG. 1;
FIG. 3 b is a second sectional view taken along line 3 — 3 of FIG. 1; and
FIG. 4 is an isolated perspective view on an enlarged scale of a component illustrated in FIG. 3 a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawing figures, a flat woven fabric or web 10 suitable for the manufacture of garments, upholstery and many other items is shown in whole or in part. Web 10 is conventionally manufactured to a standard width W (FIG. 1) with standard selvage edges 12 of a width S along each edge. Warp threads used in the selvage are of stronger and coarser material than those used in the balance of the web. This coarseness is the origin of the problem to be solved, all as will be better understood as the description proceeds.
In FIGS. 1 and 2, ink jet printing, apparatus or machinery 14 consists of a conveyance section 16 and a printing section 18 . As seen looking downstream, a direction depicted by arrow 20 , sections 16 and 18 are mounted on a right side chassis wall 22 and a left side chassis wall 24 .
In the conveyance section 16 , web 10 is initially put up on feed roller 26 and led past rollers 28 , 30 and 32 all of which insure proper tracking of web 10 . At roller 32 , web 10 contacts endless belt 34 which is entrained about conveyance rollers 36 and 38 . Platen rollers 40 and 42 further insure that web 10 aligns or tracks properly in relation to print section 18 . After passing over conveyance roller 36 , web 10 passes over heater rollers 44 and 46 past heater 48 and on to take-up roller 50 .
The printing section 18 consists of a carriage 52 mounted on spanning rails 54 and 56 . Carriage 52 supports print head 58 . As shown in simplified form in FIG. 3 a , as below reference 60 , a supply of ink 62 is contained in housing 64 under pressure 66 . A multitude of minute orifices 68 formed by techniques known to the industry are employed to deliver a desired pattern 70 of ink droplets 72 onto the web 10 . The process of delivering each droplet 72 to web 10 utilizes the well known in the art “bubble jet system”, as described and illustrated in numerous prior patents as exemplified by U.S. Pat. No. 5,867,197 issued on Feb. 2, 1999, wherein each orifice 68 is operatively associated with an internal electro thermal converter so as to be pulsed at the appropriate time resulting in the ejection of droplet 72 onto web 10 .
As seen best in FIG. 1, carriage 52 is urged in movement laterally a distance F 1 after each ink ejection, N number of times to form a lateral course. At the end of each course, web 10 is advanced a distance F 2 in direction 20 . The combination of intermittent motions F 1 and F 2 results in the printing of repetitive pattern frames individually and collectively designated 74 over the surface or body of web 10 . Because of the very small size of the orifices 68 within print head 58 , a high density of droplets 72 are deposited on web 10 . Additionally, by providing multiple print heads 58 on carriage 52 the decoration of the web surface 10 can be embodied with a variety of colors and patterns 70 .
Referring to FIG. 3 b , where part of a typical lateral sequence is shown in elevation, print head 58 is shown in phantom line perspective at position 76 at which location it will be understood to have deposited droplets 72 , reformed bubbles 80 as closures over the orifice openings 68 and moved to position 78 . In position 78 , print head 58 continues to provide an ink droplet deposited pattern 70 , followed by reformed bubbles 80 and moves on to position 60 , and so on.
A problem heretofore elusive to those in the art, arises within selvage edge 12 at which upstanding fibers 82 brush against newly formed bubbles 80 a . Fibers 82 are characteristic of the previously mentioned warp threads used within selvage 12 . In the ink jet process a combination of pressure, ink viscosity and surface tension cause a bubble to form as a closure over the outlet of each orifice 68 prior to the ejection of droplets 72 on the next adjacent frame 74 . However, it is theorized that when fibers 82 snag bubbles 80 a in position 76 , droplets 72 a are imperfectly formed at position 78 and gravity flow of ink droplets from the orifices 58 onto the web 10 mar the decorative pattern printed on the web 10 . Stated somewhat differently, it is because the fibers 82 are not present at position 78 that bubbles 80 a are still intact when print head 58 reaches position 60 , which results in a satisfactory frame 60 . The phenomenon theorized is borne out by inspection of otherwise inexplicable unsatisfactory decorative patterns and satisfactory decorative patterns following obviating the phenomenon, as will now be described. The same problem arises when print head 58 is over the right selvage edge 12 , and similarly is solved by preventing premature bursting of the bubble 80 a closures over the orifices 68 .
In FIG. 3 b , print head 58 is shown in position 76 ready to deposit a print pattern 70 on web 10 . In accordance with the present invention, a thin blade 84 is mounted in an interposed position between bubbles 80 a and selvage 12 such that fibers 82 are shielded or restrained from contacting the bubbles 80 a . Blade 84 is mounted in cantilever fashion on bracket 86 which, in turn, is secured to wall 24 with suitable fastening means 88 . Likewise blade 84 is held in position on bracket 86 by fastening means 90 . Elongated slots 92 in bracket 86 and blade 84 allow for vertical and horizontal positioning. The overall length of blade 84 should be greater than the effective length 94 which is equivalent to frame length F 2 . The leading end 96 of blade 84 should be turned upward to avoid snagging web 10 and selvage 12 .
It will be understood that a similar shield 84 is provided over the right selvage edge 12 being mounted on wall 22 and, for brevity sake will not be described, being denoted by the same reference numbers.
From what has been described, it should be readily understood that the operating mode of the jet spraying of a decorative pattern onto the woven fabric 10 contemplates the steps of (1) urging the jet spray head 58 in alternating movements between opposite selvage edges 12 transversely across the fabric 10 on a horizontally oriented plane at a selected clearance above the fabric surface to be decorated, and (2) intermittently applying and not applying pressure on a source of ink so as to cause during a pressure application the exiting flow of ink droplets 72 through microscopic openings 68 of the jet spray head 58 onto the fabric surface 10 to be decorated. As further explained, for proper control of the exiting flow of the ink in droplets 72 , there occurs a phenomenon during a non-application of pressure of a formation of plural bubble closures 80 over the microscopic openings 68 of the jet spray head 58 as caused by fluid surface tension of the ink within the microscopic openings 68 , i.e., a surface tension that must be overcome by the next application of pressure before the ink droplet 72 can exit.
The problem which occurs, and which was elusive to those in the art, was the premature bursting of the bubble closures 80 upon the unavoidable contact of these bubbles by the upstanding selvage fibers 82 which, upon this happenstance, resulted in the gravity flow of the ink from the spray head 58 otherwise than in response to and in coordinated relation to applied pressure of the well known “bubble jet system” of prior patents as exemplified by the noted '197 patent. Shielding the bubble closures 80 against this contact with the selvage fibers 82 by the simple expedient of providing an interposed position of a shield 84 between the spray head 58 and upper ends of the fibers 82 has resulted in practice in achieving improved jet-sprayed decoration by the obviating of a heretofore elusive source of decorative irregularities.
While the apparatus for practicing the within inventive method, as well as said method herein shown and disclosed in detail is fully capable of attaining the objects and providing the advantages hereinbefore stated, it is to be understood that it is merely illustrative of the presently preferred embodiment of the invention and that no limitations are intended to the detail of construction or design herein shown other than as defined in the appended claims. | In the jet straying of ink droplets in a decorative pattern onto a fabric during which a jet spray head shuttles across the fabric changing directions at opposite selvage edges, the provision in an interposed position between the spray head and upstanding selvage edge fibers of shields preventing contact therebetween which maintains bubble closures over exit openings in the jet spray head intact and obviates inadvertent gravity flow of ink as might mar the decorative pattern. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is in the general field of improved methods of pumping viscous hydrocarbons through a pipe, such as a well-bore or a pipeline.
2. General Background
The movement of heavy crudes through pipes is difficult because of their high viscosity and resulting low mobility. One method of improving the movement of these heavy crudes has included adding to the crude lighter hydrocarbons (e.g. kerosine distillate). This reduces the viscosity and thereby improves the mobility. This method has the disadvantage that it is expensive and the kerosine distillate is becoming difficult to obtain.
Another method of improving the movement of these heavy crudes is by heating them. This requires the installation of expensive heating equipment and thus is an expensive process.
The use of oil-in-water emulsions, which use surfactants to form the emulsion, is known in the art. While many surfactants serve to reduce the viscosity the effectiveness of various surfactants varies widely. Some surfactants are very effective, while others are barely effective. In fact such a wide variation is present in the effectiveness of surfactants that in general it can be concluded that the effectiveness of a particular surfactant, or combination of surfactants, is not predictable.
I have found that an aqueous solution of the following materials is effective in reducing the viscosity of viscous hydrocarbons: (a) an anionic alkyl polyether ethoxylated sulfate or (b) a combination of this material with an alcohol ether sulfate.
BRIEF SUMMARY OF THE INVENTION
Briefly stated, the present invention is directed to an improvement in the method of pumping a viscous hydrocarbon through a pipe wherein the improvement comprises forming an oil-in-water emulsion by adding to said hydrocarbon from about 20 to about 80 volume percent water containing an effective amount of (a) about 20 to about 100 weight percent of an anionic alkyl polether ethoxylated sulfate and (b) about 0 to about 80 weight percent of an alcohol ether sulfate.
The precise nature of the materials will be provided in the detailed description.
DETAILED DESCRIPTION
Insofar as is known my method is suitable for use with any viscous crude oil. It is well known that crude oils often contain a minor amount of water.
The amount of water which is added to the hydrocarbon is suitably in the range of about 20 to about 80 volume percent based on the hydrocarbon. A preferred amount of water is in the range of about 30 to 60 volume percent. The water can be pure or can have a relatively high amount of dissolved solids. Any water normally found in the proximity of a producing oil-well is suitable.
Suitable anionic alkyl polyether ethoxylated sulfates for use in my invention are represented by the formula ##STR1## wherein R is an alkyl group containing about 8 to about 14 carbon atoms, preferably about 10 to about 12 carbon atoms, a is a number in the range of 1 to about 30, preferably about 2 to about 13, b is a number in the range of 1 to about 20, preferably 1 to about 3, and M is sodium, potassium or ammonium.
Suitable anionic alkyl polyether ethoxylated sulfates are available from Stepan Chemical Company under the designation Polystep B-13, B-14 and B-28.
Suitable alcohol ether sulfates (also known as ethoxylated alcohol sulfates) for use in my invention can be represented by the following structural formula
[CH.sub.3 (CH.sub.2).sub.x CH.sub.2 (OCH.sub.2 CH.sub.2).sub.n OSO.sub.3 ]M
wherein x is an integer in the range of about 8 to about 20, preferably from about 10 to about 16, n is a number in the range of about 1 to about 50, preferably about 2 to about 30, more preferably about 3 to about 12, and M is Na, K, or NH 4 , but preferably is sodium.
The alcohol moiety of the ethoxylated alcohol sulfate can be an even or odd number or a mixture thereof. Preferably, the alcohol moiety is an even number. Also, preferably, the alcohol moiety contains 12 to 18 carbon atoms.
The relative amounts of anionic alkyl polyether ethoxylated sulfate and alcohol ether sulfate used in my invention are as follows:
______________________________________ Anionic Alkyl Polyether Alcohol Ether Ethoxylated Sulfate Sulfate (Wt. %)______________________________________Suitable 20-100 0-80Preferred 40-60 60-40______________________________________
As is implied by the figures shown above the use of the anionic alkyl polyether ethoxylated sulfate alone gives very good results in my invention. However, the use of the described combination provides even better results.
The amount of total surfactant used in my invention, based on the hydrocarbon, is shown below.
______________________________________ Amount of Surfactant (parts per million)______________________________________Suitable 50-20,000More Suitable 125-2,000Preferred 200-800______________________________________
In order to illustrate the nature of the present invention still more clearly the following examples will be given. It is to be understood, however, that the invention is not to be limited to the specific conditions or details set forth in these examples except insofar as such limitations are specified in the appended claims.
The following materials were used in the tests described herein:
Crude Oil--Goodwin lease crude from Cat Canyon oil field, Santa Maria, Calif.
Water--Goodwin synthetic (Water prepared in laboratory to simulate water produced at the well. It contained 4720 ppm total solids.)
Viscosities were determined using a Brookfield viscometer, Model LVT with No. 3 spindle. The procedure is described below.
The materials tested were the following.
Surfactants A-C were anionic alkyl polyether ethoxylated sulfates represented by the formula shown in the foregoing wherein R, a, b, and M are as shown in the following table.
______________________________________Surfactant R.sup.(1) a(PO).sup.(2) b(EO).sup.(3) M______________________________________A 8-14 2.8 1.7 NH.sub.4B 8-14 2.4 1.5 NaC 8-14 12.2 1.8 Na______________________________________ .sup.(1) Number of carbn atoms .sup.(2) PO = propylene oxide .sup.(3) EO = ethylene oxide
Surfactants D and E were sodium alkyl ether sulfates represented by the formula shown in the foregoing wherein the alcohol moiety and the moles of ethylene oxide are as shown in the following table.
______________________________________ No. of Carbon Atoms Moles ofSurfactant Alcohol Moiety Ethylene Oxide______________________________________D 12-14.sup.(1) 3E 16-18.sup.(1) 10.5______________________________________ .sup.(1) The alcohol moiety contains two more carbon atoms than shown for x in the formula.
Test Procedure
Three hundred ml of crude oil, preheated in a large container to about 93° C. in a laboratory oven, was transferred to a Waring blender and stirred at medium speed until homogeneous. Stirring was stopped, temperature recorded, and the viscosity measured using the Brookfield viscometer at RPM's (revolutions per minute) of 6, 12, 30 and 60 and then back down 30, 12, and 6 RPM. Viscosity was calculated by using a multiplication factor of 200, 100, 40 and 20 for the respective speeds times the dial reading on the viscometer.
It may be well to mention that the final result at 6 RPM is an indication of the stability of the solution being tested.
The test was repeated using 300 ml crude oil plus 300 ml of the Goodwin synthetic water containing varying amounts of the described surfactants and combinations of the described surfactants.
An additional procedure was used on the crude oil-water-surfactant composition. This procedure consisted of stirring the emulsions a second time, allowing them to set for two minutes upon completion of stirring, then making the viscosity determination as previously. This procedure is a more severe test of long term stability for emulsions.
The results for the crude alone are not being stated here. These results were in the range of 1500-9500 cp at 6 RPM.
The test results are shown in the following table.
Only the initial and final 6 RPM values are being given for the two procedures.
______________________________________Concentration First Procedure Second ProcedureSurfactant (ppm) Initial Final Initial Final______________________________________B 250 20 20 120 180C 250 40 80 500 360A 500 40 400 400 320B 500 400 140 140 80C 500 20 60 60 60D 500 700 400 300 200A + D 250 + 250 80 40 40 60B + D 250 + 250 20 40 20 20C + D 250 + 250 260 240 160 140C + E 250 + 250 60 60 40 40A 1,000 300 1280 (1) (1)C 1,000 80 200 (1) (1)D 1,000 100 880 (1) (1)______________________________________ (1) Tests were not run.
The results stated above show that Surfactants B and C at 250 ppm have good first procedure viscosities but are not so good in stability. At 500 ppm, B and C showed improved stability. Products A, B, and C, as compared to other surfactants tested in other work, give good overall results.
The combination of Surfactants B and D at 250 ppm each give excellent results.
Thus, having described the invention in detail, it will be understood by those skilled in the art that certain variations and modifications may be made without departing from the spirit and scope of the invention as defined herein and in the appended claims: | An improvement in the method of transporting viscous hydrocarbons through pipes is disclosed. Briefly, the method comprises adding water containing an effective amount of (a) an anionic alkyl polyether ethoxylated sulfate or (b) a combination of this material with an alcohol ether sulfate. The resulting oil-in-water dispersion has a lower viscosity and is more easily transported. | 5 |
BACKGROUND
[0001] The field of the present invention is devices and processes for remote collection of bio-metric data using wireless mobile devices, and in some cases, the remote control of the wireless mobile device or a bio-metric sensor.
[0002] The medical device industry has advanced to produce smaller and more effective biometric sensors. These sensors are used by a medical provider, such as a doctor or nurse, to collect important biological data regarding a patient. This data may include, for example, ECG, EKG, brain wave, temperature, pulse rate, hydration, blood chemistry, or glucose levels. In some cases, the provider is able to review the collected data and make an immediate therapeutic diagnosis, such as the case in finding an elevated temperature. In other cases, it is only by collecting data over an extended period of time that important medical results can be evaluated. In these cased, the medical provider may have to make several trips to the patient, or the patient will have to make several trips to the provider's office, before a meaningful result may be obtained.
[0003] In other cases, patient data is only able to be monitored after an important event has occurred, for example, a mild heart attack. In these cases, the most critical data is never collected as the patient is not in their provider's office when the attack occurs.
[0004] In one of the most challenge aspects of new drug development, a drug company typically pays for and orchestrates one or more human studies regarding safety and efficacy. These studies are time consuming and expensive, and rely on the voluntary participation of human subjects. These subjects must take their dosages according to predefined guidelines, and submit themselves for continual evaluation at a provider's office. Since the provider has only limited interaction with each subject, there is a substantial risk that the subject will forget of fail to follow the dosing regimen, will fail to participate in required follow-up and testing, or will have a negative reaction that is not detected in the short evaluation visit.
[0005] Accordingly, there is a need for better collection and use of bio-medical data.
SUMMARY
[0006] Briefly, the present invention provides a wireless mobile device, typically in the form of a handset that is cable of providing voice and data communication using a wide-area wireless carrier system. The wireless handset has an associated bio-metric sensor, which may be integrally formed with the handset or spaced apart and connected with a wired or wireless connection. A patient uses bio-metric sensor to locally collect data, and then transmit that data to a medical server using the wireless handset. In some cases, the wireless handset may also process the data to transmit result or summary information. In other cases, the wireless handset may process the data to perform a local operation, such as signaling an alarm or displaying results to the patient, or to make an adjustment in the bio-metric sensor or other local medical device. In some cases the wireless handset may also receive commands from the medical server, and make an adaptation to the bio-metric sensor or other medical device, such as a medication pump.
[0007] In one example, a patient uses a bio-metric sensor to collect glucose blood-chemistry data from time to time. The glucose sensor may be integral to a mobile wireless handset, or may connect using a wire or wireless communication. The mobile wireless handset may locally process the glucose level information, and present information or instructions to the patient. The wireless handset may also communicate the raw or processed data to medical server over a wireless communication channel, such as CDMA, GPRS, or UMTS. With greater computational and storage capability, the medical server may provide additional dosing or instructions to the patient. These messages may be delivered to the patient by voice or through a data message. In other cases, the medical server may send the data, or in a more critical case, an alert, to a medical provider or to an emergency responder. In some cases, the patient may have a local device for administering insulin or other medication, which may be activated or adapted from a command sent from the wireless mobile handset. This command may be locally generated responsive to a timer or to collected data, or may be a command received from a medical provider to from a medical server.
[0008] Advantageously, the disclosed patient handset enables high quality medical care to be more efficiently provided. For example, a patient is able to collect bio-metric data at almost any location, and at any time, allowing for more frequent and consistent data collection, with minimal interruption to the patient's schedule. Medical providers are able to more closely monitor patient conditions and progress, and communicate with those patients using voice or data channels. For example, a doctor may talk to a patient while viewing data results in near-real time, even though both the doctor and the patient are hundreds of miles apart. Due to the ubiquitous nature of mobile handsets, such patient handsets may be readily deployed, and used in almost every geographic location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention can be better understood with reference to the following figures. The components within the figures are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. It will also be understood that certain components and details may not appear in the figures to assist in more clearly describing the invention.
[0010] FIG. 1 is a simplified block diagram of a system for remote bio-medical data collection and device control in accordance with the present invention;
[0011] FIG. 2 is a diagram of a patient handset constructed for use in a bio-medical data collection system in accordance with the present invention;
[0012] FIG. 3 is a diagram of a patient handset constructed for use in a bio-medical data collection system in accordance with the present invention;
[0013] FIG. 4 is flowchart of a process of using a biomedical sensor that is associated with a wireless mobile handset in accordance with the present invention;
[0014] FIG. 5 is flowchart of a process for enabling a medical provider to receive data from a remote data collection device, and to issue commands to the control the device or sensor in accordance with the present invention; and
[0015] FIG. 6 is a block diagram of processes, algorithms, and data structures used in a medical server in accordance with the present invention;
DETAILED DESCRIPTION
[0016] Referring now to FIG. 1 , a distributed biometric system is illustrated. System 10 advantageously enables the remote collection of biometric data, the automated communication of the biometric data to medical personnel, and the ability of medical providers to react to and control the biometric collection devices. In system 10 , data collection, communication, and control are provided in an authenticated and secure manner, assuring patient privacy as well as safely assisting the delivery of quality medical care.
[0017] Biometric system 10 uses commercially available mobile voice and data communication systems 12 . Mobile communication system 12 may be operated by a telecommunication provider, and may use communication standards promulgated by national or international standards bodies. For example, mobile communication system 12 may comply with CDMA, CDMA 2000, WCDMA, EVDO, EVDV, GSM, GPRS, EDGE, PHS, PCS, or other telecommunication standards. The telecommunication system may also include or rely upon other communication protocols such as WiFi, 802.11, Bluetooth, WiMax, or other local or wide area data network. However, the reach and ubiquitous nature of the mobile telephone systems make the mobile telephone system the network of choice. Accordingly, the descriptions provided herein will describe the invention operating using a mobile telecommunications system, however it will be appreciated that other communication and data networks may be used.
[0018] Mobile communication system 12 enables remote voice and data communication with mobile handsets, such as mobile handsets 14 , 21 , and 28 . The communication of voice and data between a mobile communication system and its associated mobile handsets is well known, so will not be described herein. In a similar way, the construction and deployment of mobile handsets is well known, so will not be described in detail. In one example, patient handset 14 allows voice communication to human medical providers, as well as data communication with a medical server 31 . In some cases, medical providers 42 and 44 may use medical server 31 to send device control commands to the patient handset 14 .
[0019] Patient handset 14 couples to a medical or biometric sensor 16 . In one example, the medical sensor connects using a cable or line, and in another example, medical sensor 18 connects using a wireless communication, such as Bluetooth. The medical sensors 16 and 18 may be any kind of biometric or medical sensor useful for collecting patient data. For example, the sensors may provide an audio signal for hearing heart, lung, or breathing activity; may sense temperature, heart rate, blood pressure, glucose level, or other blood chemistry information; or may measure skin hydration, environment data, exercise data, or location information. It will be appreciated that the biometric or medical sensors may be constructed and configured to collect a wide range of useful information regarding patients and their environment.
[0020] In another example, patient handset 21 has a medical sensor 23 integrally formed with the handset. In this way, the patient uses a single device for voice and data communication, as well as collecting medical data. Although this structure may provide a particularly efficient housing, the integrally formed medical sensor handset provides less flexibility then the discrete sensors discussed with reference to patient handset 14 . The patient handset 14 or 21 may operate local application software for controlling the handset's respective sensor or sensors. For example, the patient handset may determine when data is collected and when data is transferred to the medical server 31 . This determination may be done according to a time schedule; may be responsive to data collected at one or more medical sensors; or may be initiated by a local command given by the patient or a medical provider. It will be appreciated that other processes and triggers may be used to start or stop data collection and transfer data to medical server.
[0021] The collected data may be sent to medical server 31 . The data may be sent in near real time, or may be collected and processed in the patient handset and then communicated to the medical server 31 from time to time. The medical server 31 is preferably stationed within the control of the mobile communication system 12 . In this way, enhanced security may be established between patient handsets and the medical server 31 . If the medical server is outside the protected environment of the mobile communication system, then additional authentication processes 33 must be used to assure the private and secure transmission of data, as well as to authenticate access to the medical server. A robust and flexible association and authentication process has been fully described in co-pending U.S. patent application Ser. No. 11/296,077 filed Dec. 7, 2005 and titled “Wireless Controller Device”, which is incorporated herein in its entirety. It will be appreciated that other authentication, association, and security processes may be used. Once the medical server 31 has received data from the patient handsets, that data may be processed or made available for use by medical providers, such as medical provider 42 and 44 . It will be appreciated that medical server 31 may operate automated processes for monitoring received data, and may automatically generate alarms or messages responsive to analyzing patient data.
[0022] In some cases, a medical provider may also be operating remotely, and may use a provider handset 28 for both voice communication and for receiving data from the medical server 31 . Advantageously, biometric system 10 enables secure collection of medical data for patient, the transmission of that medical data to a medical server, and distribution and use of the data by distributed medical providers. Further, data collection and transmission may occur simultaneously with voice communication with the patient. In this way, a medical provider may be in voice communication with a patient while monitoring near real time medical data.
[0023] To this point, the distributed biometric system 10 has been described as a data collection and distribution network. As an extension, system 10 also allows medical providers, such as medical providers 42 , 44 , and 28 to control and adjust the data collection process. For example, the authenticated medical providers may cause commands to be sent to patient handsets 14 and 21 for changing the way data is collected. These commands may be used with in the patient handset for adjusting the timing of data collection and transmission, or may be used with in medical sensors 16 , 18 or 23 for adjusting sensor configurations.
[0024] The biometric system 10 may be advantageously used in several practical applications. For example, system 10 may enable the automated and remote monitoring of patients. In this way, medical data is collected according to predefined triggers, and that data may be locally or centrally processed to evaluate patient condition. Responsive to processing the medical data, the medical server or medical providers may determine when a patient needs more direct contact with a medical facility, or in some cases may even initiate or adapt medical treatment by sending commands to a local medical device. In this way, patients may be closely monitored with less intrusion into their lives, and a more advanced medical treatment sought before conditions become critical. More effective medical treatment may thereby be delivered to patients in a more comfortable and timely manner.
[0025] In another example of use, clinical trials may use system 10 for controlling clinical studies. A medical server may be used to notify patients when to take a medication, or may even send commands to local medical devices to administer local doses. The medical server may also interrogate the patient with text messages, and solicit current medical information from the patient, or may call the patient using a voice capability the handset, and have the patient give an oral report. Since the patient handset has one or more local sensors, the medical server may also receive real-time or processed data from patients. In this way, more complete and accurate information may be obtained for trial studies, and patients having complications may be more quickly identified and removed from the study. Further, the cost of managing human clinical studies has skyrocketed, with some studies costing more than $30,000 per patient per year of study. Accordingly, a more efficient way of monitoring patients and collecting data could dramatically reduce study costs and increase the study's reliability, allowing beneficial drugs to come to market more quickly.
[0026] In other examples, system 10 may be used to monitor athletes to assess performance and stress levels, or may be used to monitor military personnel or police. Also, even though the patient handset has been described as being associated with a single patient, in some cases the patient handset may be a handset used by a medical provider, such as an emergency responder. In this way, the emergency responder moves to the location of the patient, and then uses the patient handset to collect the patient's medical data, and transmit the patient data to a nearby hospital or other medical provider. In this way, the local hospital or medical provider may better understand patient condition, and either be prepared for the patients arrival, or even direct the patient to an alternative facility. With the efficient and accurate transmission of medical data, time may be saved in moving the patient to a preferred medical treatment location.
[0027] Referring now to FIG. 2 , a patient handset system 50 is illustrated. Mobile handset 50 is similar to patient handset 21 described with reference to FIG. 1 , and is intended to operate within a distributed biometric system 10 . Handset 50 has a housing 52 holding a standard mobile handset. Typically, a mobile handset 52 will include a textual or graphical display 58 , input keys 60 , as well as internal circuitry for operating local programs as well as wide area communication. The mobile handset 52 may operate according to one or more wide area connection 54 , such as CDMA, WCDMA, UMTS, GSM, WiFi, or other wide area voice and data network. Typically, these wide-area connections are operated by a communication carrier, and the mobile handsets are particularly constructed to operate in a specific carrier's network. In some cases, mobile handset 52 also has a local area connection such as Bluetooth or 802.11. The local area connection 56 may be useful for connecting to other medical sensors, or to other peripheral devices such as headsets, medical devices, or hands-free car kits. Handset 52 also has an integrated medical sensor 62 . The medical sensor 62 may be constructed as a stethoscope, a heart rate monitor, a blood pressure monitor, a glucose monitor, or other biometric sensor. The mobile handset 52 may also have control keys 69 for allowing the patient or a medical provider to directly interact with medical sensor 62 . A speaker 64 may also be provided for sounding alarms or giving instructions. It will also be appreciated that the handsets regular speakerphone or earpiece may be used in this capacity. The mobile handset may also have alerts or alarm lights 66 associate with the medical sensor 62 . For example, lights 66 may indicate that a glucose level is dangerously low, or that the medical sensor is no longer receiving a required signal. The display 58 may also be used to display instructions on use of the medical sensor 62 , or may be used for outputting results or alarm information.
[0028] Medical sensor 62 may initiate its data collection responsive to a manual local control, as when a patient or medical provider interacts with control buttons 69 . The medical sensor 62 may also operate responsive to an application running within the mobile handset itself, and thereby may periodically begin data collection, or take data collection responsive to some other application or trigger provided by the mobile handset. In another example, and other local medical sensor provides trigger data for medical sensor 62 . The mobile handset may also receive a command from a medical provider or from a medical server, and responsive to receiving the command, initiate or a just medical sensor 62 . The sensor data may be displayed locally to the patient or local medical provider, or the data may be logged in the memory of the mobile handset. The data may also be sent continuously to an associated medical server in near real time, or may be stored locally and periodically transmitted. Mobile handset 52 may also provide local analysis of data, and present local results to the patient or local medical provider. For example, medical sensor 62 may collect blood glucose information, process the data locally, and process and present the results locally. The raw data or resulting blood level data may then be transmitted to a medical server.
[0029] Referring now to FIG. 3 , patient handset system 100 is illustrated. Patient handset 100 is similar to patient handset 21 described with reference to FIG. 1 and has many similarities with patient handset system 50 described with reference to FIG. 2 . Accordingly, mobile handset system 100 will be described with less detail. Patient handset system 100 has mobile handset 102 having a wide area connection 104 for transmitting and receiving data and voice. Mobile handset 102 also has a local area connection such as Bluetooth, Zigbee, or 802.11. The local area connection may be used to connect to a medical sensor 108 , or to a medical control device 113 , for example. The medical sensor 108 may include various control keys, alarms, and displays. The medical sensor 108 may be, for example, an EKG, ECG, blood pressure, thermometer, pulse, hydration, blood analysis, or glucose sensing device. It will be appreciated that other types of sensors may be used, or that multiple sensors may be connected. In operation, medical sensor 108 is positioned on or adjacent patient, and collects data responsive to a local or remote trigger. From time to time or in real time the medical sensor 108 communicates data back to the mobile handset 102 , which periodically transmits the data back to a medical server. The mobile handset will too may also receive commands from a medical provider or from the medical server for adjusting medical sensor 108 . In this way, a remote medical provider may interact with medical sensor 108 or the application interacting with the medical sensor operating on mobile handset 102 . In another control example, a medical control device 113 also uses the local area connection to interact with the mobile handset 102 . This medical control device 113 may be a pacemaker, IV drip, or medication pump, for example. This medical control device 113 may receive the command directly from mobile handset 102 , or the command may have been initiated from a medical server or a human medical provider, and communicated to the mobile handset via the wide area connection 104 .
[0030] In one specific example, mobile handset 102 is used by a patient having a pain medication administered using a medication pump. The medication pump has a medical control device 113 which sets the flow rate or duty cycle or period of operation. A medical sensor 108 may be attached to the patient to monitor pulse rate, skin hydration, or other biometric indicator of pain. Further, the patient may use mobile handset 102 to communicate verbally to a medical provider. Responsive to receiving data that pain has increased, or responsive to a verbal communication from the patient, a medical provider may send a command to medical control device 113 to increase pain medication. In this way, a medical provider is able to accurately evaluate the patients condition, including speaking with the patient, and enable a change in medication delivery from a remote location. Accordingly, patient system 100 facilitates the timely and efficient delivery of high quality medical care.
[0031] Referring now to FIG. 4 , a process for using a wireless medical sensor with a mobile handset is illustrated. In process 150 , a medical sensor is placed on or near a patient as shown in block 152 . This sensor may be a discrete sensor that connects or couples to a handset, or may be a sensor integrally formed in a wireless mobile handset. The sensor is configured as shown in block 154 . Configuring the sensor may include using local buttons or local commands from the mobile handset, and may include further instruction or commands from a medical server or remote medical provider. Data collection is triggered as shown in block 156 . Data collection may be triggered by a local command received at the sensor or on the handset, may be provided by an application operating on the mobile handset, or may be responsive to a command received from the medical server or remote medical provider. The collected data may be locally logged into memory as shown in block 161 , and may be locally processed as shown in block 163 . In some cases, the data logging and data processing steps may not be used, with raw data being transmitted to the medical server in near real time. In other cases, the logged data and processed data may be sent to the medical server as shown in block 167 . The data may also be locally displayed, as well as local results on display at 169 . The command may be received at the mobile handset from the wide area connection as shown in block 172 . This command may come directly from the medical server, from a medical provider connected to the medical server, or even from a medical provider operating a mobile handset.
[0032] In another example, a command may be generated locally as shown in block 177 . This local command may be from an application operating on the mobile handset, or may be responsive to a patient or medical provider pressing a key. Any of these instructions may then be used to make adjustments in the data collection process. For example, the instruction may affect how the sensor is configured, what triggers the data collection, the amount of data logged, the type of data processing performed, or the timing of data transmissions. In this way, process 150 facilitates the secure and flexible collection of medical data, the use of the medical data by medical providers irrespective of their location, and the adaptation of the sensor and patient handset. Of course, the patient handset may facilitate voice communication 179 between the patient and medical providers, even while medical data is being collected and transmitted.
[0033] Referring now to FIG. 5 , a process for a medical provider to access and control a biomedical sensor is illustrated. Process 200 allows a remote medical provider to access medical data, evaluate medical data, and control one or more devices associated with a patient. Although the medical provider may be connected to a medical server, in some cases the medical provider may be operating using a wireless mobile device, such as a portable computer or wireless handset. In these cases, the wireless mobile device provides a secure process for authenticating the medical provider to the medical server as shown in block 202 . Once the medical provider has been authenticated to the medical server, then the medical provider has to be associated with particular patients and their associated remote medical devices as shown in block 204 . In this way, a particular medical provider is only able to access data and control devices for that provider's set of patients.
[0034] Once the medical provider has been authenticated and associated with their set of patients, the medical provider may select a particular patient, and receive data collected by that patient's medical sensor or medical sensors. As previously discussed, this data may be real-time, batch transmitted, and may include summary or processed results. The medical practitioner then may view and store this medical data or may provide additional analytic tools as shown in block 211 . Responsive to viewing the data, the medical provider may send a command to remote medical device at the patient's location as shown in block 213 . This command may be used to further adapt the medical sensor, or may provide control for another device, such as an IV pump, at the patient location.
[0035] In another example, the medical provider may stand messages or data information to other medical providers for collaboration as shown in block 217 . In this way, multiple remote medical providers may cooperate in assisting a single patient, and all providers will be using the same medical data information. While receiving and analyzing medical information from the patient, the medical provider may also be in voice communication with the patient as shown in block 221 . Of course, the medical provider may also use forced vacation 221 to discuss the patient with other medical providers.
[0036] Referring now to FIG. 6 , medical server processes 225 are illustrated. The connection of a medical server to a mobile communications system, as well as the operation of a general computer server, are well known, so will not be described in detail. Instead, the general processes operating on a medical server are described. Medical server 227 has processes 232 for authenticating and associating mobile devices with the medical server. The authentication and association processes are simplified when the medical server operates with in the controlled environment of the mobile communications system, but the medical server may also be connected on a more general network system such as the Internet. The server has mobile handset authentication information 241 , which is useful for authenticating patient handset to the medical server. The mobile handset authentication information 241 may include the mobile identification number for the handset, a serial number for the handset, IP address for the handset, or other identification information. The authentication information may also have carrier information, and password requirements for the user. Once a handset has been authenticated to the server, the server may then associate a particular patient handset with that handsets authorized biometric sensors, and may provide sensor configuration and interface information as shown in block 243 . This information may be specific to the particular sensor at a patients handset, or may be global to a class of products. In another example, sensors may be configured according to the particular medical requirements of the patient.
[0037] The server 227 also maintains information for authorizing medical personnel 244 . Some medical personnel may login through existing server client processes, while others may access the server using their mobile handsets. For those using the mobile handsets, a mobile handset authentication information system to 46 is provided. In this way, a particular medical provider's handset may be authenticated to the server, and the medical provider associated with an authorized set of patients and patient records. Logging and legal requirements 248 may also be set on a global basis, a provider bases, or a patient basis. In this way, appropriate records may be maintained as to patient care.
[0038] Processes 232 enable server 227 to communicate with a patients handset and its associated sensors, as well as access rules specific to that patient. For example rules 234 may include rules for when the server initiates data collection as shown in block 251 . Alternatively, authorized medical personnel may initiate data collection as shown in block 253 , or a patient may be allowed to initiate the collection as shown in block 255 . In other cases, other remote devices may be allowed to trigger or initiate data collection as shown in block 257 . The data collection rules also may include information as to the trigger for initiating data collection, how much data to store locally, then to transmit data to medical server, and what type of local display and processing may be allowed. In some cases, the collected medical data may be processed locally and used for further adapt in the medical sensor or local application.
[0039] In other cases, server analytics 236 are applied to the received medical data by server 227 . Processing routines 262 may be applied to incoming data, and provided certain thresholds or patterns are seen, notifications may be sent to medical providers 264 or alarms may be generated 266 . The medical provider notifications 264 may include messages, automated phone calls, or other forms of notification. The alarm may also be used to notify medical providers, or may be set as a sound, illumination, or display on the patients handset. For example, if the processing routines 260 to determine that a heart rate is too high, a local alarm may be sounded at the patient's handset to warn the patient to reduce their level of exertion. In another example, responsive to the processing routines to 62 , the server may send commands to the patient's handset to 68 . These commands may then be used to adapt or configure the medical sensor, or may be used to set operation of another local medical device.
[0040] While particular preferred and alternative embodiments of the present intention have been disclosed, it will be appreciated that many various modifications and extensions of the above described technology may be implemented using the teaching of this invention. All such modifications and extensions are intended to be included within the true spirit and scope of the appended claims. | A wireless mobile device is provided, typically in the form of a handset that is cable of providing voice and data communication using a wide-area wireless carrier system. The wireless handset has an associated bio-metric sensor, which may be integrally formed with the handset or spaced apart and connected with a wired or wireless connection. A patient uses bio-metric sensor to locally collect data, and then transmit that data to a medical server using the wireless handset. In some cases, the wireless handset may also process the data to transmit result or summary information. In other cases, the wireless handset may process the data to perform a local operation, such as signaling an alarm or displaying results to the patient, or to make an adjustment in the bio-metric sensor or other local medical device. In some cases the wireless handset may also receive commands from the medical server, and make an adaptation to the bio-metric sensor or other medical device, such as a medication pump. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a rolling guide device in which a block and a rail are relatively linearly movably engaged to each other via rows of infinitely circulating rolling members, a manufacturing method thereof, and a driving device including the rolling guide device.
[0002] Heretofore, there has been known a rolling guide device in which a block and a rail are linearly movably engaged to each other via a plurality of rolling members comprising infinitely circulating balls and rollers. To be concrete, as shown in FIG. 8, the rolling guide device comprises a rail 80 , a block 90 having a recess 93 formed on a lower surface thereof in which the rail 80 fits, and a number of rolling members 100 interposed so as to form a row between a rolling member rolling surface 81 of the rail 80 and a loaded rolling member rolling surface 91 of the block 90 .
[0003] Here, the block 90 is provided with rolling member release holes 94 through which the rolling members 100 passed between each pair of the rolling member rolling surface 81 and the loaded rolling member rolling surface 91 are released and returned to an original position again to from an infinite circulation passage of the rolling members 100 .
[0004] Furthermore, when the block 90 is linearly moved relatively along the rail 80 , the rolling members 100 are linearly moved while they rolls between the rolling member rolling surface 81 and the loaded rolling member rolling surface 91 , passed between the rolling member rolling surface 81 and the loaded rolling member rolling surface 91 , returned to the rolling member release hole 94 through a return passage provided in an end plate not shown, and then supplied again between the rolling member rolling surface 81 and the loaded rolling member rolling surface 91 .
[0005] However, for example, in the case that the block 90 is fixed and the rail 80 is moved in the aforesaid rolling guide device, and when a heavy piece is installed at a rail tip portion of the forward side of the rail 80 in FIG. 8 and a moment load is applied thereonto, the load imparts an uneven deformation onto the block 90 , so that a deformation amount (an opening amount of the recess 93 ) is varied on the forward side and the backward side of the block 90 in FIG. 8, which leads to a problem that the position accuracy of the rail 80 is impaired.
[0006] In order to solve this problem, instead of the recess 93 , a through hole may be provided at the center of the block 90 to pass the rail 80 through the inside of the through hole. If constituted in this manner, even in the case that an uneven load is applied onto one side of the rail 80 and the moment load is generated, the recess 93 will not be opened, so that the rail 80 can always securely be held.
[0007] However, even in the rolling guide device constituted in such a manner, machining positions of the opposing rolling member rolling surface 81 and the loaded rolling member rolling surface 91 are required to be changed to various positions (various contact angle positions) in accordance with purposes of use, and hence, the shape of an opening 25 of the block 90 and the external shape of the rail 80 must also be changed in accordance with the above change, thereby causing a complicated problem.
SUMMARY OF THE INVENTION
[0008] Therefore, an object of the present invention is to provide a rolling guide device in which even if a large moment is applied to a rail, a block is not deformed, and even if machining positions of a rolling member rolling surface 81 and a loaded rolling member rolling surface 91 are simultaneously changed, the shape itself of the block and the rail is not required to be changed, a manufacturing method thereof, and a driving device including the rolling guide device.
[0009] A first aspect of the present invention is directed to a rolling guide device which comprises a rail in which a rolling member rolling surface is formed along its longitudinal direction, a block in which an opening comprising a through hole is formed, the rail being fitted in this opening, and a rolling member circulation passage including a loaded rolling member rolling surface corresponding to the rolling member rolling surface of the rail is formed, and a plurality of rolling members which are disposed and housed in the rolling member circulation passage and which circulate in accordance with the relative movement of the rail and block, wherein a sectional shape at right angles to the longitudinal direction of the rail and a sectional shape of the opening of the block are formed into a mutually geometrically similar longitudinal shape. In this manner, the opening of the block is made to be a through hole, and therefore, the block is a box type block of high rigidity which will not be deformed, so that it is possible to sufficiently maintain a satisfactory position accuracy of the rail even if a large moment is applied thereonto. In addition, according to the present invention, by appropriately changing the machining positions alone of the rolling member rolling surface and the loaded rolling member rolling surface, it becomes possible to optionally change a contact angle of the rolling members by one type of block and rail. Therefore, even in the case that the purpose of use and the condition of use are different by each user, it is possible to cope with these situations, thereby enabling the manufacture of the rolling guide device easily and at a low price.
[0010] A second aspect of the present invention is directed to the rolling guide device in which the sectional shape at right angles to the longitudinal direction of the rail and the sectional shape of the opening of the block are mutually formed into a curved line with respect to a part in which the rolling member rolling surface and loaded rolling member rolling surface are formed. In this manner, by forming the part of both sectional shapes into a curved line, it is possible to change the contact angle easily by changing the positions of the rolling member rolling surface and the loaded rolling member rolling surface as described above.
[0011] Moreover, a third aspect of the present invention, in the rolling guide device, is to provide a constitution in which the curved line is part of a round shape. If the curved line is a round shape, the relation between the position and the contact angle of the aforesaid rolling member rolling surface and the loaded rolling member rolling surface becomes most important, since the position of each rolling surface can be changed with high accuracy, it is thus possible to change and set the contact angle with high accuracy.
[0012] A fourth aspect of the present invention is directed to the rolling guide device in which the curved line is a part of an ellipse. If the curved line is an ellipse, though the relation of the aforesaid rolling member rolling surface and loaded rolling member rolling surface to the contact angle is not simple as in the case of the aforesaid round shape, it is possible to easily change the contact angle in proportion to the round shape.
[0013] Moreover, a fifth aspect of the present invention is directed to a manufacturing method of a rolling guide device which comprises a process of forming a rolling member rolling surface on a rail along the longitudinal direction, a process of forming a rolling member circulation passage including a loaded rolling member rolling surface corresponding to the rolling member rolling surface of the rail on a block in which an opening comprising a through hole is machined, and a process of inserting the rail into the opening of the block, and disposing and housing, in the rolling member circulation passage, a plurality of rolling members which circulate in accordance with the relative motion of the rail and block, wherein a sectional shape at right angles to the longitudinal direction of the rail and a sectional shape of the opening of the block are machined in advance into a mutually geometrically similar longitudinal shape, and machining positions of both the loaded rolling member rolling surface of the block and the rolling member rolling surface of the rail are appropriately changed, whereby the contact angle of the rolling members to the block and rail is optionally changed.
[0014] Moreover, a sixth aspect of the present invention is directed to a driving device including a rolling guide device which comprises a rail in which a rolling member rolling surface is formed along the longitudinal direction; a block in which an opening comprising a through hole is formed, the rail fits in this opening, and a rolling member circulation passage including a loaded rolling member rolling surface corresponding to the rolling member rolling surface of the rail is formed; and a plurality of rolling members which are disposed and housed in the rolling member circulation passage and which circulate in accordance with the relative motion of the rail and block; wherein a sectional shape at right angles to the longitudinal direction of the rail and a sectional shape of the opening of the block are formed into a mutually geometrically similar longitudinal shape, and there is disposed a linear motor comprising a secondary side arranged on both the main sides of the rail and a primary side arranged in the opening of the block corresponding to this secondary side.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a partially cut schematic perspective view of a rolling guide device according to an embodiment of the present invention.
[0016] [0016]FIG. 2 shows a rolling guide device according to an embodiment of the present invention, and FIG. 2 ( a ) is a schematic cross-sectional side view and FIG. 2 ( b ) is a plan view.
[0017] [0017]FIG. 3 is a cross-sectional view of a rolling guide device according to an embodiment of the present invention.
[0018] [0018]FIG. 4 is a cross-sectional view of a rolling guide device in which machining positions alone of a rolling member rolling surface 11 and a loaded rolling member rolling surface 27 are changed.
[0019] [0019]FIG. 5 is a cross-sectional view of the rolling guide device in which machining positions alone of the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 are changed.
[0020] [0020]FIG. 6 is a cross-sectional view showing a driving device according to the present invention.
[0021] [0021]FIG. 7 is a cross-sectional view showing another driving device according to the present invention.
[0022] [0022]FIG. 8 is a cross-sectional view showing a conventional rolling guide device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] In the following, embodiments of the present invention will be described in detail with reference to the drawings.
[0024] [0024]FIG. 1 to FIG. 3 show a rolling guide device according to an embodiment of the present invention, FIG. 1 is a partially cut schematic perspective view, FIG. 2 ( a ) is a schematic sectional side view, FIG. 2 ( b ) is a plan view, and FIG. 3 is a cross-sectional view. As shown in these drawings, this rolling guide device is constituted of a rail 10 , a block 20 , and a ball (rolling member) 70 .
[0025] A cross section of the rail 10 is a longitudinal shape, and to be concrete, upper and lower surfaces are substantially parallel planes in which both sides are formed into a substantially elliptical shape protruding in an arc-like shape. Moreover, on the top and bottom of the rail 10 , two groove-like rolling member rolling surfaces 11 are formed at right and left, and hence, four groove-like rolling member rolling surfaces 11 are formed in all.
[0026] The block 20 comprises a block body 21 and end plates 23 which are installed on both end faces of the block body 21 . The block body 21 is provided with an opening 25 into which the rail 10 is inserted, and on upper and lower surfaces of this opening 25 , there are formed 4 groove-like loaded rolling member rolling surfaces 27 corresponding to the respective rolling member rolling surfaces 11 of the rail 10 . Between each of the mutually opposing rolling member rolling surfaces 11 and the loaded rolling member rolling surface 27 , a plurality of balls (rolling members) 70 . . . are movably interposed.
[0027] The opening 25 is a through hole and its sectional shape is a longitudinal shape, and detailedly, upper and lower surfaces are substantially parallel planes in which both sides are formed into a substantially elliptical shape protruding like an arc-like shape. That is, a sectional shape at right angles to the longitudinal direction of the rail 10 and a sectional shape of the opening 25 are formed into a mutually geometrically similar longitudinal shape, in the case of this embodiment, an elliptical shape. Therefore, the outer peripheral surface of the rail 10 and the inner peripheral surface of the opening 25 are parallel, and clearance dimensions of both the surfaces are about the same in any part.
[0028] In the block body 21 , two rolling member release holes 51 for releasing the balls in a load area corresponding to the respective loaded rolling member rolling surfaces 27 are formed on top and bottom of the opening 25 , respectively, and hence the four holes 51 are formed in all. On the other hand, on upper and lower surfaces and on both sides of the block 21 , there are provided screw-holes 29 for fixing this block body 21 to other members.
[0029] The end plate 23 is constituted of a rectangular member having about the same shape as the end face of the block body 21 . At the center thereof, there are an opening 53 for passing the rail 10 , and a return passage 55 for forwarding the balls 70 in the load area interposed between the block body 21 and the rail 10 into a rolling member release hole 51 to return the balls to the load area again. In addition, on the outer end face of the end plate 23 is installed a sealing member 57 for preventing dirt from entering the inside and preventing lubricant from leaking from the inside.
[0030] Furthermore, a rolling member circulation passage is defined by the loaded rolling member rolling surface 27 corresponding to the rolling member rolling surface 11 of the rail 10 , the rolling member release hole 51 , and the return passage 55 .
[0031] As a method for machining the loaded rolling member rolling surface 27 in the block 20 , for example, a method can be used in which the opening 25 is perforated in the block 20 by wire cut and the like, and a groove is then formed on the inner surface thereof by grinding only to work the loaded rolling member rolling surface 27 .
[0032] Then, when the rail 10 is moved linearly in its longitudinal direction to the block 20 , the rail 10 smoothly moves as the ball 70 between the rolling member rolling surface 11 of the rail 10 and the loaded rolling member rolling surface 27 of the block 20 moves while rolling.
[0033] In the present invention, since the opening 25 is provided in the block 20 and the rail is passed inside thereof, for example, as shown in FIG. 2 ( a ), the block 20 is fixed to a fixing side member 75 , on the other hand, even if a moving side member 77 is fixed at the tip section of the rail 10 and a moment load is applied to the rail 10 , there does not occur a problem in which the opening 25 is opened and deformed, and the rail 10 always moves smoothly to the same position as in the case where the moving side member 77 is not used, so that it is possible to always maintain satisfactory position accuracy of the moving side member 77 .
[0034] On the other hand, in the present invention, as described above, since the sectional shape at right angles to the longitudinal direction of the rail 10 and the sectional shape of the opening 25 are formed into a mutually geometrically similar ellipse, that is, a longitudinal shape, the clearance dimension of the outer peripheral surface of the rail 10 and the inner peripheral surface of the opening 25 is about the same in any part. Therefore, as shown in FIG. 4 and FIG. 5, even if the same rail and block as the rail 10 and block 20 are used, the machining positions of the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 can be changed to various positions (various positions of a contact angle θ)according to purposes of use. Groove machining of the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 is easy because it can be accomplished by grinding only. That is, according to purposes of use, by changing the machining positions of both the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 appropriately, it is possible to optionally change the contact angle θ (θ 1 , θ 2 ) of the ball 70 to the rail 10 and the block 20 .
[0035] However, in the present embodiment, the sectional shape at right angles to the longitudinal direction of the rail 10 and the sectional shape of the opening 25 of the block 20 are mutually formed into an arc-like shape, that is, a curved line with respect to a part in which the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 are formed.
[0036] In this manner, by forming the part of both sectional shapes into a curved line, it is possible to easily change the contact angle simply by changing the positions of the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 as described above. Incidentally, both or one of the part of rail sectional shape and block sectional shape is a straight line, changing the contact angle is not always easy.
[0037] In the present embodiment, the aforesaid curved line is an arc-like shape, that is, part of a round shape. If the curved line is a round shape, the relation of the position and the contact angle of the aforesaid rolling member rolling surface 11 and loaded rolling member rolling surface 27 becomes most important, since the position of each rolling surface can be changed highly accurately, it is also possible to change and set the contact angle with a high accuracy.
[0038] In addition, the aforesaid curved line may be a part of an elliptical shape. In the case of an ellipse, though the relation of the aforesaid rolling member rolling surface 11 and loaded rolling member rolling surface 27 to the contact angle is not so simple as the case of the aforesaid round shape, it is possible to change the contact angle in proportion to the round shape.
[0039] [0039]FIG. 6 is a transverse sectional view showing a driving device according to the present invention. This driving device is constituted so that magnets (secondary side (secondary conductor)) 60 , 60 are installed so as to be respectively embedded on top and bottom surfaces (principal both surfaces) of the rail 10 of the rolling guide device of the same construction shown in the FIG. 4, and on the other hand, electromagnets (primary side (stator)) 61 , 61 are installed so as to be embedded on top and bottom surfaces of the inner periphery of the opening 25 of the block 20 . A linear motor formed by a pair of the magnet 60 and the magnet 61 of the upper side, and a linear motor formed by a pair of the magnet 60 and the magnet 61 of the lower side are provided at a position vertically symmetrical to the center of the rail 10 . As a linear motor, motors of various construction such as a linear direct current motor and a linear pulse motor can be applied. And, by flowing current to the electromagnets 61 , 61 , the rail 10 is drive so as to advance and reverse to the block 20 .
[0040] In this embodiment, since the rail 10 is covered by the opening 25 provided in the block 20 , it is possible to provide a position to install the magnet 60 and the electromagnet 16 not only on the upper surface side but also on the lower surface side, that is, on the principal both sides of the rail 10 . Therefore, it is possible to restrain a deformation of a structural member in the radial direction due to magnet attraction, so that thrust is increased by space saving because of two pairs of motors used.
[0041] [0041]FIG. 7 shows an embodiment in which the magnets 60 , 60 of the inside and outside of the rail 10 shown in FIG. 6 are integrated into one magnet. If the fastening between the rail 10 and the magnet 60 can be securely provided by adhesion or bolting and the like, such means simplifies the construction and reduces the cost.
[0042] Embodiments of the present invention are described in the above, but the present invention is not limited to the aforesaid embodiments, and various modifications are possible within the scope of the claims and the scope of technical idea stated in the specification and drawings. In addition, even in the case of any shape or construction or quality of material or method of use which are not directly stated in the specification and drawings, as long as they demonstrate the action and effect of the present invention, they are within the scope of the technical idea of the present invention.
[0043] For example, in the aforesaid embodiments, the block 20 is used as the fixed side, and the rail 10 is used as the movable side, conversely, the block 20 may be used as the movable side, and the rail 10 may be used as the fixed side.
[0044] Further, in the aforesaid embodiments, the sectional shape at right angles to the longitudinal direction of the rail 10 and the sectional shape of the opening 25 of the block 20 are mutually formed into round shape or a part of an elliptical shape, that is, a curved line, but other curved line may be applicable.
[0045] Furthermore, in the above embodiments, a case is shown in which balls are used as rolling members, but the present invention may be applicable to the case where rollers are used in a similar construction. | There are provided a rail 10 in which a rolling member rolling surface 11 is formed along the longitudinal direction, a block 20 in which a loaded rolling member rolling surface 27 is formed in an opening 25 comprising a through hole, a plurality of balls 70 disposed and housed between the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 which circulate according to the relative motion of the rail 10 and the block 20 . A sectional shape at right angles to the longitudinal direction of the rail 10 and a sectional shape of the opening 25 are formed into a mutually geometrically similar longitudinal shape. The block 20 is a box type with high rigidity. A contact angle of the ball 70 can be optionally changed by changing the positions alone of the rolling member rolling surface 11 and the loaded rolling member rolling surface 27 to be machined on one type of the block 20 and the rail 10. | 5 |
BACKGROUND OF THE INVENTION
[0001] This application is a continuation-in-part of national U.S. application Ser. No. 10/296,763, filed Dec. 13, 2002, and claims the benefit of international application No. PCT/IB01/01268, filed Jun. 15, 2001, and U.S. provisional patent application No. 60/213,802, filed Jun. 16, 2000.
[0002] This invention relates to the field of belt tensioners and belt tensioner systems. More particularly, the present invention relates to improvements in both mechanical type and hydraulic type belt tensioners for use with a camshaft belt drive system in automotive engine applications and the like.
[0003] A timing belt trained about two cooperating pulleys is well-known in the art of tension transmitting assemblies. There are economical advantages to the aforementioned when compared with other types of assemblies, specifically meshing gear assemblies. It is known to use an automatic tensioner in conjunction with a synchronous or timing belt drive system in order to compensate for tension variations in the belt. These variations are commonly attributable to dynamic effects such as cyclic torque variations and thermal effects that introduce changes in the length of a timing belt drive.
[0004] A tensioner is located on the normally slack side of the belt span in a belt drive system. Tensioner design is typically divided into two groups: mechanical tensioners, relying on coulomb friction as means to generate damping; and second, hydraulic tensioners, generally having a piston arrangement with a known leak-through and a one-way valve to create an asymmetrical damping which is proportional to speed. While these types of tensioners are designed to accommodate cyclic torque variations and thermal effects in a belt drive system by controlling belt tension at the slack side of the belt span, such tensioners are not designed to accommodate extreme torque reversal situations (kickback), such as engine backfiring or engine rotation in reverse (e.g., an automobile going backward while in forward gear with the clutch engaged).
[0005] In such extreme torque reversal situations, the slack side of the belt drive system becomes the tight side. The tight belt tension, on the normally slack side, causes the tensioner device to respond to the kickback and rapidly decrease belt tension by moving the pulley and its related pivot-arm away from the belt to slacken the tight side of the belt span. If the pulley movement is extreme, it can over-slacken the belt and result in tooth jump or ratcheting as the slackened belt enters the crank pulley or cam shaft pulleys. Tooth jump or ratcheting is deleterious to the operation of an engine as synchronization of the pulleys is lost.
[0006] Some tensioners have a ratchet and pawl mechanism attached to the tensioner's pivot arm to eliminate tensioner kickback and avoid tooth jump or ratcheting. U.S. Pat. No. 4,299,584 discloses a ratchet operative with a leaf-spring pawl that allows some compliance at kickback by permitting the leaf-spring to deflect slightly. U.S. Pat. No. 4,634,407 also teaches a ratchet and pawl mechanism where the ratchet operates as a one-way clutch that fixes the position of a pivot-arm such that the tensioner cannot operate to slacken the belt.
[0007] However, a common problem of ratchet/pawl devices is that the tensioner must operate primarily as a fixed idler in one direction as the ratchet mechanism limits the motion of the tensioner pivot-arm. In other words, the tensioner pivot-arm is unable to function in a direction that would allow the belt to be slackened. Under this condition, belt tooth failure and noise is reintroduced into the belt drive system when the belt cannot be at least partially slackened.
[0008] U.S. Pat. No. 5,591,094 teaches an adjustable stop spaced at a distance from the pivot-arm when the pulley is biased in a pressing engagement against a static belt. The spacing is pre-determined to allow pivot-arm movement in a direction to slacken the belt while also preventing belt teeth from becoming disengaged from a toothed pulley (i.e., tooth jump) in an extreme torque reversal situation. The problem with an adjustable stop of this nature is that its distance from the pivot-arm is determined by compensation for the thermal effects of a hot engine. Each component of the belt drive system, however, leaves space for simultaneous tensioner arm vibration. In practice, this distance is large enough to allow tooth jump, especially under conditions such as low temperature and when at least one of the belt and pulleys is covered with a coating of ice.
SUMMARY OF THE INVENTION
[0009] The new autotensioners comprise mechanisms actuated by the reversal of movement direction of the timing belts. Such a reversal of belt movement direction, normally a very rare occurrence, usually occurs during a short period of time, after which the belt returns to its normal forward or preferred movement. Each of the four mechanisms disclosed below, upon actuation by reverse belt movement, causes the autotensioner pulley axis of rotation to move in a direction that tightens the belt during reverse movement of the belt. Mechanisms are disclosed below that apply to autotensioners which have a trailing or leading geometry relative to the belt. Applied to autotensioners engaging the slack span of the belt, the mechanisms almost instantly tighten the belt in response to the reversal of belt direction. While disclosed for an automotive application, the invention is useful for any toothed belt applications where skipping or jumping of the belts over toothed gears would be deleterious to the operation of the machines.
[0010] Although the anti-tooth skip mechanism is inherently torque limited by the maximum frictional forces that can be generated between the pulley and the belt, these maximum frictional forces will change over time with polishing and glazing of the engaging pulley and belt surfaces. Therefore, torque limiters with predictable characteristics have been developed, as disclosed below, to accurately limit the torque maximum in opposition to the abnormal belt force caused by the reversal of belt direction.
[0011] The predetermined torque is the maximum allowable for a specific timing belt system. This torque is limited by means of design geometry in or adjacent to the one-way clutch in each embodiment and can be calibrated to any desired design limit. When the torque limit is reached, the one-way clutch slips or ratchets, thus limiting the torque to the design limit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. Embodiments of this invention will now be described by way of example in association with the accompanying drawings in which:
[0013] [0013]FIG. 1 is a side elevational view of a timing belt drive system;
[0014] [0014]FIG. 2 is a side elevational view of a first embodiment of the tensioning device of the present invention;
[0015] [0015]FIG. 2 a illustrates torque limitation by pawl and ratchet geometry;
[0016] [0016]FIG. 3 is a side elevational view of a second embodiment of the tensioning device of the present invention;
[0017] [0017]FIG. 4 is a side elevational view of a third embodiment of the tensioning device of the present invention;
[0018] [0018]FIG. 5 is a side elevation of a fourth embodiment of the tensioning device of the present invention;
[0019] [0019]FIG. 6 is a cross-section of an alternative form of the tensioning device including a torque limiter;
[0020] [0020]FIG. 6 a is a side view of an expandable spring clip in the tensioning device of FIG. 6; and
[0021] [0021]FIG. 7 is a cross-section of the tensioning device and torque limiter of FIG. 6 fitted within bearing raceways.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Reference will now be made to FIGS. 1 through 5.
[0023] [0023]FIG. 1 is a side elevational view of a synchronous timing belt drive 5 shown with a toothed belt comprising spans 16 , 17 , 18 and 19 and moving in the arrow direction 30 . Teeth 25 , located on the interior periphery of the belt, are spaced at multiple pitch 31 . The belt is entrained and tensioned around toothed pulleys 11 , 12 and 13 . The pulleys are illustrated as a camshaft drive of an automotive engine design that includes two exterior toothed cam pulleys 11 and 12 on camshafts 8 and 7 , and an exterior toothed crankshaft pulley 13 on crankshaft 9 . A belt-tensioning device 21 is mounted in connection with these pulleys such that it is operative in conjunction with the timing belt drive 5 . As the engine operates over a range of RPM's, the drive camshaft pulleys 11 , 12 introduce cyclic torque variations, which cause dynamic belt tension variations in belt spans 16 through 19 . The tensioning device 21 is intended to compensate as shown at 22 for torque variations, thermal growth when the engine is running, and stretch and wear of the belt which occurs during the life span of the drive 5 . The arrows 2 indicate that the belt-tensioning device 21 can rotate in either direction, however, reverse belt movement can be deleterious as explained below.
[0024] [0024]FIG. 2 illustrates a first embodiment of the present invention. The belt tensioner 21 is mounted on the engine via a pivot shaft 50 having a pivotal eccentric arm 49 to which a predetermined torque is applied, usually via a spring arrangement (not shown here). This torque generates a predetermined belt force which is transmitted to the belt via a pulley 52 attached to eccentric arm 49 by any means as is apparent to one skilled in the art, and generally through a bearing (not shown).
[0025] The tensioning device as shown in FIG. 2 is a trailing type configuration. The center 53 of arm structure 49 is located above line 70 throughout its operational range. Line 70 represents the over-center position of pulley 52 with respect to the pivot shaft 50 . A ratchet wheel 42 is attached to arm structure 49 . A plurality of pawls 40 , located in pockets within the housing structure 41 , and attached to pulley 52 , bias the ratchet wheel 42 to form a one-way clutch and permit the unrestricted rotation of pulley 52 in the counterclockwise rotational direction of the drive 5 at the belt tensioner 21 as depicted by arrow 61 . In the event of a clockwise rotational direction, depicted by arrow 60 and which generally occurs under kickback and rollback conditions, the pawls 40 engage ratchet wheel 42 locking the pulley 52 and eccentric arm structure 49 together. This generates frictional torque between the belt 18 and pulley 52 in the direction of arrow 60 . The torque upsets the abnormal belt force caused by the belt reversal. Using an existing tensioner device typical of the prior art, pulley 52 is normally pushed in an outward belt direction as the belt force, in conjunction with the arm length 55 , generates an opposing torque which overcomes the spring torque applied to the eccentric arm 49 , slackening the belt, and, in turn, potentially creating tooth jump. When using the tensioning device of the present invention, the belt 18 causes engagement of the ratchet 40 , 41 , 42 generating torque and moving the pulley 52 toward the belt, thus increasing the belt tension temporarily on the slack side and preventing tooth jump.
[0026] Rather than rely upon the frictional forces generated between the belt and pulley 52 to limit the torque applied to the anti-tooth skip mechanism when the belt reverses into direction 60 , FIG. 2 a illustrates modifying the pawl 40 engagement with the teeth of the ratchet wheel 42 . The geometric angle 130 between the tip 132 of the pawl 40 and the tooth surface 134 and the compliance of the housing structure 41 permits the limiting torque to be determined when the pawl 40 is forced to slip from any tooth surface 134 . The engaging surfaces (tip 132 and tooth 134 ), as with most similar devices, are hardened for wear resistance and therefore can be expected to retain their frictional and slippage characteristics over long periods of use.
[0027] [0027]FIG. 3 is an enlarged view of the tensioning device of FIG. 1 and illustrates a second embodiment of the present invention. The tensioner 21 functions in the same manner as explained above. The tensioner as shown in FIG. 3 is a leading type configuration. The center 53 of arm structure 49 is located below the line 70 throughout its operational range. A ratchet wheel 44 is pivotally mounted on the cylindrical surface of the eccentric arm 49 . A plurality of pawls 40 , located in pockets within housing structure 41 , attached to pulley 52 bias the ratchet wheel 44 and permit the unrestricted rotation of pulley 52 in the counterclockwise rotational direction, depicted by arrow 61 of drive 5 . In the event of a clockwise rotational direction, depicted by arrow 60 and which generally occurs during kickback and rollback conditions, the pawls 40 engage ratchet wheel 44 enabling rotation of ratchet wheel 44 together with the pulley 52 . The ratchet wheel 44 is meshed with gear 81 through teeth 45 on the inside of the volute. Gear 81 is pivotally mounted on a support structure 80 , and is attached to the pivot structure 50 via a member not shown here for clarity. Thus, pivot structure 80 is fixed. Gear 81 is meshed with teeth 46 which are part of the eccentric arm 49 . This gear train results in the eccentric arm 49 rotating toward the belt and generating an opposing torque. This opposing torque overcomes the belt force generated torque resulting from the clockwise rotational direction of the drive 5 (depicted by arrow 60 ), and increases the belt tension which, in turn, prevents tooth jump.
[0028] The embodiment of FIG. 3 utilizes a pawl 40 and ratchet wheel 44 in the anti-tooth skip mechanism, as in FIG. 2, therefore, the torque limiter modification shown in FIG. 2 a is applicable to the mechanism of FIG. 3.
[0029] [0029]FIG. 4 illustrates a third embodiment of the present invention. The belt tensioner comprises a pulley 52 , an eccentric arm structure 49 , and a hydraulic actuator unit 100 , mounted on an engine via a pivot shaft 50 and bolts 92 , 93 and 94 . Pulley 52 is attached to the eccentric arm structure 49 through a bearing fixed to the arm structure 49 via bolt 91 . The arm structure 49 , pivotally trained about pivot shaft 50 , allows the pulley 52 to rotate eccentrically around the center of pivot shaft 50 . Hydraulic actuator 100 exerts a known force through piston pin 101 at point 110 generating a predetermined torque that is transferred to arm structure 49 in conjunction with arm length 55 . This generates a predetermined belt force that is transmitted to the belt via pulley 52 .
[0030] The tensioner shown in FIG. 4 is a trailing type configuration. The center 51 of pulley 52 is located above line 70 throughout its operational range. Line 70 represents the over center position of the pulley 52 with respect to the pivot shaft 50 . A ratchet wheel 42 is attached to the arm structure 49 . A plurality of pawls 40 , located in pockets within housing structure 41 , attached to pulley 52 bias the ratchet wheel 42 and permit the unrestricted rotation of pulley 52 in the counterclockwise rotational direction of the drive 5 depicted by arrow 61 . In the event of clockwise rotational direction, depicted by arrow 60 and which occurs during kickback and rollback conditions, the pawls 40 engage ratchet wheel 42 locking the pulley 52 and eccentric arm structure 49 together. This generates a frictional torque between the belt 18 and pulley 52 in the direction of arrow 60 . The torque upsets the abnormal belt force caused by the belt reversal, moves the pulley 52 toward the belt increasing the belt tension temporarily, and, in turn, prevents tooth jump.
[0031] The embodiment of FIG. 4 utilizes a pawl 40 and ratchet wheel 42 in the anti-tooth skip mechanism, as in FIG. 2, therefore, the torque limiter modification shown in FIG. 2 a is applicable to the mechanism of FIG. 4.
[0032] In FIG. 5, a belt tensioner 21 is mounted on the engine via a pivot shaft center 51 and has a pivotal eccentric arm structure 49 to which a predetermined torque is applied usually via a spring arrangement (not shown here). This generates a predetermined belt force which is transmitted into the belt via a pulley 52 on housing 154 attached to eccentric arm structure 49 through a bearing at 71 usually of the type known as ball or roller (not shown here). The tensioner configuration shown is of the leading type, wherein the center 53 of arm structure 49 is below the line 70 throughout its operational range as above. A second pivotal structure is mounted to the base plate 148 of the tensioner and comprises a second eccentric arm structure 150 rotatable about a pivot 147 to the dotted line position 146 and a second pulley 153 mounted by a pivot 151 to the second eccentric arm structure 150 . Attached to the arm structure 150 is pawl 144 which at its tip has a gear mesh 143 . Within pulley 153 is a one-way clutch 152 biasing the arm structure to permit free rotation of the pulley 153 when the belt moves normally in direction 61 . When the engine kicks back or roll back occurs, the belt changes direction to 60 .
[0033] The one-way clutch 152 senses this change of direction and locks pulley 153 and arm structure 150 firmly together. This causes the arm structure 150 to rotate in the direction shown by arrow 145 . Pawl 144 rotates with the arm 150 resulting in the gear mesh 143 engaging mesh 142 on arm 141 which is attached to the first pivotally mounted eccentric arm structure 49 . This gearing results in the eccentric arm structure 49 rotating toward the belt and generating an opposing torque that overcomes the belt force generated torque due to the abnormal direction of the drive 5 depicted by arrow 60 , thus increasing the belt tension and preventing tooth jump. A stop 149 prevents over centering of the second arm structure 150 .
[0034] In FIG. 5, the anti-tooth skip mechanism relies upon the second belt engaging pulley 153 and one-way clutch 152 to latch upon belt movement in the direction 60 . To provide for torque limitation, the modified pawl 40 and ratchet wheel 42 of FIG. 2 a may be employed on a smaller scale for one-way clutch 152 .
[0035] The torque limiters for the anti-tooth skip mechanisms of FIGS. 2 - 5 disclosed above are applied to the pawl and ratchet wheel mechanisms. Other mechanisms for accomplishing the torque limiting function are possible. FIG. 6 illustrates another form of the present invention with emphasis on the integrated construction of the one-way clutch and torque limiter features. Housing structure 140 comprises an expandable ring mounted in the pulley 52 . A clip 160 , also shown in FIG. 6 a , is seated in housing structure 140 to provide a known expansion force. This controlled expansion force 162 , in conjunction with known friction properties of the contact area 164 of the housing structure 140 , will slip at a designed torque level, thus providing the torque limiter. A clutch structure 166 comprised of plural volutes is attached to, and located by, housing structure 140 . This clutch 166 is trained on arm structure 49 with a known diametral engagement.
[0036] In FIG. 7, the aforesaid structures are mounted inside a bearing 170 under the seals 172 . The housing 140 is trained on the outer raceway 174 , and the clutch 166 is trained on the inner raceway 176 . The clutch 166 allows rotation freely and unrestricted in the direction depicted by arrow 61 , as above. In the event of rotation in the direction 60 which generally occurs during kickback and rollback, the clutch 166 positively engages inner raceway 176 and arm structure 49 locking the pulley 52 and the arm structure 49 together, as above. Upon reaching the designed torque level, housing structure 140 contact area 164 will slip and limit the torque to the designed level.
[0037] Throughout this specification, unless the context requires otherwise, the word “comprise,” and variations such as “comprises” or “comprising,” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not to the exclusion of any other integer or step or group of integers or steps. The ratchet and pawl mechanisms forming one-way clutches are to be understood as including equivalents such as spring clutches, sprag clutches and roller ramp clutches. | A timing belt autotensioner includes a mechanism actuated by the reversal of timing belt movement direction. In automotive applications reversal of timing belt direction occurs only rarely under inadvertent or accidental circumstances. Such reversals can cause belt slackening sufficient for a toothed belt to jump gear teeth thereby changing engine cam shaft timing. Four related mechanisms are disclosed, each of which will, upon actuation by belt reversal cause the autotensioner pulley axis of rotation to move in a direction that tightens the belt during reverse movement of the belt. Thus, the belt remains tight to the toothed pulleys preventing jump or skip of the belt until the belt returns to proper forward belt movement. A torque limiter incorporated in the mechanism limits to a predetermined amount the torque generated in the mechanism by the reverse movement of the belt. | 5 |
FIELD OF THE INVENTION
This invention relates to odour removal apparatus and methods. In particular, the invention relates to odour removal apparatus and methods for removing gases which include undesirable odours from the vicinity of a toilet or lavatory bowl. However, the invention is not limited to this application.
BACKGROUND OF THE INVENTION
Most known methods of odour removal for toilets use a fan or the like which is mounted on an exterior wall of the room in which the toilet is located. Such extraction fans are often operated when a user enters the room in which the toilet is located and turns on a light for example. A disadvantage of this known system is that odours must leave the toilet bowl and enter the room before they can be removed from the room. Thus the system really only prevents odours escaping from the room in which the toilet is located rather than removing odours before they enter the room.
The fan constrictions used in these known systems are also cumbersome, making them awkward and expensive to install. Furthermore, they do not have any control system that allows characteristics of the fan to be altered to improve efficiency, performance or to provide a user with a greater range of operating conditions. For example, the known systems are prone to be noisy which can be bothersome to many users and there is no provision for altering fan operating parameters, such as speed, to reduce the noise. Known fans are often left running for long periods of time, which is inefficient and reduces the life of the fan.
Wall and ceiling fan systems typically have limited back pressure capabilities limiting the distance over which the air can be expelled. They thus typically require at least 100 mm ducting. This is very inconvenient to install.
OBJECT OF THE INVENTION
It is an object of the present invention to provide odour removal apparatus and/or methods which will at least go some way toward overcoming the foregoing disadvantages or other disadvantages of known constructions, or which will at least provide the public with a useful choice.
SUMMARY OF THE INVENTION
Accordingly, in one aspect, the invention is an odour removal apparatus for a toilet, the toilet having
a bowl an outlet from the bowl a barrier between the bowl and the outlet which substantially prevents odours from the outlet passing to the bowl, and a gases extraction means in communication with an area in the vicinity of the bowl and the outlet whereby operation of the gases extraction means substantially removes odours from the vicinity of the bowl and transfers them to the outlet.
Preferably the gases extraction means comprises a fan means operable to induce a flow of gases and entrained odours for removal of the odours from the vicinity of a toilet.
Preferably a flow control means is provided to substantially prevent odours flowing from the outlet to the bowl through the gases extraction means.
Preferably the flow control means is a one way valve.
In a further aspect the invention consists in a toilet or lavatory having
a bowl an outlet from the bowl the bowl and outlet configured in use to be adapted to provide a substantially odour impermeable barrier, a gases delivery passageway provided in or adjacent to the bowl, and a gases receiving passageway provided in communication with the outlet.
Preferably a gases extraction means is in communication with an area in the vicinity of the bowl and the outlet whereby operation of the gases extraction means substantially removes odours from the vicinity of the bowl and transfers them to the outlet.
Preferably the gases extraction means comprises a fan means operable to induce a flow of gases and entrained odours for removal of the odours from the vicinity of a toilet.
Preferably the barrier comprises a water trap.
Preferably a flow control means is provided to substantially prevent odours flowing from the outlet to the bowl through the gases extraction means.
Preferably the flow control means is a one way valve.
Preferably the apparatus includes control means for controlling the operation of the fan means.
Preferably the control means includes flow rate selection means to allow a user to vary the rate of gases flow induced by the fan means.
Preferably the fan means includes
a housing, a motor within the housing, an impeller provided within the housing and coupled to the motor so that operation of the motor imparts rotational energy to the impeller, an inlet provided in the housing adapted for attachment to a gas inlet conduit, an outlet provided in the housing adapted for attachment to a gas outlet conduit.
Preferably the width of the housing being not substantially greater than the width of the inlet or width of the outlet.
Alternatively the fan means includes
a housing, a direct current motor within the housing, an impeller provided within the housing and coupled to the motor so that operation of the motor imparts rotational energy to the impeller, an inlet provided in the housing adapted for attachment to a gas inlet conduit, and an outlet provided in the housing adapted for attachment to a gas outlet conduit.
In a further aspect the invention broadly consists in some odour removal apparatus for a toilet, the toilet having
a bowl an outlet from the bowl a barrier between the bowl and the outlet which substantially prevents odours from the outlet passing to the bowl, and a gas extraction means in communication with an overflow conduit in a cistern of the toilet and the gases extraction means being in communication with the outlet, whereby operation of the gases extraction means substantially removes odours from the bowl through the overflow conduit and transfers the gases to the outlet.
Preferably the gases extraction means comprises a fan means operable to induce a flow of gases and entrained odours for removal of the odours from the vicinity of a toilet.
Preferably a flow control means is provided to substantially prevent odours flowing from the outlet to the bowl through the gases extraction means.
Preferably the flow control means is a one way valve.
In yet a further aspect the invention consists in a toilet or lavatory having
a bowl an outlet from the bowl the bowl and outlet configured in use to provide a substantially odour impermeable barrier a gases passageway being provided between the bowl and a cistern of the toilet, a gases extraction means in communication with the cistern and the outlet and a gases transfer region being provided within the cistern so as to provide communication between the passageway and the gases extraction means, and operation of the gases extraction means substantially removing odours from the vicinity of the bowl and transferring them to the outlet.
Preferably the gases extraction means comprises a fan means operable to induce a flow of gases and entrained odours for removal of the odours from the vicinity of a toilet.
Preferably a flow control means is provided to substantially prevent odours flowing from the outlet to the bowl through the gases extraction means.
Preferably the flow control means is a one way valve.
Preferably the gases transfer region comprises a compartment within the cistern which compartment creates a seal between the passageway and the gases extraction means using the presence of water within the cistern.
Alternatively the gases transfer region comprises the air space above the water level in the cistern.
In a further aspect the invention consists in a toilet or lavatory having
a bowl an outlet from the bowl a bowl and outlet configured in use to be adapted to provide a substantially odour impermeable barrier a flushing inlet to in use receive water from a cistern, and a gases delivery passageway provided in or adjacent to the bowl and located in a region or the bowl remote from the flushing inlet.
Preferably a gases extraction means is in communication with the cistern and the outlet and a gases transfer region being provided within the cistern so as to provide communication between the passageway and the gases extraction means, and operation of the gases extraction means substantially removing odours from the vicinity of the bowl and transferring them to the outlet.
Preferably the gases extraction means comprises a fan means operable to induce a flow of gases and entrained odours for removal of the odours from the vicinity of a toilet.
Preferably a flow control means is provided to substantially prevent odours flowing from the outlet to the bowl through the gases extraction means.
Preferably the flow control means is a one way valve.
Preferably the passageway includes a region of sufficient dimension to include a gases extraction means therein.
In yet a further aspect the invention consists in a toilet or lavatory having walls adapted to conceal a gases extraction fan means.
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein purely illustrative and are not intended to be in any sense limiting.
The invention consists of the forgoing and also envisages constructions of which the following gives examples.
BRIEF DESCRIPTION OF THE DRAWINGS
One preferred form of the present invention will now be described with reference to the accompanying drawings in which:
One preferred form of the invention and modifications thereof will now be described with reference to the accompanying drawings in which:
FIG. 1 is a diagrammatic side elevation in partial cross section of a toilet system including odour removal apparatus in accordance with the present invention;
FIG. 2 is a diagrammatic side elevation in partial cross section of a practical implementation of a toilet system in accordance with FIG. 1 ;
FIG. 3 is an end elevation in cross section of the cistern of FIG. 2 ;
FIG. 4 is an end elevation in cross section of an alternative cistern arrangement for the cistern of FIG. 2 ;
FIG. 5 is an end elevation in cross section of a further alternative sister arrangement according to the invention;
FIG. 6 is a perspective view of a pan and cistern installation wherein the pan is designed to conceal a gases flow connection;
FIG. 7 is a plan view of a pan having an air inlet adjacent to the rim of the pan but at the front of the pan;
FIG. 8 is a plan view of a further arrangement of pan having an air inlet at the front of the pan;
FIG. 9 is a side elevation in cross section of the pan substantially as shown in FIGS. 7 or 8 and including the gases extraction unit;
FIG. 10 is a further side elevation in cross section of the toilet pan showing another gases extraction arrangement according to the invention;
FIG. 11 is an end elevation (from the rear) of a toilet pan of FIG. 10 , and
FIG. 12 shows an end elevation of toilet pan with another gas extraction arrangement and also including side walls on the pan as also diagrammatically illustrated in FIG. 6 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1 , a toilet or lavatory is shown generally referenced 1 having a bowl or pan construction 2 about the rim 3 of which a seat will usually be provided (not shown for clarity). The pan 2 is designed to have a water trap generally referenced 5 which provides a barrier between the central part 6 of the pan and an outlet 7 from the pan. In use, outlet 7 ends in a pan outlet 8 which will usually pass through the floor (S trap type toilet) or wall (as with P trap type toilet) of the building in which the installation is provided so as to interconnect with a sewerage system, or waste-water or septic tank for example.
As shown diagrammatically in FIG. 2 , the present invention involves removal of undesirable odours in the vicinity of the bowl 6 by use of an extraction device 15 such as a fan, and delivery of the odours to the outlet 7 . Since outlet 7 is on the other side of the water trap (which acts as a gas transfer barrier), the odours are effectively removed from the environment surrounding the bowl 6 . To ensure that odours cannot escape from the outlet 7 through the extraction path, some form of non-return device 21 is provided in that path, for example being provided before or after the extractor 15 .
Although vents are often provided in gaseous communication with toilet outlets, such vents have the purpose of preventing the water in the water trap from siphoning away through the outlet. The vents are not used for odour extraction purposes.
Turning now to FIG. 2 , a diagram of a possible practical implementation of the system is shown. The pan 2 is usually moulded from an appropriate material and the mould includes appropriate apertures 10 , which are in fluid communication with a cistern 4 . In this way liquid such as water which is in use provided in the cistern may be distributed through the apertures in order to flush the bowl 6 and ensure that water trap 5 maintains an appropriate level of liquid.
In the example illustrated in FIG. 2 , the particular toilet installation has an internal overflow conduit 11 which is in fluid communication with the flushing apertures 10 of the bowl. The overflow conduit 11 has an inlet 12 which is usually above the high water level 13 of the liquid 14 in the cistern. However, should the liquid level 13 rise to an unexpectedly high level, the liquid will enter inlet 12 and drain into the pan 6 and therefore prevent a cistern overflow situation from occurring. The provision of the inlet 12 above the usual high water level 13 of the cistern means that inlet 12 is in gaseous communication with the bowl 6 .
In FIG. 2 , the existing toilet installation as described above has been modified by the inclusion of extractor fan unit 15 which has an inlet 16 that is provided above the level of inlet 12 . The fan unit at 15 has an outlet 16 a which passes through the base of the cistern at an aperture 17 and is connected by an appropriate tube or conduit for example 18 to the outlet 7 through an appropriate aperture or connection 19 .
Operation of the system as illustrated in FIG. 2 is as follows.
Fan unit 15 includes any device which is capable of moving gases at an acceptable rate or vacuum. Usually, the device will include a motor such as a direct current electric motor which is capable of rotating at relatively high speeds and therefore moving a fan or other propelling device connected to the motor to create the needed vacuum at the inlet of the fan unit. This creates a negative air pressure in the vicinity of inlet 16 to the fan unit. Inlet 16 is provided within an optional housing 20 the lower edge of which is provided beneath the usual high water level 13 in the cistern. This creates a closed environment between inlet 16 to the fan and outlet 12 of the internal overflow conduit so that gases may be transferred between them. Accordingly, the vacuum created by the fan creates a negative air pressure in bowl 6 relative to the surrounding environment in the room in which the toilet is located. Therefore, a gases flow occurs from the bowl 6 through the housing 20 and into the fan unit 15 . From here, the gases flow continues through outlet 16 a and through the gases flow tube 18 and into the outlet 7 . Since outlet 7 is provided on the side of the water trap which is opposite the bowl 6 , odours are effectively transferred from the bowl to the sewerage/septic tank side of the toilet installation. In order to ensure that gases from the outlet 7 do not return to the toilet bowl 6 , a non-return valve 21 is provided anywhere in the extraction flow path. In FIG. 2 , a non-return device is shown provided after the outlet 16 a of the fan unit, and as another alternative, before the inlet to the fan. Such a non-return device may be a known valve which is purchased from a plumbing outlet for example, or may be one which is especially designed for this installation. For example, the valve may include a diaphragm or valve member which is biased to a normally closed position by a spring or by gravity for example, but which may be opened by negative air pressure at the outlet of the fan unit 15 being created in the air pressure in the pan outlet 7 . The valve is lifted off the valve seal by the negative air pressure created by the fan. Therefore, when the fan 15 is not in use, the valve will return to its normally closed position to prevent any odours travelling from the outlet 7 to the pan 6 .
Referring now to FIG. 4 , the cistern is shown in end elevation. Therefore, the fan 15 may be provided at one side of the cistern (being appropriately waterproofed or otherwise provided so that the liquid in the cistern does not interfere with the motor operation) and the outlet 16 of the fan may be directed to aperture 17 which is provided in alignment with the internal overflow pipe as a convenient location for the outlet 16 a to exit the cistern. Furthermore, as illustrated in FIG. 2 , the fan inlet 16 and overflow conduit 12 do not necessarily require housing 20 to be provided over the entrance. It will be sufficient for the cistern itself to provide an appropriate housing for transfer of gases between the overflow conduit and the fan provided the cistern is sufficiently air tight.
Also, it will be appreciated that an internal overflow pipe does not need to be used to implement the present invention. Therefore, the invention may make provision for the pan 2 to include in the moulding an appropriate cavity or cavities to include the fan and the appropriate apertures for connecting the fan between the bowl 6 and the bowl outlet 7 . Therefore a wide variety of arrangements is possible. For example, a specially formed aperture in the flushing assembly, or a separate new aperture provided adjacent to the bowl may be provided and the fan could be directly connected to this aperture and the fan outlet could be connected to an appropriate connector at inlet 19 provided in outlet 7 or at a point of entry to the sewerage or septic tank system which is external of the toilet assembly, if desired.
As another example, the end view of FIG. 4 clearly shows the inlet 19 to bowl outlet 7 as being provided in the form of a spigot or the like and a hose or other conduit providing the connection 18 between the fan outlet and the pan outlet 7 . However, the connection at inlet 19 may be provided as a part of the pan moulding for example i.e. simply being a cavity provided in the appropriate place within the pan unit. Of course, a separate opening to the flushing apertures may be provided so that a conduit other than the internal overflow conduit may be provided within the cistern to connect directly to the fan inlet for example. However, the construction as described with reference to the figures in this example does provide an effective retro-fittable installation.
The fan unit which is used to create the air flow by making an area of relatively low pressure i.e. negative pressure with respect to ambient room pressure in the vicinity of the toilet bowl is preferably an axial flow fan which uses a DC electric motor, for example a 15 volt motor. Use of a DC motor and appropriate control mechanism such as pulse width with modulation for the power supply ensures that the motor can be speed controlled to reduce unwanted noise etc if required. Also, the motor can operate at very high rotational speeds (and thus provide an enhanced airflow) since it is not limited by supply frequency as is the case with most AC motors. Of course, since an area of relatively low pressure is provided between the fan unit and the inlet (which will usually be adjacent to the room of the toilet pan or bowl), an area of relatively high pressure i.e. pressure which is greater than or positive relevant to ambient room pressure will be created between the fan and the outlet (which in the present invention comprises the waste or sewerage outlet behind the toilet water trap).
Turning now to FIG. 5 , a further arrangement in the cistern is shown which is similar to the arrangement illustrated in FIG. 2 . Like reference numerals indicate like features between the different drawings. Therefore, the outlet valve 11 is shown in greater detail, and in the preferred embodiment comprises a “geberit” outlet valve which has the internal overflow 12 as described in previous embodiments. The fan unit 15 is also shown and the non-return valve 21 is shown in greater detail adjacent to the inlet to the fan unit. Again, the vacuum lid 20 is illustrated. Additional features to those shown in FIG. 2 include the inlet 30 which allows liquid to enter the cistern i.e. to refill the cistern and a flexible hose 32 from the inlet 30 which is directed to the base of the cistern in order to prevent liquid entering the cistern from flowing anywhere near the inlet to the fan unit 15 .
Turning now to FIG. 6 , the cistern of FIG. 5 for example may be located on a toilet bowl or pan that has extended rear side walls 34 which substantially conceal (at least from the side) a connector which may be used to provide a connection between the outlet of the fan 15 in the cistern and a waste outlet of the toilet bowl behind the water trap. Therefore, if the installation shown in FIG. 6 is mounted in a room such that the rear wall of the cistern is adjacent to a wall, the wings 34 conceal the outlet conduit.
Turning now to FIG. 7 , a plan view of a toilet bowl or pan is shown with the cistern removed. As described previously with reference to FIG. 2 , the toilet bowl or pan typically has flushing apertures about the periphery of the bowl rim. The apertures 10 are generally illustrated in FIG. 7 , but it will be seen that the bowl or pan has been moulded to provide an air inlet aperture 60 which is quite separate from flushing apertures 10 . Therefore, in use water in flushing apertures 10 is diverted away from the air inlet aperture 60 . Also, although air inlet aperture 60 is not specifically shown as having an inlet to the body or the pan, the inlet can be more clearly shown in the side elevation in cross section of FIG. 9 . The design is such that water being flushed through apertures 10 does not enter the air inlet aperture 60 , but that the air inlet aperture 60 is open to the pan so as to extract odours therefrom.
Turning now to FIG. 8 , a plan view of a pan or system is again shown having an arrangement very similar to that of FIG. 7 , but there is a slightly different design of air inlet in that the pan is contoured so that the air inlet aperture 60 is again separated from the flushing apertures 10 , but the air inlet has extended opening regions 62 to provide a greater area of the pan periphery through which air from the bowl can enter. Therefore, improved gases extraction is anticipated using this design.
Turning now to FIG. 9 , an illustration of a pan in cross section which may be used in accordance with the air inlet illustrated in the plan views of FIGS. 7 and 8 is shown. The air inlet aperture 60 includes a cavity 66 in the front wall or the pan which leads to a further enlarged concealed cavity 68 in the front of the pan unit. The fan unit 15 has an inlet which engages with cavity 66 and the fan unit itself is provided within cavity 68 . The outlet from the fan has a one way air valve 70 to prevent odours escaping from behind the water trap. Further conduit 72 is provided within the pan moulding to allow gases flow between the one way valve 70 and the waste outlet of the pan behind the water trap.
Turning now to FIG. 10 , another toilet bowl or pan construction is shown in cross section having a moulded extraction cavity 80 from the rear of the pan which provides an inlet to which fan unit 15 is connected and concealed, and the waste outlet of the pan has a moulded aperture 82 to which the outlet of the fan unit 15 is connected to delivery the waste gases to the area behind the water trap. A one way air valve 70 should be situated somewhere between cavity 80 and aperture 82 .
Turning to FIG. 11 a rear elevation of the construction illustrated in FIG. 10 is shown. The one way air valve 70 is needed on either side of the fan to prevent reverse circulation.
In FIG. 12 , a vertical orientation of the fan unit (as opposed to a horizontal orientation shown in FIG. 11 ) is shown. This is similar to the construction illustrated in FIG. 6 however rather than the fan unit 15 being provided within the cistern, the fan is provided axially within the air extraction conduit and is concealed between side walls 34 .
Therefore, from the foregoing, it will be seen that a very effective odour removal installation is achievable with this invention. In particular, the use of the water trap in the toilet as a barrier to prevent odours is highly desirable. Usually, fan installations and the like simply remove odours from the room in which the toilet installation is located and expel them to another location, such as out of the building or into a wall or ceiling cavity. The present invention provides a significant advantage that the sewerage system behind the toilet water trap, which contains foul odours in any case, is used as a disposal point for the odours in or surrounding the toilet bowl. The advantages are that; firstly odours immediately adjacent the bowl are removed before they enter the room in which the toilet is located; and secondly the odours are easily disposed of without the necessity of making further holes in the room in which the installation is located in order to deliver the odours to a location remote from the room.
Therefore, the invention provides for drawing air or gas and entrained odours from the toilet bowl/pan and discharging them to the outlet side of the toilet bowl/or pan water trap. The conveyance of the odours may be through the cistern via air ways, for example the internal overflow pipe, or through other passages such as waterways, or airways or any appropriate spaces that will bypass the cistern and/or the flush pipe and be delivered to the side of the toilet bowl pan which is on the sewerage side of the water trap. The delivery mechanism includes some form of gas extraction means such as a fan and may be implemented using hosing, tube or pipe or through appropriate spaces in the overall pan/cistern assembly. It will be seen that the extraction means may be a fan, or pulsing cistern, or pump, being mechanically operated or otherwise. The effect of making a negative air pressure within or adjacent to a toilet bowl means that the odours do not escape the toilet bowl into the room. We have found that the outlet from the fan or extraction means does not need to be connected immediately to the outlet of the bowl on the other side of the water trap, but can be connected to quite a remote area from the water trap, for example anywhere in the septic waste. In the preferred embodiment of the invention a non return valve is provided, but will be seen that other means of preventing reverse gases flowing may be employed. For example, an anti-siphon valve or similar may be used, or the fan may be operated continuously.
Finally it will be appreciated that various other alterations may be made to the foregoing without departing from the scope of this invention as set forth in the appended claims.
Throughout the description and claims of this specification the word “comprise” and variation of that word, such as “comprises” and “comprising”, are not intended to exclude other additives, components, integers or steps. | An odor removal apparatus for a toilet wherein the apparatus and toilet has a bowl, an outlet from the bowl and a barrier between the bowl and the outlet which substantially prevents odors from the outlet passing to the bowl. A gas extraction apparatus is in communication with an area in the vicinity of the bowl and the outlet whereby operation of the gas extraction apparatus substantially removes odors from the vicinity of the bowl and transfers them to the outlet. The gas extraction apparatus comprises a fan operable to induce a flow of gases and entrained odors for removal of the odors from the vicinity of a toilet. The fan is immersed in the water in the cistern of the toilet. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This technology relates to oil and gas wells. In particular, this technology relates to valves to control the flow of annular fluid from the annulus of a well through a tubing hanger.
[0003] 2. Brief Description of Related Art
[0004] Typical drilling operations include a high pressure wellhead having a tubing hanger mounted therein. The purpose of the tubing hanger is to support tubing extending into the well. Typical tubing hangers include a production bore which extends vertically through the hanger. After the tubing hanger is set access to the annulus of the well is impeded by the body of the tubing hanger, as well as by other wellhead equipment. Despite the difficulty of accessing the annulus, however, there remains a need after the tubing hanger is set to access the annulus for such things as testing and monitoring of annular fluid. One way to access such annular fluid is by providing a port through the tubing hanger from the top of the tubing hanger to the annulus. Such a port should have a valve for controlling access to the annular fluid and limiting access to appropriate times in the production and completion process.
SUMMARY OF THE INVENTION
[0005] Disclosed herein is a wellhead assembly that may include a wellhead housing attached to a wellhead, and a production tree having a production bore and attached to the top of the wellhead housing. A tubing hanger is adapted to be connected to a tubing string and landed in the wellhead housing, the tubing hanger having a production bore and defining a tubing annulus between the tubing string and casing in a well. The assembly may further include an isolation sleeve positioned between the tubing hanger and the production tree, the isolation sleeve having a bore that provides fluid communication between the production bore of the tubing hanger and the production bore of the production tree.
[0006] A tubing annulus upper access bore extends downward from an upper end of the tubing hanger, and a tubing annulus lower access bore extends upward from a lower end of the tubing hanger, and is misaligned with the upper access bore. The lower access bore is adapted to communicate with the tubing annulus. In some embodiments, the upper and lower tubing annulus access bores may be parallel to each other and circumferentially spaced apart.
[0007] A communication cavity connects the upper and lower access bores within the tubing hanger. In some embodiments, the communication cavity may extend axially parallel to the access bores and circumferentially spaced between the access bores. A remotely actuated valve is positioned in the communication cavity for selectively opening and closing communication between the lower access bore and the upper access bore. In certain embodiments, the valve may include a perforated valve stem having an axially extending flow chamber therein. The flow chamber defines a bottom end, a top end, and cylindrical sidewalls with perforations extending therethrough.
[0008] A first lateral port extends from the lower access bore to the flow chamber, and a second lateral port extends from the upper access bore to the flow chamber, so that when the valve is in an open position, the flow chamber is in communication with the first and second lateral ports, and when the valve is in a closed position, communication between the flow chamber and at least one of the lateral ports is blocked.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present technology will be better understood on reading the following detailed description of nonlimiting embodiments thereof, and on examining the accompanying drawings, in which:
[0010] FIG. 1 is a side cross-sectional view of a wellhead assembly according to an embodiment of the present technology;
[0011] FIG. 2A is an enlarged side cross-sectional view of a perforated stem according to an embodiment of the technology in a closed position;
[0012] FIG. 2B is an enlarged side cross-sectional view of a perforated stem according to an embodiment of the technology in an open position;
[0013] FIG. 3 is an enlarged side cross-sectional view of the opening in the perforated stem of FIG. 2B ;
[0014] FIG. 4 is a top view of certain components of the wellhead assembly of FIG. 1 ;
[0015] FIG. 5A is a side cross-sectional view of a tree override assembly according to an embodiment of the present technology;
[0016] FIG. 5B is an enlarged side cross-sectional view of the top of a perforated stem and override assembly, when the perforated stem is in the open position;
[0017] FIG. 5C is an enlarged side cross-sectional view of the top of a perforated stem and override assembly, when the perforated stem is in the closed position;
[0018] FIG. 6 is an enlarged side cross-sectional view of a running tool override assembly according to an embodiment of the present technology;
[0019] FIG. 7A is a side cross-sectional view of an alternate embodiment of the present technology, including a biasing mechanism and where the perforated stem is in a closed position;
[0020] FIG. 7B is a side cross-sectional view of the embodiment of FIG. 7A , where the perforated stem is in an open position.
[0021] FIG. 8 is a side cross-sectional view of an embodiment of the present technology having two perforated stems in a parallel configuration;
[0022] FIG. 9 is a side cross-sectional view of an alternate embodiment having two perforated stems in a parallel configuration; and
[0023] FIG. 10 is a side cross-sectional view of an embodiment of the present technology having two perforated stems arranged in series.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The foregoing aspects, features, and advantages of the present technology will be further appreciated when considered with reference to the following description of preferred embodiments and accompanying drawings, wherein like reference numerals represent like elements. In describing the preferred embodiments of the technology illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the technology is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
[0025] FIG. 1 is a depiction of a wellhead assembly 10 according to an embodiment of the present technology. The wellhead assembly may include such features as a wellhead housing 12 mounted within a wellhead 14 . A casing hanger 16 may be positioned within the wellhead housing 12 to support casing, and a tubing hanger 18 may be inserted above the casing hanger 16 . In some embodiments, the tubing hanger 18 may be a five inch nominal concentric vertical tubing hanger, although other sizes are possible (e.g., six inch, seven inch, etc.). The tubing hanger 18 may typically support tubing 20 extending into the well, and may rest on, and be at least partially supported by the casing hanger 16 . The tubing hanger 18 includes a production bore 22 which provides access through the tubing hanger 18 to the tubing 20 . The area around the tubing 20 , and between the tubing hanger 18 and the casing, is an annulus 24 of the well.
[0026] During well operations, it may be desirable for an operator to access fluid in the annulus 24 to analyze conditions in the annulus 24 , such as temperature, composition of annular fluid, etc. Accordingly, annulus access valve assembly 26 is provided in the wellhead assembly 10 to provide access between the annulus 24 and the top of the tubing hanger 18 , thereby allowing monitoring of annular fluid through a tubing hanger running tool (shown, e.g., in FIG. 6 ) or production tree (shown, e.g., in FIG. 5A ) in communication with the top of the tubing hanger 18 . As used herein, the term valve has an expansive definition, and refers to any sealing mechanism or device that may be used to control the flow of annular fluid through the tubing hanger. The annulus access valve assembly 26 may be configured to have a working pressure rating of up to 10,000 pounds per square inch (psi) or more, and may typically allow access to the annulus with an operating pressure of 3,000 to 5,000 psi. Once annular fluid is brought from the annulus 24 to the top of the well, the operator can easily access the annular fluid for analysis and testing.
[0027] Referring now to FIGS. 2A and 2B , there is illustrated an enlarged view of the annular access valve assembly 26 shown in FIG. 1 . The annular access valve assembly 26 includes a valve body 28 having a valve chamber 30 . In the embodiments shown, the valve body 28 is positioned in a vertical configuration in the tubing hanger 18 . In FIG. 2A , the valve body 28 is shown in a closed position, and in FIG. 2B , the valve body 28 is shown in an open position. A first side of the valve body 28 is fluidly engaged with a lower access port 32 , which is in turn in fluid communication with a lower annular access bore 33 . A second side of the valve body 28 is fluidly engaged with an upper access port 34 , which is in turn in fluid communication with an upper annular access bore 35 . The upper annulus access bore opens to the top of the tubing hanger 18 . In some embodiments, the upper annular access bore 35 can have a profile 31 , which may be threaded or otherwise, to accept a backup plug (not shown). Such a backup plug may be useful for plugging the upper annular access bore 35 if desired, such as, for example, when the production tree is removed from the tubing hanger 18 subsea.
[0028] In FIGS. 2A and 2B , the flow path of annular fluid is shown by arrows P. When the valve body 28 is in a closed position, as shown in FIG. 2A , the valve chamber 30 does not align with the lower access port 32 , and fluid is prevented from flowing from the lower access port 32 into the valve chamber 30 . Thus, fluid communication between the lower access port 32 and the upper access port 34 is prevented.
[0029] Conversely, when the valve body 28 is in an open position, as shown in FIG. 2B , the valve chamber 30 aligns with the lower access port 32 . Thus, fluid is free to flow from the lower access port 32 into the valve chamber 30 . The valve chamber 30 is also open to the upper access port 34 , as described in greater detail below, so that when the valve body 28 is open, fluid may freely flow from the lower access port 32 , through the valve chamber 30 , and into the upper access port 34 , thereby providing fluid access from the lower access port 32 to the upper access port 34 of the tubing hanger 18 .
[0030] Also shown in FIGS. 2A and 2B is a lower hydraulic control line 38 , which may be accessed through the production tree or running tool. The lower hydraulic control line 38 may provide hydraulic fluid to an area 42 below the valve chamber 30 , and allow for hydraulic control of the position of the valve body 28 from below. For example, when the valve body 28 is in a closed position, as shown in FIG. 2A , hydraulic fluid can be provided to area 42 , thereby providing a hydraulic force F U on the valve body that acts in an upward direction. Such a hydraulic force F U pushes the valve body 28 upward from the closed to the open position. Conversely, when the valve body 28 is in the open position, as shown, for example, in FIG. 2B , hydraulic fluid may be provided to area 40 via fluid port 36 , thereby providing an opposite hydraulic force F D that pushes the valve body 28 downward from the open position to the closed position. Accordingly, the position of the valve body 28 can be controlled by means of the upper and lower control lines 36 and 38 . Furthermore, standard slim couplers, as used on various known tubing hanger systems, may be used to control hydraulic valves connected to the hydraulic lines 36 and 38 .
[0031] Referring now to FIG. 3 , there is shown an enlarged view of the valve chamber 30 and other components. As shown, valve chamber 30 is a void contained within the valve body 28 . The valve chamber 30 is enclosed by sidewalls 45 which form cylindrical sealing surfaces, and which are integral to, and form a portion of, the valve body 28 . The sidewalls 45 have upper openings 47 and lower openings 49 that provide access between the valve chamber 30 and the outside of the valve body 28 . The upper and lower openings 47 , 49 are located at an upper end 30 A and a lower end 30 B of the valve chamber 30 respectively.
[0032] FIG. 3 , the valve body 28 is in the open configuration. At the interface between the lower access port 32 and the valve body 28 , there are seals that prevent annular fluid from leaking past the valve body 28 and the tubing hanger 18 . These seals include upper and lower metal seals 48 , 50 , whose purpose is to form a dynamic seal against the surface of the valve body 28 , even as the valve body moves upward and downward between open and closed positions. Each of upper arid lower metal seals 48 , 50 is substantially cylindrical and surrounds the valve body 28 . Each of the upper and lower metal seals 48 , 50 also has a substantially U-shaped cross-section with a first metal seal leg 52 , 54 that extends substantially adjacent to the valve body 28 , and a second metal seal leg 56 , 58 that extends substantially adjacent to the tubing hanger 18 . Also shown is a stem seal ring 59 tor sealing the interface between the valve body 28 and the tubing hanger 18 at the bottom end of the valve body 30 .
[0033] In practice, the area 60 , 62 between the first and second metal seal legs of each seal 48 , 50 fills with annular fluid, and the annular fluid exerts pressure forces outwardly from the areas 60 , 62 , including against the first 52 , 54 and second 56 , 58 metal seal legs. The first metal seal leg 52 , 54 of each seal is dynamic, so that as pressure from the annular fluid acts on the first metal seal legs 52 , 54 , they are elastically deformed, and pushed into sealed engagement with the valve body 28 so that no fluid can pass between the metal seals 48 , 50 and the valve body 28 . In some embodiments, the first metal seal legs 52 , 54 may be resilient and biased against the valve body 28 even before annular fluid pressure is applied. The second metal seal legs 56 , 58 may be static, and may have thicker cross-sections than the first metal seal legs 52 , 54 . The second metal seal legs 56 , 58 are configured to seal against the tubing hanger 18 so that no fluid can pass between the upper and lower metal seals 48 , 50 and the tubing hanger 18 . In alternative embodiments (not shown), the metal seals 48 , 50 may each be symmetrical, with both the first 52 , 54 and second 56 , 58 metal seal legs being dynamic and elastically deformable.
[0034] In the embodiments shown, the inside surface of the first metal legs 52 , 54 of the upper and lower metal seals 48 , 50 is substantially straight and adjacent to the surface of the valve body 28 along the entire height of the seal 48 , 50 . Such an arrangement is advantageous because it allows transmission of pressure forces from the first metal legs 52 , 54 and into the valve body 28 over the entire height of the seal 48 , 50 . This design is in contrast to other known seal designs, many of which include a sealing surface proximate the stem of a valve body that tapers away from the valve body along part of the height of the seal. Such tapered designs can be problematic because they can lead to high stresses in the first metal legs 52 , 54 , which can in turn lead to failure of the seals. In the design of the present technology, such stresses are eliminated, thereby increasing the reliability of the upper and lower metal seats 48 , 50 , as well as increasing the amount of pressure that the seals 48 50 can withstand. In addition, in some embodiments, the sealing surfaces of the upper and lower metal seals 48 , 50 may be coated with a seal coating. Additional elastomer seals 64 are provided as backup seals to the upper and lower metal seals 48 , 50 , and also to seal the interfaces between the stem seal ring 59 , the valve body 28 , and the tubing hanger 18 . These elastomeric seals can also serve to seal off area 40 above the seals.
[0035] A seal spacer 66 having openings 68 , is provided between the upper and lower metal seats 48 , 50 . Upper and lower ends 70 , 72 of the seal spacer 66 extend into the area 60 , 62 between the first and second metal seal legs of each seal 48 , 50 and contact the seals 48 , 50 . The seal spacer 66 is not an energizing member, but rather serves to maintain the relative axial positions of the upper and lower metal seals 48 , 50 relative to one another, thereby preventing the seals 48 , 50 from moving toward one another and blocking the annular access port 32 . The openings 68 in the seal spacer 66 allows the annular fluid to pass through the seal spacer 66 and into the valve chamber 30 through the upper openings 47 in the sidewalls 45 when the valve body 28 is in the open position, as shown in FIG. 3 . In addition, the surface of the valve body 28 may be provided with a step 73 . This step 73 serves to prolong the life, and reduce or eliminate damage to, the lower metal seal 50 and the back up seals 64 by reducing contact between the sidewalk 45 of the valve body 28 and the lower metal seal 50 and back up seals 64 as the valve body 28 moves from the open to the closed position.
[0036] Referring to FIG. 4 , there is depicted a top view of the wellhead assembly 10 according to an embodiment of the present technology, without the high pressure wellhead 12 or the connector 14 (shown in FIG. 1 ). In FIG. 4 , the tubing hanger 18 is shown, along with annulus access assembly 26 , the production bore 22 , the upper annular access bore 35 , the lower hydraulic control line coupler 37 , and the upper hydraulic control line coupler 39 . Also shown are additional components, such as connectors 74 for down hole pressure and temperature (DHPT) sensors, a tubing hanger land confirm sensor 76 , a tubing hanger lock confirm sensor 78 , as well as extra hydraulic couplers 80 for attachment to additional components that may be added to the assembly in the future.
[0037] FIG. 5A depicts an alternate embodiment of the present technology that provides a different way to move the valve body 28 between an open and a closed position. In particular. FIG. 5A shows a tree override unit 82 that may be attached to a production tree 84 , and positioned above the annular access assembly 26 when the tree 84 is placed over the wellhead housing 12 . An override extension 85 is shown positioned between the tree 84 and the tubing hanger 18 . Typically, such an override would be activated if the primary hydraulic functions fail, although this is not necessary.
[0038] As best shown in FIGS. 5B and 5C , the tree override unit 82 may include an override extension 85 that includes an override piston 86 , a seal housing 88 , a dog ring 90 , and an override sleeve 92 . The top of the valve body 28 may include an override head 94 having inward protrusions 96 (best shown in FIG. 6 ). When the tree 84 is positioned above the high pressure housing 12 , the override extension 85 is substantially axially aligned with the valve body 28 . The override piston 86 and seal housing 88 seal against the override extension 85 so that fluid cannot pass between any of the override piston 86 , the seal housing 88 , or the override extension 85 . To ensure a sealed interface between these components, elastomeric seals 64 can be provided between the override piston 86 and the seal housing 88 , between the override extension 85 and the override piston 86 , and between the override extension 85 and the seal housing 88 , as shown.
[0039] In practice, hydraulic fluid can be introduced to an area 98 above the override piston 86 by means of a hydraulic line 100 or the area 110 below the override piston 86 by means of a hydraulic line 108 . lire hydraulic fluid drive the override piston 86 downwardly as the fluid enters the area 98 . The dog ring 90 , which is attached to the end of the override piston 86 , has outward facing dog edges 102 that are configured to engage the inward protrusion 96 of the override head 94 at the top of the valve body 28 . The override sleeve 92 surrounds the override head 94 on an outside surface thereof. Once attached, the override head 94 and valve body 28 are coupled to the override piston 86 via the dog ring 90 and the override sleeve 92 . As hydraulic fluid is pushed into area 98 through the hydraulic line 100 , the override piston 86 , and consequently the override head 94 and valve body 28 , are pushed downward, as shown in FIG. 5C . This downward movement of the valve body 28 causes the valve body 28 to move into a closed position, as described above. Conversely, the introduction of hydraulic fluid to area 110 causes the override piston 86 , override head 94 , and valve body 28 to rise, as shown in FIG. 5B , thereby moving the valve body 28 into an open position. Though not shown, the valve body may be attached to both the tree override unit 82 and the upper and lower hydraulic lines 36 and 38 simultaneously. Thus, an operator may have multiple different mechanisms for controlling the annulus access valve assembly 26 .
[0040] Referring to FIG. 6 , there is shown an annulus access valve assembly 26 in a tubing hanger 18 , and having a tubing hanger running tool 104 attached thereto. The tubing hanger running tool 104 includes a running tool override unit 106 substantially similar to the tree override unit 82 shown in FIG. 5A . The running tool override unit 106 is positioned above the annular access assembly 26 when the running tool 104 is placed over the tubing hanger 18 .
[0041] Like the tree override unit 82 , the running tool override unit 106 may include an override piston 86 , a seal housing 88 , a dog ring 90 , and an override sleeve 92 . The top of the valve body 28 may include an override head 94 having inward protrusions 96 . When the running tool 104 is positioned above the tubing hanger 18 , the override piston 86 is substantially axially aligned with the valve body 28 . The override piston 86 and seal housing 88 seal against the running tool 104 so that fluid cannot pass between any of the override piston 86 , the seal housing 88 , or the running tool 104 . To ensure a sealed interlace between these components, elastomeric seals 64 can be provided between the override piston 86 and the seal housing 88 , between the running tool 104 and the override piston 86 , and between the running tool 104 and the seal housing 88 , as shown.
[0042] In practice, hydraulic fluid can be introduced above the override piston 86 by means of a hydraulic line 100 or the area 110 below the override piston 86 by means of a hydraulic line 108 . The hydraulic fluid can drive the override piston 86 downwardly or upward as the amount of fluid introduced above or below the override piston 86 is varied. The dog ring 90 , which is attached to the end of the override piston 86 , has outward facing dog edges 102 that are configured to engage the inward protrusion 96 of the override head 94 attached to the valve body 28 . The override sleeve 92 surrounds the override head 94 on an outside surface thereof. Once attached, the override head 94 and valve body 28 are coupled to the override piston 86 via the dog ring 90 and the override sleeve 92 . As hydraulic fluid is introduced above the override piston 86 through the hydraulic line 100 , the override piston 86 , and consequently the override head 94 and valve body 28 , are pushed downward. This downward movement of the valve body 28 causes the valve body 28 to move into a closed position, as described above. Conversely, the introduction of hydraulic fluid to area 110 causes the override piston 86 , override head 94 , and valve body 28 to raise, thereby moving the valve body 28 into an open position. As in the embodiment of FIGS. 5A-5C , the valve body may be attached to the tool override unit 106 , the upper hydraulic line 36 , and the lower hydraulic 38 . Thus, an operator may have multiple different mechanisms for controlling the annulus access valve assembly 26 .
[0043] FIGS. 7A and 7B show an alternate embodiment of the annular access valve assembly 126 . The annular access valve assembly 126 includes a valve body 128 having a valve chamber 130 . As in the embodiment of FIGS. 1-3 , the valve body 128 has a valve chamber 130 . In FIG. 7A , the valve body 128 is shown in a closed position, and in FIG. 7B , the valve body 128 is shown in an open position. A first side of the valve body 128 is fluidly engaged with a lower access port 132 , which is in turn in fluid communication with a lower annular access bore 133 . A second side of the valve body 128 is fluidly engaged with an upper access port 134 , which is in turn in fluid communication with an upper annular access bore 135 . As discussed above with regard to the embodiment of FIGS. 2A-2B , the upper annular access bore 135 may have a profile 131 to accept a backup plug (not shown), thereby allowing for closing of the upper annular access bore 135 if desired.
[0044] FIGS. 7A and 7B , the flow path of annular fluid is shown by arrows P. When the valve body 128 is in a closed position, as shown in FIG. 7A , the valve chamber 130 does not align with the lower access port 132 , and fluid is presented from flowing from the lower access port 132 into the valve chamber 130 . Thus, fluid communication between the lower access port 132 and the upper access port 134 is prevented.
[0045] Conversely, when the valve body 128 is in an open position, as shown in FIG. 7B , the valve chamber 130 aligns with the lower access port 132 . Thus, fluid is free to flow from the lower access port 132 into the valve chamber 130 . The valve chamber 130 is also open to the upper access port 134 , as described in greater detail below, so that when the valve body 128 is open, fluid may freely flow from the lower access port 132 , through the valve chamber 130 , and into the upper access port 134 , thereby providing fluid access from the lower access port 132 to the upper access port 134 of the tubing hanger 18 .
[0046] Also shown in FIGS. 7A and 7B are an upper hydraulic control line 136 and a lower hydraulic control line 138 , which, may be accessed through the production tree or running tool. Upper hydraulic control line 136 provides hydraulic fluid to an area 140 above the valve chamber 130 , and allows for hydraulic control of the position of the valve body 128 from above. For example, when the valve body 128 is in an open position, as shown in FIG. 7B , hydraulic fluid can be provided to area 140 , thereby providing a hydraulic force F D on the valve body that acts in a downward direction. Such a hydraulic force F D pushes the valve body 128 downward from the open position to the closed position. Conversely, lower hydraulic control line 138 may provide hydraulic fluid to an area 142 below the valve chamber 130 , and allow for hydraulic control of the position of the valve body 128 from below. For example, when the valve body 128 is in a closed position, as shown in FIG. 7A , hydraulic fluid can be provided to area 142 , thereby providing a hydraulic force F U on the valve body that acts in an upward direction. Such a hydraulic force F U pushes the valve body 128 upward from the closed to the open position. Accordingly, the position of the valve body 128 can be controlled by means of the upper and lower control lines 136 , 138 , operated either individually or in combination. Alternatively, in some embodiments, lines 136 , 138 may be vent lines which allow air to enter and exit the areas 140 , 142 above and below the valve chamber 130 as the valve body 128 moves between open and closed positions. Furthermore, standard slim couplers, as used on various known tubing hanger systems, may be used to control hydraulic valves connected to the hydraulic lines 136 , 138 .
[0047] Also shown in FIGS. 7A and 7B is a biased mechanism 144 which, in the particular embodiment shown, is a spring. The biased mechanism 144 is housed above the valve chamber 130 in a recess 146 , and is arranged to provide a constant force on the valve body 128 in a downward direction. The biased mechanism 144 is useful to push the valve body 128 into a closed position in case a malfunction occurs in the hydraulic control lines 136 , 138 . The constant downward force on the valve body 128 provided by the biased mechanism 144 provides a safeguard to ensure that in the absence of opposing hydraulic control forces, the valve body 128 remains in the closed position. Although the biased mechanism 144 is shown as a spring, any other type of biased mechanism could be used.
[0048] As shown in FIGS. 7A and 7B , line 138 may run vertically down through the tubing hanger 18 , and then horizontally across to communicate with area 142 . The bottom of area 142 acts as the stop position for the valve body 128 as it moves into the closed position. Line 136 may be drilled at an angle from the top of the tubing hanger 18 to the area 140 .
[0049] FIGS. 8-10 show alternative embodiments of the present technology wherein more than one annular access assembly 226 is included in a single tubing hanger 218 having an upper annular access bore 235 . As discussed above with regard to the embodiment of FIGS. 2A-2B , the upper annular access bore 235 may have a profile 231 to accept a backup plug (not shown), thereby allowing for closing of the upper annular access bore 235 if desired. In FIG. 8 , two annular access assemblies 226 a, 226 b are shown arranged in a parallel configuration. In this embodiment, each annulus access assembly 226 a , 226 b has a valve body 228 a , 228 b with a value chamber 230 a , 230 b . In FIG. 8 , the valve bodies 228 a , 228 b are shown in a closed position. A first side of each valve body 228 a, 228 b is fluidly engaged with a separate lower access port 232 a, 232 b. A second side of each valve body 228 a, 228 b is fluidly engaged with an upper access port 234 . The use of two separate lower access ports 232 a, 232 b allows access to two different places in the annulus.
[0050] As described above with reference to a single annulus access assembly 26 , when the valve bodies 228 a, 228 b are in closed positions, the valve chambers 230 a, 230 b do not align with the lower access ports 232 a, 232 b, and fluid is prevented from flowing from the lower access ports 232 a, 232 b into the valve chambers 230 a, 230 b. Conversely, when the valve bodies 228 a , 228 b are in an open position (as shown in the analogous example of FIG. 2B ), the valve chambers 230 a , 230 b align with the lower access ports 232 a, 232 b. Thus, fluid is free to flow from the lower access ports 232 a, 232 b into the valve chambers 230 a, 230 b. The valve chambers 230 a , 230 b are also open to the upper access port 234 so that when the valve bodies 228 a, 228 b are open, fluid may freely flow from the lower access ports 232 a, 232 b, through the valve chambers 230 a, 230 b, and into the upper access port 234 .
[0051] Also shown in FIG. 8 is a lower hydraulic control line 238 . The lower hydraulic control line 238 provides hydraulic fluid to the valve bodies 228 a, 228 b below the valve chambers 230 a , 230 b, and allows for hydraulic control of the position of the valve bodies 228 a, 228 b from below. Accordingly, the position of the valve bodies 228 a, 228 b can be controlled by means of the lower control line 238 . Lines 236 , 238 may alternatively be vent lines. Although FIG. 8 shows a single lower hydraulic control line 238 in hydraulic communication with both valve bodies 228 a, 228 b, it is to be understood that the technology alternatively contemplates two separate lower hydraulic control lines, with one line running to each valve body individually.
[0052] Other components, such as upper and lower metals seals, elastomeric seals, a stem seal ring, a seal spacer, and an override head may be included with each of the parallel annulus access valve assemblies 226 a , 226 b, and have the same structure and functions as related counterparts discussed above in relation to annulus access valve assembly 26 .
[0053] The embodiment shown in FIG. 9 also includes two annular access assemblies 326 a, 326 b arranged in a parallel configuration and including valve bodies 328 a, 328 b and valve chambers 330 a , 330 b. The annular access assemblies 326 a, 326 b also include features discussed above, such as upper and lower metals seals, elastomeric seals, a stem seal, ring, a seal spacer, and an override head, and have the same structure and functions as related counterparts discussed above in relation to annulus access valve assembly 26 . One difference between the embodiment of FIG. 9 , however, and that shown in FIG. 8 , is that both annular access assemblies 326 a, 326 b of FIG. 9 are attached to a single lower access port 332 . In the embodiment shown, both valve bodies 328 a, 328 b are in a closed position.
[0054] Also shown in FIG. 9 is a lower hydraulic control line 338 . The lower hydraulic control line 338 provides hydraulic fluid to the valve bodies 328 a, 328 b below the valve chambers 330 a , 330 b, and allows for hydraulic control of the position of the valve bodies 328 a, 328 b below the valve chambers 330 a, 330 b from below. The lower hydraulic control lines can be singular or plural.
[0055] In FIG. 10 there is shown yet another pair of annulus access assemblies 426 a, 426 b. In FIG. 10 , however, the annulus access assemblies 426 a, 426 b are provided in series. Thus, in order for annular fluid to pass from the lower access port 432 to the upper access port 434 , both valve bodies 428 a, 428 b must be positioned in the open position. If either valve body 428 a, 428 b is in the closed position, fluid will not be able to pass through the closed valve body. Other than the configuration of the annulus access assemblies 426 a, 426 b in series, the existence and arrangement the components associated with each annulus access assembly 426 a, 426 b is the same as that shown and described above.
[0056] Embodiments of the present technology that include more than one annular access assembly may be advantageous because they provide redundancy to the system. For example, in the case of the parallel annulus access assemblies 226 a, 226 b of FIG. 8 , the annulus can be accessed via more than one annulus access port, thereby providing multiple samples of the annular fluid to add a degree of confidence that the fluid being analyzed is representative of the fluid as a whole in the annulus. In the case of the parallel annular access assemblies 326 a, 326 b in FIG. 9 , the provision of two assemblies means that if one assembly becomes inoperable and is stuck in the closed position, flow from the lower access port 332 can still be controlled using the remaining assembly. Finally, in the case of the series of annulus access assemblies shown in FIG. 10 , the failure of one valve body to close does not mean that access to the annulus must remain open because the other assembly can still be closed. Although three possible configurations of annulus access assemblies are shown in FIGS. 8-10 , these are only exemplary of many possible embodiments and should not be interpreted as limiting the scope of arrangements contemplated by the present technology.
[0057] While the technology has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention. Furthermore, it is to be understood that the above disclosed embodiments are merely illustrative of the principles and applications of the present invention. Accordingly, numerous modifications may be made to the illustrative embodiments and other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | A wellhead assembly including a tubing hanger adapted to be connected to a tubing string and landed in a wellhead, and defining a tubing annulus between the tubing string and casing in a well. The wellhead assembly also includes a tubing annulus upper access bore extending downward from an upper end of the tubing hanger, and a tubing annulus lower access bore extending upward from a lower end of the tubing hanger and misaligned with the upper access bore, the lower access bore adapted to communicated with the tubing annulus. A communication cavity connects the upper and lower access bores within the tubing hanger. A remotely actuated valve is in the communication cavity for selectively opening and closing communication between the lower access bore and the upper access bore. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of German patent application 10 2005 035 055.0, filed Jul. 27, 2005, herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an electric motor, in particular for a textile machine, which can be operated as a generator if the supply voltage fails, and to the use of the electric motor as a single drive for a rotor of the textile machine.
[0003] When using electric motors as the drive of rotors, in particular rotors for textile machines, which are configured as armatures of the electric motor, it is necessary to bring the electric motor, which can be operated as a generator if the supply voltage fails, to a standstill within a certain time to avoid damage to the bearing of the rotor from wobbling movements when the rotor runs down until it is at a standstill.
[0004] A multi-phase electric motor, as the drive of a rotor, is known from the published application German Patent Publication DE 44 21 406 A1 and is configured as the spinning rotor of an open end rotor spinning machine. The electric motor works as a generator if the supply voltage fails until the electric motor is braked by short-circuiting on passing a critical limit value, at which the maintenance of the generator operation is no longer sensible. The motor circuit of the electric motor comprises semi-conductor components, which are responsible for the phase-wise clocking of the current flow and the current flow direction for the motor windings. Moreover, the motor circuit comprises two relays which, if a voltage failure occurs, in each case short-circuit a line run, of which the one line run has a load resistor. After closing the one relay, the line run leading to a direct current source is interrupted in the second relay.
[0005] The direct current source is used here for the current supply of the electric motor. In this manner, the current produced by the induced voltage when braking the electric motor is guided via the line run to the load resistor. By a corresponding selection of the line resistor, the braking energy produced is reduced via the load resistor.
[0006] It has proven to be a disadvantage that the use of relays or switches increases the costs of the system and takes up a relatively large amount of installation space. In addition, when the relay is used, current constantly flows through the relay coil, so the relay does not drop out. Moreover, mechanical switches are subject to symptoms of wear, which are increased by arcing and general susceptibility to faults in relation to mechanical influences. In addition, switches and relays only operate with a limited speed.
SUMMARY OF THE INVENTION
[0007] The object of the present invention is to enhance the operating reliability of the electric motor as well as its use as a single drive of a rotor of a textile machine from the point of view of enhanced operating reliability.
[0008] This object is achieved according to the invention by providing an electric motor, in particular for a textile machine, which can be operated as a generator if the supply voltage fails. The electric motor comprises a rotor configured as the armature of the electric motor and a motor circuit for the phase control of the multiphase electric motor, which comprises a plurality of semiconductor components wherein the electric motor can be short-circuited if a predeterminable limit value is passed during generator operation. In accordance with the invention, the motor circuit is set up in such a way that the short-circuiting on passing the limit value can be carried out by activating one or more of the semiconductor components comprised by the motor circuit. According to another aspect of the invention, the invention provides for the use of the multi-phase electric motor as the single drive of a rotor of the textile machine, wherein the semiconductor components of the phase bridge provided for the phase control of the electric motor, on passing a predeterminable limit value, contactlessly short-circuit the windings of the electric motor to brake the electric motor.
[0009] It is provided that the motor circuit is set up in such a way that the short-circuiting, on passing the limit value, can be carried out by activating one or more semiconductor components comprised by the motor circuit. The use of the semiconductor elements comprised by the motor circuit for short-circuiting and therefore for braking the electric motor has the advantage that the installation of one or more additional components can thereby be dispensed with so the costs of the electric motor can be reduced compared to electric motors according to the prior art.
[0010] The semiconductor components of the phase bridge used during normal operation for the phase control are preferably used for short-circuiting the electric motor, so the use of additional switching components, for example in the form of relays, switches or additional semiconductor components and the optionally associated active connections is not necessary. In addition, no additional insulation space is necessary which would increase the structural shape of the electric motor.
[0011] Moreover, the mechanical switches or relays do not have the safety, which is provided by contactless switching on the basis of a corresponding activation of the semiconductor components. At high rotor speeds, in particular, the virtually delay-free switching if the supply voltage of the electric motor fails is particularly important to avoid damage. The contactless short-circuiting of the electric motor by means of semiconductor elements on passing a predeterminable limit value during generator operation makes it possible to fix the limit value in such a way that directly before reaching the limit value, the generator operation is ended by the short-circuiting and the electric motor is braked to avoid damage to the electric motor and/or devices connected to the electric motor. The predeterminability of the limit value in particular allows flexible adaptation of the switching off time as a function of the different load situations of the electric motor according to the invention in generator operation. Thus, the time of switching off can be varied according to the respectively present operating conditions when the supply voltage of the electric motor fails.
[0012] The semiconductor components being used for the phase control of the electric motor may preferably be activated in such a way that the windings of the electric motor are short-circuited. The requirement for an additional controllable resistor, which has to be adaptable to the mass inertia of the rotor, to discharge the voltage produced during generator operation, is not provided.
[0013] In particular, the motor circuit may comprise at least one energy store which, after passing the predeterminable limit value, maintains the activation of the semi-conductor elements in that the energy store supplies the necessary voltage to operate the semiconductor elements. In this manner, the short-circuit can be maintained until the rotor is at a standstill. For this purpose, the energy store may be designed as at least one capacitor which is designed as a function of the duration of the braking process with a corresponding capacity to implement the maintenance of the activation of the semiconductor components.
[0014] In particular, the motor circuit may be set up in such a way that the semiconductor components can be activated with a signal reflecting the operating state. For example, for this purpose, the commutation signal can be used for phase control, the presence of which at the motor circuit reflects the operating state as the drive motor. Alternatively, an additional signal can be generated, which reflects the operating state and is used to activate the semiconductor components.
[0015] The electric motor may advantageously have a measuring device for monitoring the actual values, which is in operative connection with a control device. The control device may be designed as a microprocessor and comprise a rewritable memory, whereby it is made possible to input and store the limit values to be monitored with suitable input means. The control device evaluates the measured values obtained from the measuring device and compares them with the predeterminable limit values. The activation of the semiconductor components for short-circuiting the windings of the electric motor takes place during generator operation with the aid of this desired/actual comparison. The limit value may preferably be fixable above a sensible threshold value of the electric motor working in generator operation to maintain operation of the control device and the semiconductor components of the motor circuit.
[0016] The measuring device may preferably be designed as a device for voltage and/or current measurement or output measurement, so that, on passing the limit value for the output supplied in generator operation or for the generated current, the short-circuiting of the windings is initiated. Alternatively, the measuring device may be designed as a rotational speed measuring device so that, on passing a limit rotational speed, the short-circuiting of the windings of the electric motor operating in generator operation takes place. The limit rotational speed value may, for this purpose, be fixed above a threshold value of the rotational speed, which is sensible for maintaining the supply voltage of the control device and the semiconductor components so operating reliability can be increased.
[0017] According to a further embodiment, the motor circuit may comprise a delay member, by means of which a time interval can be predetermined as the limit value and once it has been exceeded, the short-circuiting takes place by means of automatic activation of the semiconductor components. The delay member is not activated until the change-over into generator operation by suitable activation by means of the signal reflecting the operating state. At the end of the predeterminable time interval, the automatic activation of the semiconductor components takes place in such a way that these are switched through, so the short-circuit of the windings is implemented. The duration of the time interval can be input as a function of the run-down behavior of the rotor in generator operation of the electric motor, which is substantially determined by the mass inertia of the rotor.
[0018] Advantageously, the semiconductor elements used for short-circuiting the windings can be implemented as transistors. These are the transistors of the phase bridge generally used for the phase control of the electric motor, by means of which the phase-wise clocking of the current flow and the current flow direction takes place. For this purpose, the transistors can be designed as field effect transistors or bipolar transistors. The corresponding use of thyristors could equally be considered.
[0019] Furthermore, the rotor may be contactlessly mounted. For this purpose, for the contactless mounting of the rotor, the bearing can be designed as a magnetic bearing. The generator operation allows the magnetic bearing function to be maintained, the motor being short-circuited on passing the limit value to avoid unnecessary wear or possible damage to the magnetic bearing through wobbling movements of the rotor which is running down.
[0020] According to another aspect of the invention, it is provided that the semiconductor components of the phase bridge provided for the phase control of the electric motor, on passing a predeterminable limit value, contactlessly short-circuit the windings of the electric motor to brake the electric motor in order to thus avoid unnecessary wear or possible damage to the electric motor or devices connected thereto.
[0021] Advantageous developments can be inferred from the electric motor being designed as the single drive of a rotor of a textile machine. In particular, the textile machine may be an open end rotor spinning machine, which has a spinning rotor, which may also be configured as a shaftless spinning rotor. The spinning rotor may be configured in the use according to the invention as a permanent magnet armature of the electric motor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Further details of the invention can be inferred from the embodiment described below with the aid of the drawings, in which:
[0023] FIG. 1 shows a block diagram of the motor circuit of an electric motor according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] The view in FIG. 1 shows a 3-phase electric motor 1 , which can be used, for example, in a textile machine, as a single drive of a rotor. The rotor is contactlessly mounted in the embodiment presently described. For the contactless mounting of the rotor, a magnetic bearing is provided, which can be designed actively or passively. For the contactless mounting, a gas bearing or a combined gas/magnetic bearing may also be used. The rotor is designed as a permanent magnet armature of the electric motor 1 . The electric motor 1 , for each phase R, S, T, comprises a winding, which is supplied via supply lines 2 with a supply voltage V Mot .
[0025] To activate the electric motor 1 , a motor circuit 3 is provided, which is in operative connection with a control device, not shown. The control device is, for example, a microprocessor and an overwritable EEPROM as the memory.
[0026] The motor circuit 3 comprises a plurality of semiconductor components 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , which are used in a known manner for the control of the phases of the 3-phase electric motor 1 during normal operation of the drive of the rotor. Use in a textile machine, for example in an open end rotor spinning machine as the single drive of a spinning rotor is considered here, in particular. To activate the respective phase R, S, T, the control device is connected via inputs 15 , 16 , 17 , 18 , 19 , 20 to the motor circuit 3 . The respective inputs 15 , 16 , 17 , 18 , 19 , 20 have been designated according to their allocation to the respective phase R, S, T. The semiconductor components 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 are designed as lower transistors 4 and upper transistors 5 with associated gate drivers 6 , 7 , 8 , 9 , 10 , 11 .
[0027] In the block diagram shown in FIG. 1 , the reference numeral 15 designates the input for activating an upper transistor 4 of the phase R (ARO), 16 the input for activating a lower transistor 5 of the phase R (ARU), 17 the input for activating an upper transistor 4 of the phase S (ASO), 18 the input for activating the lower transistor 5 of the phase S (ASU), 19 the input for activating the upper transistor 4 of the phase T (ATO) and 20 the input for activating the lower transistor 5 of the phase T (ATU). The upper and lower transistors 4 , 5 used in the presently described embodiment are designed as field effect transistors. Alternatively, bipolar transistors or thyristors can also be used.
[0028] Gate drivers 6 , 7 , 8 , 9 , 10 , 11 are arranged mounted downstream from the respective inputs 15 , 16 , 17 , 18 , 19 , 20 and have been designated according to their allocation to the respective phase R, S, T. Here, 6 designates the gate driver of the upper transistor 4 of the phase R (GTRO), 7 the gate driver of the lower transistor 5 of the phase R (GTRU), 8 the gate driver of the upper transistor 4 of the phase S (GTSO), 9 the gate driver of the lower transistor 5 of the phase S (GTSU), 10 the gate driver of the upper transistor 4 of the phase T (GTTO) and 11 the gate driver of the lower transistor 5 of the phase T (GTTU). The upper gate drivers GTRO 6 , GTSO 8 and GTTO 10 in each case have a negation function 12 , by means of which a control signal for activating the respective upper transistor 4 is sent to the control electrode of the upper transistors 4 of the phases R, S, T. Said semiconductor components 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 are used for the phase control of the electric motor 1 during proper operation as a drive and are familiar to the person skilled in the art with respect to their application and their arrangement in terms of circuitry. The gate drivers 6 , 7 , 8 , 9 , 10 , 11 are supplied with a supply voltage UT.
[0029] A capacitor 13 and a resistor 14 , which are in turn connected via lines with the inflow of the respective upper transistor 4 of the individual phase R, S, T are allocated, in each case in parallel connection, to the gate drivers 6 , 8 , 10 .
[0030] Furthermore, a measuring device, not shown, is provided, which is connected to the supply lines 2 of the respective phases R, S, T and the control device. The measuring device is used in the embodiment described in FIG. 1 for the continuous measurement of the output supplied in generator operation by the electric motor 1 if the supply voltage U Mot fails. The measuring device passes the measured values to the control device, which evaluates them and passes the results of the evaluation in the form of a control signal, which reflects the respective active operating state, to the inputs 15 , 17 , 19 . The measuring device may alternatively be designed in such a way that the rotational speed of the rotor of the electric motor 1 which is in generator operation, or the current output in generator operation, is monitored.
[0031] During the proper operation of the electric motor 1 , the supply voltage U Mot is available so that a corresponding commutation signal used for the phase control of the electric motor 1 is present at the inputs 15 , 16 , 17 , 18 , 19 , 20 and corresponds to the control signal reflecting a proper operating state. This control signal with the logical value “1” is passed to the gate drivers 6 , 8 , 10 . Passing the control signal to the gate drivers 6 , 8 , 10 means that the negation function 12 converts the value of the control signal from “1” to “0” and that the changed control signal is passed to the control electrodes of the respective upper transistors 4 . The circuit of the upper transistors 4 is selected such that these are not switched through in the case of the present activation with the control signal of the value “0”.
[0032] If the voltage supply of the electric motor 1 fails, this brings about the automatic change-over of the electric motor 1 into generator operation. This ensures the maintenance of the operation of the control device, the motor circuit 3 and, in particular, the magnetic bearing of the rotor being used for contactless mounting. During generator operation, the rotational speed of the rotor continuously falls, which results in the falling of the output produced by the electric motor 1 in generator operation. This leads to the magnetic bearing function and the operation of the control device no longer being ensured on passing a predeterminable limit value of the output produced by the electric motor 1 in generator operation. The limit value preferably lies above a threshold value which is predetermined by the falling below of the necessary supply output for maintaining the magnetic bearing function and the operation of the control device. It is ensured in this manner that, if the supply voltage V Mot of the electric motor fails followed by the change-over into generator operation, the braking operation is initiated before the threshold value is fallen below.
[0033] On passing the predeterminable limit value of the output produced by the electric motor 1 no control signal of the value “1” signaling the normal operating state is present any longer at the inputs 15 , 17 , 19 , but the control signal adopts the logical value “0”. The control signal with the value “0” is then passed to the gate drivers 6 , 8 , 10 and is converted by the negation function 12 into the control signal with the value “1”. This brings about the activation of the upper transistors 4 of the respective phase R, S, T in such a way that these switch through and this leads to the contactless short-circuiting of the motor windings of the phases R, S, T. In this manner, the rotor is braked to prevent the magnetic bearing of the rotor in the electric motor 1 being subjected, due to wobbling movements, to unnecessary wear or possible damage in the event of an unbraked running down of the rotor in generator operation.
[0034] To maintain the activation of the upper transistors 4 of the short-circuit produced by the switching through, of the windings of the phases R, S, T during the braking of the rotor until it is at a standstill, it is necessary to provide the upper transistors 4 with a supply voltage beyond the time of the activation triggering the short-circuit. In order to maintain the through-connection of the upper transistors 4 beyond the time of the short-circuit, the capacitors 13 are used as energy stores. The capacitors 13 are charged by the voltage produced while the electric motor 1 is in generator operation. On entry of the control signal with the value “0” passed to the gate drivers 6 , 8 , 10 and with the control signal subsequently converted by the negation function 12 to the value “1”, the switched-through upper transistors 4 are supplied by the capacitors 13 with the required supply voltage for maintaining their switching state. The capacitive design of the capacitors 13 is determined according to the duration of the braking process of the rotor. The duration of the braking process may in this case be approximately in a range of a few milliseconds up to several seconds.
[0035] An alternative embodiment of the electric motor 1 according to the invention provides the activation of the lower transistors 5 in the above described manner to short-circuit the respective windings of the electric motor 1 .
[0036] Furthermore, the associated capacitors of the gate drivers 6 , 7 , 8 , 9 , 10 , with corresponding dimensioning of the capacitances, can be used as energy stores of the gate drivers 6 , 8 , 10 and the upper transistors 4 or of the gate drivers 7 , 9 , 11 and the lower transistors 5 . In this manner, the component requirement can be additionally reduced.
[0037] Furthermore, instead of, or in addition to, the measuring device, a device for time control of the generator operation may be provided. The device may be configured in the form of a delay member and, within a predefined time interval after the changeover into generator operation, allows the signal leading to the short-circuit of the windings of the electric motor 1 to be produced by gate drivers 6 , 7 , 8 , 9 , 10 , 11 to initiate the braking process of the rotor by short-circuiting the windings. | An electric motor for a textile machine can be operated as a generator if the supply voltage fails. The electric motor comprises a rotor configured as the motor armature and a motor phase control circuit comprising a plurality of semiconductor components wherein the electric motor can be short-circuited if a predeterminable limit value is passed during generator operation. The motor circuit causes the short-circuiting on passing the limit value by activating one or more of the semiconductor components. The multi-phase electric motor is used as the single drive of a rotor of the textile machine. wherein the semiconductor components of the phase control bridge. on passing a predeterminable limit value, contactlessly short-circuit the electric motor to brake the electric motor. | 3 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. patent application, Ser. No. 09/711,418, filed Nov. 13, 2000, titled “Multi-Segment Air Bag Tether Construction.”
TECHNICAL FIELD
[0002] This disclosure relates to multi-segment air bag tether systems and to a pattern-wise arrangement of such tether segments in relation to air bag panels on a fabric blank, thus resulting in increased fabric utilization and an overall cost savings per finished air bag. The air bag tether system as described herein is comprised of two multi-segment congruent tether groups that are joined to one another and to a respective air bag panel. The segments that comprise each tether group are cut substantially on the bias with respect to the warp or the fill of the fabric blank. This multi-segment construction decreases the amount of fabric that is used in the manufacture of the air bag and tether systems, while providing sufficient elongation for the tether system to be functional.
BACKGROUND
[0003] Because of the speed with which an air bag inflates, it is necessary for the protection of vehicle occupants to control the volume of space that the air bag occupies in the vehicle cabin. Traditionally, air bag tethers have been used to control the excursion of an air bag as it inflates. As gas is released, causing the air bag to rapidly inflate, it is necessary to keep such inflation from occurring in an uncontrolled manner. Tethers, which are sewn to the interior portions of the front and rear panels of an air bag, keep the inflating air bag from expanding so rapidly as to adversely affect the safety of the vehicle occupant, as the vehicle occupant contacts the air bag.
[0004] Tethers are conventionally strip-shaped pieces of fabric that are aligned in pattern-wise arrangement on a fabric blank, or that are aligned in relation to air bag panels that may be cut from the same blank. These tethers typically include a circular portion in the center area of the tether strip used for attachment of the tether strip to the air bag panel. It is understood in the industry that such tethers should have a capacity for elongation (that is, the tethers should be able to stretch to accommodate the rapid excursion of the bag). For this reason, conventional strip-shaped tethers have historically been cut on the bias with respect to the warp and fill of the fabric. However, utilizing these one-piece tethers increases the amount of fabric needed to create an appropriate number of tethers for a plurality of air bags, thus resulting in increased production costs.
SUMMARY
[0005] The present air bag tether system, with groups of tether segments attached to each bag panel, addresses the problems of fabric utilization and tether elongation. Using a multi-segment tether system in place of conventional one-piece tethers improves fabric utilization by allowing these bias-cut tether segments to be arranged around air bag panels into spaces that might otherwise be considered fabric waste. The segments that comprise the tether groups are each cut substantially on a bias with respect to the warp and fill of the fabric blank. This multi-segment approach, rather than one-piece tethers, leads to an improved fabric utilization, while providing a tether system that is capable of sustaining the forces exerted by the inflating air bag.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 shows a side view of an air bag comprised of a front bag panel and a rear bag panel;
[0007] [0007]FIG. 2 shows a cross-sectional view of the air bag of FIG. 1, revealing a tether system incorporated therein;
[0008] [0008]FIG. 3A shows a plan view of a tether segment of the present invention that is cut substantially on the bias with respect to the warp or fill of a fabric blank;
[0009] [0009]FIG. 3B shows a plan view of a circular reinforcement as may be included in the air bag tether system of the present invention;
[0010] [0010]FIG. 3C shows a plan view of a multi-segment tether group, as comprised of two of the tether segments of FIG. 3A and the circular reinforcement of FIG. 3B;
[0011] [0011]FIG. 3D shows a plan view of a multi-segment tether group, in which two of the tether segments of FIG. 3A are attached to an air bag panel by a circular seam, but without the inclusion of the circular reinforcement of FIG. 3B;
[0012] [0012]FIG. 4 shows a plan view of a multi-segment tether group that is suitable for attachment to an air bag panel and that is comprised of three of the tether segments of FIG. 3A and the circular reinforcement of FIG. 3B;
[0013] [0013]FIG. 5 shows a plan view of a multi-segment tether group that is suitable for attachment to an air bag panel and that is comprised of four of the tether segments of FIG. 3A and the circular reinforcement of FIG. 3B;
[0014] [0014]FIG. 6A shows a plan view of an alternate pattern for the tether segment of the present invention, as would be attached to the front panel of an air bag;
[0015] [0015]FIG. 6B shows a plan view of an alternate pattern for the tether segment of the present invention, as would be attached to the rear panel of an air bag;
[0016] [0016]FIG. 6C shows a plan view of a multi-segment tether group, as comprised of two of the tether segments of FIG. 6A, as would be attached to the front panel of an air bag;
[0017] [0017]FIG. 6D shows a plan view of a multi-segment tether group, as comprised of two of the tether segments of FIG. 6B, as would be attached to the rear panel of an air bag;
[0018] [0018]FIG. 7A shows a plan view of yet another alternate pattern for a tether segment of the present invention;
[0019] [0019]FIG. 7B shows a plan view of a circular reinforcement as may be included with the tether segments of FIG. 7A; and
[0020] [0020]FIG. 7C shows a plan view of a multi-segment tether group, as comprised of two of the tether segments of FIG. 7A and the circular reinforcement of FIG. 7B, as would be attached to an air bag panel.
DETAILED DESCRIPTION
[0021] In order to describe the invention, it is necessary that certain terms be defined. The term “substantial bias” is intended to refer to a cut made diagonally across the weave of a fabric at an angle of 25 to 65 degrees with respect to the warp and fill. The term “front” shall refer to that portion of an air bag that is nearest a vehicle occupant, while the term “rear” shall refer to those portions of an air bag that are furthest from the vehicle occupant (e.g., in the case of front-seat air bags, nearest the windshield). The term “tether segment” refers to a component of a tether system that is attached to a first air bag panel and to a tether segment that is attached to the second air bag panel (for instance, a tether segment on the front bag panel is attached to a corresponding tether segment on the rear bag panel). Each tether segment is cut on the bias with respect to the warp and fill of a textile fabric. The term “ether group” shall refer to two or more tether segments attached to an air bag panel, with or without the inclusion of a reinforcement between them. The term “tether system” shall refer to a pair of tether groups joined along their respective end portions, which in combination succeed in preventing the uncontrolled excursion of an inflating air bag from adversely affecting a vehicle occupant with whom such a bag comes into contact.
[0022] Turning now to the Figures, FIG. 1 shows a side view of an air bag 10 . Air bag 10 is comprised of a front bag panel 4 and a rear bag panel 6 , panels 4 and 6 being substantially circular, although other panel geometries could also be used.
[0023] [0023]FIG. 2 shows a cross-sectional view of air bag 10 , revealing the arrangement of a tether system therein. Tether segments 14 (shown in FIG. 3A as being cut substantially on the bias with respect to the warp or the fill of a fabric blank) are attached to front bag panel 4 and rear bag panel 6 . Tether segments 14 are shown in lapped fashion in the interior of air bag 10 . The joining of tether segments 14 is shown as being achieved by means of rectangular seam 18 , but such joining may be accomplished by any other means, such as welding, gluing, or other seaming techniques. Tether segments 14 are substantially rectangular in shape, each having one flared end which is positioned toward the center area of respective bag panels 4 , 6 .
[0024] Reinforcement 12 (shown in FIG. 3B) may also be attached to front bag panel 4 , as well as rear bag panel 6 . It is common for reinforcements, having a circular or other shape, to be used in the production of air bags 10 . Reinforcements 12 may be circular in shape or may, for example, be in the shape of an n-sided polygon (where n is in the range of 4 to 12). In one embodiment, reinforcements 12 are included with tether segments 14 to form tether panel 24 . Such reinforcements 12 are particularly important in preventing tears around the mouth of air bag 10 , at the location of the inflation media.
[0025] Tether segment 14 is part of a multi-segment tether panel 24 that is shown in FIG. 3C. Tether panel 24 is comprised of two tether segments 14 and at least one reinforcement 12 . Tether segments 14 and reinforcement 12 are secured to one another and to a bag panel 4 or 6 by seam 22 , as indicated by a dotted line in FIG. 3C. It should be noted that tether segments 14 are cut substantially on the bias with respect to the warp or the fill of a fabric blank. The angle of the bias cut should be in the range of 25 to 65 degrees, and preferably an angle of about 45 degrees.
[0026] [0026]FIG. 3D shows a variation of tether panel 24 of FIG. 3C. In this embodiment, reinforcement 12 is omitted. Tether segments 14 are attached to bag panel 4 or 6 by means of seam 22 . In this variation, tether segments 14 do not contact one another, but nevertheless act in cooperation with one another and bag panel 4 (not shown) to form tether group 28 .
[0027] Turning now to FIG. 4, a three-segment tether panel 34 is shown. Three-segment tether panel 34 is comprised of three tether segments 14 and reinforcement 12 . Tether segments 14 and reinforcement 12 may be secured to bag panel 4 or 6 by means of seam 22 . Three-segment tethers 34 are useful for reducing bag oscillation during deployment.
[0028] [0028]FIG. 5 shows a four-segment tether panel 44 . Four-segment tether panel 44 is comprised of four tether segments 16 and reinforcement 12 . Seam 22 secures tether segments 16 and reinforcement 12 to bag panel 4 or 6 . Four-segment tether panels 44 have an even greater ability to reduce oscillation during bag deployment.
[0029] [0029]FIG. 6A shows a variation of tether segment 14 . Front tether segment 54 has a widened end portion that eliminates the need for reinforcement 12 . An arc 53 in the central portion of the widened end provides half of what will be an opening 55 in front tether 64 (see FIG. 6C). Opening 55 is useful for alignment of segments 54 . Seam 22 may be used to attach tether segments 54 to front bag panel 4 to create front tether panel 64 .
[0030] [0030]FIG. 6B shows a variation of tether segment 14 , as would be attached to rear bag panel 6 . Rear tether segment 56 has a widened end, similar to that of front tether segment 54 . Rear tether segment 56 is also cut on the bias with respect to the warp and fill of a fabric blank. Tether segment 56 has a small arc 58 in the central portion of the widened end, which provides half of what will be an opening 60 in rear tether panel 66 (see FIG. 6D). Opening 60 is used to insert inflation media into the air bag. Tether segment 56 also has a ventilation opening 57 that is also present in rear tether panel 66 . Again, seam 22 may be used to secure tether segments 56 to rear bag panel 6 . Reinforcement 12 is not necessary, but may be used for additional support, if desired. FIG. 7A shows yet another variation of tether segment 14 . Tether segment 74 has an arced end portion and is slightly truncated in comparison to tether segment 14 . Like tether segment 14 , tether segment 74 also is cut substantially on the bias with respect to the warp and fill of a fabric blank.
[0031] [0031]FIG. 7B shows a reinforcement 72 as may be used with tether segment 74 . As illustrated in FIG. 7C, tether panel 84 is comprised of two tether segments 74 and reinforcement 72 . Seam 82 may be used to secure tether segments 74 and reinforcement 72 to one another and to bag panel 4 or 6 . Like reinforcement 12 , reinforcement 72 may be circular in shape or may be in the shape of an n-sided polygon (where n is in the range of 4 to 12).
[0032] The multi-segment tether system of the present invention includes multiple tether segments 14 (or alternately 54 or 74 ) and may or may not include reinforcements 12 (or alternately 72 ). These tether segments 14 are positioned with one end portion secured to the central area of bag panel 4 or 6 and one end portion directed toward the periphery of bag panel 4 or 6 . The tether system is formed by joining the periphery end portions of tether segments 14 that are attached to front bag panel 4 to the periphery end portions of tether segments 14 that are attached to rear bag panel 6 . Although sewing is a preferred means of attaching tether system components (e.g., seams 18 , 22 , and 82 ), other attachment means can be employed, such as welding, gluing, and the like.
[0033] By incorporating these various multi-segment tether systems, the present invention represents a useful advancement over the prior art. | The present invention relates to air bag tethers formed from multiple bias-cut tether segments. Groups of tether segments are attached to the front and rear air bag panels and are then connected to one another to form a functional tether system. This multiple-segment construction, with its bias-cut segments, decreases the amount of fabric that is used in the manufacture of the air bag and tethers, while providing sufficient elongation for the tether system to be functional. | 1 |
This is a divisional of copending application Ser. No. 411,704 filed on 9/25/89, now U.S. Pat. No. 4,970,250.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to epoxidized polyamide wet strength resins containing lecithin and their use in paper and molded pulp products made of cellulose fibers such as wood pulp.
2. Background and the Prior Art
In the manufacture of wet strength paper and molded pulp products, a wet strength resin is added to the pulp slurry. Wet strength resins are typically of the epoxidized polyamide, urea formaldehyde or melamine formaldehyde types. These resins provide cross-linking to impart wet strength required by various paper and molded pulp products.
During the paper or molded pulp drying process, polymers such as those of melamine formaldehyde and urea formaldehyde may become a health hazard due to release of formaldehyde. Also, the epoxidized polyamide polymers as well as the melamine formaldehyde and urea formaldehyde polymers can at times stick to hot dryer surfaces. This problem is particularly acute with the epoxidized polyamide wet strength resins in the making of molded pulp products. Thus, in the manufacture of molded pulp products, wherein melamine formaldehyde wet strength resin is used, we have found that sticking is not a problem. However, the use of epoxidized polyamide in place of the melamine formaldehyde caused undesirable sticking of resin and pulp to the drier and furthermore the internal bond strength of the dried molded pulp product was weak. Also, it appears that urea formaldehyde wet strength resins are also not as susceptible to sticking to heated drier surfaces as with the epoxidized polyamides.
The application of various release agents to paper making dryer surfaces as well as to heated platens in pressing glue coated wood particles to make panels is well known for preventing sticking of resin to such surfaces. However, such application of a surface lubricant means the addition of another process step with the consequent increase in production time as well as an additional cost due to the amount of lubricant needed. Also, for release of molded pulp products from molds, additional difficulties are encountered in application of release agents due to the contoured and curvilinear surfaces of such molds.
In the making of wood based panels such as particleboard, by using melamine formaldehyde glues, press operators have applied an emulsion of five parts of lecithin in four parts aqua ammonia of 26 Baume and 91 parts of water as a release agent on the press surfaces. Such release agent is sold by Borden, Inc. under the designator PC-803L.
U.S. Pat. No. 4,076,896 of Feb. 28, 1978, shows the manufacture of laminates by impregnating paper with a melamine formaldehyde glue containing lecithin wherein the lecithin increases the release characteristics of the resin when pressing out a panel. Japanese patent publication JP55-139430 to Matsushita Elec. Works relates to the manufacture of a laminated sheet which includes impregnating paper or cloth with a thermosetting resin containing lecithin wherein the resins are said to include phenol resins, epoxy resins, polyester resins and melamine resins. U.S. Pat. No. 4,267,240 of May 12, 1981 to Formica Corp. relates to a release sheet comprising a web of paper having one side coated with various materials including lecithin.
The Kamikaseta et al U.S. Pat. No. 4,634,727 of Jan. 6, 1987 relates to a polyvinyl acetate emulsion adhesive for bonding wood and other porous substances wherein lecithin is added directly to the adhesive emulsion or the lecithin is first emulsified with aqueous ammonia before addition to the adhesive. In this 727 patent, the lecithin is said to assist in release of the adhesive from the press platens and increases the bonding strength of the adhesive. The 727 patent states that various additional polymers may be added to the lecithin containing polyvinylacetate such as urea resin, phenol formaldehyde resin and melamine resin.
Japanese patent publication, JP 1045894 to OJI Paper KK relates to the manufacture of paper which is said to have improved releasability by having release agents added to a layer of paper wherein the release agents include lecithin. Japanese Patent publication JP 88-057206 to Kobe relates to the production of a laminate by preimpregnating a paper substrate with a solution containing a surfactant and a cure accelerator for a phenolic resin varnish wherein lecithin is referred to as a cure accelerator. U.S. Pat. Nos. 1,977,251 to Stallmann of Oct. 16, 1934 and 3,947,383 to Baggett of Mar. 30, 1976 describe reaction products of ammonia and epichlorohydrin for use as a paper wet strength resin additives.
SUMMARY OF THE INVENTION
We have now found that the addition of lecithin in epoxidized polyamide wet strength resins eliminates the sticking problem encountered on the heated driers in the manufacture of paper and particularly in the manufacture of molded pulp products. The lecithin is preferably dispersed in an emulsifying or dispersing agent prior to its incorporation in the epoxidized polyamide. The epoxidized polyamide containing lecithin is added to the pulp slurry prior to forming of the molded product or paper on the wire mesh. Alternatively, each of the epoxidized polyamide and lecithin can be added separately to the aqueous pulp slurry. The addition of lecithin also improves the internal bonding of pulp in paper and molded pulp products which utilize epoxidized polyamide wet strength resins.
DESCRIPTION OF THE INVENTION
The epoxidized polyamide wet strength resins are water soluble cationic thermosetting resins. They are generally sold as aqueous solutions containing from about 10% to 35% by weight of resin solids, i.e., about 10% to 35% by weight of the epoxidized polyamide. Curing of such polyamides in paper and molded pulp products on hot drying surfaces increases the wet strength of the paper or molded pulp product. Generally, sufficient wet strength resin is added so that the wet strength of the paper or molded pulp product is greater than about 15 percent of its dry strength. Wet strength is the load required to break the paper when completely wet with water. The strength measurements may include wet tensile, wet mullens (burst), and wet tear. Paper and other pulp products manufactured without any additives do not have wet strength. By the term paper, we mean to include paperboards, toweling, tissue, food board, linerboard and corrugating medium. By the term molded pulp products, we mean to also include molded pulp/textile containing products. Molded pulp products are contoured products made of pulp such as egg packaging items, food trays, plates, flower pots, bottle protectors, and the like. Illustrative of molded pulp products which contain textiles, there can be mentioned contoured products such as the interior part of automobile doors, panels, etc. In contoured products, the contour is a part of the permanent shape of the article involved and such products often have surfaces which are that of compound curves.
Epoxidized polyamide wet strength resins are well known materials and their composition and method of preparation are amply described in the literature such as in the following U.S. Pat. Nos.: 3,565,754; 3,733,290; 3,793,279; 3,887,510, 3,914,155; and 4,501,862. As can be seen from the above references, amides which may be reacted with epihalohydrins, e.g., epichlorohydrin, to form the polyamide wet strength resin are also referred to as polyaminopolyamides. The polyaminopolyamides are generally prepared by reacting polycarboxylic acids, or their esters with polyalkylenepolyamines such as those having two primary amine groups and at least one secondary or tertiary amine group. The polycarboxylic acids or esters thereof can be aromatic or aliphatic. The acids are generally C 2 to C 20 saturated aliphatic dicarboxylic acids and the esters can be formed by reacting such acids with alkanois having from 1 to about 4 carbon atoms. The polyaminopolyamides are then epoxidized to form the epoxidized polyamide wet strength resins. Some of the epoxidized polyamide wet strength resins are modified with other reactants or the starting materials for such resins are modified. Thus, the polyaminopolyamide can be reacted with other compounds such as urea or formaldehyde or the acids can be substituted such as in the case of nitrilotriacetic acid.
A preferred class of epoxidized polyamide wet strength resins are disclosed in U.S. Pat. No. 3,887,510 which issued to Chan et al on June 3, 1975. In the Chan et al patent, dicarboxylic diesters derived from C 3 to C 6 saturated aliphatic dicarboxylic acids and respectively C 1 to C 3 saturated aliphatic monohydric alcohols are reacted with a polyalkylenepolyamine to prepare the polyaminopolyamide. As to the acids from which the esters are derived, there can be mentioned malonic, succinic, glutaric and adipic acids. The alcohols can be singly or in combination, methanol, ethanol, n-propanol or isopropanol. Methyl esters such as dimethyladipate and dimethylgluterate are the preferred esters.
Illustrative of of suitable polyalkylenepolyamines of the Chan et al patent, there can be mentioned: diethylenetriamine; triethylenetetramine; tetraethylenepentamine; dipropylenetriamine; 4-methyldiethylenetriamine; 5-methyldipropylenetriamine; 4,7-dialkyltriethylenetetramine; and dihexylenetriamine. The polyalkylenepolyamines of the Chan et al patent have the generic formula:
H 2 NC n H 2n (NRC n H 2n ) x NH 2 wherein R is either C 1 to C 4 alkyl or hydrogen, x can vary from 1 to about 5 and n can vary from about 2 to 6. In some cases however, it is desirable to increase the spacing of secondary amine groups and this can be done by substituting a diamine such as ethylenediamine, hexamethylenediamine and the like for a portion of the polyalkylenepolyamine. A preferred epoxidized polyamide is that made from the polyamide resulting from reaction of dimethyl gluterate and diethylene triamine.
The incorporation of lecithin in a pulp slurry containing epoxidized polyamide inhibits sticking of the wet strength resin or pulp fibers to the surfaces of the driers. Furthermore, such use of lecithin increases the bonding strength of the pulp to itself or through the action of wet strength resin. The quantity of lecithin used in the aqueous pulp slurry to obtain the advantages of this invention varies over a broad range such as from about 0.1 percent to 15 percent or more by weight of lecithin based on the weight of the wet strength resin solids, i.e., the epoxidized polyamide. Preferably the quantity of lecithin in the pulp slurry is from about 2 to about 10 percent by weight of lecithin based on the weight of the resin solids.
A preferred composition of this invention is a stable concentrate of the wet strength resin and lecithin which can be added to the aqueous pulp slurry. Such composition contains at least 61 percent of water and comprises an aqueous solution of epoxidized polyamide wet strength resin having a solids content of from about 8 to 35 percent by weight of said composition, from about 0.1 percent to 12 percent by weight of lecithin based on the weight of said resin solids and from about 61 percent to about 92 percent by weight of water and wherein said composition has a pH of about 3 to 5. Preferably, such composition contains from about 10 percent to 30 percent by weight of said resin solids and 6 to 10 percent lecithin, based on said resin solids and 67 to about 89 percent of water. These concentrates can also contain small quantities, e.g., up to about 2 or 5% by weight based on the weight of resin solids, of various solvents, emulsifiers or dispersing agents for the lecithin.
The lecithin can be added to the aqueous pulp slurry directly or it can first be added to the wet strength resin which is subsequently added to the aqueous pulp slurry. Preferably the lecithin is incorporated in the wet strength resin, as the above described concentrate, before addition of these chemicals to the pulp slurry. Lecithin is not soluble in water. Therefor it is preferred that a solution, emulsion or dispersion of the lecithin be used. Alternatively, hydrolized lecithin can be employed or the lecithin itself can be intimately dispersed into the wet strength resin or pulp slurry such as by mixing. A preferred way for getting the lecithin into the wet strength resin or directly into the aqueous pulp slurry is by first emulsifying the lecithin in aqueous ammonia water such as an emulsion containing 5 parts lecithin, 4 parts aqua ammonia of 26 Baume and 91 parts of water.
The molded pulp products and various paper products of this invention are made by conventional techniques except that a small quantity of lecithin is used together with the epoxidized polyamide wet strength resin in the aqueous pulp slurry in making such products. Illustratively, the molded pulp products can be made by depositing pulp fibers from a slurry on to a foraminous, e.g., wire mesh, mold. There can be single or multiple molds which can be fixed or as part of a conveyer so that a continuous operation can be realized. Molds on a conveyer often involve a rotating cylinder with suitable porting connections. Wet preforms from the initial mold are often pressed to a desired thickness and then dried under restraint between matched heated dies or in an oven. The drying process will vary depending upon the density of the finished product but can vary from about 1 to about 3 minutes. The thickness of the molded pulp products can vary over a wide range such as that of about 0.1 inch to about 0.4 inch.
Briefly, in the production of various papers, including paperboard, the paper furnish, after stock preparation and proper dilution, is usually sent to the paper machine through one or more screens or other devices to remove dirt and fiber bundles. It then proceeds to a flow spreader to provide a uniform flowing stream of the width of the machine. The flow spreader discharges the slurry into a headbox, where turbulence is controlled, fiber flocculation is minimized, and the proper head is provided to cause the slurry to flow out through the slice and onto a moving wire at the proper velocity. The sheet leaving the "wet end" is pressed to remove additional water by mechanical means. At this stage, the wet sheet has reached the point where further water removal by mechanical means is not feasible and evaporative drying must be empolyed. The evaporative driers are generally steam heated cylinders, with alternate sides of the wet paper exposed to the hot surface as the sheet passes from cylinder to cylinder.
During the manufacture of paper or molded pulp products, several additives are introduced at the "wet end" of the process, i.e., in the pulp slurry, to give the finished products the required physical properties. One of these additives is the wet strength resin. During drying on hot surfaces, the wet end additives, including the wet strength resins, may cause residual build-up on heated dryer surfaces. This bulid-up will cause the molded product or paper to stick to the dryer causing dryer wrap or breaks in the case of cylinder dryers or the need for manual removal of the contoured molded product in the case of molded pulp products. The use of lecithin as set forth in this invention overcomes or minimizes these sticking or breaking problems. Additionally, the lecithin increases the strength of internal bonding in paper and molded pulp products. The percentage of dry pulp solids in the aqueous pulp slurry vary over a wide range but, initially, prior to the draining of water are on the order of about 0.5 to 5 percent of the slurry. The quantity of epoxidized polyamide to dry pulp solids in the slurry will generally vary from about 0.1% to about 5%.
In order that those skilled in the art may more fully understand the inventive concept presented herein, the following examples are set forth in the appended claims. All parts and percentages are by weight unless otherwise stated.
EXAMPLE 1
Epoxidized poylamide wet strength resin, namely Cascamid C-20, was added to a pulp slurry at a rate of 2.25% (45 pounds of wet strength resin solids per ton of dry pulp solids) to form a 0.65 gm/cm 3 molded pulp sheet. Cascamid C-20 is an aqueous solution of wet strength resin sold by Borden, Inc., having 20 parts of epoxidized polyamide in 80 parts of water and wherein the polyamide, prior to epoxidation is the reaction product of dimethylgluterate and diethylenetriamine. The sheets were formed in a deckel box, pressed to a thickness of 2.5 mm and dried on matching die driers at 530° F., for 2.5 minutes. Several of the sheets were observed to stick to the upper die drier as the lower one descended. The sheets also showed evidence of picking which was determined through visual observation and roughness of test specimens. In an attempt to cut specimens for testing, the sheet broke across the center internally at a place intermediate its top and bottom surfaces due to internal bond failure resulting from what was attributed to improper cure of resin and/or moisture escaping from the center.
EXAMPLE 2
Laboratory handsheets were prepared as in Example 1 above except that the resin addition level was reduced to 0.5% (10 pounds of wet strength resin solids per ton of dry pulp solids) and a contoured die disc was not used. Test samples were placed between heated press platens for drying. Upon lowering the lower plate, the specimens stuck to the upper plate and again showed bonding failure through the center of the specimen, i.e., internally in a plane intermediate its top and bottom surfaces.
EXAMPLE 3
Laboratory handsheets were prepared as in Example 2 above except that 0.1% of PC-803-L (by weight, based on the weight of resin solids in C-20) and 0.5% Cascamid C-20 (by weight, based on the weight of dry pulp solids) were each added separately to the slurry. Handsheets did not show signs of sticking or internal failure on cutting. PC-803-L is an aqueous emulsion of lecithin in ammonia. The aqueous emulsion consists of 5 parts of lecithin in 4 parts of ammonia aqua of 26 Baume and 91 parts of water and is sold by Borden, Inc. as a protective coating to be applied to platen surfaces used to make particleboard with melamine formaldehyde glues.
EXAMPLE 4
Laboratory handsheets were prepared as in Example 2 above except that 0.5% Cascamid C-20 (by weight, based on the weight of dry pulp solids) mixed with 0.1% of PC-103-L (by weight, based on the weight of wet strength resin solids) before addition to the slurry. The sheets did not show signs of sticking or internal failure. Cascamid C-20 is an aqueous solution of wet strength resin sold by Borden, Inc. having 20 parts of epoxidized polyamid in 80 parts of water and wherein the polyamide, prior to epoxidation is the reaction product of dimethylgluterate and diethylenetriamine. PC-103-L is a product sold by Borden, Inc. and referred to as a protective coating. It is composed of an aqueous emulsion of 5 parts lecithin in 4 parts of ammonia aqua of 26 Baume and 91 parts of water.
EXAMPLE 5
A mixture of Cascamid C-20 (69.32%) at 20% solids, 29.64% of PC-803L and 1.04% hydrochloric acid was applied to pulp/synthetic pulp slurry at 0.5% (10 pounds per ton) as in 1 above showed no signs of sticking nor of internal failure and had satisfactory properties with respect to percent swell, burst flexural strength and modules of elasticity. This was 10.69% lecithin by weight based on weight of the resin solids.
EXAMPLE 6
Specimens were prepared as in Example 5 above except that the resin was applied at 1% (20 pounds of resin solids per ton of dry pulp solids) and the PC-803L and hydrochloric acid were not used. The sheets stuck to drier surface and showed signs of internal failure.
EXAMPLE 7
Specimens were prepared as in Example 1 above except that the resin mixture was 69.32%, Cascamid C-25 at 25% solids, 29.64% of PC-803L and 1.04% hydrochloric acid. Specimens showed no signs of sticking or internal failure. The amount of lecithin in the PC-803L amounted to 8.6% of lecithin on the resin solids. | A composition comprising epoxidized polyamide wet strength resin and lecithin. The composition provides wet strength to paper and molded pulp products and at the same time increases the internal bonding of the paper or molded pulp products. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority to U.S. Provisional Appl. No. 61/375,784, filed Aug. 20, 2010, which is incorporated in its entirety by reference herein. The present application is related to the following U.S. patent applications, filed on even date herewith, and incorporated in their entireties by reference herein: U.S. patent application Ser. No. ______ (Attorney Ref. No. VAERO.001A); U.S. patent application Ser. No. ______ (Attorney Ref. No. VAERO.002A); U.S. patent application Ser. No. ______ (Attorney Ref. No. VAERO.003A); U.S. patent application Ser. No. ______ (Attorney Ref. No. VAERO.004A); and U.S. patent application Ser. No. ______(Attorney Ref. No. VMOTO.002A).
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to generators utilizing superconductivity.
[0004] 2. Description of the Related Art
[0005] The phenomenon of superconductivity was discovered in 1911 in the Netherlands by Kamerlingh Onnes and collaborators (see, H. K. Onnes, Commun. Phys. Lab. University of Leiden, Suppl., 34b (1913)). Since that time, it has been exploited for many applications.
[0006] The phenomenon of superconductivity is one of the most amazing physical phenomena discovered thus far. It falls under a larger category of physical phenomenon known collectivity as “critical phenomenon,” “phase transitions,” or “correlated systems.” Substances that exhibit these phenomena undergo a transformation that affects their physical properties on a macroscopic scale in a dramatic and observable way. This radical change in behavior usually occurs at a particular temperature called the “critical temperature.” The onset of the transitions are predictable and are accompanied by a highly correlated behavior below the critical temperature, for the electrons in the substance, as in the case of superconductors, or for the particles making up the substance as in the case of superfluids. For a general discussion of critical phenomenon, see Tinkham, M. Introduction to Superconductivity, 2 nd ed., McGraw-Hill, (1996). The phenomenon of superconductivity is discussed herein and a certain property of its behavior is identified for its useful potential applications in certain embodiments described herein (e.g., for oscillators, sensors, generators, and motors).
[0007] As mentioned above, superconductivity is one of the many manifestations of critical phenomenon known in physics. Superconductivity is characterized by the complete absence of electrical resistance in a substance below the critical temperature. Not all materials exhibit superconductivity. Known superconductors include some metals or alloys of metals, which become superconducting at temperatures around 4 to 30 degrees Kelvin. More recently, certain ceramic materials have been discovered that exhibit superconductivity at a relatively high temperature around 93 degrees Kelvin (see, Bendorz, J. G., Müller, K. A., Z. Phys. B64, 189 (1986)). This is particularly useful as it can be conveniently attained using liquid nitrogen which is at 77 degrees Kelvin. This class of “high temperature superconductors” (HTS) has opened up a whole new avenue of possibilities of superconductivity; however, this technology remains largely undeveloped.
SUMMARY
[0008] In certain embodiments, an alternating current (AC) generator is provided. The generator comprises a pair of two opposing cylinders. Each cylinder comprises a high-temperature superconductor material at a temperature. The superconductor material is in a superconducting state in the presence of an external magnetic field below a critical field strength, wherein the critical field strength is a function of the temperature of the superconductor material. Each cylinder further comprises a first superconducting coil configured to apply a non-zero time-invariant magnetic field strength to the superconductor material. Each cylinder further comprises a second superconducting coil configured to apply a time-varying magnetic field strength to the superconductor material. A sum of the non-zero time-invariant magnetic field strength and the time-varying magnetic field strength cycles between at least a first field strength below the critical field strength for the superconductor material at the temperature and at least a second field strength above the critical field strength for the superconductor material at the temperature, such that the superconductor material cycles between a superconducting state and a non-superconducting state. The generator further comprises a piston configured to move within the two cylinders. The piston comprises a permanent magnet having a magnetic field that interacts with the superconductor material of each of the two opposing cylinders. A time-varying force is applied to the magnet by an interaction of the magnet's magnetic field with the superconductor material. The generator further comprises a pickup coil positioned so that movement of the magnet induces an electrical current in the pickup coil.
[0009] In certain embodiments, a method of operating a generator is provided. The method comprises providing a generator comprising a pair of two opposing cylinders. Each cylinder comprises a high-temperature superconductor material at a temperature. The superconductor material is in a superconducting state in the presence of an external magnetic field below a critical field strength, wherein the critical field strength is a function of the temperature of the superconductor material. Each cylinder further comprises a first superconducting coil configured to apply a non-zero time-invariant magnetic field strength to the superconductor material. Each cylinder further comprises a second superconducting coil configured to apply a time-varying magnetic field strength to the superconductor material. A sum of the non-zero time-invariant magnetic field strength and the time-varying magnetic field strength cycles between at least a first field strength below the critical field strength for the superconductor material at the temperature and at least a second field strength above the critical field strength for the superconductor material at the temperature, such that the superconductor material cycles between a superconducting state and a non-superconducting state. The generator further comprises a piston configured to move within the two cylinders. The piston comprises a permanent magnet having a magnetic field that interacts with the superconductor material of each of the two opposing cylinders. A time-varying force is applied to the magnet by an interaction of the magnet's magnetic field with the superconductor material. The generator further comprises a pickup coil positioned so that movement of the magnet induces an electrical current in the pickup coil. The method further comprises applying the non-zero time-invariant magnetic field strength to the superconductor material of each of the cylinders by using the first superconducting coil of each of the cylinders. The method further comprises applying a time-varying force to the magnet which moves the magnet by using the second superconducting coil of each of the cylinders to apply the time-varying magnetic field strength to the superconductor material of each of the cylinders, such that the superconductor material of each of the cylinders cycles between a superconducting state and a non-superconducting state. The method further comprises using the magnet to induce an electric current in the pickup coil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A schematically illustrates a superconductor material at a temperature greater than the critical temperature immersed in an external magnetic field then cooled below its critical temperature.
[0011] FIG. 1B schematically illustrates a superconductor material at a temperature greater than the critical temperature in zero external magnetic field then cooled below its critical temperature.
[0012] FIG. 2 is a photograph of a small permanent magnet floating above a superconductor material that is below its critical temperature.
[0013] FIG. 3 is a plot of normalized critical field versus temperature for YBCO high temperature superconductor material having a critical temperature at about 93 degrees Kelvin. The region below the curve is the superconducting state, and the region outside the curve is the normal or non-superconducting state.
[0014] FIG. 4 is the plot of FIG. 3 with a plot of a time-varying external magnetic field applied at a specific temperature superimposed over the applied external time-invariant or constant magnetic field.
[0015] FIG. 5 schematically illustrates a superconducting AC generator in accordance with certain embodiments described herein.
[0016] FIG. 6 illustrates the phase relationship between the magnetic fields in a two opposing cylinder generator.
DETAILED DESCRIPTION
[0017] In certain embodiments described herein, a new oscillator based on the phenomenon of superconductivity is realized and identified for its many potential applications (e.g., oscillators, sensors, generators, and motors). This oscillator is based on the Meissner Effect of superconductivity, and is used to create a “Superconducting Oscillator” that can be used to apply a time-varying force to a magnet, which has many potential applications among which are motors of all types, and various sensors. Certain embodiments described herein exploit one property which has many potential applications (e.g., in oscillators, sensors, generators, and motors).
[0018] The absence of electrical resistance is only one of the properties exhibited by superconductors below the critical temperature. Another very striking effect is the Meissner Effect, named after W. Meissner (see, W. Meissner, R. Ochsenfeld, Naturwiss, 21: 787 (1933)). It was observed that when a superconducting material is cooled in the presence of a magnetic field, when the temperature dropped below the critical temperature, the magnetic field was expelled from the superconductor, as shown schematically in FIG. 1A . This is because the superconductor acts as a perfect diamagnet, expelling the magnetic field. The mechanism by which this occurs is simple; the external magnetic field induces currents in the superconductor. These currents circulate in such a way as to generate a magnetic field that opposes the external field, thus the net field in the superconductor is zero. The same effect also occurs if the magnetic field is introduced after the superconductor is cooled below its critical temperature, as shown in FIG. 1B . This property has the striking effect of causing the superconductor to repel the source of the external magnetic field. FIG. 2 is a photograph showing this phenomenon using a small permanent magnet floating above a superconductor that is below its critical temperature due to the force applied to the magnet by the interaction of its magnetic field with the superconducting material opposing the force of gravity on the magnet. In FIG. 2 , the magnet is Neodymium type, the superconductor is ceramic HTS type, YBCO cooled to liquid nitrogen temperature.
[0019] Superconductivity in the presence of an external magnetic field follows certain limitations. For a fixed temperature below the critical temperature, as the external magnetic field strength is increased, superconductivity is lost. The value of the magnetic field strength required to destroy the superconducting state generally increases as the operating temperature is lowered below the critical temperature. This phenomenon follows an empirical law (depicted in FIG. 3 ) in the form of:
[0000]
H
c
(
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H
c
(
0
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[
1
-
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T
T
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[0020] FIG. 3 is a plot of normalized critical field strength versus temperature for YBCO high temperature superconductor material having a critical temperature at about 93 degrees Kelvin. The region below the curve is the superconducting state, and the region outside the curve is the normal or non-superconducting state. FIG. 3 shows that the superconducting region is confined inside the critical field strength curve. As the temperature changes above and below the critical temperature, the superconductor switches between the normal and superconducting states. This oscillation however is very slow, as the temperature change is slow in nature.
[0021] The switch between the normal and superconducting states also occurs as the magnetic field strength is switched above or below the critical field strength. In this case, however, the oscillation is instantaneous, because the mechanism responsible is a second order phase transition. In certain embodiments, a convenient temperature can be chosen and a time-varying (e.g., oscillating) component field strength can be applied at the critical field strength value, as schematically illustrated in FIG. 4 . Such a configuration will cause the superconductor material to oscillate between the normal and superconducting states at the frequency of the applied field. This in turn will impose a time-varying (e.g., periodic) behavior on the Meissner effect. Thus, a magnet floating above the superconductor will exhibit up and down oscillations at the frequency of the applied field. Since this change of state is virtually instantaneous at a particular fixed temperature, the oscillation of the superconductor will lag the applied field by the relaxation time for the superconductor. This is the time it takes to form the ordered state, in the femtosecond range, which is a very short time. This process is shown schematically in FIG. 4 .
[0022] FIG. 4 is the plot of FIG. 3 with a plot of a time-varying external magnetic field strength applied to the material at a specific temperature superimposed over the applied external time-invariant or constant magnetic field strength. A time-varying external magnetic field strength (e.g., square wave, with zero minimum) applied at a specific temperature, and superposed over the applied external constant field strength, will force the material into the normal state region, thus destroying superconductivity. During the next half cycle, the total field strength is less than the critical field strength, and superconductivity is restored. The driving frequency is that of the applied field. The limiting frequency is due to the relaxation time for the superconductor, on the order of 10 −15 seconds in certain embodiments. Since the relaxation time of the superconductor material is of the order of 10 −15 seconds, the applied frequency can be very high, e.g., in the terahertz range. Most practical applications will be at much lower frequencies, e.g., in the Hz, kHz, MHz, or GHz ranges. For most mechanical applications, the frequency is likely to be in kHz range. The superconductor material lags the applied field by a phase factor of the order of the relaxation time. In FIG. 4 , the driving field of the example oscillator is applied at about 70 degrees Kelvin, which is well below the critical temperature, utilizing DC external field strength of about 0.36 (H c /H 0 ) where H 0 =H c (0). In certain embodiments, the AC field strength can be applied anywhere on the critical field strength (e.g., at a point of low field strength, but not too close to the critical temperature).
[0023] In certain embodiments, the operating temperature is selected to be at or below 93 degrees Kelvin. The operating temperature of certain embodiments is chosen to be sufficiently below the critical temperature since near the critical temperature some instability could take place as the superconductor material transitions between states. As the temperature is chosen increasingly below the critical temperature, the required field strength to change states will increase. Therefore, it becomes a design trade-off issue which will be determined depending on the particular application (e.g., oscillators, sensors, generators, and motors) for a specific requirement. A helpful criterion for determining an appropriate operating temperature below the critical temperature is to know the error margin in the specific temperature control mechanism being used. For example, if a heater with a feedback loop is used that has a response of 0.5 degree Kelvin above or below a chosen operating temperature (set point), then this set point should be at least 0.5 degree Kelvin below the critical temperature. It is a good design practice to select an operating temperature that is two, three, or more times the error margin below the critical temperature (e.g., at least 2 to 5 degrees Kelvin).
[0024] As mentioned above, the superconducting state is destroyed if the superconductor is immersed in a strong magnetic field. This transition to the normal, non-superconducting state is quite rapid, unlike the transition which occurs at the critical temperature. The reverse is also true, when the strong field is reduced below the critical field value, the superconducting state returns just as rapidly. Making use of this phenomenon, the AC generator design of certain embodiments described herein is that of two opposing inline cylinders. FIG. 3 schematically illustrates an example design of an AC generator having two opposing inline cylinders. Each cylinder contains a superconductor material 4 , 7 (e.g., disk or base), and the cylinders share a common piston 10 , which comprises a permanent magnet with its magnetic field oriented (shown by arrow 12 ) such that is parallel to the surface, of the superconductor material 4 , 7 . Each cylinder comprises a coil 5 , 8 wound around each of the cylinders, which can be referred to as the “primary” coil 5 , 8 . The primary coil 5 , 8 of certain embodiments comprises a superconducting wire, and is maintained at a prescribed current and magnetic field strength. Besides the primary coil 5 , 8 , each cylinder comprises a secondary, smaller coil 6 , 9 that are pulse driven and wound around the cylinder (e.g., around the primary coil 5 , 8 ), with the secondary coil 6 , 9 comprising a superconducting material or a non-superconducting material (e.g., copper) in certain embodiments. Each of the two cylinders shown in FIG. 3 is substantially identical to the other with its own set of primary and secondary coils.
[0025] The center housing 16 (e.g., tube) which houses the magnetic piston 10 is under vacuum in certain embodiments. In certain embodiments, the entire assembly is contained in a liquid nitrogen bath enclosed in a dewar 17 having a liquid nitrogen intake 1 , a vent 2 , and is filled with liquid nitrogen to level 3 .
[0026] Around the center housing 16 is a pickup coil 11 which comprises high-temperature superconducting material in certain embodiments. The entire system in certain embodiments is cooled to liquid nitrogen temperature, and the primary coils 5 , 8 are charged with enough current to bring them sufficiently below the critical field strength for the superconductor material 4 , 7 to remain in the superconducting state. The secondary coil 6 , 9 of one cylinder is energized, such that the sum of the primary and secondary field strengths will exceed the critical field strength, and the superconductor material 4 , 7 will enter the normal or non-superconducting state. No repulsive force is generated in this cylinder, while a repulsive force is generated in the opposite cylinder causing the piston 10 to move towards the cylinder with the higher magnetic field strength. In the next half cycle, the secondary coil 6 , 9 of the first cylinder is turned off, and the secondary coil 6 , 9 of the opposing cylinder is energized causing a reversal of the initial state, the repulsion is now in the first cylinder and not in the second, causing the piston 10 to move in the opposite direction. As this cycle repeats, the magnetic piston 10 moves back and forth thus inducing a current in the pickup coil 11 . The induced current will be alternating at the same frequency as the driving frequency between the two secondary coils 6 , 9 , but will lag slightly in phase. The phase lag is of the order of the relaxation time for the superconductor material 4 , 7 , and the mechanical response time of the piston 10 , which is very small.
[0027] FIG. 4 shows an example operating cycle of the generator in accordance with certain embodiments described herein. The horizontal line at 0.5 depicts the primary DC field strength which is constant for both cylinders. When the pulsed field is on for cylinder 1 , it is off for cylinder 2 ; thus the total magnetic field for cylinder 1 is greater than for cylinder 2 . At this stage in the cycle, the superconductor material 4 , 7 in cylinder 1 will be normal, non-superconducting state and producing no repulsion, while the superconductor material 4 , 7 in cylinder 2 is in the superconducting state and produces a repulsion causing the piston 10 to move away from the superconductor material 4 , 7 . In the next half cycle the pulsed field is reversed: off for cylinder 1 and on for cylinder 2 , thus cylinder 1 produces a repulsion, while cylinder 2 does not, and the piston 10 moves in the opposite direction. The motion of the magnetic piston 10 induces alternating current in the pickup coil 11 .
[0028] Certain embodiments of the system described herein are configured to generate alternating current in the pickup coil 11 , thus certain such embodiments are used primarily as an alternating current generator. The frequency of the generated current is the same as the frequency of the alternating pulsing of the secondary coils 4 , 7 . The advantage of certain embodiments of this device is that the pulsed fields are small thus using little energy input, but when combined with the field from the primary coil 5 , 8 , the resulting field is enough to put the superconductor material 4 , 7 into the normal non-superconducting state. The Meissner effect in the opposing cylinder is now unopposed, and causes the magnetic piston 10 to move. This movement causes the induced current in the pickup coil 11 . The work done by the superconductor material 4 , 7 induces heat in the superconductor material 4 , 7 , this heat is removed at the expense of the liquid nitrogen. Thus the energy input into the system also includes the energy needed to make the liquid nitrogen in addition to the pulsed fields. The efficiency of this device in certain embodiments is largely that of the superconductor material 4 , 7 , and thus should be very high.
[0029] The choice of the currents for the primary coil 5 , 8 and secondary coil 6 , 9 is a trade-off between the desired performance requirements, and the quality of the superconductor material. The current in the primary coil 5 , 8 is selected to be sufficient to bring the applied field from that primary coil 5 , 8 to within range of the critical field at the chosen operating temperature. The remaining field used to exceed the critical field is to be applied by the secondary coil 6 , 9 . The range of the current flowing through each coil is a particular design parameter. For example, if the critical field at some operating temperature is about 8 Tesla, the field from the primary coil 5 , 8 can be set at 7 Tesla. This can be done by charging the primary coil 5 , 8 accordingly to deliver 7 Tesla. The remaining 1 Tesla can be applied using the secondary coil 6 . 9 . In certain embodiments, the secondary coil 6 , 9 is pulsed slightly above the critical field to ensure that the total field exceeds the critical field even accounting for slight temperature fluctuations. When the secondary coil 6 , 9 is pulsed on and off in sequence, the Meissner effect takes place sequentially, and the piston 10 oscillates. The pulsed field is smaller than the primary field in certain embodiments to avoid pulsing a high current, since even superconductors exhibit some AC losses. The question of how to divide the current between the primary and secondary coils also depends on properties of the superconductor. Since the Meissner effect operates in presence of the field of the primary coil 5 , 8 , the superconductor critical current will be affected by the presence of this field. In general, critical currents diminish slightly with applied field for all superconductors to varying degrees. For well prepared YBCO, the reduction in critical current is small, and can be compensated for by choosing a smaller field of the primary coil 5 , 8 as needed. This in turn will use a larger field from the secondary coil 6 , 9 , thus pulsing of slightly higher current.
[0030] The same trade-offs mentioned above apply to the pick-up coil 11 , with the desired output being electrical energy in the form of AC voltage and current. The applied power in the secondary coils 6 , 9 is amplified through the superconductor and appears as AC power at the output. The cost of this conversion is heat dissipation in the superconductor which is removed by the liquid nitrogen. Thus the input energy into the system is the energy used to liquefy the nitrogen, the energy to charge the primary coils 5 , 8 , and the energy to pulse the secondary coils 6 , 9 . Of these, the energy used in the secondary coil is the least amount. The output is the generated AC power. Under ideal circumstances, the output energy should equal the input energy. In reality the efficiency of this system will be less than 1, but is expected to be in the 0.9 to 0.99 range. Most electrical motors or generators efficiency is about 0.8.
[0031] Various embodiments have been described above. Although this invention has been described with reference to these specific embodiments, the descriptions are intended to be illustrative of the invention and are not intended to be limiting. Various modifications and applications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined in the appended claims. | An alternating current (AC) generator and method of operating the generator are provided. The generator includes a pair of two opposing cylinders. Each cylinder includes a high-temperature superconductor material at a temperature. The superconductor material is in a superconducting state in the presence of an external magnetic field below a critical field strength, wherein the critical field strength is a function of the temperature of the superconductor material. A sum of a non-zero time-invariant magnetic field strength and a time-varying magnetic field strength cycles between at least a first field strength below the critical field strength for the superconductor material at the temperature and at least a second field strength above the critical field strength for the superconductor material at the temperature, such that the superconductor material cycles between a superconducting state and a non-superconducting state. The generator further includes a piston configured to move within the two cylinders. The piston includes a permanent magnet having a magnetic field that interacts with the superconductor material of each of the two opposing cylinders. A time-varying force is applied to the magnet by an interaction of the magnet's magnetic field with the superconductor material. The generator further includes a pickup coil positioned so that movement of the magnet induces an electrical current in the pickup coil. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation, under 35 U.S.C. § 120, of copending international application No. PCT/EP02/10144, filed Sep. 10, 2002, which designated the United States; this application also claims the priority, under 35 U.S.C. § 119, of German patent application No. 101 45 145.8, filed Sep. 13, 2001; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a vibration damping configuration in a system with a vibration-generating unit and a housing for holding the unit.
[0003] For the purposes of the present invention, a unit may be any desired power machine, in particular an electric motor or possibly an apparatus which is driven by it and is thought to produce undesirable vibration as a result of the operation of the power machine. A unit such as this is frequently accommodated for its own protection or for protection of the users in a housing which can itself oscillate or can be stimulated by the oscillations of the unit and furthers the undesirable noise generation by the unit.
[0004] The problem of preventing or reducing undesirable sound emission from a unit such as this and/or from its housing is very old, and a large number of approaches have been adopted in order to solve the problem.
[0005] For example, it is known for the connection between the housing and the unit, by means of which it is held on the housing, not to be designed to be rigid, but to provide spring systems between the unit and the housing, which allow the unit to oscillate with a relatively large amplitude without the amplitude being transmitted completely to the housing, where it would be emitted as sound. However, since oscillation forces are transmitted, even if to a reduced extent, from the unit to the housing with a suspension system such as that, it is never entirely possible to prevent the housing from being caused to vibrate.
[0006] Another widely used approach is to surround a vibrating unit with layers composed of silencing material. These layers are admittedly effective against sound transmitted through the air, but the transmission of structure-borne sound from a unit to its housing can be prevented only to a limited extent.
[0007] One novel approach which has been adopted relatively recently is electronic noise suppression, in which the noise signal to be suppressed is sampled and a noise with the same amplitude but with the opposite phase is produced via a loudspeaker and is destructively superimposed on the noise to be suppressed. However, this method is effective only in the far field, that is to say at a distance from the noise source where, to a good approximation, this noise source can be assumed to be a point source, and the distance between it and the loudspeaker can be ignored. In the near field, where these approximations are not valid, there is virtually no point in using the method since in fact it allows noise to be cancelled out locally in some cases, but at other points the noise to be suppressed and the noise from the loudspeaker are constructively superimposed on one another.
SUMMARY OF THE INVENTION
[0008] It is accordingly an object of the invention to provide a vibration damping system, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which provides for a vibration-generating unit and a housing in which the sound emission through the housing is minimized by way of a novel effective principle.
[0009] With the foregoing and other objects in view there is provided, in accordance with the invention, an assembly comprising a housing and a vibration-generating unit mounted to said housing. The assembly further comprises:
[0010] a damped spring configuration mounting said unit to said housing and connecting at least one connecting point of said unit to a connecting point of said housing;
[0011] said spring configuration having at least one individual spring element and at least one additional oscillation-enabled element configured to oscillate at a different resonant frequency that said individual spring element.
[0012] The dissipation of vibration or oscillation energy which is injected into the arrangement from the vibration-generating unit also occurs in conventional assemblies in which, for example, rubber buffers are provided as spring configurations between the unit and the housing. These admittedly convert a small proportion of the injected vibration or oscillation energy to friction heat and thus dissipate it, but are well away from achieving the dissipation power which can be achieved according to the present invention by the spring configuration having an internal degree of oscillation freedom. This allows oscillation movement in the interior of the spring configuration, with an amplitude which may assume relatively high values in comparison to the amplitude of the coupling points to the unit or to the housing at the ends of the spring configuration. It is obvious that major internal movements of the spring dissipate considerably more vibration or oscillation energy into heat than in the case with conventional spring configurations which have no such internal degree of freedom. This dissipated energy can no longer be emitted as a noise from the unit or from the housing.
[0013] This degree of freedom is preferably created by the spring configuration being formed from two or more individual spring elements which are connected in series between the unit and the housing. The junction point between the individual spring elements can thus oscillate with a degree of freedom of their own.
[0014] In order to make it possible to stimulate this degree of freedom effectively it is expedient for the individual spring elements to have different spring constants.
[0015] In order to achieve a high dissipation power, the oscillation amplitude of the internal degree of freedom must not be excessively low since, if it were to be zero, the dissipation would also be zero. In order that the amplitude of the internal degree of freedom is not excessively low, it must be able to store a suitable amount of oscillation energy; for this purpose, it is expedient to suspend a mass which can oscillate between each of the individual spring elements.
[0016] The oscillation of the internal degree of freedom can be described by an expression in the form x=e −αt , where x is the deflection, t is the time and α is a complex constant which is determined in a manner known per se by the spring constant and the damping of the internal degree of freedom. The damping should preferably be only sufficiently strong that |Re α|<10 |Im α|. In order on the other hand to ensure damping propagation of the internal resonance, which also makes it possible to stimulate this by means of injected oscillations which are not matched precisely to its resonant frequency, the damping should be at least sufficiently strong that |Re α|<0.1 |Im α|.
[0017] In general, a unit is mounted in a housing at two or more suspension points, with spring configurations with an internal degree of freedom between the unit and the housing expediently being provided at all of these suspension points.
[0018] Masses, which can oscillate, of these two or more spring configurations may be connected to one another in order to maintain as high a degree of symmetry as possible for the entire system which can oscillate, and in order to avoid a chaotic oscillation response, in which the intensity of the various spectral components of the emitted noise varies with time.
[0019] The configuration according to the invention is preferably a refrigerator and the unit is preferably a compressor for this refrigerator.
[0020] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0021] Although the invention is illustrated and described herein as embodied in a vibration damping configuration, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0022] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a schematic of a spring configuration according to the fundamental principle of the invention;
[0024] [0024]FIG. 2 is a graph plotting the damping response of a spring configuration according to the invention, in comparison with damping by way of an individual spring;
[0025] [0025]FIG. 3 is a diagrammatic section through a refrigerator, as an example of a system of the unit and housing according to the invention;
[0026] [0026]FIG. 4 is a perspective view of a spring configuration in the refrigerator shown in FIG. 2; and
[0027] [0027]FIG. 5A is a plan view onto a first exemplary embodiment of a support configuration for the compressor of the refrigerator;
[0028] [0028]FIG. 5B is a side elevational view thereof;
[0029] [0029]FIG. 5C is a plan view of an alternative embodiment of the configuration; and
[0030] [0030]FIG. 5D is a plan view onto an further alternative embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown an idealized illustration of a spring configuration for a system with a vibration-generating unit and a housing. The spring configuration is formed from two individual spring elements 1 , 2 , which are illustrated here as helical springs. It will be understood that, in principle, the spring elements 1 may be springs of any desired type. Particularly suitable are solid bodies composed of a highly dissipating, rubber-elastic material. The springs are connected to one another at a point 3 and, at their ends remote from the point 3 , they are connected to a respective body 4 or 5 , one of which represents the vibration-generating unit and the other represents the housing. For the purposes of the present description, it shall be assumed that 4 is the unit and 5 is the housing.
[0032] The individual spring elements 1 , 2 have mutually different spring constants k 1 , k 2 . The two spring constants are superimposed, according to the principle of springs in series, to form an equivalent spring constant or overall spring constant
K = 1 1 k 1 + 1 k 2 = k 1 k 2 k 1 + k 2
[0033] which determines the oscillation response of the unit and housing with respect to one another.
[0034] Each of the individual spring elements 1 , 2 can intrinsically oscillate at an actual frequency which is governed by its spring constant and its mass. If vibration is injected from the unit 4 into the spring configuration, then this leads to stimulation of natural oscillations of the springs 1 , 2 . Since these are coupled, the spring configuration can oscillate not only at the frequency which is governed by the overall spring constant K but, furthermore, at the natural frequencies of the springs 1 and 2 as well as at their sum and difference frequencies.
[0035] The natural frequencies of the springs 1 , 2 are expediently in the upper audible spectral range, but they may also be higher than this since the resonances are broadened widely by damping. An individual spring can thus provide effective damping in its resonant spectral range; below this range, it is only slightly effective, as is shown in an idealized form in the upper part of FIG. 2. The spring configuration according to the present invention, on the other hand, damps a considerably broader spectral range, which is composed of the resonant spectral ranges of the two individual springs and, in addition, the difference frequency spectral range, as is shown in the lower part of FIG. 2, where dashed lines are in each case used to show the contribution of the individual springs and the difference frequency for damping, and a solid line is used to illustrate the overall damping of the system.
[0036] That component of the movement of the unit 4 which stimulates one of the two or more oscillations of the spring configuration and resonance is broken down by dissipation within the spring configuration, so that it no longer reaches the housing 5 and can no longer stimulate noisy vibration on the housing 5 .
[0037] [0037]FIG. 3 shows a second refinement of the invention, applied to a refrigerator. One major source of noise in household refrigerators are the compressors used in them, and the electric drive motors which are used in the compressors. These can cause the capsule that surrounds the compressor to oscillate at a large number of different frequencies, and the object is to limit the transmission of these frequencies to the housing of the refrigerator.
[0038] The capsule of the compressor 11 which is arranged in a lower corner of the housing 10 conventionally has a number of lugs 12 which are used for attachment to mounting rails 13 in the housing.
[0039] [0039]FIG. 4 shows a perspective view of one such lug 12 and of the spring configuration 14 which is located between it and the mounting rail 13 . The spring configuration 14 is composed of two individual spring elements 15 , 16 in the manner of rubber buffers, between which a free mass or an inertia body 17 is arranged. The inertia body 17 acts as an energy store for the various degrees of oscillation freedom of the spring configuration and improves the effectiveness with which the natural oscillations of the spring configuration are stimulated by an externally injected oscillation.
[0040] This mass may expediently be chosen such that the oscillation frequency of the inertia body 17 is in the oscillation range in which the compressor capsule is stimulated by the motor and it is intended to be damped. The resonant frequency of the resonator that is formed from the spring elements 15 , 16 and the inertia body 17 is
ν = 1 2 π K m ,
[0041] where m is an equivalent mass which is composed of the mass of the inertia body 17 and contributions from the spring elements 15 , 16 . Since the spring elements 15 , 16 are composed of a highly damping material, the Q-factor of this resonator is extremely low, so that the inertia body 17 can be stimulated to oscillate in a very wide frequency band around its resonant frequency ν. With this refinement, there is no need for the natural frequencies of the spring elements 15 , 16 to be different in order to make it possible to stimulate the oscillation of the inertia body 17 .
[0042] It should also be noted that the spring configuration shown in FIG. 4 can oscillate not only in a single direction, for example longitudinally along its axis, but also transversely with respect to this axis, and the various movement directions may also each have different spring constants.
[0043] All this means that there is no need for complex computational optimization in order to achieve effective vibration damping with the illustrated spring configuration. As soon as the natural frequency—or one of the natural frequencies if the different possible movement directions are considered—of the inertia body 17 is approximately of the same order of magnitude as the oscillations of the compressor 11 to be damped, the spring configuration 14 effectively damps the transmission of these oscillations to the housing 10 .
[0044] Various modifications of the spring configuration 14 are possible. For example, the inertia body 17 need not be a rigid body, as assumed above, but may also itself in turn represent a spring element, so that the spring configuration 14 overall comprises three spring elements connected in series.
[0045] Another possibility is to provide a series arrangement with more than one inertia body 17 , for example a series arrangement comprising three spring elements which are each separated by an inertia body, in order in this way to damp the oscillation fed in from the compressor 11 in two successive steps. In this case, different masses may be provided for each of the two inertia bodies and/or different spring constants may be provided for the springs surrounding them in order to produce different natural frequencies for the inertia bodies by effective damping in different frequency ranges.
[0046] A further modification of the invention is illustrated in the plan view of FIG. 5A and the side elevation of FIG. 5B.
[0047] Conventionally and as shown in the plan view of FIG. 5A, the housing of the compressor 11 is provided with four lugs 12 . A spring configuration 14 for connection to the mounting rails 13 of the housing is disposed on each of these lugs 12 . The inertia bodies 17 of the spring configurations 14 are in this case fused to a single plate 18 , which is clamped in at each of the four points between the spring elements 15 , 16 of the four spring configurations 14 .
[0048] This fusion results in the compressor 11 being suspended in a more robust manner in the housing 10 than in the case of four independent inertia bodies.
[0049] In the exemplary embodiment illustrated in FIG. 5C, only a plan view of which is shown, the four inertia bodies 17 are connected to one another by springs 19 , and can thus oscillate with respect to one another. This also makes it possible to use the dissipation capability of the springs 19 for absorption of vibration energy.
[0050] In the variant shown in FIG. 5D, the inertia bodies of the four spring configurations are fused to form a ring 20 , and the spring elements 15 and 16 each act at different points on the ring. An arrangement such as this furthers the stimulation of bending oscillations in the ring 20 , and is particularly useful when the ring itself is composed of a vibration-damping material. | An assembly of a vibration-generating unit and a housing accommodating the unit includes a vibration damper. The unit is retained on the housing by way of at least one dampened spring configuration that is linked with the unit on the one hand and the housing on the other hand, each at a respective connecting point. The spring configuration has at least one single spring element that is capable of oscillating with a resonant frequency different from that of the single spring element. | 5 |
REFERENCE TO RELATED PROVISIONAL APPLICATION
This application claims the benefit of provisional application Ser. No. 60/336,349 filed Oct. 24, 2001.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the art of fracturing subterranean formations and more particularly to a method for determining frictional pressure drop of proppant-laden slurries using surface pressure data. The invention used in the process of designing and analyzing stimulation treatments of subterranean formations such as fracture treatments.
INTRODUCTION TO THE TECHNOLOGY
A typical hydraulic fracturing treatment involves pumping of fracturing fluid to initiate and propagate a down-hole fracture, followed by varying concentrations of proppant in order to keep the fracture propped open after the pumping stops. This results in creation of a conductive pathway that enables the hydrocarbons to move with a relative ease, ultimately resulting in an increased production. Hydraulic fracturing treatments are generally designed in advance by inputting the best possible information pertaining to fracturing fluids, formation rock properties, etc. in any of the several fracturing simulators used by well services companies.
During the actual execution of the job however, the fracture geometry can be more appropriately judged by observing the net pressure trends. Net pressure trends are more critical in the proppant stages because any incorrect interpretation may lead to an early termination of the treatment and hence the designed objectives may not be achieved. On other hand, extending the job when a screen out is imminent may lead to a proppant pack in the tubular and may incur additional expenditure. Net pressure is defined as the pressure in excess of closure pressure, which, in turn, is the minimum pressure, required for the fracture to remain open. Net pressure is usually calculated from bottom hole pressures.
Bottom hole pressures (BHP) may be measured using downhole pressure gauges, live annulus, dead strings, or memory gauges. However, in most of the treatments around the world, such devices are not available due to economic feasibility or other restrictions. Therefore, in practice, the bottom hole pressure is ascertained by field personnel, based on the pressures recorded at the surface. This computation requires knowledge of fluid frictional pressures. Though several correlations and pressure charts are available and capable of predicting accurate frictional pressures, these charts typically don't include proppant-laden fluids and therefore, are not completely accurate for hydraulic fracturing fluids.
There is thus a need for new procedures for better determination of the slurry frictional pressures based on the recorded surface pressures in the proppant stages.
SUMMARY OF THE INVENTION
The invention pertains to a unique procedure of analyzing surface pressures to obtain a correlation capable of predicting pressure drops in proppant laden slurry. The procedure is based on close monitoring of surface pressure to define a “net pressure rate” which defines an increase or decrease of net pressure while the job is being pumped, and then relates it with the pressure changes observed with the onset of proppant stages of varying concentrations. The process results in defining “Frictional Pressure Multipliers” corresponding to different proppant concentrations. These frictional pressure multipliers are then used to develop correlations to predict pressure drop during proppant stages.
PRIOR ART
In comparison to the pad fluid, proppant-laden slurries are more complex to model because of the existence of two-phase flow consisting of base gel and solid proppant. On a typical hydraulic fracturing job, surface pressure show a decreasing trend with the introduction of proppant stages. This reduction in surface pressure is primarily due to the increment in fluid density caused by the addition of solids in the fluid. A closer look however, reveals that the loss of pressure is not entirely due to an increase in hydrostatic pressure. This observed difference could be attributed to the additional friction pressure introduced because of the proppants. Major factors that contribute to increased friction pressures are proppant concentration, tubular size, flow rate, and slurry viscosity. For simplicity the proppant friction has been traditionally quantified as an increment to the base gel friction, so it can be included in existing models. Lack of proper modeling and theoretical understanding of the proppant-laden slurry, has however contributed to the limited data available in this field of investigation.
Historically, the researchers have found it relatively easy to generate theories for predicting friction pressure losses for Newtonian fluids in comparison to the viscoelastic non-Newtonian fluids. The same can be extended to proppant laden slurries, where there are several expressions for predicting friction pressures for slurries composed of Newtonian fluids and solid particles. However, there are not enough theories for how particles affect the friction pressure of highly non-Newtonian fluids.
Literature review clearly reveals that the researchers in past have traditionally used two distinct methods to define the friction pressure drop of proppant laden slurries. A first method attempts to define the slurry frictional pressures by using friction multipliers that are a function of relative viscosity of slurry and base gel. The second method attempts to define the total pressure drop as a sum of base gel friction and additional pressure drop due to proppant.
Einstein in 1905, based on his work on Newtonian quiescent solutions, was the first to propose relative viscosity of dilute suspension as a function of particle volume fraction (Einstein, A.: Ann. Physik (1905) 17, 459; (1906) 19, 271-89). The relation is give as
μ s u s μ = 1 + αϕ ( 1 )
where μ sus , μ, φ, and α are the viscosity of dilute suspensions, viscosity of suspending medium, volume fraction solids, and a constant, respectively. Later, this approach of defining slurry viscosity as a function of particle volume fraction was used by several researchers trying to model slurry friction pressure as a function of slurry viscosity.
Hannah, Harrington and Lance proposed that total slurry friction was the product of base-gel friction and a multiplier to account for the proppant (See Hannah, R. R., Harrington, L. J., and Lance, L. C.: “ Real Time Calculation of Accurate Bottomhole Fracturing Pressure From Surface Measurements with Measured Pressure as a Base ” paper SPE 12062 presented at the 1983 SPE annual Technical Conference and Exhibition, San Francisco, October 5-8.). Based on their approach,
f s =f b ×CF (2)
where, f s is the slurry friction factor, f b is the base-gel friction factor, and CF is the proppant friction multiplier. The authors were more focused on obtaining the friction pressure multipliers, as the base-gel friction information was obtained using the standard pressure charts available from service companies that pump the fluids. During the process they assumed a turbulent friction factor versus Reynolds number equation with a slope of −0.2, and obtained the following correlation for proppant multiplier
CF=μ r 0.2 ρ r 0.8 (3)
where, ρ r is the relative slurry density. In: “ Transport Characteristics of Suspensions: Part VIII. A Note on the Viscosity of Newtonian Suspensions of Uniform Spherical Particles ” J. Colloid Sci. (1965) 20, 267-77, Thomas, D. G. defined a relative slurry visocosity μ r as the ratio of slurry viscosity to the viscosity of suspending medium, μ. Following equation was proposed to define, μ r ,
μ s μ = μ r = 1 + 2.5 ϕ + 10.05 ϕ 2 + 0.00273 ⅇ 16.6 ϕ ( 4 )
where, μ s is the slurry viscosity, and φ is the particle volume fraction. This suggests that the relative viscosity, μ r , is a function of proppant volume fraction with ρ r being the ratio of proppant-laden and proppant free fluid densities. It is implied that overall, the friction multiplier is a function of proppant density, proppant concentration, and fluid density only and appears to have no relationship with fluid rheology, flow rate, proppant size, or tubular diameter. The general application of such a correction factor would therefore be suspicious. However, CF has been reported to predict the increase in friction pressure with proppant addition accurately. These tests were carried out with the slurry flowing down the annulus where the tool joint collars may have significant effect on flow profile due to obstruction of flow.
In “ Shear Rate Dependent Viscosity of Suspensions in Newtonian and Non - Newtonian Liquids ” Chem. Eng. Sci. (1974) 29, 729-35, Nicodemo, L., Nicolais, L. and Landel, R. F. proposed an expression, popularly known as Landel's correlation, to fit the limits of both infinite and high solids concentration. The relationship is given by
μ r = ( 1 - ϕ ϕ m ) - 2.5 ( 5 )
where φ m is the maximum obtainable volume concentration of particles where the slurry can still be sheared. For cubical packing, φ m is given as 0.48 and for loosely packed sand it is around 0.62. Its value in literature is generally found to be between 0.56 and 0.66. Although some of the suspensions used in the study exhibited non-Newtonian behavior at the lowest shear rates, they all behaved as if Newtonian at the high shear rates where the viscosity was calculated.
None of these expressions, or variant of them proposed by different authors, account for observed non-Newtonian effects due to addition of proppants. It has been shown that even for Newtonian fluids, the slurry viscosities are a function of flow shear rate. The existence of shear effects for simple Newtonian fluids suggests there might be considerably greater shear effects for non-Newtonian fracturing fluids. In “ Fluid Flow Considerations in Hydraulic Fracturing ” SPE 18537 presented at the Society of Petroleum Engineers Eastern Meeting in Charleston, W.Va., Nov. 1-4, 1988, K. G. Nolte accounts for the effects of shear effects on viscosity in his paper on fluid flow considerations during hydraulic fracturing. He proposes that for an externally imposed shear rate, γ o , the presence of particles obstruct the shear flow and locally increase the shear rate by a multiplier say m, resulting in a final shear rate of mγ o . As a result of increase in shear rate, shear stress also increases, thus resulting in increase of apparent viscosity. Apparent viscosity multiplier, m μ , defines the ratio of shear stresses in the presence of particles to the shear stresses in absence of particles as follows
m μ = m × μ a ( m γ o ) μ a ( γ o ) ( 6 )
where, μ a (x) denotes the apparent viscosity of the fluid system at the shear rate x. For Newtonian fluids, apparent viscosity is independent of shear rate and hence apparent viscosity multiplier is same as shear rate multiplier. Thus,
m μN =m (7)
where, m μN is Newtonian apparent viscosity multiplier. He further proposed that Newtonian shear rate multiplier m can be determined by the Landel correlation shown by Eq. (5) by using m=m μN =μ r , or the following Frankel Archivos correlation disclosed in Govier, G. W. and Aziz, K.: The Flow of Complex Mixtures in Pipes van Nostrand Rheinhold Co., New York City, (1972), pp 98:.
m μ N = ( 1 + 1.125 ( ϕ / ϕ m ) 1 / 3 ( 1 - ϕ / ϕ m ) 1 / 3 ) ( 8 )
in standard notations. For Power law fluids, with exponent, n as the flow behavior index, it can be easily shown that
m μ = m m 1 - n = m n ( 9 )
Combining the fact that m=m μN =μ r and Eq. (9), the Landel correlation of Eq. (5) can now be given as
m μ = ( 1 - ϕ ϕ m ) - 2.5 n ( 10 )
Shear rate multiplier can now be modified to accommodate the effect of Power Law fluids, with yield value of τ y as follows,
m μ = m τ y + K ( m γ ) n m γ γ τ y + K γ n = 1 + r m n 1 + r ( 11 )
where, r=Kγ n /τ y . As per the observations made, the correlations predicted the viscosity with reasonable accuracy. However, the scope of the Nolte's study was not extended to predicting the frictional pressure losses in slurries.
In another study by Keck, Nehmer, and Strumolo, “ A New Method for Predicting Friction Pressures and Rheology for Proppant - laden Fracturing Fluids ” SPE 19771 presented at the 64 th Annual Technical Conference and Exhibition of the Society of Petroleum Engineers held in San Antonio, Tex., Oct. 8-11, 1989, a new correlation predicting relative slurry viscosity was presented
μ r = { 1 + [ 0.75 ( ⅇ 1.5 n ′ - 1 ) exp - ( 1 - n ′ ) γ . / 1000 ] 1.25 ϕ 1 - 1.5 ϕ } 2 ( 12 )
For this study, the value of φ m was assumed to be 0.66. A more meaningful friction multiplier could be obtained by using a derivation similar to that given by Hannah et al., but using a maximum drag reduction asymptote slope of −0.55 on a plot of friction factor versus Reynolds number. Resultant equation was given as
M=μ r 0.55 ρ r 0.45 (13)
where M is the friction multiplier.
In “ Experiments on the Suspension of Spheres in Inclined Tubes - I Suspension by Water in turbulent Flow” Chem. Eng. Sci . (1967) 22, 1133-45. 1967, Round and Kruyer proposed that the pressure drop through vertical pipe for fluids containing a sphere can be separated into three components, the pressure drop resulting from liquid flowing in the tube without the sphere present, the pressure drop caused by the drag force on the sphere, and the pressure drop owing to flow line disturbance because of the sphere. The last two components were then combined, and measured with sphere in vertical tube flowing with water.
In “ Drag Coefficients and Pressure Drop for Hydrodynamically Suspended Spheres in a vertical tube with and without Polymer Addition” Cdn. J. Chem. Eng . October 1973) 51, 536-41, Latto, B, Round, G. G., and Anzenavs, R. extended the work by adding polymer to the water, showing that with addition of polymer, the values of pressure drop observed were less than the ones determined by Round and Kruyer. Based on his experiments, the following correlation was proposed for single spheres hydro-dynamically suspended in polymer with a concentration range of 0 to 50 ppm by weight
Δ p p = 0.633 ( d p d ) 2.94 [ ( ρ s - ρ f ) d sin θ ] ( 14 )
where, Δp p is the sum of friction pressures mentioned above, d p is the particle diameter, d is the tubular diameter, ρ s is the density of slurry and θ is the tube inclination.
In “ Friction Pressures of Proppant - Laden Hydraulic Fracturing Fluids ” SPE Production Engineering November 1986) 437-45, Shah and Lee presented a detailed theory and empirical master curve for predicting the effect of proppant that is based on extending the work of Molerus and Wellmann on horizontal pipes. Froude number, which is defined as the ratio of inertial force to gravitational force, was used extensively in their analysis. According to this study, the pressure drop of proppant-laden fluids Δp t , can be expressed as the sum of pressure drop of clean fluid, Δp fl , and an additional pressure drop, Δp p , due to proppant. Hence,
Δp t =Δp fl +Δp p (15)
The study basically revolves around four dimensionless parameters namely Δp D , the dimensionless pressure drop, {overscore (ν)}/ν, the dimensionless slip, N Frp , the particle Froude number, and N Fr *, the terminal Froude number. The study proposes that the dimensionless slip, {overscore (ν)}/ν, is a unique function of the dimensionless numbers N Frp and N Fr *. To calculate N Fr *, the settling velocity of proppant in the fluid needs to be calculated first. The correlations for this has been published in another study carried out by Shah in “ Proppant Settling Correlations for Non - Newtonian Fluids under Static and Dynamic Conditions ” Trans., AIME, 273, Part 2 (1982) 164-70. In summary, the increased friction pressure caused by proppant was obtained with a modified Froude number analysis, and led to a universal empirical curve for friction pressure in vertical piping systems.
Lord, D. L. and McGowan, J. M. in “ Real - Time Treating Pressure Analysis Aided by New Correlation ” SPE 15367 presented at the 61 st Annual Technical Conference and Exhibition of the SPE held in New Orleans, La., Oct. 5-8, 1986 proposed a laboratory correlation for HPG fluids that could be readily used for field applications. This correlation relates tubing diameter, flow rate and gel/proppant concentration to predict tubular friction pressure for polymer-laden fluids and also proppant-laden slurries. Eq. (14) shows the relation
ln ( 1 / σ ) = 2.38 - 8.024 / v _ - 0.2365 G / v _ - 0.1639 ln G - 0.028 P ⅇ 1 G ( 16 )
where G is the gel concentration in lbm/Mgal, {overscore (ν)} is the average tubular velocity ft/sec, P is the proppant concentration in lbm/gal, and σ is the drag ratio defined as
σ=Δ p G,P /Δp o (17)
where, Δp o is the friction pressure of the Newtonian water solvent, and Δp G,P is the frictional predicted frictional pressure drop of fluid with or without slurry. Δp o given in oilfield units by
Δ p o =0.40429 d −4.8 q 1.8 L (18)
where, d is the tubular diameter in inches, L is the length of the tubular in feet, and q is the flow rate in bbl/min.
DETAILED DESCRIPTION
The above and further objects, features and advantages of the present invention will be better understood by reference to the appended detailed description and to the drawings wherein:
FIG. 1 is a typical plot of the pressure measured at the surface during hydraulic treatment. Read the treating pressure from left y-axis and slurry rate and proppant concentration from the right y-axis. Note the points denoted for different stages in the job. Proppant stabilized pressure must be noted for every stage along with the end of the stage stabilized pressure.
FIG. 2 shows details of proppant pressure drop measuring procedure according to the invention. The increase of the surface pressure in the preceding stage is taken account of in the subsequent stages with an assumption that pressure would continue to change at the same rate for the displacement of tubing volume in time.
FIG. 3 is a plot showing the procedure of generating e values by using the friction pressure multipliers;
FIG. 4 shows the friction exponent e is plotted against average flow velocity for slurries of various proppant specific gravities ranging from 2.54 to 2.72 flowing in tubular of varying internal diameters;
FIG. 5 shows the values of the friction exponent e after including the effect of proppant specific gravities;
FIG. 6 shows the data of FIG. 5 , “collapsed” in one line by introducing the effect of diameter in the plotting;
FIG. 7 shows the values of a modified form e p of the friction exponent e plotted against average flow velocity for different gel types;
FIG. 8 shows the plot of calculated vs. measured values of proppant friction exponent;
FIG. 9 is a plot generated by FracCADE™ and shows the results of pressure-match using a hypothetical error. Pressures are in psi and should be read from left Y-axis whereas slurry rate and proppant concentration shown in bbl/min and in ppa respectively, should be read from right Y-axis
The approach adopted for the current study is a combination of the methods described in above sections. Friction pressure drops are calculated for individual proppant stages and transformed into friction multipliers by relating them with base gel friction pressure. As stated in literature review, here the total friction is considered as the sum of base gel and proppant friction. Later on, plots of friction pressure multipliers versus ratio of solids volume fraction are generated to define a proppant friction exponent that is used to describe the proppant friction pressure trends.
A survey of around 300 hydraulic fracture jobs containing recorded surface pressure data was carried out. The major criterion used for job selection was majority of proppant stages had to be one or more tubular volumes so that the surface pressure responses could be adequately observed. Apart from this, it was also important to have a record of instantaneous shut in pressure (ISIP) for each job, to ascertain base-gel friction accurately. Around 168 hydraulic fracturing jobs that met the criterion were selected for the study.
The base fluid was composed of different gel concentrations of Carboxymethylhydroxypropyl guar (CMHPG), cross-linked with zirconate based crosslinker and the proppant size for all the jobs was 20/40 mesh. Varieties of proppants with differing specific gravities were used for the study. Varieties of proppants with differing specific gravities were used. Though proppant concentrations as high as 10 ppa were observed for some cases, the majority of data was restricted to 8 ppa.
The technique used in computing friction pressures was similar to the one used in generating friction pressure correlation for CMHPG fluids (Pandey, V. J.: “ Friction Pressure Correlation for Guar - Based Hydraulic Fracturing Fluids ” SPE 71074 presented at the SPE Rocky Mountain Petroleum Technology Conference held in Keystone, Colo., May 21-23, 2001). In this approach it was extended to the proppant stages as well. Friction pressure drops for the fracturing fluids without proppant can be computed by obtaining the value of ISIP by shutting down the pumps before beginning the pad stage or somewhere in the early portion of the pad if it is sufficiently large. Before the shut down the well must be fully displaced with a fluid of known density for accuracy in hydrostatic pressure calculations. Friction pressure can be computed using the following equation
Δp f =p s −p bh +Δp H (19)
where, Δp f is the tubular friction pressure, p bh is the bottom hole pressure, p s is the surface pressure, and Δp H is the hydrostatic pressure. Surface pressure is noted at the point when the pad fluid just makes its entry on the perforations and the pressure appears to level out temporarily. It is assumed that at this point net pressure is low and has no significant effect on the calculation. Perforation frictions are neglected because several data points are usually available for one tubular diameter and flow rate enabling the data analyst to take the mean. FIG. 1 shows a typical surface pressure plot generated during a hydraulic fracturing job. The points where the pressure-data points should be picked are clearly shown in the plot. For an ISIP based pressure data, the frictional pressure gradient can be computed using the following simple relationship
Δ p f L = p s - I S I P D e p t h ( 20 )
FIG. 1 also shows the recorded surface pressure data for proppant stages from one of the jobs that were selected for the purpose of study. Note the decrease in the surface pressure as subsequent proppant stages are introduced. The loss of pressure is attributed to the increase in hydrostatic pressure. However, a detailed analysis shows that the surface treating pressures are higher than expected if the drop had been purely due to the increased fluid density.
Friction pressure losses corresponding to individual proppant stages can be determined by using measured surface pressure before starting the proppant stage, pressure as the stage hits the formation change in hydrostatic pressure, and the net pressure rate. The jobs selected for the study followed a “staircase” mode for stepping up the proppant concentration and the stages were sufficiently large to monitor the surface pressure as the new proppant concentration made its way into the fracture.
FIG. 2 shows the details of an idealized pressure response. Surface pressure in the pad increases from point A to B where point A corresponds to the stabilized pad pressure that was used to compute the frictional pressure drop of the fluid without proppant, using Eq. (20). ISIP used for computing frictional pressure of pad is also shown in the plot. With the onset of proppant stage however, the surface pressure declines and levels out at point D. If the pressure losses were purely due to the increase of hydrostatic pressure, the surface pressures would have theoretically been at point C, if a negative net pressure does not exist at that point. This indicated that the numerical difference between point D and C is the additional frictional drop imparted to the fluid with the addition of the proppant. However, at this point it must also be realized that before the proppant was introduced in the fluid, surface pressures showed an increasing trend. The precise reason for the increase (or decrease) of surface pressures, which may be due to changes in fluid rheology, friction generated as the fluid propagates in the fracture, excessive near well bore restrictions, or simply an extension of the fracture, cannot be determined without the presence of live BHP or BHP gauges. However, it is important that such effects be accounted for to arrive at meaningful results. Further, for how long the pressures would have continued to increase cannot be predicted but an assumption is made that they would continue to increase at the same rate (psi/min) for the time required to displace the entire tubing volume with proppant. Thus the difference B−A′ is now considered to be the gain in net pressure in a particular stage and is deducted from the computed frictional pressure drop. Following equation summarizes the procedure.
Δp p =( p HYDs −p HYDf )−( p B −p D )− p net (21)
where, p B and p D are the surface pressures corresponding to points B and D shown in FIG. 2 , and P net is the net pressure described above. In some cases, as was observed during the study, there is apparently no gain or loss in the surface pressures during pad or proppant stages. In any event, the net pressure gain or loss is recorded for subsequent proppant stages. Total net pressure deducted while calculating pressure drop of a particular proppant stage, is the sum of net pressure build up till that stage. This is to make sure that the additional surface pressure gained as the treatment progresses to the point of interest is effectively removed. For example net pressures deducted in pressure drop calculation of 6 ppa stage in a pad-2-4-6-8 scheme would be the sum total of net pressures till the 4 ppa stage. It must be borne in mind that net pressure values can be positive or negative depending on the observed pressure gain or loss. Once the frictional pressure drops for individual stages are obtained, a friction multiplier, M f can be generated as follows
M f = Δ p f + Δ p p Δ p f ( 22 )
Landel's correlation shown in Eq. (5) proposes to define the relative slurry viscosity in terms of proppant volume fraction by fixing the value of the exponent to −2.5. In this study plots of friction multiplier, M f defined in Eq. (22), versus 1−{φ/φ m } were generated and it was observed that the value of exponent changed considerably for different scenarios. In terms of frictional multiplier, a higher absolute value of e would reflect a higher value of frictional pressures based on the following equation
M f = [ 1 - ϕ ϕ m ] - e ( 23 )
Value of φ m used in this study was 0.56. Though most of correlations, depict the relationship between proppant volume fraction φ and relative slurry viscosity μ r , this study emphasized on finding the values of exponent e for various cases and exploring its dependence on various other parameters like specific gravity, tubular internal diameter, and average flow velocity.
Proppant volume fraction φ can be calculated using the following relation
ϕ = p p a ( 8.33 × S . G . p ) + p p a ( 24 )
where, ppa is proppant concentration in lbm/gal. Friction pressure data were sorted on the basis of tubular diameter, gel concentration and proppant specific gravity. Gel concentrations recorded for the study were 30, 35, 40, and 45 lbm/Mgal flowing through tubular inner diameters of 2.441, 2.99, 3.92 and 4.0 inches, at several rates. Proppant specific gravity varied from 2.54 and 2.57 for resin-coated sands, 2.65 for Ottawa sand, 2.72 for Econoprop, and 3.25 for Caroboprop. Slurry hydrostatic pressures were computed using the surface proppant concentration noted recorded by the densitometers at the blender.
Several plots of In {Mf} versus In[1−{φ/φ m }] were generated. e was obtained as the slope of the line by setting the intercept to the origin of the plot at zero. FIG. 3 shows a typical plot used for generating the e values. The flow rate was 20 bbl/min of 35 lbm/Mgal in a tubular internal diameter of 2.99 inches. Proppant was Econoprop with a specific gravity of 2.72.
FIG. 4 depicts a plot of friction pressure exponent e vs. the average flow velocity {overscore (ν)} in ft/s for various proppant types in a base gel of 35 lbm/Mgal. Higher proppant specific gravity exhibited higher e values for the same flow velocity in one particular tubular size. This effect was noted for almost all data sets of same flow velocity but different specific gravities. On an average with nearly 6.5% increase in proppant specific gravity, the exponent increased by nearly 7.5%. Effect of proppant density was taken into consideration by plotting e′ vs average flow velocity {overscore (ν)}, where e′ is given by
e′=e×{S.G. p −S.G. w } a (25)
where S.G p and S.G. W are the specific gravities of proppant and water respectively, and a is the coefficient to be determined by plotting the data. Specific gravity of water is unity. FIG. 5 shows the plot of normalized e′ values for the data in the plot of FIG. 4 . The reduction in scatter of the data points is evident. It can also be noted that the trend for various tubular diameters is linear and the trend lines would be almost parallel to one another. Further, for the same flow rate, the normalized e values are lower for higher tubular diameter.
After the effect of proppant specific gravities are taken into consideration, the data pertaining to one tubular diameter is represented by a linear trend which shows a decrease in e′ with the increase in average flow velocity. This can be seen in FIG. 5 . Though the lines appear to exhibit a similar slope, it is apparent from the plot that the separation is some function of tubular internal diameter through which the slurry was flowing. Using several runs of trial and error procedure the data was successfully collapsed by plotting modified form of e′, given as e p and explained by following relation
e p =e×{S.G. p −S.G. w } a ×d z (26)
where d is the tubular internal diameter in inches, and {overscore (ν)} is the average flow velocity in ft/s. z can be determined by generating the mentioned plots. FIG. 6 shows the plot of e p generated for all the data available for 35-lbm/Mgal fluid. The data set appears to significantly collapse into a single linear trend.
Proppant friction exponents corresponding to other gel concentrations were plotted in a similar manner and linear trend showing nearly identical slopes and intercepts were observed. Fluid base gel viscosity does not appear to significantly affect the plots of e p vs. {overscore (ν)}, since the curves representing all the fluid types under study, i.e. 30, 35, 40, and 45 lbm/Mgal, overlap on one another, when plotted on one plot. This is shown in FIG. 7. A high correlation coefficient (0.9847) was observed. Correlation obtained from the plot is given as
e p =0.9035−0.0091×{overscore (ν)} (27)
Based on Eq. (26) and Eq. (27), e can be calculated as
e =(0.9035−0.0091×{overscore (ν)})×{ S.G. p −S.G. W } a ×d z (28)
where, d is the tubular diameter in inches, and {overscore (ν)} is the average flow velocity in ft/s. Friction multiplier M f can now be obtained from e using the relation shown in Eq (28) and the pressure drop due to addition of proppant can be predicted by using the following relation
Δ p s l L = M f × Δ p g e l L ( 29 )
where, Δp sl is the frictional pressure drop in the slurry and Δp gel is the frictional pressure drop of the base gel.
FIG. 8 shows the plot of e values that were obtained by using the correlation vs. the e values that were used in the development of correlation. Note that the slope of the distribution is around unity. Correlation Coefficient R 2 is around 0.9817 indicating that a deviation from the measured data may still exist. The deviation of calculated values of proppant friction coefficient with measured values however does not have very significant effect on the friction pressure drop when a comparison is carried out. Due to the exponent nature of e values, the variation often translates to difference in pressure drops at higher proppant stages. However, even this is not very significant. Consider for example, the plot shown in FIG. 9 showing the measured and the matched surface pressure responses. The job was carried with 35 lbm/Mgal fluid down 2.99 inch tubular internal diameter at 20 bbl/min. For proppant specific gravity of 2.72 (Econoprop) and an average velocity of 38.41 ft/s, this amounts to an e value of around 0.616. This compares very well with 0.62, which was the actual e values used for a good pressure match, indicating that the predicted deviation is only 0.504%. For the purpose of demonstration, a hypothetical error of around 9% is introduced and the plot is redrawn with an e value of 0.56. The results are shown in the plot of FIG. 9 . The simulated surface pressures in the plot do not seem to differ much from the measured value, and the simulated BHP matches the calculated BHP (using measured surface pressure and input fluid/proppant friction) for most of the job. Base gel fluid friction values were based on a correlation previously developed for CMHPG fluids and checked against the observed ISIP and pad pressure. Note that both these points are matched adequately in the plot.
Plot of FIG. 4 sheds some light on the diameter dependence of proppant friction exponent. It clearly shows that for the same average velocities and proppant specific gravities, smaller diameters tend to have larger values of proppant friction exponent. It has been shown through experiments conducted for borate cross linker based HPG fluids in vertical tubulars that after a certain critical flow velocity, the proppant in the slurry has a tendency to migrate towards the center of the pipe. Further, based on several jobs, it can be said that the event of proppant landing on the perforations is often marked by leveling out of surface pressures and the landing is consistent with the calculated time based on displacement volume and slurry rate. This would mean that the velocity profile in turbulent regime is mostly flat as there has been little indication that the proppant in the core would land ahead of the calculated time. Thus with the increase in proppant concentration at the surface, the diameter of internal core would increase to a point where it may lead to aberration of pipe-wall flow and contribute to higher friction pressures. These effects will be more pronounced for lower diameter tubular since relatively lower proppant concentrations would cause a rapid increase in the supposed proppant core diameter leading to an earlier proppant to wall interaction. This would eventually lead to a steeper increase in friction multipliers for lower diameter tubulars compared to larger diameters, for the same proppant volume fraction. Based on the definition of proppant exponent, this means a larger e value.
It must be borne in mind that use of correlation such as this may be restricted to the range of average velocities that have been used to define it. The correlation was generated using average flow velocities in the range of 20 to 80 ft/s. Most of the hydraulic fracturing treatments pumped these days should fall in this range. Furthermore the correlation may be valid mainly for proppant sizes closer to 20-40 mesh where the average grain size is around 0.026 inch. The effect of change in the friction pressure with the change in proppant size is currently not studied. The proppant friction pressure data used for developing these correlations was largely from vertical wells, and it remains to be seen if it can be extended to deviated wells. Due to gravitational effects and settling of proppant it is possible that e values for deviated wells may be higher.
The correlation shown by Eq. (28) can be used to calculate the values of proppant friction coefficient e, which can tremendously aid in generating the BHP or net pressures in the absence of dead strings or BHP gauge. The base-gel friction can be obtained by using the ISIP technique described in the text above.
These calculations can be programmed on a spreadsheet for easy field use or, according to a preferred embodiment of the present invention, integrated into a design software such as FracCADE (mark of Schlumberger). This can be carried out in two ways. Firstly, for the design mode, inbuilt calculator that makes use of input values of proppant, concentration, proppant specific gravity, tubular diameter and the rate at which the job has to be pumped can provide the e values. Provision can be made for the user to input his own e values if he is not satisfied with the correlation-obtained value.
Provision can be made for the user to click on these values and define the surface pressures, or it could also be automatic. As soon as the real time data has a minimum of three data points, the user can calculate friction multipliers and thus compute the e value for an averaged rate and proppant volume fraction. If real-time pressure match is run at this point, the software will suggest this value to the user. | The present invention relates to a method of determining the proppant friction generated in a fracture of a subterranean formation during a hydraulic fracturing treatment involving injection stages of pad and of proppant-laden fluids. This method is based on close monitoring of surface pressure to define a “net pressure rate” which defines an increase or decrease of net pressure while the job is being pumped, and then relates it with the pressure changes observed with the onset of proppant stages of varying concentrations. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/103,593, filed on Oct. 8, 2008. The entire disclosure of the above application is incorporated herein by reference.
FIELD
The present disclosure relates to variable displacement vane pumps. More specifically, the present invention relates to a variable displacement vane pump and system whose output flow is continuously variable and which can be selected independent of the operating speed of the pump.
BACKGROUND
Mechanical systems, such as internal combustion engines and automatic transmissions, typically include a lubrication pump to provide lubricating oil, under pressure, to many of the moving components and/or subsystems of the mechanical systems. In most cases, the lubrication pump is driven by a rotating component of the mechanical system and thus the operating speed and output of the pump varies with the operating speed of the mechanical system. The lubrication requirements of the mechanical system do not directly correspond to the operating speed of the mechanical system.
To deal with these differences, prior art fixed displacement lubricating pumps were generally designed to operate effectively at a target speed and a maximum operating lubricant temperature resulting in an oversupply of lubricating oil at most mechanical system operating. A pressure relief valve was provided to return the surplus lubricating oil back into the pump inlet or oil sump to avoid over pressure conditions in the mechanical system. In some operating conditions such as low oil temperatures, the overproduction of pressurized lubricating oil can be 500% of the mechanical system's needs. The result is a significant amount of energy being used to pressurize the lubricating oil which is subsequently exhausted through the relief valve.
More recently, variable displacement vane pumps have been employed as lubrication oil pumps. Such pumps generally include a control ring, or other mechanism, which can be operated to alter the volumetric displacement of the pump and thus its output at an operating speed. Typically, a feedback mechanism is supplied with pressurized lubricating oil from the output of the pump to alter the displacement of the pump to operate and to avoid over pressure situations in the engine throughout the expected range of operating conditions of the mechanical system.
While such variable displacement pumps provide some improvements in energy efficiency over fixed displacement pumps, they still result in a significant energy loss as their displacement is controlled, directly or indirectly, by the output pressure of the pump which changes with the operating speed of the mechanical system, rather than with the changing requirements of the lubrication system. Accordingly, such variable displacement pumps must still be designed to provide oil pressures which meet the highest expected mechanical system requirements, despite operating temperatures and other variables, even when the mechanical system operating conditions normally do not necessitate such high requirements.
Another variable displacement pump control system is described within U.S. Pat. No. 7,018,178. The control system includes an electrical solenoid coupled to a variable displacement pump for varying the displacement of the pump during engine operation. While an electric solenoid may provide an additional degree of pump control, several disadvantages from its use exist. In particular, a solenoid requires a continuous supply of current to keep it active through operation of the pump. The use of the electrical power offsets the benefit of controlling the pump to minimize the amount of time where the pump provides excess lubricant flow. Furthermore, the maximum force capability of the solenoid is limited by the size of the electromagnet and the current applied thereto. For certain applications, the size of the electromagnet required to provide the desired force may be prohibitive for packaging the solenoid within an automotive environment. Accordingly, a need exists for an improved lubrication system capable of producing a desired lubricant flow while minimizing the energy required to do so.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
A lubrication system for a power transmission device includes a variable displacement vane pump including a moveable control ring for varying the displacement of the pump. A linear actuator directly acts on the control ring for moving the control ring between maximum and minimum pump displacement positions. The linear actuator includes an electric motor for rotating a drive member. The drive member engages a driven actuator shaft to cause linear translation of the actuator shaft in response to rotation of the drive member. A control system includes a controller for signaling the actuator to extend or retract the actuator shaft to vary the pump displacement.
Furthermore, a lubrication system for a power transmission device includes a variable displacement vane pump having a pivotable pump control ring for varying the displacement of the pump. A control system is operable to vary the displacement of the pump during operation of the pump to achieve an output pressure selected from a continuously variable range of output pressures from the pump which are independent from the operating speed of the pump. The control system includes a linear actuator coupled to the control ring for moving the control ring between minimum and maximum pump displacement positions. The linear actuator includes an electric stepper motor for bi-directionally rotating a nut threadingly engaged with an axially moveable actuator shaft. A coupler interconnects the shaft and the control ring and has multiple degrees of freedom to allow concurrent axial movement of the actuator shaft and rotation of the control ring.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is a cross-sectional view of an exemplary directly controlled variable displacement vane pump;
FIG. 2 is a sectional view of a portion of the pump and actuator assembly shown in FIG. 1 ;
FIG. 3 is an enlarged fragmentary perspective view of the pumping system depicted in FIGS. 1 and 2 ;
FIG. 4 is a schematic of an open loop control system for controlling the variable displacement vane pump;
FIG. 5 is a schematic depicting a closed loop control system cooperating with the variable displacement vane pump;
FIG. 6 is a fragmentary perspective view of an alternate connector coupling the actuator shaft and the control ring;
FIG. 7 is a fragmentary perspective view of another alternate connector coupling the actuator shaft and the control ring;
FIG. 8 is a fragmentary perspective view of another alternate connector coupling the actuator shaft and the control ring;
FIG. 9 is a fragmentary perspective view of another alternate connector coupling the actuator shaft and the control ring;
FIG. 10 is a fragmentary perspective view of another alternate connector coupling the actuator shaft and the control ring;
FIG. 11 is a fragmentary perspective view of another alternate connector coupling the actuator shaft and the control ring;
FIG. 12 is a fragmentary perspective view of another alternate connector coupling the actuator shaft and the control ring;
FIG. 13 is a sectional view of another alternate connector coupling the actuator shaft and the control ring; and
FIG. 14 is a fragmentary perspective view of another alternate connector coupling the actuator shaft and the control ring.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Example embodiments will now be described more fully with reference to the accompanying drawings.
With reference to FIGS. 1-3 , a pumping system 10 is shown plumbed in communication with an exemplary power transmission device 12 . Power transmission device 12 is shown schematically and may include any number of devices including an internal combustion engine, a transmission, a transfer case, an axle assembly or the like. Pumping system 10 includes a variable displacement pump 14 including a housing 16 with a flange 17 for mounting pump 14 to power transmission device 12 . Alternatively, housing 16 may be integrally formed with the power transmission device. An inlet 18 extends through housing 16 interconnecting a low pressure gallery 20 with a sump 22 storing the fluid to be pumped. An outlet 24 of housing 16 interconnects a high pressure chamber 26 with power transmission device 12 .
Pump 14 includes a pump rotor 28 rotatably mounted within a rotor chamber 32 . A drive shaft 34 is fixed for rotation with pump rotor 28 to provide energy for pumping the lubricant. A plurality of pump vanes 36 are coupled to rotor 28 and radially slidable relative thereto. The radial outer end of each vane 36 engages an inner surface 38 of a pump control ring 40 . A plurality of pumping chambers 44 are defined by inner surface 38 , pump rotor 28 and vane 36 . Control ring 40 includes an integrally formed pivot pin 46 positioned within a recess 48 formed in housing 16 . It should be appreciated that control ring 40 may be pivotally mounted within housing 16 via many other suitable methods as well. Inner surface 38 of pump control ring 40 has a circular cross-sectional shape. An outer surface 50 of rotor 28 also has a circular cross-sectional shape. The center of surface 38 is eccentrically located with respect to the center of surface 50 . Accordingly, the volume of each pumping chamber 44 changes as rotor 28 rotates. The volume of chambers 44 increases at the low pressure side of the pump in communication with inlet 18 . Pumping chambers 44 decrease in size at the high pressure side in communication with outlet 24 of pump 14 . The change in volume of pumping chambers 44 generates the pumping action by drawing working fluid from sump 22 and delivering pressurized fluid from outlet port 24 .
The output of pump 14 may be varied by rotating pump control ring 40 about pivot pin 46 . In particular, the amount of eccentricity between inner surface 38 of pump ring 40 and the outer surface 50 of rotor 28 changes as control ring 40 is rotated.
A radially outwardly protruding arm 60 is integrally formed with control ring 40 and protrudes outside of pumping chambers 44 . An actuator assembly 62 is coupled to arm 60 and is operable to move control ring 40 between a first position, a second position and any point therebetween. In the first position, the control ring provides maximum eccentricity and maximum pump flow. At the second position, control ring 40 is positioned at a minimum eccentricity relative to rotor 28 and a minimum of output occurs.
To reduce the magnitude of force required to be provided by actuator assembly 62 , a first pressure balance chamber 64 is formed on a first side of control ring 40 while a second pressure balance chamber 66 is formed on an opposite side of control ring 40 . First pressure balance chamber 64 and second pressure balance chamber 66 are each in fluid communication with pressurized fluid provided from outlet 24 . This arrangement effectively balances the forces acting on control ring 40 thereby minimizing the force required to move control ring 40 and vary the pump output. It should be appreciated that the pressure balanced arrangement may be desirable but is not a requisite portion of pumping system 10 . With the pressure balancing chambers, actuator 62 may function but may be tasked to provide a greater input force to move control ring 40 .
Actuator assembly 62 includes an electric stepper motor 70 including a stator 72 and a rotor 74 supported in a housing 75 . Rotor 74 is coupled to a nut 76 that is threadingly engaged with an externally threaded actuator shaft 78 . Housing 75 includes a flange 79 coupled to pump housing 16 . Flange 79 may alternatively be fixed to power transmission device 12 . Actuator shaft 78 includes a distal end 80 coupled to arm 60 by a connector 81 . A yoke 82 includes a first end 84 rotatably coupled to arm 60 via a pin 86 . A second end 88 of yoke 82 is bifurcated defining a slot 90 bounded by first and second fingers 92 , 94 . A clevis pin 96 rotatably interconnects yoke 82 and actuator shaft 78 .
Referring to FIG. 4 , actuator assembly 62 is in communication with a controller 100 , a power supply 102 and a drive 104 . Controller 100 may be programmed with an algorithm or algorithms referencing speed, pressure, flow or temperature maps to enable the controller to control the flow of the pump using an open loop control system as depicted in FIG. 4 . FIG. 5 depicts a closed loop control system including a pressure sensor 106 in communication with controller 100 .
In operation, driveshaft 34 begins to rotate and drive rotor 28 . Lubricant pressure and flow begin to increase at outlet 24 . At start-up, controller 100 locates control ring 40 in the first position. As such, flow increases linearly with the speed of driveshaft 34 . At a particular speed, the flow produced by pump 14 will exceed the lubrication requirements of power transmission device 12 . At this time, controller 100 provides a signal to drive 104 . Drive 104 is in receipt of electrical power from power supply 102 . Drive 104 generates electrical pulses and supplies pulses to electric stepper motor 70 causing nut 76 to rotate in one of two directions to extend or retract actuator shaft 78 as signaled by controller 100 . Because actuator shaft 78 is directly coupled to control ring 40 , the linear motion of actuator shaft 78 changes the eccentricity of the pump and thus the pump output flow.
When the open loop control system of FIG. 4 is implemented, controller 100 continues to signal drive 104 to position control ring 40 based on any one or more of speed, pressure, flow or temperature mappings of the control algorithm. A dedicated pressure sensor associated with pump 14 is not required. Alternatively, the closed loop feedback system depicted in FIG. 5 includes pressure sensor 106 providing a signal indicative of the pressure output by pump 14 to controller 100 . Controller 100 outputs a signal to drive 104 to position control ring 40 and cause pump 14 to output a desired lubricant pressure.
FIG. 6 depicts an alternate method of drivingly interconnecting actuator shaft 78 and arm 60 . A threaded sleeve 110 includes a threaded throughbore 112 . Actuator shaft 78 is threadingly engaged with threaded bore 112 . A connector 114 includes a first end having a reduced diameter and an externally threaded portion 116 as well as another portion 118 including a transversely extending through aperture. Threaded portion 116 is engaged with threaded bore 112 to fix threaded sleeve 110 to connector 114 . An elongated slot 120 extends through arm 60 in a direction substantially perpendicular to the direction of travel of actuator shaft 78 . A pin 122 extends through slot 120 and the aperture formed in connector 114 to drivingly interconnect actuator shaft 78 and control ring 40 while allowing the requisite degrees of freedom to allow control ring 40 to rotate while actuator shaft 78 linearly translates.
FIG. 7 depicts another alternate method of interconnecting actuator shaft 78 and control ring 40 . A driver 130 includes one end having an internally threaded bore 132 and an opposite end having a substantially spherical outer surface 134 . Threaded bore 132 is coupled to an externally threaded end 136 of actuator shaft 78 . Arm 60 includes a cam surface 138 engaged by spherical surface 134 of driver 130 . A spring 140 is positioned within a cavity 142 shown in FIG. 1 . Spring 140 biases arm 60 into engagement with spherical surface 134 . In this manner, a constant engagement between surface 138 and spherical surface 134 will be maintained throughout operation of pumping system 10 . Furthermore, spring 140 urges control 40 toward the position of maximum eccentricity.
With reference to FIG. 8 , another alternate method for interconnecting actuator shaft 78 and control ring 40 is illustrated. A clevis 150 includes a threaded internal bore 152 fixed to an externally threaded portion of actuator shaft 78 . Clevis 150 includes a bifurcated end opposite threaded bore 152 including a first leg 154 spaced apart from a second leg 156 . A connector 158 includes a first end 160 positioned between first leg 154 and second leg 156 . A first arm 164 and a second arm 166 are integrally formed with control ring 40 . A second end 162 of connector 158 is positioned between first and second arms 164 , 166 . A pin 168 interconnects connector 158 with control ring 40 and allows relative rotation therebetween. Once clevis 150 is threadingly engaged with actuator shaft 78 and connector 158 is pinned to control ring 40 , connector 158 is rotated in alignment with clevis 150 to allow insertion of another pin 170 rotatably interconnecting connector 158 to clevis 150 .
Another alternate interconnection method is shown in FIG. 9 . A clevis 180 includes an open frame portion 182 having a through aperture 184 extending through one portion of the frame. An opposite portion of the frame includes integrally formed and spaced apart first and second legs 186 , 188 . A distal portion of actuator shaft 78 extends through aperture 184 . A nut 190 threadingly engages an externally threaded portion of actuator shaft 78 to fix clevis 180 to actuator shaft 78 . A connector 192 includes a cylindrically shaped portion 194 and a radially protruding shaft portion 196 . A flattened portion 198 is formed at the distal end of shaft portion 196 and positioned between first and second legs 186 , 188 . A pin 200 rotatably interconnects connector 192 and clevis 180 . Cylindrical portion 194 is rotatably coupled to control ring 40 by being positioned within a cylindrically shaped seat 202 of an integrally formed arm 204 . Shaft portion 196 extends through a slot 206 formed in arm 204 .
FIG. 10 depicts another method of interconnecting actuator shaft 78 and control ring 40 . In particular, a ball joint assembly 210 and a connector 212 couple actuator shaft 78 to a bifurcated pair of arm portions 214 , 215 integrally formed with control ring 40 . Ball joint assembly 210 includes a socket 216 having a first end fixed to actuator shaft 78 and a second end defining a substantially spherical concave surface 220 . Ball joint assembly 210 also includes a ball stud 222 including a shank 224 and a ball 226 integrally formed with each other. Ball 226 engages spherical surface 220 of socket 216 . Connector 212 is threadingly engaged with shank 224 and positioned between arms 214 , 215 . A pin 228 rotatably interconnects connector 212 and control ring 40 .
FIG. 11 depicts a similar connection system to that described in relation to FIG. 10 . Accordingly, like elements will retain their previously introduced reference numerals including an “A” suffix. The connection system of FIG. 11 eliminates connector 212 A and utilizes pin 228 A to rotatably interconnect shank 224 A and control ring 40 .
FIG. 12 shows another connection including a ball joint assembly 230 including a socket 232 fixed to actuator shaft 78 and a ball shank 234 fixed to a clevis 236 . Ball shank 234 may be coupled to clevis 236 via a threaded interconnection or another load transferring method. Clevis 236 includes a bifurcated end 237 coupled for rotation with arm 60 by a pin 238 .
As shown in FIG. 13 , another method of drivingly interconnecting actuator shaft 78 and a control ring 239 is depicted. In this arrangement, a ball stud 240 is fixed to the distal end of actuator shaft 78 . Control ring 239 includes an integrally formed pocket having a cylindrically shaped surface 244 . The cylindrical surface 244 extends an arc length greater than 180 degrees to retain a spherically shaped ball 246 of ball stud 240 therein. Surface 244 extends substantially the entire width of control ring 239 to allow ball stud 240 to be inserted within the recess prior to interconnection to actuator shaft 78 . Conversely, ball stud 240 may be fixed to actuator shaft 78 and then subsequently coupled to control ring 239 .
Yet another method for interconnecting actuator shaft 78 and control ring 40 is depicted at FIG. 14 . A ball joint assembly 250 and an adapter 252 couple actuator shaft 78 to control ring 40 . One end of adapter 252 is fixed to a distal end of actuator shaft 78 via a threaded connection. An opposite end of adapter 252 is coupled to a socket 254 of ball joint assembly 250 via another threaded interconnection. A ball stud 256 extends between bifurcated arms 258 , 260 of control ring 40 . A pin 262 rotatably interconnects ball shank 256 with control ring 40 .
A number of coupling techniques have been described to facilitate a ridged mounting of actuator housing 75 to pump housing 16 or another portion of power transmission device 12 . The connection provides sufficient degrees of freedom to allow actuator shaft 78 to linearly translate and transfer a force to the pivotally moveable control ring 40 . While many of the interconnections have been described as threaded couplings, it should be appreciated that any number of methods for fixing two components relative to one another such as pinning, riveting, welding, press-fitting, adhesive bonding or the like, are contemplated as being within the scope of the present disclosure. Furthermore, while the closed loop control system was previously described as being in communication with a pressure sensor, it should be appreciated that any number of other sensors may be implemented to provide controller 100 with data for decision making relating to the control of actuator 62 and pumping system 10 .
Furthermore, the foregoing discussion discloses and describes merely exemplary embodiments of the present disclosure. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations may be made therein without departing from the spirit and scope of the disclosure as defined in the following claims. | A lubrication system for a power transmission device includes a variable displacement vane pump including a moveable control ring for varying the displacement of the pump. A linear actuator directly acts on the control ring for moving the control ring between maximum and minimum pump displacement positions. The linear actuator includes an electric motor for rotating a drive member. The drive member engages a driven actuator shaft to cause linear translation of the actuator shaft in response to rotation of the drive member. A control system includes a controller for signaling the actuator to extend or retract the actuator shaft to vary the pump displacement. | 5 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a unique locking device and particularly to an exterior slide bolt type-locking device for securing doors and gates. More particularly, the invention relates to a slide bolt type lock in which the locking mechanism is integrated into the slide bolt.
[0002] Conventional slide bolt locks are widely know and used to lock structures such as gates, entry doors and overhead doors. It is well known for conventional slide bolt designs to use a separate padlock or other non-integrated locking system. The present locking device is structured to mechanically integrate with the slide bolt to lock and unlock the protected entryway.
[0003] Several patents are illustrative of earlier, similar devices. U.S. Pat. No. 4,095,828 [East] describes a slide lock, including barrel and bolt members, for securing a gate or similar structure. The shackle of the padlock is inserted into and around a first aperture in the bolt extension and then through a second aperture in both the bolt extension and the barrel to secure the bolt in the closed position. The barrel has longitudinal extensions that limit tampering with the bolt and lock when the bolt is engaged by folding over the outer surfaces of the barrel and the shackles of the padlock when inserted in the locking mechanism. Unlike the current invention the padlock shackles are not locked directly into and through the slide bolt and barrel housing.
[0004] U.S. Pat. No. 4,234,220 [Finch, et al.] discloses a tamper proof exterior locking system that includes dual sets of shackles for securing padlocks to the slide bolt assembly. An external housing extending outward from the back plate extends over and around the padlocks when inserted onto the shackles, preventing tampering. Both padlocks are engaged regardless of the position of the slide bolt, i.e., engaged or disengaged. The differences from the described invention are that one set of shackles is fixedly mounted to the back plate and the second set is insertable into and through the cover plate when the slide bolt is positioned. Again, this patent does not disclose the shackles of the padlock directly connected to the slide bolt.
[0005] The present invention will allow the locking mechanism to include the slide bolt as an integral part of the locking device, and not as a separately combined apparatus. None of the patents discussed above provide for the integration of the actual locking apparatus onto or through the shaft of the slide bolt, or though the barrel housing, nor do they provide for the disengaged locking of the slide bolt device.
[0006] It is an object of the present invention to provide a single locking device that can be locked in either the engaged or disengaged position using an integrated locking apparatus. It is a further object of the present invention to provide a slide bolt locking device that has an integral key-way or combination lock integrally mounted to the shaft of the slide bolt so that the locking mechanism is always attached to the locking device whether in the engaged or disengaged position.
[0007] It is an additional object of the present invention to permit the locking of the slide bolt locking device in both the engaged and in the disengaged position to prevent tampering with the locking device. It is yet another object of the present invention to substantially eliminate tampering with the slide bolt locking device, whether engaged or disengaged, by integrally mounting the locking apparatus to and through the shaft of the slide bolt and through the barrel housing.
[0008] Other objects will appear hereinafter.
SUMMARY OF THE INVENTION
[0009] The present slide bolt locking device invention comprises an entryway locking apparatus including a slide bolt with an integrated key or combination lock. The locking device has a body and a shaft movable into and out of engagement with a slide bolt keeper. The invention further comprises a means for attaching the barrel housing and the slide bolt keeper to a structure such as a door or other entryway closing apparatus such as a gate. The locking device has a locking mechanism with means to engage and disengage directly onto the shaft while the shaft is engaged with the slide bolt keeper, and also while the shaft is disengaged from the slide bolt keeper. Two apertures in the barrel housing for the slide bolt are provided to accommodate the means for locking mechanism to engage and disengage directly onto or through the slide bolt shaft. The invention may also be accomplished by a single aperture in the shaft to accommodate the means for locking mechanism to engage and disengage directly onto said shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front view of the locking device of the present invention showing the locking mechanism engaged.
[0011] FIG. 2 is a front view of the locking device of the present invention showing the locking mechanism disengaged.
[0012] FIG. 3 is a front view of the locking device of the present invention showing the locking mechanism disengaged and swung outward for withdrawing the bolt from the keeper.
[0013] FIG. 4 is a front view of the locking device of the present invention showing the locking mechanism disengaged, swung outward, and being re-aligned with the disengaged bolt locking position.
[0014] FIG. 5 is a front view of the locking device of the present invention showing the locking mechanism disengaged, swung inward, and being re-aligned with the disengaged bolt locking position.
[0015] FIG. 6 is a front view of the locking device of the present invention showing the locking mechanism re-engaged in the disengaged bolt locking position.
[0016] FIG. 7 is a view of a structure entry door showing the locking device of the present invention mounted to the entry door.
[0017] FIG. 8 is a view of a fence and gate system showing the locking device of the present invention mounted to the gate and adjoining fence structure.
[0018] FIG. 9 is a view of an overhead door system showing a pair of the locking devices of the present invention mounted to the door at two points and the opposing door rail structure.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The principles and operation of the present invention are better understood with reference to the drawings and the accompanying description. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings. In order to aid in understanding of the invention, reference numerals that are referred to in the specification with respect to one or more figures may appear in additional figures without a specific reference to such additional figures in the specification.
[0020] The following detailed description is of the best presently contemplated modes of carrying out the invention. Referring now to the drawings in detail, there is shown in FIG. 1 one form of the locking device 10 of the present invention. The locking device 10 can be made of any well-known lock material, such as metals and metal alloys, and is comprised of a lock body 12 , locking pins 14 a, 14 b, and a slide bolt 16 slidably mounted within barrel housing 18 to enable the mounting of the locking device 10 to a structure. The slide bolt or movable shaft 16 is housed within the barrel housing 18 and is movable into and out of a slide bolt keeper 20 also having means to enable the mounting of the keeper 20 to the structure. Both the barrel housing 18 and slide bolt keeper 20 have means to mount these elements to structures, i.e., flanges 13 , 15 , to facilitate the mounting of each of each to a structure through a series of apertures in the flanges 13 , 15 . Attachment of the locking device 10 to a structure can be accomplished using any known fastening means to mount the flanges 13 , 15 of the barrel housing 18 and slide bolt keeper 20 to the structure. In the drawings the fastening means 22 are shown as screws.
[0021] The locking 12 of the invention is comprised a locking mechanism (not shown) internal to the lock, two locking pins 14 a, 14 b that extend upward out of the body of the lock 12 , extending toward the slide bolt 16 . Locking pin 14 a fits into a cooperating and appropriately sized aperture 24 a in movable shaft 16 when the lock 12 is in the engaged or locked position. Locking pin 14 b is integrally attached and made part of the slide bolt 16 at an aperture 24 b into which the locking pin 14 b is permanently fixed. An H-shaped aperture 26 in the barrel housing 18 spans the space between and includes the aperture 24 a and the attachment point 24 b to facilitate the sliding movement of movable shaft 16 and locking means 12 back and forth within the barrel housing 18 . A second aperture 28 in barrel housing 18 , having similar dimensions to aperture 24 a, facilitates the securing of the locking means 12 while movable shaft 16 is disengaged from the slide bolt keeper 20 to be more fully described below.
[0022] Referring to FIG. 2 , locking means 12 is shown in an unlocked position exposing a notch 30 in locking pin 14 b, which facilitates locking of the locking mechanism in lock 12 . Locking pin 14 b may be welded or permanently attached by any other well-known method to the movable shaft 18 . When the locking mechanism 12 is in the unlocked position, rotational movement of the slide bolt 16 along the longitudinal axis within the barrel housing 18 and lateral movement of the slide bolt 16 and attached locking device 12 through the H-shaped aperture 26 will permit the withdrawal of the slide bolt 16 from the keeper 20 . FIG. 2 also shows the locking pin 14 a in the unlocked position withdrawn from the locking aperture 24 a within barrel housing 18 . Locking pin 14 a may be attached permanently to locking means 12 with an outward length sufficient to fully engage the locking aperture 24 a, but not overly long to block the rotation of the slide bolt 16 within the barrel housing 18 in order to permit disengagement of the locking pin 14 a from the slide bolt 16 and facilitate lateral movement of the slide bolt 16 .
[0023] In the first embodiment of this invention, locking means 12 is swung outward and away from slide bolt 16 substantially perpendicular to the plane of the mounted locking device 10 such that locking pin 14 b can move through the H-shaped aperture 26 , facilitating the lateral sliding of shaft 16 out of and away from the slide bolt keeper 20 . See FIG. 3 that shows the locking means 12 in the unlocked position and rotated away from the barrel housing 18 , but with the locking device 10 still engaged within the keeper 20 . With reference to FIG. 5 , this view shows the slide bolt 16 slidably moved leftward so that locking pin 14 a can engage the apertures 24 a, 28 . In FIG. 6 , the locking device 10 is shown with locking pins 14 a, 14 b in the locked position along the slide bolt 16 , but with the movable shaft 16 in the disengaged position, withdrawn from the slide bolt keeper 20 . Locking pin 14 a is located within the second aperture 28 of the barrel housing 18 , as well as in aperture 24 a of slide bolt 16 . Locking pin 14 b is now located on the other, or left, side of the H-shaped aperture 26 and the notch 30 is reengaged within locking means 20 .
[0024] In a second embodiment of the present invention, locking pin 14 a also has a notch 32 and can be removed from locking device 12 . The locking pin 14 a can be repositioned into the aperture 28 of slide bolt 16 in order to reengage the locking device 12 with notch 32 located along the body of locking pin 14 a. FIG. 4 shows locking pin 14 a being relocated from the left side of locking means 12 into the second aperture 28 of the barrel housing 18 as well as into the aperture 24 a of the movable shaft 16 . The locking pin 14 a is shown as not yet engaged with the locking means 12 until the locking means 12 is reengaged with the notches 30 , 32 of both locking pins 14 a, 14 b as shown in FIG. 6 .
[0025] With the operation and structural configuration of the present invention described above, FIG. 7 shows the invention mounted on an exterior door 50 with a doorjamb 52 . The locking device 10 is mounted across the space between the door 50 and the doorjamb 52 such that the flanges 13 of barrel housing 18 are mounted to the door 50 and the flanges 15 of slide bolt keeper 20 are mounted to the doorjamb 52 . In this manner the slide bolt 16 may be withdrawn from and reinserted into the keeper 20 to unlock and relock the door 50 . Similarly, in FIG. 9 , there is shown a pair of the locking devices 10 of the present invention used to secure an overhead door 54 having door rail structures 56 . The door rails 56 are used to mount the slide bolt keeper 20 and the overhead door receives the barrel housings 18 so that the slide bolt 16 can operate to engage and lock, or be withdrawn and unlock, the door 54 when the two parts of the locking device 10 are aligned for sliding engagement.
[0026] Finally, FIG. 8 shows the locking device 10 of the present invention mounted a gate 58 to an enclosure fence 60 . The locking device spans the gap between the gate 58 and the opposing gatepost 62 with the flanges 13 of barrel housing 18 mounted to the gate 58 and the flanges 15 of slide bolt keeper 20 mounted to the gatepost 62 . With the slide bolt aperture of both the barrel housing 18 and the keeper 20 aligned, the slide bolt 16 can operate to engage and lock, or be withdrawn and unlock, the gate 58 when the two parts of the locking device 10 are aligned for sliding engagement.
[0027] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein. | The invention relates to a secure slide bolt device, and can be utilized in a number of different structures and on different structures access points. More specifically the invention relates to a slide bolt having a locking mechanism integral with and part of the slide bolt. The invention is designed specifically so that the locking mechanism locks into the slide bolt, rather than being a separate and distinct mechanical lock. | 4 |
This application is based on Japanese Patent Application No. 2009-179926 filed with the Japan Patent Office on Jul. 31, 2009, the entire content of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a controller, and more specifically, to a technique of monitoring data transmitted and received between a controller configuring an FA system and a device/apparatus such as a remote device.
2. Related Art
The network system in FA (Factory Automation) has one or a plurality of PLCs (Programmable Logic Controller) responsible for the control of an input device and an output device of an industrial robot and other production facilities arranged inside a production factory, and a device which operation is controlled by the PLC connected to a network of a control system. The PLC and the device cyclically communicate through the network of the control system to transmit and receive IN data and OUT data (hereinafter referred to as I/O data), and control the production facilities.
FIG. 1 shows one part of the network system. In the example, Ethernet (registered trademark) is used as a communication protocol, and a controller 1 such as the PLC and the motion controller and a remote device 2 transmit and receive the I/O data through a switching hub 3 . The controller 1 includes a CPU 1 a responsible for control, a memory 11 b for storing programs for the CPU 1 a to operate, and a connection interface 1 c for connecting to the network. The program stored in the memory 1 b includes a system program for performing the basic operation, and a user control program (hereinafter also referred to as a user program) for actually performing the control. Other than the program, in the memory 1 b , a work area used by the CPU 1 a when executing the operation is ensured, and a memory area for storing the IO data and the like is ensured. A nonvolatile memory and a volatile memory are used for such memories depending on the application. As shown in the figure, the connection interface 1 c includes an RJ45, which is a connector for attaching the terminal of a connection cable 5 complying with the communication protocol, a PT: pulse transformer, a PHY: physical layer, a Mac: media access controller, and the like.
The remote device 2 includes a connection connector 2 a to the network such as the RJ45. The terminal of the communication cable 5 connected to the switching hub 3 is attached to the connection connector 2 a to plug into the network. In FIG. 1 , a plurality of remote devices 2 is drawn as if connected to one area of the switching hub 3 for the sake of convenience of illustration, but is connected to a plurality of ports arranged at the switching hub 3 . The remote device 2 may further connect an external device 4 such as a motor if it operates on its own.
When failure occurs in the FA network system, the IO data is sometimes verified to analyze the cause etc. thereof. In this case, a protocol monitor 6 is connected to the network so that the IO data transmitted on the network is acquired at the protocol monitor 6 , and the protocol monitor 6 performs analysis based on the acquired 10 data.
The protocol motor 6 includes a CPU 6 a , a memory 6 b , and a connection interface 6 c with respect to the network. The connection interface 6 c may have a configuration similar to that of the controller 1 . The memory 6 b includes a buffer area for storing system programs serving as a basic function for operating the protocol monitor 6 , control conditions of the monitor function, and the acquired monitor data. The control conditions are set by the user or the technician specializing in network.
The monitor data buffer can automatically stop when receiving up to the buffer capacity, and can continue the operation continuously, as a ring buffer, to the control condition by discarding the data in order from the oldest. The monitor data of the monitor data buffer is generally saved as a file.
FIG. 2 shows an example of monitoring the IO data transmitted and received between the controller 1 and the servo driver, which serves as the remote device 2 , in the network system. As shown in the figure, the controller 1 , the remote device (servo driver) 2 , and the protocol monitor 6 are connected to predetermined ports P 1 , P 2 , P 3 of the switching hub 3 . A port in the switching hub 3 is set as a mirror port and then the protocol monitor 6 is connected to such port for the protocol monitor 6 to acquire the data transmitted and received between the controller 1 and the remote device 2 . The port P 3 is the port set as the mirror port.
When set to such mirror port, all communication frame data transmitted and received at a certain port (port P 2 connected with the remote device (servo driver) in the figure) are transferred to the mirror port (port P 3 ). Thus, all communication frame data including the IO data can be captured by the protocol monitor by connecting the protocol monitor 6 to the mirror port.
FIG. 3 is a view showing a transmission/reception buffer structure of a driver unit in the protocol monitor 6 , and a correlation of transmission/reception and transfer of the data. A reception buffer and a transmission buffer are ensured as a software structure of a general Ethernet (registered trademark) to realize a full-duplex communication (simultaneous execution of the reception process and the transmission process). The respective buffer generally forms a structure of the ring buffer by a plurality of buffer (eight, 0 to 7 in the figure) arrays, and a storage end pointer and a next storage pointer.
The function of the ring buffer will be described using the reception operation by way of example. The Ethernet controller provides the reception data mirrored and transferred from the switching hub 3 to the Ethernet driver unit (reception request). The Ethernet driver unit stores the reception data in the reception buffer (“reception buffer 6 ” in the figure) set with the next reception storage pointer by the reception request from the Ethernet controller. Thereafter, the next reception storage pointer is incremented by one to prepare for the next reception. The pointer is returned to the reception buffer 0 when reaching the end of the data array.
The high-order module (TCP/IP and frame monitor in the figure) reads out the reception data stored in the reception buffer (“reception buffer 2 ” in the figure) indicated with the reception storage end pointer at an arbitrary timing, and the read reception data is stored in the monitor data buffer in the memory 6 c . Thereafter, the reception storage end pointer is incremented by one to prepare for the next reading. The pointer is returned to the reception buffer 0 when reaching the end of the data array. Therefore, continuous reception process is performed by assuming the data array as the ring structure by the data array and the process by the pointer. Such description is the same for the transmission process.
Therefore, the data transmitted and received between the controller 1 and the remote device 2 are stored in the monitor data buffer, and the analyzing function stored in the protocol monitor 6 is operated to analyze the data stored in the monitor data buffer. A management system using the protocol monitor is disclosed in Japanese Unexamined Patent Publication No. 2000-224184.
SUMMARY
In the management using the conventional protocol monitor, the protocol monitor 6 serving as an external device having the protocol monitor function is prepared in addition to the controller such as the PLC and the motion controller, and such protocol monitor 6 is connected to the mirror port of the switching hub 3 having the mirror port function to plug into the network.
Such protocol monitor function is required to be used when trouble occurs in the controller and the network configuration, and thus such protocol monitor is normally prepared after the trouble occurs, and then plugged into to the network. However, the trouble needs to be reproduced after plugging the protocol monitor 6 to the network to perform the analysis, and thus considerable time and effort are required to investigate the cause such as for a case with poor reproducibility.
If the switching hub existing in the FA network system does not correspond to the mirror port function, a switching hub having such function is to be newly prepared and replaced, which merely increases cost and complicates the replacement task.
Furthermore, the protocol monitor 6 used as the external device traces the data flowing on the network line, compares with the control condition set in the memory 6 b , and controls the monitor function (start, stop of monitor). In order to correctly perform such control, the control condition (specific data pattern etc.) to register needs to be correctly performed, which can only be set by a technician familiar with the protocol monitor. Furthermore, the abnormality in the system that can be detected by the protocol monitor is merely the data pattern on the communication frame, and improperness of control timing, and those requiring advanced algorithm that depends on plural data cannot be detected.
In accordance with one aspect of the present invention, there is provided an FA controller including: abnormality diagnosis function of determining presence of abnormality of a network to be connected; protocol monitor function of monitoring data communicated with a device connected to the network; and function of holding the data monitored with the protocol monitor function in advance when abnormality is detected by the abnormality diagnosis function.
The controller includes a PLC and a motion controller. Such controller has a function of detecting abnormality (failure) of the device connected to itself and the network, and the network. The abnormality diagnosis function can be realized by the function of detecting abnormality. The abnormality diagnosis function can respond to various types of detectable abnormalities as the controller itself detects the abnormality thereof. That is, the protocol monitor prepared as a conventional external device detects abnormality from the pattern of the acquired data, and thus the detectable abnormality is limited and a time lag occurs even for detection. In the present invention, on the other hand, there are a great variety of detectable abnormalities, and detection can be made instantaneously. Thus, the possibility the data may get lost by the time lag in which the abnormality detection is delayed can be suppressed as much as possible. Furthermore, the controller incorporates the protocol monitor function, and an external device, a connection cable, and a switching hub having a mirror port function etc. do not need to be prepared when using the relevant function. Furthermore, the trouble reproduction experiment for performing the monitor does not need to be performed when the monitor operation is constantly started. Therefore, rapid response can be obtained based on the abnormality and the failure that occurred first. The protocol monitor function of the present invention merely needs to be a function of collecting and holding data, and may not have the function of analyzing based on the data. This obviously does not inhibit the provision of the function of analyzing. The data communicated with the device to be monitored may be the transmission data and the reception data, but is preferably at least the reception data received from device.
(2) A ring buffer is arranged, and the data communicated with the device adopts a communication method of once being stored in the ring buffer; where the ring buffer is set with a buffer amount larger than the buffer amount necessary for performing the communication, communicates with the device at the setting of the ring buffer with large buffer amount at normal times, uses the data held in the ring buffer as monitor data, continues the communication using a small region of one part where the data after abnormality is detected is stored in the ring buffer when abnormality is detected by the abnormality diagnosis function, and holds the data stored in regions other than the region used to continue the communication.
The communication at normal times can be performed using the ring buffer without any problem even if a ring buffer with large buffer amount is used. Since the buffer amount is large, a relatively great amount of past data is stored in the ring buffer, and hence the past data can also be used as monitor data. Therefore, a monitor data buffer does not need to be particularly prepared and the process of transferring data thereto is also eliminated, as opposed to the related art. When abnormality occurs, the data generated before the occurrence is held, and analysis is performed based on the data held thereafter. The communication can be continued even after the occurrence of abnormality since the small region functions as the ring buffer.
(3) The controller may correspond to Ethernet (registered trademark) or EtherCAT (registered trademark). In the present invention, the switching hub is not an essential configuration since the protocol monitor is not used as the external device. Thus, application can be preferably made to the EtherCAT (registered trademark). In other words, the EtherCAT (registered trademark) corresponds to high-speed communication, where the desired communication speed cannot be obtained, and the merits of the EtherCAT (registered trademark) is reduced by half if the switching hub is mounted as in the Ethernet (registered trademark). The high-speed communication can be maintained in the FA system of the EtherCAT (registered trademark) by using the present invention.
(4) On the premise of invention of (2), the ring buffer is assumed to be set in the Ethernet driver unit. The transfer to the monitor data buffer and the capture process are eliminated since the ring buffer set with a large buffer amount can be used as a conventional monitor data buffer. The communication process using the ring buffer can be performed regardless of the size of the buffer amount as long as a buffer amount of more than necessary can be ensured. Thus, high-speed can be more responded as the transfer process to the monitor data buffer is eliminated, and it becomes more suitable to the EtherCAT (registered trademark). Since the EtherCAT (registered trademark) can be complied, application can be made also to the network system of the communication protocol corresponding to the Ethernet (registered trademark).
In the present invention, if abnormality (failure) is detected with the controller, the data (monitor data) monitored and acquired before can be held instantaneously since the protocol monitor function is incorporated in the controller. There are a great variety of detectable abnormalities (failures), and monitoring for analyzing the cause of the various types of abnormalities can be performed.
If communication is performed using a ring buffer with large buffer amount, the state in which the past data is stored in the ring buffer last long compared to the device adopting a communication method using a general ring buffer, and thus the ring buffer can be used as a storage region of the monitor data. As a result, the process of separately transferring and copying the past data to the monitor data buffer and the like as in the related art is eliminated, whereby the configuration can be simplified and the process becomes simple and convenient and also high-speed respondable. Furthermore, when abnormality occurs, the past data can be held without being lost by overwrite involved in the communication by narrowing the region of the ring buffer to use for communication. Therefore, the held data are subsequently analyzed with the analyzing device, and the like, which can then be used to specify the cause of abnormality and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a conventional example;
FIG. 2 is a view showing a conventional example;
FIG. 3 is a view showing a conventional example;
FIG. 4 is a view showing one example of an FA network system incorporating a controller according to the present invention;
FIG. 5 is a view showing another example of an FA network system incorporating a controller according to the present invention;
FIG. 6 is a view describing an abnormality detection function;
FIG. 7 is a view describing a communication method using a ring buffer at normal time;
FIG. 8 is a view describing a communication method using the ring buffer at time of occurrence of abnormality; and
FIG. 9 is a flowchart describing the operation.
DETAILED DESCRIPTION
FIG. 4 shows one example of an FA network system including a controller 10 for FA such as a programmable controller and a motion controller according to the present invention. In the present embodiment, Ethernet (registered trademark) is used for the communication protocol. The controller 10 performs transmission and reception of IO data such as IN data/OUT data with a remote device (slave) 23 through a switching hub 21 . The remote device 23 includes a servo driver for controlling the operation of a servo motor 24 a , an inverter for controlling the operation of a normal motor 24 b , an I/O terminal, a valve, and the like. The remote device 23 has a connector 23 a for attaching the terminal of a protocol compliant communication cable 22 such as the RJ45, and is connected to a predetermined port of the switching hub 21 through the communication cable 22 .
The controller 10 includes a CPU 11 responsible for control, a memory 12 for storing programs and the like for the CPU 11 to operate, and a connection interface 13 for connecting to the network. Such hardware configuration is similar to the related art. As shown in the figure, the connection interface 13 includes the RJ45, which acts as a connector for attaching the terminal of the communication cable 22 complying with the communication protocol, the PT: pulse transformer, the PHY: physical layer, the Mac: media access controller, and the like. These are also implemented with those similar to the related art.
In the present invention, the controller 10 is mounted with a data collecting function of the protocol monitor. Such collecting function (protocol monitor function) can be implemented with an application program. That is, the basic hardware configuration for implementing the protocol monitor function can be shared with the hardware of the controller such as the PLC, and can be integrated as hardware. The memory 12 stores a monitor system program in addition to the system program for performing the basic operation of the controller, and the user control program (sometimes also referred to as user program) for actually performing the control. The monitor system program is a program for implementing the protocol monitor function. The CPU 11 executes each program stored in the memory 12 to function as the original controller for performing the control of the FA system, or to function as the protocol monitor. One of such functions may be operated, or both functions may be operated in parallel.
Furthermore, the memory 12 includes a monitor data buffer for storing the IO data for analysis. The monitor data buffer can automatically stop when receiving up to the buffer capacity, and can continue the operation continuously, as a normal ring buffer, to the control condition by discarding the data in order from the oldest.
Although not illustrated, the memory 12 ensures a work area used by the CPU 11 when executing the operation and ensures an IO memory area for storing the IO data and the like in addition to the programs. A nonvolatile memory and a volatile memory are used for such memories depending on the application.
The controller 10 does not need to use the mirror port function of the switching hub as in the related art as the protocol monitor function is incorporated. As a result, the switching hub 21 that is not mounted with the mirror port function can be used, and use can be made in a network system where the switching hub does not exist, as shown in FIG. 5 . FIG. 5 is an example applied with respect to the EtherCAT (registered trademark). The EtherCAT responds to FA in compliance with the Ethernet (registered trademark) and is a communication protocol enabling higher speed communication, and adopts a configuration of connecting with wiring across the remote device 23 .
In the present embodiment, the controller 10 itself that controls each device and apparatus connected to the FA network system detects abnormality, and the controller 10 directly stops the incorporating protocol monitor to stop the monitoring in the protocol monitor and to hold the previous data. The abnormality detection on the system thus can respond not only to the data pattern on the communication frame, but also to the inappropriateness of control timing and the detection by an advanced algorithm that depends on plural data, whereby the protocol monitor can be easily stopped without requiring a special setting skill. Furthermore, since the controller itself can perform the control on the stop/start operation of the protocol monitor function, the data communicated at the moment (immediately before) of occurrence of trouble can be left as the monitor data.
Accompanied therewith, the control condition of the monitor function stored in the memory 6 b of the protocol monitor 6 of the related art is described in the user control program of the controller and stored in the memory 12 . In other words, as shown in FIG. 6 , one user control program is an abnormality detection function block FB as shown in the figure. When the function block FB detects abnormality, one of the contacts of an error detection unit is turned ON and a stop flag, which is the output, is turned ON. As hereinafter described, the protocol monitor is stopped when the stop flag is turned ON, so that the data collected until immediately before can be left as is as the monitor data. When the contact of the error detection unit is turned OFF, the stop flag is also turned OFF, and the monitor can be resumed. Therefore, since the control of start/stop of the monitor can be described with the ladder program, the monitor function can be controlled, not limited to a technician specializing in network, as long as the technician has the ability of a control programmer of the controller.
The determination logic of stopping the monitor when the contact of the error detection unit is turned ON may be communication time-out, link down, control data abnormality, control timing abnormality, and the like. The abnormality determination may not only be the user program, and the system may automatically determine the abnormality (transmission error such as link down, FCS error) of a certain extent and then stop.
In the present embodiment, the buffer amount of the ring buffer for temporarily storing the transmission/reception data is made greater than normal, as shown in FIG. 7 . In other words, in the present embodiment, a reception buffer and a transmission buffer are ensured in the Ethernet driver unit to realize a full-duplex transmission (simultaneous execution of reception process and transmission process) as a software structure same as in a general case. The respective buffers form a structure of a general ring buffer by a buffer array (represented with 16 buffers, 0 to 15 for the sake of convenience in the figure) of a buffer amount longer than the buffer amount required in the general communication, and a storage end pointer and a next storage pointer.
The transmission data and the reception data stored in the respective ring buffer thus can be used as the data buffer of the frame monitor by having a long buffer amount. Actually, the buffer amount is a several hundred to a several thousand.
The transmission and reception using the ring buffer at the normal time in which abnormality has not occurred merely has larger data array, and can be carried out by the pointer process same as in the general case. In other words, the Ethernet controller provides the reception data to the Ethernet driver unit (reception request). The Ethernet driver unit stores the reception data in the reception buffer (“reception buffer 12 ” in the figure) set with the next reception storage pointer by the reception request from the Ethernet controller. Thereafter, the next reception storage pointer is incremented by one to prepare for the next reception. The pointer is returned to the reception buffer 0 when reaching the end of the data array.
The high-order module (TCP/IP and frame monitor in the figure) reads out the reception data stored in the reception buffer (“reception buffer 9 ” in the figure) indicated with the reception storage end pointer at an arbitrary timing. Thereafter, the reception storage end pointer is incremented by one to prepare for the next reading. The pointer is returned to the reception buffer 0 when reaching the end of the data array. Therefore, continuous reception process is performed by assuming the data array as the ring structure by the data array and the process by the pointer. Since the reception timing of the reception data of the controller 10 and the readout timing of the high-order module are indefinite, the data that is in the middle of being provided from the Ethernet controller to the TCP/IP of higher order tend to accumulate in the reception buffer if the readout delays. In the example of FIG. 7 , the reception data stored in the reception buffers 9 to 12 from the reception storage end pointer to the next receivable pointer become the data that is in the middle of being provided from the Ethernet controller to the TCP/IP of higher order. The past reception data stored in the previous data (reception buffers 0 to 8 , 13 to 15 in the figure) are then set with the next receivable pointer and remain until the reception data is subsequently stored.
Thus, the past data is held in the reception buffer for a constant period even after provided to the TCP/IP of higher order, where the past data after the provision can be used as is as the data of the frame monitor since the ring buffer with large buffer amount is adopted in the present embodiment. The information of the reception time and the transmission time necessary as the frame monitor data are ensured as one part of the data structure of the reception buffer and the transmission buffer, and stored with the reception cause and the transmission cause of the Ethernet driver. The above description is the same for the transmission process.
Therefore, the storage (copy) process to the monitor data buffer as in the related art is eliminated. In the present embodiment, the influence of performance on the reception process and the transmission process is no different from a general case although the data array of the ring buffer becomes large, and the process can be carried out at higher speed than the related art since the copy process to the monitor data buffer is eliminated.
The buffer area storing the past data after the provision is sequentially changed by the provision to the TCP/IP of higher order and the change of the pointer involved in the acceptance of new reception data. Thus, when some kind of failure occurs, the past data is rewritten by the newly received reception data by the movement of the next receivable pointer if communication is continued using the entire ring buffer, and hence the data for specifying the cause of occurrence of failure may be lost. This is the same for the transmission process.
As shown in FIG. 8 , in the present embodiment, when failure occurs, the array of the ring buffer is made small, and the reception data is received and provided within the small array. The past data stored in other data regions thus can be held as is, and used as the frame monitor data.
Specifically, when the frame monitor operation stops after the application detects some kind of error, the pointer at the relevant time point is set as a capture stop pointer. In FIG. 8 , the capture stop pointer is set with respect to the reception buffer 5 and the transmission buffer 7 . The buffer amount necessary for general communication is ensured from the capture stop pointer to continuously operate the communication state even after the stop of the frame monitor (reception buffers 5 to 12 , transmission buffers 7 to 14 indicated with heavy frame in the figure). The general communication uses the range of such buffer as the ring buffer for communication operation. The capture head data pointer is positioned next to the buffer used in the general communication. From such pointer to the capture stop pointer through the ring structure (reception buffers 13 to 4 , transmission buffers 15 to 6 in the figure) are used as the frame monitor data.
FIG. 9 is a flowchart showing the functions of the present embodiment. The controller 10 (CPU 11 ) initializes the Ethernet driver unit by turning ON the power (S 1 ). Here, the Ethernet controller is initialized, and the ring buffer for transmission and reception, to be described later, is prepared.
In the present embodiment, the protocol monitor function does not influence the original system performance of the controller from the structure of the ring buffer and the control algorithm, and thus starts the monitor (capture) with the start of driving (S 2 ).
After the capture is started, communication is started using all regions of the ring buffer (reception buffers 0 to 15 , transmission buffers 0 to 15 in FIGS. 6 and 7 ) (S 3 ). As described above, the stop flag is turned ON when the controller detects failure/abnormality, and thus communication is carried out using the maximum ring buffer that uses all regions as long as the state, in which the stop flag is turned OFF (No in S 4 ), continues.
When the stop flag is turned ON (Yes in S 4 ), the capture stop pointer is set and the communication is continued using a minimum ring buffer of a predetermined area therefrom (S 5 ). The data (monitor data) remaining in the buffer other than the regions set to the minimum ring buffer becomes the data immediately before the occurrence of failure/abnormality, and thus the monitor data is uploaded to a predetermined analysis tool. An arbitrary means can be used to upload the monitor data, and for example, the monitor data may be converted to the file system information and uploaded from the high-order computer with the FTP function and the like. In the high-order computer, the cause etc. of failure/abnormality can be analyzed based on the uploaded monitor data. The network system can continue a stable communication using the ring buffer even by using the minimum ring buffer by setting a buffer amount that does not affect the communication.
When a restart command of the monitor function is provided from the programming tool device and the like at the timing the monitor data is uploaded, the branch determination of the processing step S 6 becomes Yes, and the process returns to the processing step S 3 to return to the state of performing transmission and reception using all ring buffers.
In the present embodiment, the protocol monitor function is mounted to the controller itself, and monitoring is performed from the beginning of the start of driving, and thus the data can be monitored from the first state even when failure/abnormality occurred for the first time. Thus, the data at the relevant time can be reliably held and analyzed even for the abnormality etc. of low occurrence frequency.
The monitor data is handled as a normal file. The network monitor software has various types, each of which has a data format of the monitor data file. The monitor data of the present invention does not particularly depend on the data format, and data format conversion and the like may be performed, if necessary. The analysis of the data sequence etc. and the analysis of the network load can be performed using the saved monitor data. The possibility an electrical disturbance such as noise to the network occurred can be indirectly analyzed by adding transmission error such as CRC error to the saved monitor data.
Furthermore, use can be made to the analysis of a so-called data mining such as semantic analysis of data since all input/output data with the remote device (servo motor, inverter motor, I/O, valve etc.) are stored as data transmitted and received with the controller. Furthermore, the data transmitted and received with the controller can be used as data to perform operation analysis on mechanical components actually driven by the remote device (servo motor, inverter motor, I/O, valve, etc.) with a 3D-CAD and the like, and can be used to analyze the behavior of the mechanical facilities before occurrence of trouble. | This invention enables an abnormality analysis to be easily and reliably performed in the FA system of the EtherCAT (registered trademark). A controller has a protocol monitor function of operating in a monitor system program, and constantly monitors data communicated with a remote device. The controller has an abnormality diagnosis function of detecting abnormality, and thus holds the data monitored immediately before when abnormality is detected. As the protocol monitor function is incorporated, a protocol monitor does not need to be newly plugged into the network as an external device after the occurrence of abnormality, and the data that becomes the cause can be held from the abnormality that occurred first by monitoring from the beginning of the operation of the system and can be used for analysis. | 6 |
SUMMARY OF THE INVENTION
The invention described herein relates to apparatus for obtaining soil samples for reliable detection of volatile organics and hydrocarbon analysis. An external housing has a proximal end, a distal end, an exterior surface and an interior surface. A split sleeve has an outside surface configured for a sliding fit with the external housing interior surface and also has an inside surface. A shaft extends axially through and is spaced from the split sleeve inside surface and further has a proximal end and a distal end. A plunger is connected to the distal end of the shaft and is configured for a sliding fit with the split sleeve inside surface. Means is provided on the shaft proximal end for accessing and moving the shaft in axial position within the split sleeve. Means is also provided for adjustably fixing the shaft in axial position within the split sleeve.
In another aspect of the invention, apparatus is described for obtaining soil samples, which includes an external tubular housing having a housing passage therethrough, a distal end and a proximal end. A sleeve is configured to lie within the housing passage and has a distal end and a proximal end. The sleeve further has a sleeve passage therethrough. A flange is formed on the sleeve proximal end adjacent the external tubular housing proximal end. A shaft extends through the sleeve passage and has a shaft distal end and a shaft proximal end. A plunger is attached to the shaft distal end for axial movement and sliding fit within the sleeve passage. Means is provided for fixing the shaft in a plurality of axial positions within the sleeve.
In yet another aspect of the invention, soil-sampling apparatus is disclosed for obtaining samples for use in detection of volatile organic and hydrocarbon compounds. An exterior tubular housing has an open sampling end and a housing passage therethrough. A split sleeve is disposed in fixed position within the housing passage and has an open sampling end and a sleeve passage therethrough. A split flange is formed on the split sleeve abutting the exterior tubular housing at an end thereon opposing the open sampling end. A shaft extends through the sleeve passage and the split flange and is disposed for axial movement therein. A plunger is attached to the shaft and has a surface disposed for sliding fit within the sleeve passage from positions spaced from to positions proximate to the split sleeve open sampling end. Further, means is provided for adjustably fixing the shaft in axial position within the sleeve passage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective of an assembly of the present invention.
FIG. 2 is an exploded perspective of a split sleeve utilized in the present invention.
FIG. 3 is an exploded perspective of a shaft and plunger assembly utilized in the present invention.
FIG. 4 is a section along the line 4 — 4 of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Investigations have shown that it is difficult if not impossible to get reliable soil samples for volatile organics and hydrocarbons analysis from a conventional brass ring preserved soil sample. Such a soil sample is obtained through the use of the device shown in U.S. Pat. No. 5,343,771, Turriff et al. Soil samplers to provide reliable samples at the site of the sampling should be configured to extract a known volume of sample from the soil being analyzed and afford easy transfer of the soil sample to a secure container for transfer to the analysis laboratory. Ideally, the sampler should provide no contamination and admit no contamination to the sample, should be rugged in construction for on site use and should be easy to clean between samples. Further, the sampler should be able to readily transfer the soil sample to a forty milliliter or twenty milliliter vial at the site of the sampling so that the vials may be transferred to a laboratory for performance of purge and trap sampling. Volatiles should not be lost in the transfer step or inaccurate data will result.
Certain EPA testing protocols have recently been implemented which require sample collecting of a specific volume of soil followed by deposit of the soil sample into specified sizes of storage vials for transfer to laboratories for analysis. The invention disclosed herein relates to acquisition of soil samples for on site transfer to 40 milliliter and 20 milliliter vials which are sealed and then transferred to the laboratories. FIG. 1 shows the soil sampler 10 in assembled condition having an exterior housing 11 with a shoulder 12 located about midway along the axial length of the exterior housing. The exterior housing has a distal end 13 with a chisel-like edge 14 at the distal end. A thin groove 16 has a thin cable 17 wrapped therearound and secured with a crimped bushing 18 . The opposing end of the thin cable 17 is wrapped around a screw 19 and secured to the screw with another crimped bushing 21 . The screw 19 engages threads formed in the top of a knurled set screw 22 which has a threaded shank 23 configured to engage threads in a threaded hole 24 which is axially oriented in the external housing 11 .
A split sleeve shown generally at 26 in FIG. 2 has two half sleeves 26 a and 26 b, the distal ends 25 a and 25 b of which are shown extending from the distal end 13 of the external housing 11 in FIG. 1. A knob or handle 27 is shown in FIG. 1 at the proximal end of the sampler 10 which is attached by means of a shaft 28 (FIG. 3) to a plunger 29 (FIGS. 1 and 3 ). The shaft 28 extends through a passage 43 within the half sleeves 26 a and 26 b and has a threaded distal end 31 which mates with a threaded hole 32 in the proximal end of the plunger 29 . The distal end of the plunger 29 is shown extending from the distal ends 25 a and 25 b of the split sleeve 26 in FIG. 1. A thin teflon disc 30 is shown in FIG. 3, which is placed against the distal end of plunger 29 when the plunger is withdrawn axially into the split sleeve 26 preparatory to obtaining a predetermined volume of soil for a sample as hereinafter described. The thin disc 30 has a diameter that fits snugly within the inside diameter of the assembled split sleeve 26 . The thin disc prevents grit from becoming embedded in the end of the plunger 29 and further inhibits migration of grit or other foreign matter between the outside diameter of the plunger and the inside diameter of the split sleeve. This prevents scoring of both parts and prevents contamination of the plunger distal end and analyte carryover.
The split sleeve 26 (FIG. 2) has a split flange shown at 33 a and 33 b which is fixed, as by brazing, to the proximal ends of the split sleeve portions 26 a and 26 b, respectively. The split sleeve portions have adjacent edges 34 a and 34 b (FIG. 2) when assembled. A hole is formed through the edges 34 a and 34 b of the split sleeve having hole halves 36 a and 36 b as also seen in FIG. 2 . The hole halves 36 a and 36 b form a through hole in the side of the assembled split sleeves 26 a and 26 b allowing passage of the tip of the threaded portion 23 on set screw 22 , so that the tip of the threaded portion 23 may contact the surface of the shaft 28 . Shaft 28 has a narrow groove 37 formed in the periphery thereof which is spaced from a wider groove 38 around the periphery of the shaft. The split flange 33 a and 33 b has a flat surface thereon shown at 39 a and 39 b. When the shaft 28 is positioned axially within the split sleeve assembly 26 a and 26 b so that the groove 37 is aligned with the flat surface formed by 39 a and 39 b, the wide groove 38 is positioned directly beneath the tip of the threaded portion 23 on the set screw 22 . In this fashion, the plunger 29 is drawn a predetermined distance from the distal end of the split sleeve assembly and fixed in this position by the set screw 22 . This predetermined distance provides for a volume between the distal end of the plunger 29 and the distal ends 25 a and 25 b of the split sleeve assembly 26 . Thus, a predetermined volume is obtained which will fit into a vial, thereby providing a defined sample size.
As described hereinbefore for thin groove 37 and wider groove 38 , another thin groove 41 is shown in the periphery of the shaft 28 spaced a predetermined distance from another wide groove 42 in the periphery of the shaft. When the handle 27 is drawn away from the distal end of the sampler 10 until the narrow groove 41 appears aligned with the flat surfaces 39 a and 39 b, the wide groove 42 is disposed directly underneath the tip of the threaded portion 23 on the set screw 22 . Therefore, when the set screw 22 is advanced to contact the surface of the groove 42 the shaft 28 is locked axially in place. The plunger 29 is thus withdrawn from the distal end of the sampler 10 to provide a volume between the distal end 25 a and 25 b of the split sleeve assembly and the distal end of the plunger 29 which is sufficient to be deposited within a predetermined size sample vial.
With reference now to FIG. 4, an amplifying description of the relative positions of the various parts of the soil sampler 10 will be undertaken. The shaft 28 is seen to be centrally located within the passage 43 extending axially along the length of the split sleeve assembly presented by the split sleeve half 26 a. The shaft threaded portion 31 is configured to engage threads in hole 32 in plunger 29 . The shaft also has a threaded portion 44 on the proximal end thereof which is configured to engage threads 46 in knob or handle 27 . Plunger 29 can thus be manipulated axially within the through passage 43 to occupy any desired position therealong. The plunger 29 is seen in both FIGS. 1 and 4 extended as far as possible toward the distal end of the soil sampler 10 . As described hereinbefore in conjunction with FIG. 3, the handle 27 may be drawn upwardly in FIG. 4 to align the thin groove 27 with the upper surface 39 a so that the wide groove 38 is positioned directly beneath the tip of the threaded portion 23 of the set screw 22 . The thin disc 30 may then be placed within the split sleeve 26 in position to overly the distal end of the plunger 29 . As a result, the plunger 29 is drawn upwardly in FIG. 4 a predetermined distance from the distal end of the soil sampler and fixed there in position so that the aforementioned predetermined volume of soil sample is obtained when the distal end of the soil sampler is forced into the ground at the sampling site. The volume of the soil sample obtained in this manner may be appropriate for insertion into a twenty milliliter sample vial, for example. A shoulder 47 a in FIG. 4 ( 47 a and 47 b in FIG. 2) is formed near the distal ends 25 a and 25 b of the two split sleeve halves 26 a and 26 b. The twenty milliliter vial for receiving the soil sample has an upper opening with a lip surrounding the opening. The shoulder 47 a (and 47 b ) is sized to contact the lip of the twenty milliliter vial and prevent insertion of the soil sampler 10 further into the interior of the vial. Consequently, the soil is freely deposited into the vial by pushing the handle 27 downwardly to eject the sample. In similar fashion, when the narrow groove 41 is aligned with the surface 39 a (FIG. 4) the wide groove 42 is disposed beneath the tip of the threaded portion 23 of the set screw 22 and the shaft is fixed in position by the set screw when the threaded portion is advanced to seat against the periphery of the groove 42 . The result is that the distal end of the plunger 29 is positioned within the passage 43 farther from the distal end of the split sleeve assembly so that a larger soil sample is obtained within the passage 43 when the distal end of the soil sampler 10 is thrust into the soil surface at the sampling site. When the soil sampler is withdrawn from the soil surface with the sample contained inside the passage 43 , the sampler's distal end is inserted into an upper opening in a larger vial, i.e., a forty milliliter vial, having a surrounding lip at the opening. The sampler entry into the vial is limited by contact between the vial lip and the shoulder 12 on the external housing 11 . The sample is deposited within the vial by pushing the handle 27 down to expel the soil sample from the distal end of the passage 43 . It should be noted that the shaft 28 is held centrally located within the passage 43 by the plunger 29 and a hole 48 a (and 48 b as seen in FIG. 2) in the flange halves 33 a and 33 b, respectively. It should also be noted that the sampler is designed to be held in one hand while pushing handle 27 with fingers on the same hand to expel the sample. The receiving vial may be held by the other hand. This facilitates sample taking, sample isolation and sample containment at the sampling site.
When a sample is taken, it is desirable to clean the sampler to avoid contamination of subsequent samples. The set screw 22 is backed out of the threaded hole 24 in the external housing 11 and is therefore removed from the half holes 36 a and 36 b in the split sleeve 26 . The split sleeve and shaft assembly is removable through the upper portion of the external housing 11 as seen in FIG. 4 and the split sleeve portions are separated from the shaft and plunger. The thin disc 30 is deposited in the vial with the sample and is replaced with a new disc when the soil sampler is used to obtain a subsequent sample. All surfaces on all other parts of the sampler assembly are thereby readily accessible for thorough cleaning prior to reassembly for subsequent sample taking.
In addition, it should be noted that plunger 29 has an outer surface 49 which has a low static and dynamic friction coefficient characteristic. This feature may be obtained through the use of Teflon material for the plunger 29 or through the use of a Teflon coated plunger in the best mode of the invention. It is envisioned, however, that other means, materials and configurations may be utilized to obtain the low friction coefficient on the outer surface 49 of the plunger 29 . The low coefficient of friction characteristic between the outer surface 49 of the plunger and the surface of the passageway 43 is desirable because a sliding fit is necessary between these two surfaces. If debris was allowed to migrate between the surfaces 49 and 43 , binding between the plunger and the split sleeve assembly would occur causing rapid degradation of the soil sampler 10 and possible loss of volatiles from the sample. It should also be noted that in the best mode of the invention a relatively close fit is desirable between the outer surface of the split sleeve assembly 26 and the inner surface 51 (FIG. 4) of the external housing 11 . Although these surfaces are not required to move relative to one another during operation of the soil sampler, it is still desirable to prevent migration of debris between them as much as possible. Cleansing of the parts following the taking of a sample and disassembly will remove any debris that has been able to intervene between these two surfaces.
A soil sampler is disclosed herein which quickly and consistently produces uniform soil samples and which is operable with one hand to deposit the samples immediately into appropriate sample containers on the site of the sampling without contaminating the sample or losing analytes.
Although the best mode contemplated for carrying out the present invention has been shown and described herein, it will be understood that modification and variation may be made without departing from what is regarded to be the subject matter of the invention. | A soil sampler provides samples for on site disposition in forty and twenty milliliter vials for subsequent off site volatile organic analysis. A split sleeve contains a plunger positioned within the sleeve on a shaft to obtain a desired volume of soil when the sampler is thrust into the soil. An outer shell contains the split sleeve and a set screw device fixes the shaft and plunger in desired position within the sleeve. Metering marks on the shaft provide predetermined sample size indication. | 4 |
FIELD
A hydraulic breakout machine used to apply torque to couple and uncouple threaded tubular components. There is described a method of accurately measuring applied torque in a hydraulic breakout machine and a hydraulic breakout machine that measures applied torque in accordance with the teachings of the method.
BACKGROUND
Operation of a typical breakout machine involves positioning the work piece in the headstock and closing the clamp cylinder onto the work piece, which anchors the work piece to the bed, then positioning the tailstock at the appropriate position and closing the clamping cylinders. The generated force is applied through the fixed moment arm, which applies that generated torque to the work piece. The magnitude of the torque is variable, by adjusting the pressure that is applied to the torque cylinders.
Breakout machines currently use hydraulic pressure supplied to the torque cylinders to determine the magnitude of the torque being applied to the work piece. The hydraulic pressure supplied to the torque cylinders is varied to adjust the torque output. The torque cylinder piston area (break side) and the piston area minus the rod area (make side) are set, as well as the moment arm length or the torque cylinders. At a given pressure, the force generated multiplied by the torque arm length is used to determine the magnitude of the torque applied by one of the torque cylinders and then multiplied by two. Two torque cylinders applying torque in unison is the preferred method, as it reduces the amount of error. There are errors caused by the hydraulic system, mechanical system, as well as the geometry of the machine that limit its accuracy and performance.
Hydraulic system errors are the total sum of all the small losses due to flow through the hydraulic components and force lost to friction operating components. Pressure and flow moves pistons or valve spools and have spring forces to work against. Each hydraulic component has a number of seals or wear rings that cause pressure losses. The clamp cylinders along with the torque cylinders are relatively large cylinders that all have large stiff seals and large wear rings. These components can be designed to minimize these losses, but the combination of these components can cause significant total loss. The system pressure applied to the torque cylinders must be accurate when varied from 0 through 3,000 psi. An error of 100 psi is not significant at the maximum system pressure of 3,000 psi, but such an error is significant to the accuracy of the lower range of torque application. The hydraulic error outlined is one of the errors that limits the accuracy of the torque that can be applied at the low end of its range. Generally, existing machines offer a minimum torque application of 4,000 lb-ft to 5,000 lb-ft is specified for the “make up” range. Current drilling industry practice is to use smaller diameter tools with smaller diameter threaded connections, which call for lower make up torques being applied. This limits the applications of current breakout machines.
Mechanical errors are caused by the bearings, hinges, pivot points, and hoses all causing friction during operation. Good design practice reduces the friction these items cause. A good maintenance/lubrication program will minimize the friction and wear caused, but will not eliminate it. As the machine is operated friction and wear will occur.
The arrangement of the torque cylinders causes an error due to the arc the cylinders travel through a make/break cycle. The moment arm length changing through the torque cylinder travel causes this error, the moment arm length is used to determine the magnitude of the torque being applied. Breakout machines that use the system pressure to determine the torque being applied must have a set moment arm length. Using a moment arm length in one position or an average moment arm length all add an error due to the geometry. Again, good design practice can be used to minimize this error. One method is to limit the arc length the torque cylinders travel. Smaller arc travel results in less moment arm length change, but require more arc travel cycles to complete one full revolution of the work piece.
The errors combine to create a total amount of error affecting the accuracy of the torque being applied. The effects of wear and tear on a machine and its systems results in a breakout machine that requires re-certification on a annual or bi-annual basis to maintain accurate torque application. The re-certification process is at the end users expense and can be very expensive. The result of the re-certification process, is a chart that indicates the actual torque being applied for a given torque setting read on the breakout machine. This can be very confusing to the operator who has go back and forth between the chart and the machine to determine the torque output, increasing the possibility of operator error.
SUMMARY
According to one aspect, there is provided a method of accurately measuring applied torque in a hydraulic breakout machine. The method involves using at least one sensor to measure reactive torque and using the reactive torque measurement as an accurate indication of applied torque.
According to another aspect, there is provided a hydraulic breakout machine that includes a bed with a headstock fixed to the bed. The headstock has clamping cylinders for clamping a work piece to the headstock. A tailstock is movable along the bed. The tailstock has clamping cylinders for clamping a work piece to the tailstock. The tailstock or the headstock has torque cylinders for applying rotational torque to the work piece. At least one sensor is provided for measuring reactive torque.
Measuring reactive torque avoids inaccuracies caused by the hydraulic, mechanical and geometry errors described above. There will hereinafter be described how to measure reactive torque using one or more sensors on the headstock. There is more than one way that this can be done. The preferred way is to provided a reactive torque bracket which is mounted for limited rotational movement within to the headstock. The reactive torque bracket is anchored to the headstock by load sensors, which limit rotational movement and measure reactive torque.
Although beneficial results may be obtained from the apparatus described above, in order to increase the lower operating range of the breakout machines, it is preferred that there be provided two torque cylinders on the tailstock and means for deactivating one of the torque cylinders for operation in lower torque ranges.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to be in any way limiting, wherein:
FIG. 1 is a side elevation view of a hydraulic breakout machine.
FIG. 2 is a headstock end elevation view of the hydraulic breakout machine of FIG. 1 .
FIG. 3 is a tailstock end elevation view of the hydraulic breakout machine of FIG. 1 .
FIG. 4 is partially cutaway end elevation view of a reactive torque bracket.
DETAILED DESCRIPTION
A hydraulic breakout machine, generally identified by reference numeral 10 , will now be described with reference to FIGS. 1 through 4 .
Structure and Relationship of Parts:
Referring to FIG. 1 , breakout machine 10 is used for breaking and making threaded connections used on tools and equipment, for example, tools and equipment that may be used for drilling wells. Breakout machine 10 includes a bed 12 and a hydraulic power console 14 . Bed 12 extends from zero to approximately sixteen feet or more and has a fixed head stock 16 . Bed 12 also includes a movable tailstock 18 , which can traverse the length of bed 12 . Referring to FIGS. 2 and 3 , headstock 16 and tailstock 18 both have hydraulic clamping cylinders 20 mounted in them. Clamping cylinders 20 are mounted in a radial configuration about a work piece centerline 21 . In this configuration, clamping cylinders 20 can be stroked open and closed in unison to clamp on work pieces of various diameters. Clamping cylinders 20 on headstock 16 are closed on the work piece holding it in a fixed position. Tailstock 18 is then positioned along the work piece by traversing the length of bed 12 . Clamping cylinders 20 of tailstock 18 are then closed at the appropriate position. In this position, tailstock 18 or headstock 16 is capable of applying a torque in a make or break rotation to the work piece. Referring to FIG. 3 , tailstock 18 has its radial mounted clamping cylinders 20 held in a large bearing 22 that is free to rotate about the center of the clamping cylinders 20 . In turn, a rotating bracket 24 (also referred to as a torque application head) that holds clamping cylinders 20 has two moment arms 26 to which torque cylinders 28 are mounted which can be activated to apply a force through the moment arms 26 resulting in torque being applied to the work piece. In operation, clamping cylinders 20 of headstock 16 and tailstock 18 can be operated individually. Torque cylinders 28 mounted to rotating bracket 24 of tailstock 18 can also be operated independently from clamping cylinders 20 . Referring to FIG. 1 , hydraulic power console 14 includes a pump 30 , a hydraulic reservoir 32 , and controls 34 to allow operation and the ability to vary supplied pressure to radial clamping cylinders 20 and torque cylinders 28 .
Referring to FIG. 4 , a reactive torque bracket 36 is positioned in headstock 16 supported by bearing 38 . Reactive torque bracket 36 is similar to rotating bracket 24 of tailstock 18 . Reactive torque bracket 36 has stop members 39 that engage load cells 40 , which are attached to a mounting plate 41 on headstock 16 . Load cells 40 prevent reactive torque bracket 36 from rotating, and measure the amount of torque experienced by bearing 38 . While two load cells 40 are shown, the actual number may vary, and there may only be a single push/pull load cell 40 . In the depicted embodiment, it is preferred that reactive torque bracket 36 be free to rotate a minimal amount to prevent erroneous readings from any loads on load cells caused by forces other than reactive torque. Each load cell 40 is mounted between both headstock 16 , via mounting plate 41 , and reactive torque bracket 36 , via stop member 39 . Referring to FIG. 1 , load cells 40 are coupled to a gauge 42 on hydraulic power console 14 and function as sensors to provide an accurate measurement of reactive torque upon headstock 16 . As will hereafter be described, reactive torque gives an accurate indication of the actual torque applied as it is not distorted by the inherent hydraulic, mechanical and geometry errors previously described.
Referring to FIG. 1 , breakout machine 10 has a switch 44 that changes from operating on two torque cylinders to one torque cylinder. This can be an automatic pressure sensing switch or a manually selected switch.
The description above and the drawings show rotating bracket 24 with tailstock 18 and reactive torque bracket 36 positioned in headstock 16 . In an alternative embodiment, the position of these elements may be reversed, such that torque cylinders 28 and rotating bracket 24 are at headstock 16 , and reactive torque bracket 36 is positioned in tailstock 18 , with suitable adjustments made to the rest of breakout machine 10 to accommodate for this change, as well as to the operation steps described below.
Operation:
Referring to FIG. 1 , in operation, clamping cylinders 20 on headstock 16 are closed on the work piece. Tailstock 18 is then positioned along the work piece by traversing the length of bed 12 and then closing clamping cylinders 20 of tailstock 18 at the appropriate position. Referring to FIG. 3 , torque cylinders 28 are then activated to apply a force through the moment arms 26 resulting in torque being applied to the work piece. Instead of using hydraulic pressure delivered to torque cylinders 28 to determine torque output, breakout apparatus 10 determines the torque output utilizing load cells 40 . Referring to FIG. 4 , as pressure is applied by torque cylinders 28 , a reactive torque is applied to reactive torque bracket 36 . However, the rotational movement of reactive torque bracket 36 relative to headstock 16 is limited by load cells 40 positioned about the periphery of reactive torque bracket 36 that anchor reactive torque bracket 36 to headstock 16 . Referring to FIG. 1 , the reactive torque, as measured by load cells 40 , is shown as a torque reading by gauge 42 on hydraulic power console 14 . The errors outlined previously are still present, but by using reactive torque all of those errors are taken into account, resulting in an accurate torque reading. This results in a direct torque reading by the operator that is more accurate and not sensitive to the position of moment arms 26 . The likelihood of operator error is therefore reduced. The wear and tear of operation, which results in changes in the hydraulic and mechanical error, does not affect the resultant reactive torque reading; therefore the requirement for re-calibration of torque output can be greatly reduced, which significantly reduces operating costs. Once reactive torque is utilized for the torque output, the entire layout of the breakout machine may be refined to optimize efficiency. It is no longer necessary to minimize the amount of arc travel to minimize the moment arm error. A simple increase in the arc travel from 30 to 40 degrees rotation changes one full work piece rotation from 12 arc cycles to 9 arc cycles, increasing operator efficiency.
A further feature that significantly increases the ability of breakout machine 10 is its ability to apply low make up torque. Prior art breakout machines are limited in their ability to apply a torque below approximately 5,000 lb-ft. Breakout machine 10 can apply an accurate torque well below that of any other breakout machine. Below a given pressure supplied to the torque cylinders one of the torque cylinders has both sides vented, eliminating that cylinder from providing any force. As previously described, this is made possible through switch 44 , which is preferably pressure or manually activated.
In summary, breakout machine 10 advances breakout machine performance in two ways:
1. The use of load sensors measures reactive torque, thereby eliminating hydraulic and mechanical system errors, as well errors due to the geometry.
2. The hydraulic control circuitry has provisions to selectively allow the elimination of one torque cylinder from the load calculation, resulting in a significant reduction in the applied torque.
These differences result in less error, an increase in the lower torque range and a significant reduction of maintenance and operating costs.
In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.
The following claims are to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, and what can be obviously substituted. Those skilled in the art will appreciate that various adaptations and modifications of the described embodiments can be configured without departing from the scope of the claims. The illustrated embodiments have been set forth only as examples and should not be taken as limiting the invention. It is to be understood that, within the scope of the following claims, the invention may be practiced other than as specifically illustrated and described. | A method of accurately measuring applied torque in a hydraulic breakout machine involves using at least one sensor to measure reactive torque, and using the reactive torque measurement as an accurate indication of applied torque. | 4 |
TECHNICAL FIELD
This invention relates to a system for the measurement of the radius of the cornea of an eye, and more particularly to the provision of a dual image formed to produce a parallel line offset-overlap pattern in measurement of the parameters related to cornea radius.
BACKGROUND ART
In ophthalmology, devices known as keratometers have been used to measure the curvature of radius of the cornea. One method is to measure an image size for a fixed object. In another approach, the image size is caused to be fixed by varying the size of the object viewed through a microscope after reflection from a cornea. Systems involving the use of the calibration on zoom lenses have also been employed in the keratometer art.
Difficulty has been encountered in various systems by reason of the fact that the human eye is not quiescent, but constantly moves back and forth, making difficult certain of the measurements involved.
DISCLOSURE OF THE INVENTION
In accordance with the present invention, a pair of linear parallel spaced apart objects are viewed as reflected from the cornea, the view being taken through a square rod of refractile transparent material mounted in the field of view of the microscope where a diagonal cross sectional plane of the rod is common to the optical axis of the microscope. Means are provided for rotating the rod about the optical axis of the microscope to produce a parallel line offset-overlap pattern of the objects as viewed through the rod. Means are then provided for measuring the angle between a perpendicular from the long axis of the objects and the axis of the rod at which angle the pattern is produced to provide data by which the radius of the cornea can be calculated.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic elevation view of a system embodying the present invention;
FIG. 2 is an enlarged view of the rod of FIG. 1;
FIG. 3 is a bottom view of portions of the unit shown in FIG. 1 with the rod rotated 90° from the position shown in FIG. 1;
FIG. 4 illustrates a view of the pattern involved in the present measurement;
FIG. 5 illustrates a parallel line offset-overlap pattern of the pattern of FIG. 4;
FIG. 6 is a top view of an embodiment of the invention adapted to be secured to the housing of objective lenses of a microscope normally used in eye examination treatment procedures;
FIG. 7 is a bottom view of the unit of FIG. 6;
FIG. 8 is a top view of the system of FIG. 6 with the keratometer components moved into position for use thereof;
FIG. 9 is a top view of the keratometer in the same operative position, but rotated 90° relative to the microscope mounting;
FIG. 10 is a side view, partially broken away of the unit of FIG. 6; and
FIG. 11 is a top view of the unit of FIG. 8 with the top panel partially broken away.
DETAILED DESCRIPTION
Referring now to FIG. 1, an ophthalmologist's microscope 10 is shown in position for viewing the cornea 20 of a patient. The microscope 10 is provided with dual paths which include an objective lens 12 in one path and an objective lens 14 in the other path. In accordance with the present invention, a rod 30 of transparent refractile material is employed together with a pair of objects or light sources 32 and 34. Rod 30 is shown as being square for illustrative purposes; however, a prism and for example, a double edge prism can also be utilized with the present invention. As used throughout the present description, the term rod shall include a prism structure. Sources 32 and 34 form a unique object pattern as viewed solely through lens 12 and rod 30.
The radius of the cornea 20 is to be determined in accordance with the geometrical relationships expressed in the following equation:
r=2KI/O (1)
where:
r=the radius of cornea 20;
K=the focal length in the microscope objective lens (FIG. 1);
O=the separation between the light sources 32 and 34 (FIG. 3);
I=l sin 45×sin α=Image produced by the cornea, where α (FIG. 3) is the angle between a perpendicular from the long axis of objects 32 and 34 and the axis of rod 30 at which the parallel line offset-overlap pattern is achieved, and l is the length of the side of the rod 30 (FIG. 2).
The invention involves the use of the parallel sources 32 and 34. Rod 30 is mounted with its cross sectional diagonal coinciding with the axis 12a as shown in FIG. 2. Rod 30 is rotatable about the axis 12a in a plane parallel to the plane common to the axes of objects 32 and 34.
Referring to FIG. 3, objects 32 and 34 are light sources, in one form, elongated slim fluorescent lamps. By way of example, objects 32 and 34 may be of the order of 25 cm. in length and spaced apart a distance O of about 8.5 cm. (FIG. 3). Microscope 10 may have an objective lens 12 of focal length of about 17.5 cm. In FIG. 2, rod 30 has been shown enlarged with the cross sectional plane corresponding with the axis 12a. The rod 30 may have a length L of about 3 mm to about 7 mm depending on the size of the image to be measured.
In FIG. 3, the rod 30 is shown mounted on a rotatable disc 36 which is supported on a tray 38. Disc 36 may be rotated in a plane perpendicular to the axis 12a and in a plane parallel to the plane common to the axes of sources 32 and 34.
Disc 36 is provided with an actuating arm 40 which is coupled to a rod 42 which is driven by micrometer screw 44. Micrometer screw 44 may be employed in connection with a calibrated scale 46 to indicate the angle through which the rod 42 is actuated as the micrometer screw 44 is rotated.
Referring now to FIG. 4, objects 32 and 34 appear as solid bars 32a and 34a when viewed through lens 12 of microscope 10 of FIG. 1 with the length of the rod 30 parallel to the lengths of the objects 32 and 34. However, as disc 36 is rotated, there will be one angle α at which the pattern of FIG. 4 is changed to the pattern shown in FIG. 5. The double image of sources 32 and 34, by reason of the view of the same through a square rod, is caused to form the parallel line offset-overlap pattern of FIG. 5. In such pattern, the object image bar 32b is parallel to and aligned with the image bar 34a with the bar 32a being offset to one side of the line 32b and 34a. Image bar 34b is offset to the other side. Once the angle α is determined, then all other elements of Equation (1) are known, except the radius r, and the radius r can then be readily calculated.
Having described the invention in terms of the schematic representations and diagrams of FIGS. 1-5, there will now be presented a description of a preferred embodiment of the invention.
Referring to FIG. 6, a cylindrical adaptor 50 is provided in a configuration suitable to be clamped as by a screw clamp 51 to the housing of a microscope objective lens. By this means, objective lenses, such as lenses 12 and 14, FIG. 1, on the microscope will be positioned to view objects through a transparent disc 52 which may contain a filter lens. In the following description, it will be presumed that the axis of the microscope will be in a vertical position so that the disc 52 would be in a horizontal plane and so that adaptor 50 would be secured to vertical cylindrical portions of the microscope object housing. In such configuration, a main frame comprising a flat horizontal mounting plate 54 is secured to the lower end of adaptor 50. Thus, when adaptor 50 is secured to the microscope, it will remain in a fixed position relative to the microscope. The plate 54 is also fixed, immovable related to adaptor 50.
Mounting plate 54 slidably and rotatably supports a subframe 56 comprising a lower tray or panel, a portion of which is seen through adaptor 50. Disc 52 is mounted in subframe 56. In addition to disc 52, a fixture 58 is supported from subframe 56 beneath plate 54. A bearing 60 supported from subframe 56 serves to mount a fixture 62 which is rotatable in bearing 60 relative to subframe 56. Bearing 60 serves to support a rod 64. Rod 64 corresponds to the rod 30 shown in FIG. 1 and may comprise, for example, a prism.
An arm 66 is secured to and extends from the fixture 62 which supports the rod 64. Arm 66 is provided with a contact roller 68 and is normally biased by a spring (not shown in FIG. 6) in a counter-clockwise direction. Roller 68 bears against the end of a travelling bar 70. Bar 70 may be manually adjusted for movement in the direction of arrow 72 by the action of a micrometer screw 74. A counter 76 is geared to the micrometer screw 74 so that a suitable reading can be obtained from counter 76 indicating the number of revolutions of the micrometer screw 74. This, in turn, is calibrated in terms of the angle 78 that the rod 64 makes relative to a line 80 which is perpendicular to the length or the long dimension of subframe 56.
As best seen in FIG. 7, a bottom view of the unit of FIG. 6, the lower panel of subframe 56 has an arcuate portion 82 cutaway in the region of the arm 66 and the bar 70. Fixture 58 can be seen through an opening in the bottom of subframe 56. The bearing unit 60 is also visible from the bottom. A clear aperture 60a extends through the center of the bearing 60 to accommodate a view of the object beneath the microscope through the aperture 60a.
A pair of slots 84 and 86 extend the length of the bottom panel of subframe 56. They are long, narrow slits and are parallel to each other and perpendicular to line 80, FIG. 6. Slot 84 is closer to the center of aperture 60a than slot 86. A light pipe 88 extends from a point adjacent micrometer screw 74 along the length of subframe 56 immediately above slot 84, namely portion 88a. A portion 88b extends laterally from portion 88a and a third longitudinal portion 88c. The portion 88c lies immediately above the slot 86.
While not an integral part of the fixture of FIGS. 6-8, a light source 90 is provided for projecting a beam of light 92 along the end of the light pipe 88 so that the portions of the light pipe 88 viewed through slots 84 and 86 corresponds to the light sources 32 and 34 of FIG. 3.
As shown in FIG. 8, subframe 56 and the structure it supports has been slidably displaced to the left relative to the axis of the adaptor 50 so that the bearing 60 carrying the rod 64 is centered under an objective lens such as objective lens 12 of FIG. 1. In this position, the second objective lens is blocked out so that the only view the operator of the microscope has is through the aperture 60a by way of the rod 64.
In FIG. 8, it will be noted that a spring 100 is coupled to arm 66 to bias arm 66 counter-clockwise so that the roller 68 of FIGS. 6 and 7 will maintain with the bar 70.
With the structure thus far described in connection with FIGS. 6-8, the unit is to be clamped onto a microscope. When its use as a keratometer is required, it will be displaced from the portion shown in FIGS. 1 and 2 to the position shown in FIG. 8 wherein a median point on rod 64 is at the axis of one of the two objective lenses. In this position, the two elongated lighted slots 84 and 86 will appear to the viewer through the rod 64. The micrometer-type adjusting screw 74 will then be rotated to change the angle 78 at which the axis of the rod 64 makes relative to line 80, FIG. 6. The adjustment is made until the pattern illustrated in FIG. 5 is viewed through the rod 64. At this point, the counter 76 may be read and the reading utilized in connection with Equation (1) to determine the curvature of the cornea.
In FIG. 8, a flat thin bar 102 is provided on which the fixture 58 is mounted. The flat bar 102 is supported by bolts 104 to the plate 54. It is by use of the bar 102 that the lower panel and all the apparatus supported thereon can be rotated relative to the plate 54 and into the position illustrated in FIG. 9. Rotation through ninety degrees permits measurement of curvature of an eye along two mutually perpendicular planes as well as at intermediate angles if desired.
Thus, in the position shown in FIG. 9, ninety degrees from the position shown in FIG. 8, and at other angles, the curvature of the cornea can be obtained relative to any axis with respect to the axis of measurement at the position shown in FIGS. 6-8.
As best shown in FIGS. 10 and 11, the micrometer screw 74 is mounted in a block 110 which is secured to the subframe 56 so that as the micrometer screw 74 is rotated, a slide unit 70a moves in accordance with arrow 72 and carries the bar 70 to move arm 66 through action of the roller 68 which is mounted on a short shaft depending from arm 66. The mounting bar 102 is secured through slide structure 112 (FIG. 11) which in turn is secured to the upper panel 64 so that the bar 102 is supported by the plate 54 and in turn supports the lower panel 56 so that the lower panel 56 can move between the positions shown in FIGS. 6 and 8 and can rotate between the positions shown in FIGS. 8 and 9.
When the keratometer portions of the system are not in use, such portions of the system will occupy positions shown in FIG. 6 so that the usual unimpeded use of the microscope can proceed. The keratometer elements are readily available and may simply be brought into position by sliding from the position shown in FIG. 6 to the positions shown in FIGS. 8 and 9.
Having described the invention in connection with certain specific embodiments thereof, it is to be understood that further modifications may now suggest themselves to those skilled in the art, and it is intended to cover such modifications as fall within the scope of the appended claims. | An instrument with a microscope brings into focus the cornea of a patient's eye for measurement of the radius of curvature of the cornea. Included is a pair of parallel spaced apart linear objects in a plane perpendicular to the optical axis of the eye and of the microscope. A square rod of refractile transparent material is mounted in the field of view of the microscope with a diagonal of the cross-section thereof common to the optical axis of the microscope. Structure is provided for rotating the rod around the optical axis of the microscope to produce a parallel line offset-overlap pattern of the objects as viewed through the rod. Structure is further provided for measuring the angle between a perpendicular from the long axes of the objects, and the orientation of the rod at which the pattern is produced. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an image forming apparatus such as a copying apparatus, a printer or a facsimile apparatus, and particularly to the technique of making a plurality of conveyance paths capable of being selected in conformity with the disposed state of a separable image reading portion.
2. Related Background Art
As a conventional image forming apparatus, the construction of an ordinary copying apparatus is shown in FIG. 8 of the accompanying drawings. In an image reading portion R, the image of an original placed on platen glass 1 is directed to a CCD 3 by an optical reading system 2 comprising an illuminating lamp, a reflecting mirror, and a lens and is converted into an electrical signal.
On the basis of this electrical signal, in an image forming portion P, a laser beam is applied to a photosensitive drum 4 uniformly charged by a primary charger 5, whereby an electrostatic latent image is formed. This electrostatic latent image is visualized into a toner image by a toner supplied from a developing device 6.
On the other hand, a sheet fed by sheet feeding means 7 has its skew feed corrected by its leading end striking against stopped registration rollers 8, and is sent to a transfer portion 9 by the registration rollers 8 being rotated so as to be synchronized with the toner image formed on the photosensitive drum 4.
In the transfer portion 9, the toner image on the photosensitive drum 4 is electrostatically attracted from the back of the sheet by a corona charger or the like, whereby the toner image is transferred onto the sheet.
The sheet onto which the toner image has been transferred has its electrostatic attractive force with respect to the photosensitive drum 4 removed by a separating charger 10, and thereafter is conveyed to a fixing portion 14 by a suction belt conveying portion 11.
The suction belt conveying portion 11 effects the conveyance of the sheet by a rubber belt 13 made of chloroprene while sucking the sheet by are drawn by a fan 12.
The sheet on which the toner image has been fixed by the fixing portion 14 is discharged onto a tray 16 outside the apparatus through a sheet discharging portion 15. Or the sheet is sent to a refeeding conveyance path 17 for both-surface copying or to a post-step such as sorting or stapling.
However, with the digitization of the image forming apparatus, there have been provided many products in which the image reading portion R (reader portion) and the image forming portion P (printer portion) can function as discrete members.
Between a case in which the image forming portion P is made to function as a printer and a case in which the image forming portion P is made to function as a copying apparatus, different processes are carried out in the sheet discharging process.
For example, when the image forming apparatus is used as a printer, a sheet processed as the head page is often discharged with its face down, and when the image forming apparatus is used as a copying apparatus, the sheet is often discharged with its face up, after which the sheets are subjected to a post-process such as stapling.
Which conveyance path is selected depends on a method whereby the installer (service engineer) of the image forming apparatus changes and installs a changeover member or the like in conformity with respective states.
SUMMARY OF THE INVENTION
The present invention has been made in order to solve the above-noted problem which is peculiar to the earlier technology, and the object of the invention is to enable a sheet conveying path to be easily or automatically changed in conformity with the disposed state of an image reading portion to thereby achieve an improvement in the setting work property during the installation or the like of an image forming apparatus.
To achieve the above object, the present invention provides an image forming apparatus including:
sheet feeding means;
image forming means for forming an image on a sheet fed;
a plurality of conveying paths for directing the sheet on which the image has been formed to discharging portions;
changeover means for selecting a desired conveying path from the plurality of conveying paths; and
changeover controlling means for controlling the changeover means in conformity with whether reading means for reading the image of an original has been set at a predetermined position in a body of the apparatus.
As described above, according to the present invention, the changeover means changes over the conveying path in conformity with the presence or disposed position of the image reading portion. Accordingly, for example, the conveying path changeover work by a service engineer becomes unnecessary and the setting work property of the image forming apparatus is improved.
Accordingly, when the image forming apparatus is used as a printer in which an image reading portion is not disposed in the upper portion of an image forming portion, a sheet on which an image has been formed can be discharged with its face down, and when the image forming apparatus is used as a copying apparatus, the sheet can be discharged by the mounting of a reader with its face up, and an improvement in the usability of the apparatus can be achieved. Also, the malfunctioning of the apparatus can be prevented. Also, the discharging of the sheet to a sheet containing portion which becomes unuseable upon the mounting of the reader is reliably inhibited, and this is convenient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an image forming apparatus with reading means according to a first embodiment of the present invention.
FIG. 2 illustrates the image forming apparatus according to the first embodiment of the present invention.
FIG. 3 illustrates an image forming apparatus with reading means according to a second embodiment of the present invention.
FIG. 4 illustrates the image forming apparatus according to the second embodiment of the present invention.
FIG. 5 illustrates an image forming apparatus according to a third embodiment of the present invention.
FIG. 6 illustrates an image forming apparatus according to a fourth embodiment of the present invention.
FIG. 7 illustrates the image forming apparatus with reading means according to the fourth embodiment of the present invention.
FIG. 8 illustrates an image forming apparatus according to the earlier technology.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some embodiments of an image forming apparatus to which the present invention is applied will hereinafter be described in detail with reference to the drawings.
In the image reading portion R (reader portion) of FIG. 1, the image of an original placed on a platen glass plate 1 is directed to a CCD 3 by an optical reading system 2 comprising an illuminating lamp, a reflecting mirror and a lens and is converted into an electrical signal.
On the basis of this electrical signal, in an image forming portion P (printer portion), a laser beam is applied to a photosensitive drum 4 uniformly charged by a primary charger 5, whereby an electrostatic latent image is formed. This electrostatic latent image is visualized into a toner image by a toner supplied from a developing device 6.
On the other hand, a sheet fed by sheet feeding means 7 has its leading end striking against stopped registration rollers 8, whereby a skew feed of the sheet is corrected and the sheet is fed to a transfer portion 9 by the registration rollers 8 being rotated so as to be synchronized with the toner image formed on the photosensitive drum 4.
In the transfer portion 9, the toner image on the photosensitive drum 4 is electrostatically attracted from the back side of the sheet by a corona charger or the like and is thereby transferred onto the sheet.
The sheet onto which the toner image has been transferred has its electrostatic attractive force with respect to the photosensitive drum 4 removed by a separating charger 10, and thereafter is conveyed to a fixing portion 14 by a suction belt conveying portion 11.
The suction belt conveying portion 11 effects the conveyance of the sheet by a rubber belt 13 made of chloroprene while sucking the sheet by are drawn by a fan 12.
The sheet having had the toner image thereon fixed by the fixing portion 14 is discharged to a tray 16 outside the apparatus through a sheet discharging portion 15 which is provided on the side portion of the image forming portion P. Or the sheet is sent to a sheet re-feeding conveyance path 17 for both-surface copying or sent to a post-step such as sorting or stapling.
FIG. 1 shows a state in which the image reading portion R is installed at a predetermined position in the image forming portion P. The reference numeral 19 designates detecting means for detecting the image reading portion R, and by this detecting means 19 detecting the image reading portion R, the sheet is conveyed to the sheet discharging portion 15 by changeover means 18 and is discharged onto the sheet discharging tray 16.
When at this time, the sheet is discharged straight from the sheet discharging portion 15, the sheet after image formation is discharged with its image bearing surface facing up. Also, it is possible to reverse (switch back) the front surface and the back surface of the sheet by the vertical conveying path portion 17a of the sheet refeeding conveyance path 17 and discharge the sheet from the sheet discharging portion 15 with its face down.
The changeover means 18 can selectively change over a conveying path H1 for conveying the sheet to the sheet discharging portion 15 and a conveying path H2 for conveying the sheet to a sheet discharging portion 21, by driving means such as a solenoid, not shown. That is, the changeover means 18 can selectively change over a plurality of conveying paths.
Also, the aforedescribed detecting means 19 is capable of detecting the presence or absence of the image reading portion R by a photosensor or the like, but the detecting method is not restricted thereto.
Next, FIG. 2 shows a state in which the image reading portion R has been removed from the predetermined position in the image forming portion P. At this time, the detecting means 19 detects the absence of the image reading portion R, and control means, not shown, controls the changeover means 18 to thereby change over the sheet conveying path to the sheet discharging conveyance path H2, and the sheet is discharged from the sheet discharging portion 21 which is provided on the upper surface portion of the image forming portion P onto a newly provided sheet discharging tray 24. Also, at this time, an electric signal is inputted to the image forming portion P from the outside so that the image is formed.
In this case, the sheet after image formation is discharged with its image bearing surface facing down.
Accordingly, the detecting means 19 detects the presence or absence of the image reading portion R and in conformity with the detection result, the changeover means 18 automatically changes over the conveying path to the conveying path H1 or the conveying path H2, thus eliminating the conveying path changeover work by a service engineer and improving the setting work property of the image forming apparatus.
[Embodiment 2]
A second embodiment of the image forming apparatus to which the present invention is applied will hereinafter be described in detail with reference to the drawings. In the following description, structural elements similar to those in the first embodiment are given the same reference characters and need not be described.
FIG. 3 shows a state in which the image reading portion R is installed at a predetermined position in the image forming portion P. The reference numeral 25 denotes engagement means engaged with the foot 26 of the image reading portion R and for changing over the changeover means 18 in its engaged state so as to direct a sheet to the sheet discharging portion 15.
Thereby, the sheet on which an image has been formed is conveyed to the sheet discharging portion 15 and is discharged onto the sheet discharging tray 16.
When at this time, the sheet is discharged straight, the sheet after image formation is discharged with its image bearing surface facing up.
Next, FIG. 4 shows a state in which the image reading portion R has been removed from the predetermined position in the image forming portion P. At this time, the engagement means 25 is disengaged from the foot 26 of the image reading portion R, whereby the engagement means 25 is elevated and changes over the changeover means 18 to the conveying path H2, and the sheet is discharged from the sheet discharging portion 21 onto a newly provided sheet discharging tray 24.
At this time, the sheet after image formation is discharged with its image bearing surface facing down. The engagement means 25 is upwardly biased by a spring, not shown, and is connected to and operatively associated with the changeover means 18.
[Embodiment 3]
A third embodiment of the image forming apparatus to which the present invention is applied will now be described in detail with reference to the drawings. In the following description, structural elements similar to those in the first embodiment are given the same reference characters and need not be described.
FIG. 5 shows a case where the image reading portion R has slid from a state (a first position) in which the image reading portion R is installed at a predetermined position in the image forming portion P to a second position.
The reference numeral 26 designates detecting means for detecting that the image reading portion R is in the first position (broken line position). The image reading portion R is in the first position and the detecting means 26 detects the image reading portion R, whereby the conveying path H1 is selected by the changeover means 18, and a sheet, on which an image has been formed, is conveyed to the sheet discharging portion 15 and is discharged onto the sheet discharging tray 16.
When conversely, the image reading portion R is in the second position (solid line position), the conveying path is changed over to the conveying path H2 by the changeover means 18, and the sheet is discharged from the discharging portion 21 to the upper portion of the image forming portion P.
The image reading portion R is guided onto the image forming portion P by a slide rail, not shown.
The aforedescribed detecting means 26 detects the position of the image reading portion R by a photosensor or the like, but it is not restricted thereto.
[Embodiment 4]
A fourth embodiment of the image forming apparatus to which the present invention is applied will now be described in detail with reference to the drawings. In the following description, structural elements similar to those in the first and second embodiments are given the same reference characters and need not be described.
FIG. 6 shows a state in which the image reading portion R has been removed from a predetermined position in the image forming portion P. At this time, the engagement means 25 is disengaged from the foot 26 of the image reading portion R, whereby the engagement means 25 is elevated and changes over the changeover means 18 to the conveying path H2, and a sheet is discharged from the sheet discharging portion 21 to a sheet discharging tray 124 provided on the upper surface of the body.
At this time, the sheet after image formation is discharged with its image bearing surface facing down. The engagement means 25 is upwardly biased by a spring, not shown, and is connected to and operatively associated with the changeover means 18.
Also, the changeover means 18 can selectively changeover the conveying path H1 for conveying the sheet to the sheet discharging portion 15 and the conveying path H2 for conveying the sheet to the sheet discharging portion 21, i.e., a plurality of conveying paths. Accordingly, it can select face-down sheet discharging and face-up sheet discharging as desired. It is also possible to control changeover means 18' to thereby reverse (switch back) the front surface and the back surface of the sheet by the vertical conveying path portion 17a of the sheet refeeding conveyance path 17 (dots-and-dash line path) and discharge the sheet from the sheet discharging portion 15 with its face down. The reference character 17b designates a forwardly and reversely rotatable roller provided in the reverse switch-back path or vertical conveying path portion 17a.
FIG. 7 shows a state in which the image reading portion R is installed at a predetermined position in the image forming portion P. The reference numeral 25 denotes engagement means engaged with the foot 26 of the image reading portion R and for changing over the changeover means 18 in its engaged state so as to direct the sheet to the sheet discharging portion 15.
Thereby, the sheet on which an image has been formed is conveyed to the sheet discharging portion 15 and is discharged onto the sheet discharging tray 16.
When at this time, the sheet is discharged straight, the sheet after image formation is discharged with its image bearing surface facing up.
Even if the above-described solenoid is driven, the changeover means 18 is not changed over. Accordingly, malfunctioning is prevented. | An image forming apparatus including a sheet feeding device, an image forming device for forming an image on a sheet fed, a plurality of conveying paths for directing the sheet on which the image has been formed to discharging portions, a changeover device for selecting a desired conveying path from the plurality of conveying paths and a changeover controlling device for controlling the changeover device in conformity with whether a reading device for reading the image of an original has been set at a predetermined position in a body of the apparatus. | 7 |
BACKGROUND INFORMATION
[0001] Mechanically Actuated Self Cleaning Fluid Drainage System needs to be both commercially viable and robust in environments that contain heavy debris and grit accumulation associated with decaying roof drainage systems. For example, U.S. Pat. No. 7,610,721 issued Nov. 3, 2009 shows a device although suitable for roof drainage systems where the debris is light but it falls short of commercially viable solution where debris is heavier in nature. There is therefore a need for an improved Mechanically Actuated Self Cleaning Fluid Drainage System.
SUMMARY OF THE INVENTION
[0002] In summary, this invention is a combination fluid flow channel and scavenging system to eject debris from the channel. This combination is configured to minimize the potential for jamming and economize on overall width. The channel includes a back wall, channel floor, and upward ramp extending forward to an outer lip. The scavenging system includes a pivoted actuator with a face plate on a framework adapted for reciprocating rolling contact between retracted and forward positions relative to the back wall. The scavenging system rolls on tracks as it traverses the channel. The channel profile and scavenging system are configured to maximize the angle between face plate and ramp surface thereby minimizing the potential for jamming of the scavenging system during operation while economizing on channel width. The outer lip includes a flat top surface for transient support of the face plate framework at the end of its forward movement. The scavenging system further includes flexible wiper blades for sequential wiping contact with debris as it traverses the channel, and a forward-extending slider blade spring-biased toward the channel.
DRAWINGS
[0003] FIG. 1 a is a left front perspective view of my fluid flow channel and scavenging system 100 in the park position while attached to a structure.
[0004] FIG. 1 b is a left front perspective view of the fluid flow channel and scavenging system 100 in the open position while attached to a structure.
[0005] FIG. 2 a is a left front perspective view of the fluid flow channel and scavenging system 100 in the park position.
[0006] FIG. 2 b is an exploded view of with left front perspective of the channel and scavenging system 100 .
[0007] FIG. 2 c is an end view of fluid flow channel 200
[0008] FIG. 3 a is left rear perspective view of scavenging assembly 300 .
[0009] FIG. 3 b is an exploded left rear perspective view of scavenging assembly 300 .
[0010] FIG. 3 c is an exploded view of caster assembly 330 .
[0011] FIG. 4 a is a rear perspective view of scavenging system 440 .
[0012] FIG. 4 b is a rear partial view of actuator 150 mounted to scavenger assembly 300 with actuator expanded.
[0013] FIGS. 5 a and 5 b are end views of fluid flow channel 200 and scavenging system 100 depicting angular relationships.
[0014] FIG. 6 a through 6 c are successive end views of fluid flow channel 200 and scavenging system 100 depicting interaction between scavenger system 440 and fluid flow channel 200 .
[0015] FIG. 7 a through 7 e are successive end views showing interaction between flexible wiper 315 and fluid flow channel 200 .
[0016] FIGS. 8 a through 8 e are successive end views showing the spatial relationship between scavenger system 440 and structure 7 .
[0017] FIGS. 9 a through 9 c show prior art successive end views of the Gutter Drainage and Debris Removal System 10 (prior art U.S. Pat. No. 7,610,721).
[0018] FIG. 10 is a prior art block diagram showing remote control of the Gutter Drainage and Debris Removal System 10 (prior art U.S. Pat. No. 7,610,721).
[0019] FIG. 11 is a block diagram showing centralized remote control for geographically separate installations of system 100 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] With reference now to the drawing figures: FIG. 1 show a combination fluid flow channel and scavenging system 100 (hereinafter referred to as system 100 ) mounted to structure 7 under the edge of a sloped roof surface with scavenger assembly 300 in the retracted or park position. System 100 allows fluid to flow along its length with the capability to expel accumulated solids in a direction roughly perpendicular to its length. Fluid flow systems tend to collect debris in the fluid flow channel; reliable function requires debris removal to promote drainage. FIG. 1 b shows system 100 mounted to structure 7 with scavenger assembly 300 in the forward position after debris expulsion resting on fluid flow channel 200 . It also shows actuator 150 (prior art defined in U.S. Pat. No. 7,610,721) attached to hinge clip 218 with a shaft (not shown).
[0021] FIG. 2 a shows system 100 separate from supporting structure. FIG. 2 b is an exploded view of system 100 that shows actuator 150 (prior art U.S. Pat. No. 7,610,721) pivotally connected to hinge clip 218 through pivot tab 154 using a shaft (not shown). Scavenger assembly 300 is fixed to actuator 150 to with fasteners. Spring loaded piano hinge 320 is fixed to the face of scavenger assembly 300 as shown in FIG. 2 a by suitable fasteners. The piano hinge 320 is optional for heavy debris.
[0022] FIG. 2 b shows wear plates 220 attached to fluid flow channel 200 . Wear plates 220 are stainless steel 0.035″ thick, 4″ wide with a profile to match the interior surface of fluid flow channel 200 . Wear plates 220 provide a running surface for scavenger assembly 300 as it traverses the profile of fluid flow channel 200 . Wear plates 220 are located approximately 28.5″ from center, and suitably fixed to fluid flow channel 200 . Fluid flow channel 200 is aluminum 0.05″ thick, 120″ in length, 3.8″ in height, and 6.8″ in width.
[0023] FIG. 2 c shows features of fluid flow channel 200 as follows: registration edge 201 and registration surface 202 , which together determine the vertical and horizontal location of hinge clip 218 and the pivot axis for actuator 150 as shown in FIG. 2 b . Registration surface 202 is approximately 3″ tall. Material occlusion ramp 204 is angled to reduce debris buildup behind scavenger assembly 300 . Channel floor 206 is 1.8″ across and supports scavenger assembly 300 . Curved surface 208 is a transitional surface from channel floor 206 to ramp surface 210 . Curved Surface 208 has a radius of 3.3″ and a sweep of 45°. Ramp surface 208 supports scavenger assembly 300 as debris is pushed out of fluid flow channel 200 . Ramp surface 208 is approximately 2″ long. Ramp angle 212 is 45°. Top surface 210 is a resting surface for scavenger assembly 300 . Stop surface 216 limits over travel of spring loaded piano hinge 320 . Fluid flow channel 200 is secured to structure 7 (shown in FIG. 1 a ) by regularly spaced fasteners.
[0024] FIG. 3 a shows scavenger assembly 300 . FIG. 3 b is an exploded view of scavenger assembly 300 . It shows face plate framework 302 which consists of face plate 304 , rear plates 306 and end caps 310 . The overall length of face plate framework 302 is 118.5″. Face plate framework 302 provides the necessary rigidity to clear 10′ long sections of fluid flow channel 200 without buckling or twisting. Face plate framework 302 is approximately 4.4″ tall by 2.9″ wide. Rear plate 306 slopes at approximately a 30° angle. Face plate 304 , rear plate 306 , and end caps 310 are all constructed of 0.032″ thick aluminum and suitably joined to each other.
[0025] FIG. 3 b also shows a spring loaded piano hinge 320 and caster assembly 330 . Spring loaded piano hinge 320 includes mounting plate 322 and wiper plate 324 . Mounting plate 322 is 0.05″ thick aluminum, and 118.5″ long by 1.5″ wide. Wiper plate 324 is 0.05″ thick aluminum, and 118.5″ in length and 1.5″ wide. Wiper plate 324 is joined to mounting plate 322 by stainless steel pins 0.125″ in diameter. Stainless steel torsion springs (not shown) provide approximately 2-3 inch-pound of torque total and bias wiper plate 324 against fluid flow channel 200 . Spring loaded piano hinge 320 aids in evacuating debris that accumulates in fluid flow channel 200 . Caster assembly 330 is suitably fixed to face plate framework 302 at a distance of approximately 28.5″ from center with fasteners. Castor assembly 330 aids in supporting scavenger assembly and reducing friction as it traverses fluid flow channel 200 .
[0026] FIG. 3 b also shows flexible wiper 315 , which normally spans the entire length of scavenger assembly 300 , except at caster assembly 330 locations. Flexible wiper 315 is fixed to face plate framework 302 using adhesive or fasteners. Flexible wiper 315 is fabricated in a continuous extrusion process and is made of EPDM Rubber with an approximate Shore A Durometer of 50. FIG. 7 a shows wiper body 316 , frontal blade 317 , mid blade 318 , and trailing blade 319 . Flexible wiper 315 is approximately 0.86″ tall overall. Measured from wiper body 316 , mid blade 318 is 0.35″ tall. Trailing blade 319 and frontal blade 317 are 0.31″ tall. Trailing blade 319 and frontal blade 317 are angularly separated from mid blade 318 by 35°. Mid blade 318 , trailing blade 319 , and frontal blade 317 are 0.07″ thick. Wiper body 316 is 0.28″ thick.
[0027] FIG. 3 c is an exploded view of caster assembly 330 . Caster assembly 330 is comprised of caster bracket 332 , roller 334 , shoulder screw 336 , and lock Nut 338 . Caster bracket 332 is 0.075″ thick stainless steel with a height and width of 1.4″. Roller 334 is nylon with a diameter of 0.75″ and a width of 0.48″. Shoulder screw 336 is McMaster-Carr part number 94035A532. Lock nut 338 is McMaster-Carr part number 90101A225.
[0028] FIG. 4 a shows scavenging system 440 consisting of actuator 150 mounted to scavenger assembly 300 while viewing the rear side of scavenger assembly 300 .
[0029] FIG. 4 b is a partial view of actuator 150 mounted to scavenger assembly 300 with actuator 150 expanded. In FIG. 4 b orbital shaft (prior art not shown) defined in U.S. Pat. No. 7,610,721, is replaced by lock nut 338 , shoulder screw (not shown), and roller (not shown) in an arrangement similar to caster assembly 330 shown in FIG. 3 c.
[0030] FIGS. 5 a and 5 b show resistance angle 510 as the angle created by a line originating at the hinge axis of hinge clip 218 and ending at the intersection of roller 334 and wear plate 220 and the tangent of roller 334 and wear plate 220 . The cosine of angle 510 yields the fraction of actuator force available to overcome rolling resistance at the interface of roller 334 and wear plate 220 . As angle 510 increases, the system requires more air pressure to operate. FIG. 5 a shows a resistance angle 510 which is approximately 67°.
[0031] FIG. 5 a shows parking angle 520 as the angle between face plate 304 of scavenger assembly 300 and wear plate 220 . When parking angle 520 is less than approximately 78°, system 100 will remain in its retracted or park position without air pressure. As parking angle 520 decreases, resistance angle 510 increases.
[0032] FIG. 5 b shows pinch angle 500 which is defined as the angle between face plate 304 and ramped surface 210 ( FIG. 2 c ).
[0033] FIGS. 6 a , 6 b , and 6 c sequentially show the interaction between spring loaded piano hinge 320 , ramped surface 210 , top surface 214 , and striker surface 216 .
[0034] FIGS. 7 a - 7 e sequentially show the rotational interaction between flexible wiper 315 and the profile of fluid flow channel 200 as scavenger system 440 traverses during scavenging.
[0035] FIGS. 8 a - 8 e sequentially show the spatial interaction between scavenger system 440 and structure 7 .
[0036] FIG. 9 a is prior art that shows gutter section 14 mounted on support structure 7 , drip edge 19 , scavenger blade 16 , and wiper 13 , in the park position.
[0037] FIG. 9 b is prior art that shows drip edge 19 , scavenger blade 16 , gutter section 14 , and pinch angle 500 .
[0038] FIG. 9 c is prior art that shows drip edge 19 , scavenger blade 16 , gutter section 14 , wiper 13 and gap 517 in the forward position.
[0039] FIG. 10 is a prior art block diagram that shows co-located electrically actuated valves.
[0040] FIG. 11 is a block diagram which shows scavenger systems 440 connected in parallel with air line open 820 (line 820 ) and air line close 822 (line 822 ). Pneumatic solenoid valve 810 controls lines 820 and 822 . Pressurization of line 820 causes scavenger system 440 to move to the forward position as shown in FIG. 1 b . Pressurization of line 822 causes scavenger system 440 to retract to park position as shown in FIG. 1 a . As either line 822 or 820 are pressurized, air in the other line is exhausted through a port in pneumatic solenoid valve 810 . Compressed air line 808 conveys pressurized air from air compressor 806 to pneumatic solenoid valve 810 . 24V line 818 transmits control power from programmable logic controller and power supply (PLC) 826 to pneumatic solenoid valve 810 . Programmable logic controller and power supply 826 controls air compressor 806 through control line 824 and receives air compressor 806 feedback through logical signal and telemetry line 812 . Control panel 800 contains circuitry necessary to signal PLC 826 to initiate scavenging routines, and control panel 800 can communicate through a logical signal and telemetry line 812 or by wireless receiver and transmitter 816 with PLC 826 .
Operational Description of the Invention
[0041] Wear plates 220 ( FIG. 2 b ) provide lower contact friction for spring loaded piano hinge 320 ( FIG. 3 b ) because the coefficient of friction between aluminum and stainless steel is less than aluminum against aluminum. Wear plates 220 are also rolling interface for roller 334 ( FIG. 3 c ) and eliminate wear on fluid flow channel 200 .
[0042] FIG. 3 b shows face plate framework 302 , by comparison (prior art) FIG. 9 b shows scavenging blade 16 (U.S. Pat. No. 7,610,721) in profile. Face plate framework 302 is fashioned with enclosed box structures that have higher strength to weight ratios compared to an open channel construction of scavenging blade 16 . The increased rigidity and strength of face plate framework 302 is needed to remove heavier debris from fluid flow channel 200 .
[0043] FIG. 5 b shows pinch angle 500 at approximately 44°. Pinch angle 500 implies the likelihood of scavenging difficulty. As the pinch angle becomes smaller, it is harder to expel solids during scavenging. FIG. 9 b (prior art) shows a smaller pinch angle 500 of 22° for a similar position in the scavenging cycle.
[0044] FIGS. 6 a , 6 b , and 6 c show how spring loaded piano hinge 320 enhances the debris ejection process. As wiper plate 324 pivots about top surface 214 , torque supplied by torsion springs in spring loaded piano hinge 320 accelerates the debris ejection process. Stop surface 216 limits rotational over travel of spring loaded piano hinge 320 .
[0045] FIGS. 7 a , 7 b , 7 c , 7 d , and 7 e illustrate how flexible wiper 315 interacts with fluid flow channel 200 during scavenging to remove small debris from fluid conveyance channel 200 . As flexible wiper 315 advances during scavenging it experiences counter clockwise rotation relative to fluid flow channel. By consecutively exposing debris to additional wipers, this aids in removal of small debris. By comparison, prior art FIGS. 9 a - 9 c show a wiper 13 with a continuous surface.
[0046] FIGS. 8 a , 8 b , 8 c , 8 d , and 8 e illustrate how the gap between drip edge 19 and upper lip 312 is minimized throughout the scavenging cycle; this minimizes the opportunity for debris to fall behind the scavenging blade assembly 300 during a scavenging cycle. FIG. 9 c (prior art) shows a larger gap 527 . This improvement results from the choice of fluid flow channel 200 profile and scavenger system 440 pivot axis location.
[0047] Prior art shown FIG. 10 box diagram shows a co-location of all electrically actuated (pneumatic solenoid) valves. This prior art diagram and description (see column 4 line 26 of U.S. Pat. No. 7,610,721) describe a bank of centrally located electrically actuated valves with pneumatic (air) lines 32 and 34 running to systems 10 . Because lines 32 and 34 must be alternately pressurized and vented during operation, the need for compressed air increases as lines 32 and 34 grow in length and internal diameter. This approach is sufficient for smaller buildings and houses.
[0048] FIG. 11 shows a relocated pneumatic solenoid valve 810 from a central bank to a branch location near each dependant series of scavenging systems 440 . By lengthening compressed air line 808 and shortening air lines 820 and 822 , the performance of scavenging system 440 is improved and the amount of compressed air needed per cycle is reduced. This improvement allows system 100 to be more easily employed on large homes and buildings.
[0049] FIG. 11 also shows a remote control panel which by virtue of wires 812 or wireless 816 communications permits central control 800 over separate system 100 installations on geographically separate buildings. Prior art FIG. 10 describes remote control of individual or groups of actuators within a single structure. By contrast FIG. 11 describes a means to remotely control entire installations of systems 100 located on separate structures in different geographical locations.
[0050] The foregoing description of a preferred embodiment of the invention, including dimensions, is illustrative. The concept and scope of the invention are not limited by details of the description but only by the following claims.
[0000]
PARTS LIST
Number
Name
FIG.
7
Structure
1a, 1b, 5a, 6a
10
Gutter Drainage and Debris Removal
9a
System (prior art)
13
Wiper (prior art)
9c
14
Gutter Section (prior art)
9a-9c
16
Scavenging Blade (prior art)
9a-9c
19
Drip Edge
8a-8e, 9a-9c
32
Pneumatic Line (prior art)
10
34
Pneumatic Air Line (prior art)
10
100
Combination Fluid Flow Channel and
1a, 1b, 2a, 2b
Scavenging System
150
Actuator defined in U.S. Pat. No.
1b, 2b, 4a, 4b
7,610,721
154
Pivot Tab
2b
200
Fluid Flow Channel
1a, 1b, 2b
201
Registration Edge
2c
202
Registration Surface
2c
204
Material Occlusion Ramp
2c
206
Channel Floor
2c
208
Curved Surface
2c
210
Ramp Surface
2c
212
Ramp Angle
2c
214
Top Surface
2c
216
Stop Surface
2c
218
Hinge Clip
2b, 5a, 5b
220
Wear Plate
2b, 5a, 5b
300
Scavenger Assembly
1a, 1b, 2b, 3a, 3b, 5a, 8a
302
Face Plate Framework
3b
304
Face Plate
3b
306
Rear Plate
3b
310
End Cap
3b
312
Upper Lip
8a-8d
315
Flexible Wiper
3b, 7a-7e
316
Wiper Body
7a
317
Frontal Blade
7a-7e
318
Mid Blade
7a-7e
319
Trailing Blade
7a, 7e
320
Spring Loaded Piano Hinge
2b, 3b, 6a
322
Mounting Plate
3b
324
Wiper Plate
3b, 6a-6c
330
Caster Assembly
3b, 3c
332
Caster Bracket
3c
334
Roller
3c, 5a
336
Shoulder Screw
3c
338
Lock Nut
3c, 4b
440
Scavenger System
4a
500
Pinch Angle
5b, 9b
510
Resistance Angle
5a, 5b
520
Parking Angle
5a
527
Gap
9c
800
Control Panel
11
806
Air Compressor
11
808
Compressed Air Line
11
810
Pneumatic Solenoid Valve
11
812
Logical Signal and Telemetry Line
11
816
Wireless Receiver and Transmitter
11
818
24 Volt Line
11
820
Air Line Open
11
822
Air Line Close
11
824
Compressor Power Control Line
11
826
Programmable Logic Controller and
11
Power Supply | A fluid flow channel includes a scavenging system to eject debris from the channel. The channel includes a back wall, channel floor, and upward ramp extending forward to an outer lip. The scavenging system includes a pivoted actuator with a face plate on a framework adapted for reciprocating rolling contact between retracted and forward positions relative to the back wall. The scavenging system rolls on tracks as it traverses the channel. The channel profile and scavenging system are configured to maximize the angle between face plate and ramp surface thereby minimizing the potential for jamming of the scavenging system during operation while economizing on channel width. The outer lip includes a flat top surface for transient support of the face plate framework at the end of its forward movement. The scavenging system further includes flexible wiper blades for sequential wiping contact with debris as it traverses the channel, and a forward-extending slider blade spring-biased toward the channel. | 4 |
BACKGROUND
[0001] Posttraumatic stress disorder (PTSD) is an anxiety disorder resulting from exposure to shocking and/or distressing events. Many veterans experience PTSD because of their wartime experiences. For example, PTSD can result in persistent flashbacks, nightmares, difficulty sleeping, and significant impairment of social and occupational function.
[0002] PTSD is understood to result in neuroendocrinological changes as well, as brain morphology. As a result, some patients are known to have atypical biochemical levels associated with the sympathetic nervous system, or the system that controls the “fight or flight” response. Fear is thought to be closely associated with these neurobiological conditions.
[0003] Various attempts have been made to treat PTSD including psychotherapy, medication, and combinations of therapies. However, while medications have shown benefit in reducing PTSD symptoms, there is no clear drug treatment for PTSD. This may be because such treatment is symptom-oriented and does not necessarily cause the patient to recover from the disorder.
[0004] Alternative approaches to solving the problems presented by PTSD could desirably treat the neurobiological conditions established by the traumatic events rather than merely reducing the symptoms suffered by patients experiencing PTSD. For example, psychological and neuropsychological studies suggest a correlation with treating areas of the human brain, such as the hippocampus and amygdale, and improvement for veterans suffering with PTSD.
[0005] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent upon a reading of the specification and a study of the drawings.
SUMMARY
[0006] The following examples and aspects thereof are described and illustrated in conjunction with systems, tools, and methods that are meant to be exemplary and illustrative, not limiting in scope. In various examples, one or more of the above-described problems have been reduced or eliminated, while other examples are directed to improvements.
[0007] A technique for influencing the human brain can be applied to treat neurobiological conditions through influencing the brain to operate at a desired, therapeutic frequency by producing specific sound beats, which are converted by the inner ear into electrical signals received by the hippocampus. For example, the human brain can be stimulated with a beat in the theta (θ) frequency range to influence the brain to relax and enter into a therapeutic state. Alternatively, the human brain can be stimulated with a beat in the alpha (α) frequency range to stimulate active thinking. Over a series of treatments the brain of an individual suffering from PTSD, or other neurobiological conditions, can be influenced to operate at a normal frequency. Advantageously, as the frequency is adjusted, the symptoms of PTSD recur less often until the individual ceases to experience the symptoms or has at least experienced a decreased recurrence of the symptoms.
[0008] A system for influencing a human brain to operate at a frequency includes a fluid filled chamber having various audio reproduction devices. The audio reproduction devices are coupled to a processing device producing audio signals prepared to influence the human brain to operate at a frequency conducive to function in a particular therapeutic state. The audio reproduction devices can produce waves in both audible and inaudible frequencies. In response to the stimulation, cells within the human brain can respond to the audio frequencies by influencing cellular water action potential. In one implementation, multiple frequencies can be combined into a monaural beat, a single united resonance frequency to induce the therapeutic state. Monitoring devices can be distributed inside and/or outside the chamber to record the brainwaves emanating from the human brain.
[0009] A method for influencing a human brain of an individual to operate at a frequency includes stimulating the human brain with audio waves while the individual is immersed in a fluid medium. While stimulated, the individual can be monitored for adherence to the frequency using one or more sensors to identify the frequency of operation of the individual's brain waves. In one implementation the audio waves can be projected through the fluid medium in more than one frequency where the difference between the frequencies produce a monaural beat stimulating the human brain at the desired frequency. Additionally, the audio waves can be interspersed with music to provide an engaging experience.
[0010] In one embodiment, monaural beats are produced based on the acoustical design of a chamber shaped to optimize delivery of frequencies to an individual within the chamber. In a further embodiment, the shape of the chamber is designed based on the acoustical characteristics of a musical instrument, such as the cello.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 depicts an example of a system for influencing a human brain to operate at a frequency.
[0012] FIG. 2 depicts components of a system for influencing a human brain to operate at a frequency.
[0013] FIG. 2 a depicts an example of a chamber used for influencing a human brain to operate at a frequency.
[0014] FIG. 3 depicts a flowchart of an example of a method for influencing a human brain to operate at a frequency.
[0015] FIG. 4 depicts an example of a computing system representative of the computing systems discussed herein.
DETAILED DESCRIPTION
[0016] In the following description, several specific details are presented to provide a thorough understanding. One skilled in the relevant art will recognize, however, that the concepts and techniques disclosed herein can be practiced without one or more of the specific details, or in combination with other components. In other instances, well-known implementations or operations are not shown or described in detail to avoid obscuring aspects of various examples disclosed herein.
[0017] FIG. 1 depicts an example of a system 100 for influencing a human brain to operate at a frequency. FIG. 1 includes stimulation module 102 , individual 104 , environment 106 , and monitor 108 .
[0018] In the example of FIG. 1 , the stimulation module 102 can include devices 103 for producing audible, vibratory, magnetic or other known or convenient signals. For example, the stimulation module 102 can include devices 103 such as speakers, one or more ultrasonic transducers, or other known or convenient devices for stimulating an individual 104 while the individual 104 is within environment 106 . The stimulation provided by devices 103 can be administered at a predetermined, desired frequency, or an individual 104 can adjust the frequency to a desired level corresponding to the type of therapy that the individual 104 desires to undertake. The devices 103 can produce therapeutic effects by inducing cellular regeneration and brainwave entrainment.
[0019] In the example of FIG. 1 , environment 106 can be a chamber 216 capable of holding the individual 104 . The individual 104 is a person, such as one suffering from post traumatic stress disorder (PTSD) and having brainwave patterns that may have erratic, non-standard, or otherwise undesirable frequencies. The environment 106 can be filled with a solution, such as saline water, so that the individual 104 floats within. Alternatively, the solution may be a diamagnetic solution. The diamagnetic solution capable of expressing a magnetic field in opposition to an externally applied electromagnetic field device 103 , such as a tensor, thus causing a repulsive effect. The environment 106 can be heated so that the solution is at a desired temperate, such as body temperature, to provide comfort to the individual 104 in the chamber 216 .
[0020] In the example of FIG. 1 , monitor 108 includes devices for collecting signals emanating from the individual 104 by, for example, an electroencephalogram (EEG) electrocardiogram (ECG/EKG), galvanic skin response sensor, heart rate variability monitor, and other known or convenient monitoring device. The monitor 108 can collect brainwaves emanating from the individual 104 and identify a transition from the original frequency to the desired frequency. In another embodiment, monitor 108 can collect infrared emanations from the individual 104 and the environment 106 , which can be used to adjust one or more modules of system 200 , discussed below.
[0021] FIG. 2 . depicts components 202 - 220 of a system 200 for influencing a human brain to operate at a desired frequency. The components depicted are logically represented as modules of various individual systems; however, one or more components 202 - 220 may be combined or divided to provide functionality to a particular solution. FIG. 2 includes user interface 202 , monitoring system 204 , processing unit 206 , storage 208 , sound generation 210 , water management 212 , sensors 214 , chamber 216 , ultra sonic transducer 218 , and heater 220 .
[0022] The chamber 216 is illustrated in greater detail in FIG. 2 a . Chamber 216 can be constructed so that it is large enough to hold an adult individual 104 while the individual 104 floats in a solution within the chamber 216 . In designing the chamber 216 , the walls can be spaced so as to provide optimal acoustics for experiencing the sound. In some embodiments, the walls of the chamber 216 are designed based on the acoustical resonance characteristics of a musical instrument. For example, in one embodiment the chamber 216 is based on a cello's design to produce acoustics optimized for delivering beats to the individual 104 within the chamber 216 . In another embodiment, the chamber 216 is based on dimensions derived using vaastu architecture. Vaastu shastra is a traditional Hindu system of building design based on directional alignments and mathematical dimensions. Vaastu-based architecture is one technique that can be used by the chamber 216 to transmit a wavelength of light and/or sound to affect cellular regeneration by stimulating cellular fluid. In humans, in response to the stimulation, cells within the brain can respond by entraining to the wavelength transmitted by the chamber 216 .
[0023] The chamber 216 can be “tuned” based on manipulating its dimensions to generate specific, desirable frequencies used in various therapeutic treatments, such as PTSD, and other applications. In one embodiment, dimensions of the chamber 216 are based on a golden ratio associated with the Fibonacci sequence, or a Fibonacci-like sequence, such as 1:2:3:5:8:5:3:2:1. By definition, the first two Fibonacci numbers are 0 and 1, and each subsequent number is the sum of the previous two. The middle number (e.g. “8” in the example above) of the sequence can represent a center point within the chamber 216 . Based on the Fibonacci ratio, concave and convex curves of the outer confines of the chamber 216 can be tuned to produce a desired wavelength of light for generating musical tonal waves.
[0024] Parabolic curves or semi-circle structures (“curves”) within the chamber 216 can be used to redirect the light back to the center point. In a particular embodiment, a curve at the center point can have golden rectangular dimension of sqrt(5)/2, and successive curves can extend from each direction of the center point to end with a maximum radius at the end of the inner golden rectangle.
[0025] Golden rectangle-based dimensions can be used within the center structure of the chamber 216 . In one embodiment, the ratio of the width of the golden rectangle to its length is 1:1.618, and the outer body of the chamber 216 has a ratio is 1:1.618. The inner and outer rectangle can have a ratio of 4:5 to create 4:5 relational tuning.
[0026] In a particular embodiment, a golden arc ratio of 1:2, 4:5, 2:3 is used to tune the chamber 216 based upon a major 3rd 4:5 ratio. The minimum width can be based on Vaastu architectural parameters. The dimension of the ratio can increase from the center point of chamber 216 to expand out to a 1:1 ratio form center point and then 1:2 ratio on both sides of center line resulting in an example sequence, 5:2:1:1:2:5.
[0027] In the example of FIG. 2 , one or more ultrasonic transducers 218 can be devices for generating vibrations to stimulate an individual 104 floating in chamber 216 . The ultrasonic transducers 218 can be coupled to the processing unit 206 to receive signals to reproduce as ultrasonic waves. In a preferred environment, the ultrasonic vibration is in a range of 0.1-10 HZ to cause micro-adjustments to the ear canal processing the vibration.
[0028] As shown in FIG. 2 a , a series of transducers 228 can be coupled to chamber 216 . In one embodiment, an ultrasonic transducer 218 has a magnetically positive first end 230 and a magnetically negative second end 232 . When positioned along opposing sides of the chamber 216 , the negative end 232 of one ultrasonic transducer 218 interacts with the positive end 504 of another ultrasonic transducer 230 to produce a magnetic field within the chamber 216 . The magnetic field can act as the tensor field to interact, in the chamber 216 , with a diamagnetic solution to produce a repulsive effect having a therapeutic effect on the individual 104 . Alternatively, the chamber 216 may be filed with a saline solution.
[0029] In one embodiment, heater 220 may be a far-infrared (FIR) heater. The FIR heater 220 heats ambient air in the chamber 216 at a wavelength to facilitate FIR penetration into bone marrow, for example. The FIR heater 220 can operate at a selectable range of 4-1000 microns to provide high absorption by the human body and deep penetration of the skin.
[0030] In the example of FIG. 2 , user interface 202 can be a physical interface, a graphical interface, or another known or convenient interface for the monitoring system 204 . The user interface 202 can receive instructions from an attendant controlling the stimulation of the individual 104 . For example, the user interface 202 can be used to start and stop stimulation, select a type of music to play, control water temperature, display data about the individual, and provide any other known or convenient data about the individual receiving the stimulation.
[0031] In the example of FIG. 2 , monitoring system 204 can include devices for displaying data to an attendant monitoring stimulation of an individual in the chamber 216 . For example, a panel display, CRT (cathode ray tube) display, or other monitoring device may be used. The attendant may be a human person, an operating process within the processing unit 206 , or a combination of both.
[0032] In the example of FIG. 2 , processing unit 206 can be a system or device for analyzing biometric data from sensors. For example, processing unit 206 can be a conventional processor coupled to a memory storing instructions for execution by the processor to use in reducing the electrical signals produced by the sensors to graphs, charts, and other human interpretable representations.
[0033] In the example of FIG. 2 , storage repository 208 can include data collected from the individual 104 . As used in this paper, a repository 208 can be implemented, for example, as software embodied in a physical computer-readable medium on a general- or specific-purpose machine, in firmware, in hardware, in a combination thereof, or in any applicable known or convenient device or system. The repositories described in this paper are intended, if applicable, to include any organization of data, including trees, tables, comma-separated values (CSV) files, traditional databases (e.g., SQL), or other known or convenient organizational formats.
[0034] In an example of a system where a repository is implemented as a database, a database management system (DBMS) can be used to manage the repository. In such a case, the DBMS may be thought of as part of the repository or as part of a database server, or as a separate functional unit (not shown). A DBMS is typically implemented as an engine that controls organization, storage, management, and retrieval of data in a database. DBMSs frequently provide the ability to query, backup and replicate, enforce rules, provide security, do computation, perform change and access logging, and automate optimization. Examples of DBMSs include Alpha Five, DataEase, Oracle database, IBM DB2, Adaptive Server Enterprise, FileMaker, Firebird, Ingres, Informix, Mark Logic, Microsoft Access, InterSystems Cache, Microsoft SQL Server, Microsoft Visual FoxPro, MonetDB, MySQL, PostgreSQL, Progress, SQLite, Teradata, CSQL, OpenLink Virtuoso, Daffodil DB, and OpenOffice.org Base, to name several.
[0035] Database servers can store databases, as well as the DBMS and related engines. Any of the repositories described in this paper could presumably be implemented as database servers. It should be noted that there are two logical views of data in a database, the logical (external) view and the physical (internal) view. In this paper, the logical view is generally assumed to be data found in a report, while the physical view is the data stored in a physical storage medium and available to a specifically programmed processor. With most DBMS implementations, there is one physical view and an almost unlimited number of logical views for the same data.
[0036] In the example of FIG. 2 , sound generation unit 210 can include speakers or other devices for reproducing sound to stimulate an individual. In one embodiment, the sound generation unit 210 can operate in a range that resonates with an organ of the individual 104 , such as for example, the stomach, spleen, pancreas, lungs, kidneys, liver, heart, large intestines, small intestine, thyroid, or gallbladder. The sound generation unit 210 can be installed using waterproof speakers or transducers embedded in the chamber 216 . Alternatively, speakers could be placed above water, mobile for relocation to various positions, and otherwise installed as is known or convenient.
[0037] In the example of FIG. 2 , sensors 214 can include sensors for collecting biometric data from an individual, such as those sensors discussed in reference to monitor 108 .
[0038] In the example of FIG. 2 , water management unit 212 can include piping, tubing, or other systems for moving water and/or a solution to and from the chamber 216 . Additionally, water management unit 212 can include pumps or other devices for moving the water and/or solution to and from the chamber 216 in a continuous re-circulating slow flow.
[0039] In the example of FIG. 2 , heater 220 can be a device for altering the temperature of the fluid in the chamber 216 to the individual's 104 body temperature, or higher or lower temperatures. Heater 220 may include a sensor to determine the temperature of the fluid in the chamber 216 . In one embodiment, Heater 220 utilizes an inline water heater.
[0040] FIG. 3 depicts a flowchart of an example of a method 300 for influencing a human brain to operate at a frequency. The method is organized as a sequence of modules in the flowchart 300 . However, it should be understood that these and other modules associated with other methods described herein may be reordered for parallel execution or into different sequences of modules.
[0041] In the example of FIG. 3 , the flowchart starts at module 302 with stimulating the individual with audio waves while the individual is immersed in a fluid medium, wherein the audio waves are produced as beats embedded in music. Cellular regeneration is induced by the audio waves to affect brainwave entrainment. The music can include a track that is interesting, entertaining, soothing or otherwise desirable. The beats can be embedded in this music as a second track mixed in with the music that is audible but may be barely noticeable. In this way, an individual listening to the music can be stimulated by the beat while enjoying the music. In an alternative embodiment, the beats are produced without an accompanying musical track.
[0042] One designing the music can take into account the desires of the individual to be stimulated with the beat as well as the kind of stimulation that the individual requires. For example, an individual requiring a relaxing therapeutic session can receive a beat in the theta ( 0 ) range whereas an individual requiring a focused stimulating session can receive a beat in the alpha (a) range. Through exposure to the beat, the brain can respond to the beat and after multiple sessions the brain can begin to adopt the beat.
[0043] In the example of FIG. 3 , the flowchart continues to module 304 which monitors the biofeedback from the individual 104 for adherence to the desired frequency by utilizing one or more sensors that identify the individual's 104 operating brain frequencies. Prior to receiving the stimulation, the individual's 104 brain waves may not operate at the desired frequency. While stimulating the individual with the beat, the brain can adhere to, and begin to operate at, the desired frequency by resonating the beat's slow oscillation frequency with the hippocampus. This can induce and entrain, for example, a relaxed state or a focused state in the brain of the individual. Sensors can collect the brain waves emanating from the individual, and an attendant can monitor the brain waves for adherence to the frequency. Having monitored the individual for adherence to the frequency, the flowchart terminates.
[0044] The system 400 may be a conventional computer system that can be used as a client computer system, such as a wireless client or a workstation, or a server computer system. The system 400 includes a device 402 , I/O devices 404 , and a display device 406 . The device 402 includes a processor 408 , a communications interface 410 , memory 412 , display controller 414 , non-volatile storage 416 , I/O controller 418 , clock 422 , and radio 424 . The device 402 may be coupled to or include the I/O devices 404 and the display device 406 .
[0045] The device 402 interfaces to external systems through the communications interface 410 , which may include a modem or network interface. It will be appreciated that the communications interface 410 can be considered to be part of the system 400 or a part of the device 402 . The communications interface 410 can be an analog modem, ISDN modem or terminal adapter, cable modem, token ring IEEE 802.5 interface, Ethernet/IEEE 802.3 interface, wireless 802.11 interface, satellite transmission interface (e.g. “direct PC”), WiMAX/IEEE 802.16 interface, Bluetooth interface, cellular/mobile phone interface, third generation (3G) and fourth generation (4G) mobile phone interfaces, code division multiple access (CDMA) interface, Evolution-Data Optimized (EVDO) interface, general packet radio service (GPRS) interface, Enhanced GPRS (EDGE/EGPRS), High-Speed Downlink Packet Access (HSPDA) interface, or other interfaces for coupling a computer system to other computer systems.
[0046] The processor 408 may be, for example, a conventional microprocessor such as an Intel Pentium microprocessor or Motorola power PC microprocessor. The memory 412 is coupled to the processor 408 by a bus 420 . The memory 412 can be Dynamic Random Access Memory (DRAM) and can also include Static RAM (SRAM). The bus 420 couples the processor 408 to the memory 412 , also to the non-volatile storage 416 , to the display controller 414 , and to the I/O controller 418 .
[0047] The I/O devices 404 can include a keyboard, disk drives, printers, a scanner, and other input and output devices, including a mouse or other pointing device. The display controller 414 may control in the conventional manner a display on the display device 406 , which can be, for example, a cathode ray tube (CRT) or liquid crystal display (LCD). The display controller 414 and the I/O controller 418 can be implemented with conventional well known technology.
[0048] The non-volatile storage 416 is often a magnetic hard disk, flash memory, an optical disk, or another form of storage for large amounts of data. Some of this data is often written, by a direct memory access process, into memory 412 during execution of software in the device 402 . One of skill in the art will immediately recognize that the terms “machine-readable medium” or “computer-readable medium” includes any type of storage device that is accessible by the processor 408 .
[0049] Clock 422 can be any kind of oscillating circuit creating an electrical signal with a precise frequency. In a non-limiting example, clock 422 could be a crystal oscillator using the mechanical resonance of vibrating crystal to generate the electrical signal.
[0050] The radio 424 can include any combination of electronic components, for example, transistors, resistors and capacitors. The radio is operable to transmit and/or receive signals.
[0051] The system 400 is one example of many possible computer systems which have different architectures. For example, personal computers based on an Intel microprocessor often have multiple buses, one of which can be an I/O bus for the peripherals and one that directly connects the processor 408 and the memory 412 (often referred to as a memory bus). The buses are connected together through bridge components that perform any necessary translation due to differing bus protocols.
[0052] Network computers are another type of computer system that can be used in conjunction with the teachings provided herein. Network computers do not usually include a hard disk or other mass storage, and the executable programs are loaded from a network connection into the memory 412 for execution by the processor 408 . A Web TV system, which is known in the art, is also considered to be a computer system, but it may lack some of the features shown in FIG. 4 , such as certain input or output devices. A typical computer system will usually include at least a processor, memory, and a bus coupling the memory to the processor.
[0053] In addition, the system 400 is controlled by operating system software which includes a file management system, such as a disk operating system, which is part of the operating system software. One example of operating system software with its associated file management system software is the family of operating systems known as Windows® from Microsoft Corporation of Redmond, Wash., and their associated file management systems. Another example of operating system software with its associated file management system software is the Linux operating system and its associated file management system. The file management system is typically stored in the non-volatile storage 416 and causes the processor 408 to execute the various acts required by the operating system to input and output data and to store data in memory, including storing files on the non-volatile storage 416 .
[0054] Some portions of the detailed description are presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self-consistent sequence of operations leading to a desired result. The operations are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
[0055] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
[0056] The present example also relates to apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, flash memory, magnetic or optical cards, any type of disk including floppy disks, optical disks, CD-ROMs, and magnetic-optical disks, or any type of media suitable for storing electronic instructions, and each coupled to a computer system bus.
[0057] The algorithms and displays presented herein are not inherently related to any particular computer or other apparatuses. Various general purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct a more specialized apparatus to perform the required method steps. The required structure for a variety of these systems will appear from the description below. In addition, the present example is not described with reference to any particular programming language, and various examples may thus be implemented using a variety of programming languages.
[0058] It will be appreciated to those skilled in the art that the preceding examples are exemplary and not limiting. It is intended that all permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the true spirit and scope of the present disclosure. It is therefore intended that the following appended claims include all such modifications, permutations and equivalents as fall within the true spirit and scope of these teachings. | A technique for influencing the human brain can be applied to treat PTSD through stimulating the brain with a beat in, for example, the theta (θ) frequency to influence the brain to relax. Alternatively, the human brain can be stimulated with a beat in the alpha (α) frequency to stimulate active thinking. Over a series of treatments the brain of an individual suffering from PTSD can be influenced to operate at a normal frequency. Advantageously, as the frequency is adjusted, the symptoms of PTSD recur less often until the individual ceases to experience the symptoms or has at least experienced a decreased recurrence of the symptoms. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/639,723, filed Apr. 27, 2012, which is hereby incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a covering that is placed over goods in preparation for shipping and method of using the same.
[0004] 2. Description of the Background of the Invention
[0005] The transportation or shipment of goods is a complex and costly process that includes many actors, including shippers, manufacturers, wholesalers, and retailers. During shipping, some goods require added protection to keep them from being damaged while other goods need to be kept at or near a constant temperature, i.e., cold products kept cold and hot products kept hot. One method of shipping fragile goods includes the use of extra packing materials such as bubble wrap, which is discarded once the goods are delivered. In addition, a common method of transporting temperature sensitive items is the use of trucks with refrigerated or heated trailers. The use of additional packing materials and special trucks results in added costs, which are ultimately passed on to the consumer. Furthermore, many of the existing devices that are used to insulate goods cannot be readily adjusted to fit pallets of goods that vary in height, length, and width. Additionally, many existing devices are cumbersome and cannot be placed on a pallet of stacked goods efficiently by a single person and/or require the use of ladders and other similar devices. For theses reasons, a reusable, adjustable, insulated covering that can be easily and efficient placed on a stack of temperature sensitive items in preparation for shipping would be an important improvement in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1A is an isometric view of one embodiment of the cap and wrap portions of a covering;
[0007] FIG. 1B is an isometric view of the cap and wrap portions of FIG. 1A assembled;
[0008] FIG. 2 is an elevational view of an exterior side of a wrap portion of another embodiment of the covering;
[0009] FIG. 3 is an isometric close-up view of a lift strap portion disposed on the exterior side of the wrap portion of FIG. 2 ;
[0010] FIG. 4 is an elevational view of an interior side of the wrap portion of the covering of FIG. 2 ;
[0011] FIG. 5 is an isometric view of one embodiment of the cap portion of the covering;
[0012] FIG. 6A and FIG. 6B are views of a pull cord stored on a storage rack;
[0013] FIG. 7 is an elevational view of another embodiment of an exterior of the covering;
[0014] FIG. 8 is an elevational view of an interior side of the wrap portion of the covering of FIG. 7 ;
[0015] FIG. 9 is an isometric view of another embodiment of a cap portion of the covering;
[0016] FIG. 10 is an isometric view of a further embodiment of a cap portion of the covering;
[0017] FIG. 11 is a isometric view of a storage rack;
[0018] FIG. 12 is a partial front elevational view of a wrap portion hung on a storage rack;
[0019] FIG. 13 is a front elevational view of a wrap portion of the covering hung on a storage rack and a cap portion attached to the wrap portion;
[0020] FIG. 14 is a front elevational view of the storage rack of FIG. 11 ;
[0021] FIG. 15 is a right side view of a portion of the storage rack taken along the lines 15 - 15 of FIG. 14 ; and
[0022] FIG. 16 is a right side view of a portion of the storage rack taken along the lines 16 - 16 of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Disclosed is a thermal insulated covering comprising a cap and wrap portion for use in providing temperature protection for goods in transit. FIGS. 1A and 1B show an isometric view of one embodiment of a covering 18 . FIG. 1A illustrates a wrap portion 120 ′ and a cap portion 360 of the covering 18 , and FIG. 1B shows the wrap portion 120 ′ attached to the cap portion 360 .
[0024] FIG. 2 illustrates another embodiment of the covering 18 having a wrap portion 20 with an exterior side 22 . The exterior side 22 of the wrap portion 20 contains a vertical strip of loop fasteners 24 that extends down the height of the exterior side adjacent a first end portion 25 . A person of ordinary skill in the art would understand that hook fasteners and loop fasteners make up one type of fastener (i.e., a hook and loop fastener), and that the parts are interchangeable. Furthermore, any type of fastener that has a male and female portion, e.g., a snap button, could be used in place of the hook and loop fasteners without departing from the spirit and scope of the present invention.
[0025] The vertical strip of loop fasteners 24 will be mated with vertical band of hook fasteners 56 contained on the interior side 50 of the wrap portion 20 as shown in FIG. 4 . The exterior side 22 also contains a horizontal strip of both hook and loop fasteners 26 on a top portion 28 that extends the length of the wrap portion 20 . Horizontal loop portion 26 A of the horizontal strip 26 has a color that is different from that of the hook portion 26 B. For example, horizontal loop portion 26 A could be red and horizontal hook portion 26 B could be black. The purpose of the different coloring is to indicate to a user when to start folding the wrap portion 20 when the wrap portion is being removed from a cap portion 60 , 160 , 260 , or 360 each of which is discussed in more detail below.
[0026] The exterior side 22 of the wrap portion 20 further contains two sets of lift straps 30 A, B and 32 A, B on a bottom portion 38 . When wrap portion 20 is wrapped about a pallet of stacked goods, the lift straps 30 A, B are disposed on a first side of the pallet of stacked goods and lift straps 32 A, B are disposed on a second side of the pallet of stacked goods adjacent to the first side of the pallet of stacked goods. An enlarged view of the lift straps 30 , 32 is shown in FIG. 3 . The two sets of lift straps 30 A, B and 32 A, B enable a user to lift and secure the bottom portion 38 of the wrap portion 20 to prevent the bottom portion 38 from interfering or becoming damaged by the fork of a forklift, when the wrapped pallet of stacked goods is moved. As shown in FIG. 3 , the lift straps 30 , 32 comprise an attachment portion 40 that is covered with loop fasteners and a tab 42 that is covered on one side with hook fasteners. To raise the bottom portion 38 of the wrap portion 20 , the tab 42 is pulled up and pressed against the attachment portion 40 thereby mating the hook fasteners of the tab 42 with the loop fasteners on the attachment portion 40 .
[0027] The exterior side 22 also has two loops 44 A, B attached to a top edge 46 . In one embodiment, the loops 44 A, B are made of plastic. The two loops 44 A, B are used to store the wrap portion 20 on a storage rack 300 (discussed in more detail below). A pocket 48 with a transparent window 49 may also be included on the exterior side 22 of the wrap portion 20 . The pocket 48 is used to hold shipping document concerning the pallet of stacked goods covered by the covering 18 and the transparent window 49 enables a user to easily view the shipping documents.
[0028] FIG. 4 shows the interior side 50 of the wrap portion 20 . The interior side 50 contains three horizontal bands of hook fasteners 52 A, B, C that extend the length of the interior side 50 . Horizontal band 52 A is located adjacent to the top edge 46 , horizontal band 5213 is located below horizontal band 52 A, and horizontal band 52 C is located below horizontal band 52 B. The horizontal bands of hook fasteners 52 A, B, C are used to attach the wrap portion 20 to the cap portion 60 , 160 , 260 , or 360 . The horizontal bands of hook fasteners 52 are located at varying vertical distances to enable the wrap portion 20 to be used with pallets of stacked goods of varying vertical heights. For example, if a high (e.g., seven feet), pallet of stacked goods is to be wrapped, then horizontal band 52 A would engage the cap portion 60 . Likewise, if the pallet of stacked goods is on the shorter side (e.g., 4 feet), then the horizontal band 52 C would be used to engage the cap portion 60 , 160 , 260 , or 360 .
[0029] The interior side 50 of the wrap portion 20 also has a vertical band of hook fasteners 56 that extends the height of the interior side 50 adjacent a second end portion 57 . The vertical band of hook fasteners 56 engages the vertical strip of loop fasteners 24 of the exterior side 22 when the wrap portion 20 is wrapped about a pallet of stacked goods thereby securing the wrap portion 20 around the goods. The wrap portion 20 is therefore long enough to completely cover each of the four sides of a pallet of goods and has a flap 58 that overlaps a portion of the wrap portion 20 located on the first side of the pallet of goods when the wrap portion 20 is wrapped about the pallet of stacked goods (see also FIGS. 1A and 1B with respect to wrap portion 120 ′ and FIG. 7 with respect to wrap portion 120 ). Furthermore, the extension of the strips and bands of hook and loop fasteners, 24 , 52 , and 56 , along the height and length of the interior and exterior of the wrap portion 20 enables the wrap portion 20 to be used with pallets of goods of varying heights, widths, and lengths.
[0030] FIG. 5 shows another embodiment of the covering 18 having a cap portion 60 . The cap portion 60 has a top 61 and four sides 62 A, B, C, D (side 62 C is a mirror image of side 62 A and side 621 ) is a mirror image of side 62 B). Sides 62 A, B, C, D are covered with loop fastener portions 64 A, B, C, D, which engage horizontal bands 52 A, B, or C of the interior side 50 of the wrap portion 20 to secure the wrap portion 20 to the cap portion 60 . A bottom edge 66 of side 62 A contains a pull cord loop 68 . The pull cord loop 68 on the cap portion 60 is used in conjunction with a pull cord 70 (as shown in FIGS. 6A and 6B ) when the cap portion 60 is to be placed on a pallet of stacked goods that are stacked relatively high. In addition, two handles 72 A, B are located on upper edge 74 of side 62 C, which is disposed opposite to side 62 A. The two handles 72 A, B are provided to assist the user with placing the cap portion 60 on and removing the cap portion 60 from the pallet of stacked goods.
[0031] FIG. 7 shows a further embodiment of the covering 18 having a wrap portion 120 . The wrap portion 120 has an exterior side 122 . The wrap portion 120 has three vertical strips of loop fasteners 124 A, B, C that extend the height of the wrap portion 120 and are disposed adjacent to each other and adjacent a first end portion 125 . One or more of the vertical strips of loop fasteners 124 A, B, C are mated with the vertical ribbon of hook fasteners 156 contained on the interior side 150 of the wrap portion 120 when the wrap portion 120 is wrapped about the pallet of stacked goods. Also, disposed adjacent the vertical strips of loop fasteners 124 A, B, C, opposite the first end portion 125 , are a pair of steel rings 126 A, B. The steel rings 126 A, B are used along with attachment straps 132 A, B (discussed below) to more firmly attach the wrap portion 120 around the pallet of stacked goods.
[0032] The horizontal attachment straps 132 A, B are attached to and extend away from a second end portion 128 of the wrap portion 120 . The second end portion 128 of the wrap portion 120 is disposed opposite the first end portion 125 . The attachment straps 132 A, B comprise a portion of hook fasteners 134 and a portion of loop fasteners 136 . When the wrap portion 120 is wrapped about a pallet of stacked goods, attachment strap 132 A is passed through corresponding steel ring 126 A and attachment strap 132 B is passed through corresponding steel ring 126 B. The portion of hook fasteners 134 of each attachment strap 132 A, B is then folded back about steel ring 126 A, B, respectively, so that the portion of hook fasteners 134 of each attachment strap 132 A, B is mated with the portion of loop fasteners 136 of each strap 132 . The addition of the steel rings 126 A, B and the attachment straps 132 A, B provides a tighter fit of the wrap portion 120 around the pallet of stacked goods. A tighter fit of the wrap portion 120 around the goods on the pallet, enables a user to use less shrink-wrap or other packing material to hold the goods together during transport.
[0033] The wrap portion 120 ′ shown in FIGS. 1A and 1B is substantially the same as wrap portion 120 shown in FIG. 7 . The difference between wrap portion 120 ′ and wrap portion 120 , is that wrap portion 120 ′ does not include attachment straps 132 A, B nor steel rings 126 A, B. Otherwise, wrap portion 120 ′ contains the same components and is used in the same manner as wrap portion 120 .
[0034] FIG. 8 shows the interior side 150 of the wrap portion 120 . The interior side 150 contains a horizontal ribbon of hook fasteners 152 that extends the length of the wrap portion adjacent a top edge 154 . The vertical ribbon of hook fasteners 156 extends down the height of the interior side 150 of the wrap portion 120 and is attached adjacent the second end portion 128 . The horizontal ribbon of hook fasteners 152 is used to engage the cap portion 60 , 160 , 260 , or 360 similar to the horizontal bands of hook fasteners 52 A, B, C of the interior side 50 of the wrap portion 20 . The vertical ribbon of hook fasteners 156 is used to engage one or more of the vertical strips of loop fasteners 124 A, B, C on the exterior side 122 of the wrap portion 120 . Furthermore, the extension of the strips and ribbons of hook and loop fasteners, 124 , 152 , and 156 , along the height and length of the interior and exterior of the wrap portion 120 enables the wrap portion 120 to be used with pallets of goods of varying heights, widths, and lengths.
[0035] FIG. 9 shows another embodiment of the covering 18 having a cap portion 160 . The cap portion 160 has a top 161 and four sides 162 A, B, C, D (side 162 C is a mirror image of side 162 A and side 162 D is substantially a mirror image of side 162 B). A plurality of vertical stripes of loop fasteners 164 extend the height of the cap portion 160 and are located on each side 162 A, B, C, D of the cap portion 160 at varying distances from each other. In addition, one side of the cap portion 160 may include a pocket with a transparent window similar to the pocket 48 and transparent window 49 discussed above. Furthermore, on a portion 168 of side 162 B is an opening 170 and flap 172 . The inside portion 174 of the flap 172 has a vertical stretch of loop fasteners 176 that engages vertical stripe 164 ′, which is adjacent to the opening 170 . The opening 170 is provided to enable easier mounting of the cap portion 160 on a pallet of stacked goods. The plurality of vertical strips of loop fasteners 164 engage one or more of the horizontal bands of hook fasteners 52 disposed on the interior side 50 of the wrap portion 20 or horizontal ribbon of hook fasteners 152 of the wrap portion 120 or 120 ′ when the wrap portion is wrapped around the pallet of stacked goods thereby securing the wrap portion 20 , 120 , or 120 ′ to the cap portion 160 .
[0036] FIG. 10 shows a further embodiment of the covering 18 having a cap portion 260 . The cap portion 260 has a top 261 and four sides 262 A, B, C, D (side 262 C is a mirror image of side 262 A and side 262 D is a mirror image of side 262 B). A horizontal belt of loop fasteners 264 is attached adjacent a bottom edge 266 around all four sides 262 A, B, C, D of the cap portion 260 . The horizontal belt of loop fasteners 264 engages one of the horizontal strips of hook fasteners 52 A, B, or C disposed on the interior side 50 of the wrap portion 20 or horizontal ribbon of hook fasteners 152 of the wrap portion 120 when the wrap portion is wrapped around the pallet of stacked goods thereby securing the wrap portion 20 , 120 , or 120 ′ to the cap portion 260 .
[0037] FIGS. 1A and 1B show another embodiment of the covering 18 having a cap portion 360 . The cap portion 360 has a top 361 and four sides 362 A, B, C, D (side 362 C is a mirror image of side 362 A and side 362 D is substantially a mirror image of side 362 B). A plurality of vertical stripes of loop fasteners 364 extend the height of the cap portion 360 and are located on each side 362 A, B, C, D of the cap portion 360 at varying distances from each other. In addition, side 362 B of the cap portion 360 may include a pocket 48 with a transparent window 49 . Furthermore, on a portion 368 of side 362 B is an opening (not shown) and a flap 372 . The inside portion (not shown) of the flap 372 has a vertical stretch of loop fasteners that engages a vertical stripe 364 ′ on the exterior of side 362 B, which is adjacent to the opening. The opening is provided to enable easier mounting of the cap portion 360 on a pallet of stacked goods. The plurality of vertical strips of loop fasteners 364 engage or horizontal ribbon of hook fasteners 152 of the wrap portion 120 ′ (or 120 ) or one or more of the horizontal bands of hook fasteners 52 disposed on the interior side 50 of the wrap portion 20 when the wrap portion is wrapped around the pallet of stacked goods thereby securing the wrap portion 20 , 120 , or 120 ′ to the cap portion 360 .
[0038] Various materials that are strong, durable, and flexible may be used to form the wrap portions 20 , 120 , and 120 ′ and cap portions 60 , 160 , 260 , and 360 . For example, in one embodiment four layers of material are enclosed by a fabric. The first layer consists of a material such as a coated textile that is impermeable to moisture and air, the second layer consists of a thermal insulated material for example a nanofiber or microweave fabric, the third layer consists of a polyester filler material, and the fourth layer consists of a fabric such as coated denier fabric, nylon, polyester, vinyl, nanofiber, or microweave fabric. One of ordinary skill in the art would understand that any materials that serve the same purpose as those mentioned above may be used. Stitching at the ends of the layers keeps them from moving within the enclosing fabric.
[0039] Another embodiment contains five layers consisting of the same materials mentioned above that are held together by stitching through a fabric binding at the ends of the layers. The first layer consists of fabric, the second layer consists of a polyester filler, the third layer consists of a thermal insulated material, the fourth layer consists of a polyester filler, and the fifth layer consists of a material that is impermeable to moisture and air. Another embodiment consists of three layers, the first being fabric, the second being polyester filler, and the third layer being fabric.
[0040] FIGS. 11-16 show different views of a storage rack upon which the coverings 18 are stored. Turning to FIG. 11 , a storage rack 300 has a first frame member 302 and a second frame member 304 . Both the first frame member 302 and the second frame member 304 are shaped, in one embodiment, like an upside down “U” and have cross bar member 306 and 308 , respectively. The frame members can have any suitable shape without departing from the spirit and scope of the invention (e.g., the frame members could have square corners rather than curved or rounded corners). The first frame member 302 is connected to the second frame member 304 by a pair of tracks 310 A, B, which are attached to an underside of each of crossbar members 306 and 308 and are substantially parallel to each other. The first frame member 302 is also connected to second frame member 304 by a first support bar 312 and second support bar 314 . The first support bar 312 is attached at one end to a lower portion 316 of a first arm 318 of the first frame member 302 and at the other end to a lower portion 320 of a first arm 322 of the second frame member 304 . The second support bar 314 is attached at one end to a lower portion 324 of a second arm 326 of the first frame member 302 and at the other end to a lower portion 328 of a second arm 330 of the second frame member 304 .
[0041] Wheels 332 A, B are attached to lower ends 334 of the first arms 318 , 322 , respectively, and 332 C, D are attached to lower ends 336 of the second arm 326 , 330 of the respective first and second frame members. The wheels 332 A, B, C, D have locks to prevent the storage rack 300 from moving when a covering 18 is being removed from or placed onto the storage rack. Alternatively, the storage rack 300 may contain a separate braking mechanism to prevent movement of the storage rack during the loading and unloading of the covering 18 from the storage rack 300 .
[0042] Turning to FIG. 12 , each track 310 A and 310 B also contains movable storage hooks 338 A-N. The same number of movable storage hooks 338 A-N are provided on each track 310 A, B because each covering 18 requires the use of two storage hooks to be properly hung. When a covering 18 is to be hung on the storage rack, the wrap portion 20 , for example, is first folded about the exterior side 22 several times (discussed below) thereby exposing a portion of the interior side 50 . The wrap portion 20 is then hung on the storage rack 300 by placing plastic loop 44 A on a movable storage hook 338 contained on one of the tracks 310 and loop 44 B on a corresponding movable storage hook 338 contained on the other track. The cap portion 60 , 160 , 260 , or 360 is then attached to the wrap portion 20 by mating loop fasteners portions of the cap portion, i.e., 64 , 164 , 264 , and 364 of cap portions 60 , 160 , 260 , and 360 , respectively, with the horizontal band of hook fasteners 52 A of the interior side of the wrap portion 20 (see FIG. 13 ).
[0043] In addition, a first location or storage facility may contain stationary tracks that are used to store the covering 18 when it is not being used. These stationary tracks can be attached to or mated with the tracks 310 A, B in a manner that enables the movable storage hooks 338 to travel from the stationary tracks to the tracks 310 A, B and vice versa without interruption. This arrangement increases efficiency by eliminating the need to unhook the covering 18 from the storage hooks 338 on the storage rack 300 and place them on separate hooks hanging from the stationary tracks.
[0044] As shown in FIG. 11 , the second frame member 304 also comprises two confinement bars 340 and 342 . The two confinement bars 340 , 342 prevent the coverings 18 from extending beyond the plane created by the three sides of the second frame member 304 thereby preventing the coverings from swinging or moving about while the storage rack 300 is being moved or if too many coverings 18 are placed on the storage rack.
[0045] Turning to FIG. 14 , the first frame member 302 also contains attachment members 344 and 346 . The attachment members 344 , 346 may be any other suitable attachment mechanism such as a D-ring (see FIG. 15 ) and are drilled into or soldered onto the first and second arms 318 , 326 , respectively, of the first frame member 302 at the same height. The attachment members 344 , 346 enable a chain 348 (see FIG. 11 ) to be attached to and extend between the first and second arms 318 , 326 , respectively, of the first frame member 302 . The chain 348 may be fixed to one attachment member and removably attached to the other, or the chain 348 may be removably attached to both attachment members 344 , 346 . The chain 348 keeps the coverings 18 between the first and second frame members 302 , 304 , respectively. By confining the coverings 18 between the two frame members, movement of the storage rack is easier and more efficient as the coverings 18 are not moving or swinging about. When the coverings 18 are to be placed on a pallet of stacked goods, the chain 348 is removed from one or both of the attachment members to enable efficient removal of the coverings 18 from the storage rack 300 .
[0046] The second arm 326 of the first frame member 302 also contains a pull-cord hook 350 , which may be any suitable shape, for example, J-shaped (see FIG. 16 ). The pull cord hook 350 drilled into or soldered onto the second arm 326 of the first frame member 302 . The pull cord 350 allows for storage of the pull cord 70 so that it is not lost or misplaced after the coverings 18 have been placed on the pallet of stacked goods.
[0047] To use the covering 18 on a pallet of stacked goods that is to be shipped, a user first locates a storage rack 300 that has cap portion 60 and wrap portion 20 of covering 18 stored on it at a first location (e.g., warehouse). Although the method is discussed in terms of a single covering 18 , the rack may contain multiple coverings that can be used to cover multiple pallets of goods. If the pallet of stacked goods is of a small or medium height, the user removes the cap portion 60 from the wrap portion 20 and places it on the top of the goods located on a pallet. If the pallet of stacked goods is tail, the user moves the storage rack close to the pallet of stacked goods to be covered, e.g., within two to three feet of the pallet of stacked goods. The user then attaches the pull cord 70 , which is stored on pull cord hook 350 of the storage rack, to the pull cord loop 68 of the cap portion 60 . The pull cord 70 is then thrown over the top of the pallet of stacked goods. The user then walks around the pallet of stacked goods to where the pull cord 70 has fallen, picks up the pull cord 70 , and pulls the pull cord 70 . When the user pulls the pull cord 70 , the cap portion 60 detaches from the wrap portion 20 which is hanging from the storage hooks 338 of the storage rack 300 . The user then positions the cap portion 60 on top of the goods. Once the cap portion 60 is properly placed on the pallet of stacked goods, the pull cord 70 is removed from the pull cord loop 68 and placed back on pull cord hook 350 .
[0048] The wrap portion 20 is then removed from the storage rack 300 . The interior side 50 of the wrap portion is placed adjacent the goods on the pallet with first end portion 25 being aligned with one edge of the pallet of stacked goods. One of the horizontal bands of hook fasteners 52 A, B, or C of the interior side 50 of the wrap portion 20 is first attached to the loop fastener portion 64 A of the cap portion 60 , then attached to the loop fastener portions 64 B, 64 C, and 64 D, in that order. Depending on what cap embodiment is used (i.e., 60 , 160 , 260 , or 360 ), the horizontal bands of hook fasteners 52 may engage vertical stripes of loop fasteners 164 , 364 of cap portion 160 , 360 , respectively, or horizontal belt of loop fasteners 264 of cap portion 260 . The user then unfolds the wrap portion 20 as he walks around the pallet of stacked goods and continues to mate the horizontal band of hook fasteners 52 of the wrap portion 20 with loop fastener portions 64 B, 64 C, and 641 ) of the cap portion 60 , in that order. When the user has completely covered all four sides of the pallet of stacked goods, the user then folds the remaining portion or flap 58 of the wrap portion 20 over the first side of the pallet of stacked goods so that the vertical band of hook fasteners 56 of the interior side 50 engages the vertical strip of loop fasteners 24 of the exterior side 22 , thereby securing the wrap portion 20 around the goods.
[0049] After the wrap portion 20 is securely attached to the cap portion 60 , a user may then lift the bottom portion 38 of the wrap using one of the pairs of lift straps 30 or 32 . As mentioned above, the tab 42 of the lift straps are lifted up and mated with attachment portion 40 . A forklift can then be used to pick up the pallet of stacked goods and place it on a delivery vehicle for shipment to a second location e.g., distribution center or retail store.
[0050] Once the wrapped goods have been moved from the first location to the second location the covering 18 is removed. To remove the covering 18 the flap 58 is detached from the vertical loop strip 24 of the wrap portion 20 . The exterior side 22 of the wrap portion 20 is then folded about itself. The first fold occurs by bring the second end portion 57 near an edge of the pallet of stacked goods below the intersection of the third and fourth sides 62 C and 62 D, respectively, of the cap portion 60 (see FIG. 5 ). As the user is folding the exterior side 22 about itself, the horizontal band of hook fasteners 52 A, B, or C are being detached from the loop fastener portions 64 , 164 , 264 , or 364 of the cap portion 60 , 160 , 260 , or 360 , respectively. The second fold occurs by bringing the first fold near an edge of the pallet of stacked goods below the intersection of the second and third sides 62 B and 62 C, respectively, of the cap portion 60 . The third fold occurs by bringing the second fold near an edge of the pallet of stacked goods below the intersection of the first and second sides 62 A, and 62 B, respectively, of the cap portion 60 . And the fourth fold occurs by aligning the third fold with the first end portion 25 . By wrapping the wrap portion 20 in this manner, the interior side 22 , particularly horizontal bands of hook fasteners 52 , of the wrap portion 20 is exposed. The user than grasps all the folds and lifts the wrap portion 20 away from the pallet of stacked goods, thereby detaching the last portion of the horizontal bands 52 A, B, or C from the cap portion 60 .
[0051] Once the folding is completed, the user moves the folded wrap portion 20 to the storage rack 300 . There the user positions the folded wrap on the storage rack 30 such that the plastic hook 44 A is engaged with storage hook 338 on track 310 A and the plastic hook 44 B is engaged with corresponding storage hook 338 on track 310 B, or vice versa,
[0052] Next the cap portion 60 is removed from the pallet of stacked goods. If the pallet of stacked goods is tall, the user pushes side 62 A up so that side 62 C is lowered. The user than grasps the handles 72 A, B and pulls the cap portion 60 off the pallet of stacked goods. The user then aligns upper edge 74 of the cap portion 60 with top edge 46 of the folded wrap portion 20 so that the hook fastener portion 64 C engages the horizontal band of hook fasteners 52 A. Although any hook fastener portion 64 can be attached to any horizontal band of book fasteners 52 , the most efficient storage of the cap portion 60 and wrap portion 20 is by mating the hook fastener portion 64 C with the horizontal band of hook fasteners 52 A. If a storage rack 300 is not present at the second location, then the wrap and cap portions of the covering 18 may be hung or stored on hooks contained in the delivery vehicle. Assuming that a storage rack 300 is present at the second location, the storage rack 300 with the stored coverings 18 is then placed back into the delivery vehicle and transported back to the first location or to a third location e.g., an inspection facility. The coverings 18 may also be inspected by a user for cleanliness or damage. The inspection may take place at the first location, the second location, or a third location.
[0053] The specific design of the various cap portions 60 , 160 , 260 , and 360 , wrap portion 20 , 120 , and 120 ′, and the storage rack 300 mentioned above enable a single user to efficiently remove or place a covering on a pallet of stacked goods that is short, medium, or tall without the help of another or having to use a ladder, chair or other elevation device. This provides for more efficient preparation and shipping of goods as less time is needed to prepare and deliver the pallet of stacked goods.
INDUSTRIAL APPLICABILITY
[0054] Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved. | A method of preparing goods for transport is disclosed. A covering for the goods is provided that includes a wrap portion removably carried by a storage rack and a cap portion removably attached to the wrap portion, wherein the cap portion includes an attachment member. A force transmission member is secured to the attachment member of the cap portion and the cap portion is removed from the wrap portion. The force transmission member is moved to position the cap portion atop the goods. The wrap portion is removed from the storage rack, wrapped about the goods, and secured to the cap portion. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to the mixing and melting of plastic material in an extruder and, more particularly, to the screw which performs these operations in the extruder.
In thermoplastic extruders, screws are used to mix, plasticize and convey the platic material axially along the cylinder bore from the point where the plastic enters in the form of pellets or other solid form to the other end where the plastic exits in the form of a liquid melt. Conventionally, these functions are performed by varying the pitch, thickness and lead of the screw threads at spaced intervals along the length of the screw. The root diameter of the shaft portion of the screw is sometimes also varied uniformly to increase or decrease the cross sectional area and, therefore, the pressure within an axial section along the screw length. Thus, the plastic is mixed, melted and conveyed along successive sections of the screw length. Examples of some typical extruder screw configurations are illustrated in U.S. Pat. Nos. 3,197,814; 3,486,192 and 3,023,456.
However, it has always been difficult to mix the plastic thoroughly to continuously melt new solid material as the pellets tend to form a solid plug adjacent to the screw shaft as they enter the extruder and where they are inclined to remain as they come under the pressure of the operating screw. The rotating screw thread wipes against the extruder bore wall. The shearing action of the plug compressed against the bore wall creates heat which melts off the solid plug surface along the threads ' outer peripheral surface. The melted plastic becomes susceptible to being damaged by overheating unless it can be conveyed away and be replaced by an unmelted portion of plastic material. Some prior screw designs attempt to expedite the melting process by inserting a fluted section in the screw to force the plastic over a plurality of axially extending dam-like radial edges to increase the shearing action on the plastic to promote raising its temperature and shorten the melting time. Other prior art screws incorporate reverse threads along a section to reverse the flow and increase the mixing action. But such devices only operate on a relatively small portion of the material at a time and still represent a separation of the mixing, plasticizing and conveying, or pumping, steps. Further, the fluted, or dam-type, screws tend to work satisfactorily only after the plastic has already been partially melted.
SUMMARY OF THE INVENTION
This invention combines the steps of mixing, melting and conveying the plastic material by continuously subjecting the plastic to high shear forces of brief duration. The material closest the shaft of the screw is forced outwardly while the material nearest the wall of the extruder bore, which contains some partially melted plastic, is simultaneously urged radially inward toward the screw axis of rotation. Thus, along a major portion of the screw length, the melted plastic is forced into shearing contact along many interfaces with the unmelted portion of the plastic. This both raises the temperature of the unmelted portion of plastic and decreases the temperature of the melted portion of plastic to more uniformly distribute the heat throughout the entire amount of plastic being conveyed by the screw. This mitigates the possibility of overheating (and potential degradation) of the melted plastic while increasing the temperature (and thereby shortening the time and energy required) to melt the unmelted portion of the plastic material.
The mixing and radial shearing action are provided by a plurality of recessed pockets and/or raised lobes, and the edges defining them, in the shaft portion of the screw. As the screw rotates, the plastic material is forced radially inward, with respect to the axis of screw rotation, into the recessed pockets or beneath the raised lobe surface, thereby producing many interfaces in relative movement between portions of the plastic material within each pitch length for the entire length of the screw, or a shorter length as desired. Since the plastic material melts along the extruder bore wall from shear in the melt film due to screw rotation, a sleeve-like section of melted plastic begins to form on the outermost edges of the screw over the compressed plastic plug where it is wiped off by the screw thread. The continuous radially inward and outward movement of the plastic operates to alternately increase and decrease the thickness of this melted plastic layer which facilitates both the cooling of the thinner portions of the layer (most recently melted) and mixing of the unmelted portions of the plastic with the thicker (relatively cooler) portions of the melted plastic.
Since each pocket and raised lobe is of a relatively short radial height or depth and extends annularly around the shaft for only a portion of its circumference, the multiplicity of radial shearing interface contacts is of a short duration which mitigates against overheating during the shearing action while promoting maximum mixing, all while simultaneously conveying the plastic axially downstream in the extruder bore. Thus, there is no volume restricting structure required to provide plastic melting at a sacrifice to extruder speed and production capacity. The unique design permits melting, mixing and axial conveyence of the plastic to occur simultaneously within each pitch distance of the screw without restricting the extruder to operate at a lower speed than otherwise required in order to adequately perform any one of these functions. Therefore, the extruder can operate faster.
Depending on the type of plastic used and the degree of mixing desired, the screw may be divided into sections wherein only lobes or pockets are provided. Since the lobes extend above the shaft surface and are not interconnected, but spaced apart, plastic can move around their side walls as well as over their upper surface and the shearing action produced is not as intense as that produced by the plastic moving into and out of the pockets wherein all of the plastic must eventually pass out over the pocket walls.
The pockets and lobes, being positioned along the pitch length of the helical screw thread, can operate to mix and promote melting for as far as they extend on the shaft. Thus, the speed of the melting process is increased since the continuous shifting and mixing pushes new solid plastic against the bore wall to be melted without choking off the conveying capacity of the screw by requiring special plasticizing sections of small cross-sectional area. Solid material is not allowed to accumulate and remain unmelted adjacent the shaft surface to thereby lengthen the overall melting time.
It is, therefore, an object of the invention to provide an extruder screw which operates to facilitate heat transfer between the melted and unmelted portions of plastic within the extruder.
Another object of the invention is to provide an extruder screw which operates to continuously mix and facilitate melting the plastic along the working length of the screw.
Another object of the invention is to mix, melt and convey the plastic at the same axial location on the screw.
Another object is to reduce the tendency of the melted plastic to remain laminar as it moves along the screw length.
Another object of the invention is to provide an extruder screw which operates to continuously force portions of the plastic radially inward and outward, with respect to the axis of screw rotation, to increase the shearing action within the plastic.
Still another object is to increase the speed with which the plastic is melted as it travels axially along the screw length by forcing melt film against the barrel wall, thus creating a higher shear rate and faster melting.
A feature of the invention is the provision of pockets and/or raised lobes in the screw shaft.
Another feature of the invention is that the intense radially inward and outward shearing forces on the plastic operate to prevent the plastic from becoming plugged in the pockets or adhering to the lobes during operation.
An advantage of the invention is that the screw can be run faster because plasticizing and mixing is more thorough and finished in a shorter length of time.
These and other objects, features and advantages of this apparatus will become apparent as the attached figures are reviewed while reading the detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a section of the screw showing the recessed pockets.
FIG. 1a is an end view of the shaft member of the screw shown in FIG. 1.
FIG. 2 is another perspective drawing of a section of the screw showing the recessed pockets in a checkerboard pattern on the shaft member.
FIG. 3 is a cross sectional side view along the axis of a pitch length portion of a regular prior art screw within the extruder bore.
FIG. 4 is a cross sectional side view through section A--A of the screw in FIG. 1 positioned within the bore of an extruder through the recessed pocket within the screw shaft.
FIG. 5 is a cross sectional view through section B--B of the screw shown in FIG. 1 which has rotated to show another pocket within the shaft.
FIG. 6 is a developed view of the surface area of the shaft along the pitch length between screw threads showing unequal rectangular areas of the bottom surfaces of the pockets.
FIG. 7 is a developed view similar to that shown in FIG. 6 but wherein the recessed land portion areas are shown in a quadrangular configuration.
FIG. 8 is another developed view similar to FIG. 6 wherein the recessed land portion areas are in a more uniform rectangular shape.
FIG. 9 is a developed view of the screw shown in FIG. 10.
FIG. 10 is a perspective view of a screw section showing the raised lobes on the shaft.
FIG. 11 is side elevational view of a plastic extruder having the screw operatively mounted therein.
FIG. 12 is a cross sectional end view of a screw having chamfered pockets forming flat bottom surfaces.
FIG. 13 is cross sectional end view of the shaft as shown in FIG. 10.
FIG. 14 is a cross sectional view of an embodiment having raised lobes on the shaft wherein the upper land surface area of the lobes is planar and parallel to the shaft axis of rotation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a screw 10 constructed according to the principles of the invention. The single thread 16, or flight, having an outer diameter 19 is helically wound about the shaft member portion 8 and has a circular end view profile. The diametric distance 18 between opposed shaft surface portions 14 represents the root diameter of the screw. Spaced axially along the screw's longitudinal axis of rotation 20 are a plurality of recessed land portions 12 which are also referred to as pockets. In the preferred embodiment, the shaft is cylindrical for its entire length, but it is contemplated that a section could be tapered if desired. Throughout the figures, like numerals will refer to like items and primes and alphabetical letters will differentiate between more than one like item.
In FIGS. 1, 2, 6 and 8, these recessed pockets 12 have a top plan view area in the shape of a parallelogram with two opposite edges 23, 23' extending substantially parallel with axis 20 and two other edges 22, 22' extending somewat transversely thereof. The recessed bottom surface land area 15 of pockets 12 in both FIGS. 1 and 2 is substantially the same shape as the surface 14 portion of shaft member 10 which is interposed between pockets 12 in a checkerboard-like pattern. In FIG. 2, there is one more pocket 12 per pitch length of the screw than shown in the embodiment of FIG. 1. The pockets extend around the shaft along a path following the screw thread, i.e. a spiral path.
The recessed land portions are defined by bottom land surface areas 15, which are parallel to the shaft member surface 14 which in turn is substantially cylindrical for the entire working length of screw 10, and a wall 24 formed between bottom surface 15 and shaft member 14. As shown in FIGS. 1, 1a, and 6, the upper and lower parts of continuous wall 24 are defined by bottom edges 17, 17', 21, 21' and top edges 22, 22', 23, 23'. Edges 17, 21, 22 and 23 are shown in the figures as being sharply defined. In some embodiments, side edges 17, 17', 23, 23', which extend substantially coaxially with the shaft may blend into surfaces 15 and 14 so smoothly as to render them imperceptible or even nonexistent. In fact, all of the pocket or lobe edges are made smooth to the extent necessary to prevent plastic from accumulating on them. In this connection, it is anticipated that recessed land portions 12 may be formed by machining a flat spot to form bottom surface 15 in shaft member 14 so that part of circumferential sidewall 24 is eliminated and bottom surface 15 is parallel not with the cylindrical surface 14 of the shaft member, but with the longitudinal axis of rotation instead. A cross section of a screw having such chamfered pockets 12 forming flat bottom surfaces 15e, 15f, 15g, 15h is shown in FIG. 12.
In each of the various configurations of recessed pockets 12, the shaft member surface 14 is made continuous for each pitch length by providing a neck area 26 thereon between contiguous corners of adjacent pockets 12 so that the pockets and recessed bottom land surfaces 15 thereof are not interconnected.
FIGS. 6, 7 and 8 are developed views of the shaft surface portions 14, 15 having different patterns of recessed bottom land surfaces 15a, 15b, 15c, respectively. Thus, depending on the type of plastic being used, the screw speed, tolerances between the screw thread and internal bore of the extruder and other such parameters, various area configurations for the pockets and their relative proportional area to that of the shaft member may produce optimum results depending upon the selected parameters. Areas 15a and 15a' have different rectangular shapes, while areas 15b in FIG. 7 have quadrangular shaped areas (the non-parallel sides of which can be extended to form triangular shaped areas) and areas 5c in FIG. 8 are of uniform rectangular shape.
Operation of this screw in a plastic extruder can perhaps be better understood if compared to the operation of a standard screw (i.e. a screw having a continuous, smooth surfaced shaft portion of constant root diameter for at least a portion of its length and a helical screw thread also having a constant outside diameter which fits into the cylindrical bore of an extruder).
In FIG. 3, such a prior art extruder is shown having a solid bed, or plug, of plastic particles or pellets 30p packed along the pitch distance between successive turns of screw thread 16p mounted within the cylindrical bore 32p of the extruder barrel. As the screw turns, the screw threads urge the plastic to move in the direction of arrow 34p. The heat from the shearing action of the screw thread squeezing the plastic against the bore wall 32p begins to melt the plastic according to the operating principles of screw extruders. The melted plastic forms roughly a cylindrical shape 31p and it tends to remain stationary, relative to the solid plug, along the outer diameter of the screw thread. Since it cannot easily pass the next screw thread in an axial direction, a major portion of it begins to accumulate on the forward side of the thread. This accumulation and relative movement of melted plastic is designated by arrowed numeral 36p. Eventually, as the screw moves the plastic plug 30p axially within the extruder, the entire amount of plastic is likewise mechanically worked and melted.
The operation of a screw containing pockets is illustrated in FIGS. 4 and 5. The screw thread outer diameter 19, shaft root diameter 18, and extruder inner bore surface diameter 27 are all constant throughout the axial working length of the extruder. In FIG. 4, the plug of plastic has begun to melt and form the cylindrical shape 31. As the screw turns and the threads move forwardly in direction 34, a portion of the plug of plastic pellets is forced radially inwardly into the recessed pocket 12 which induces the melted plastic to shift to fill the gap 38 formed thereby between the outer periphery of the plastic plug and the extruder inner bore wall 32. The radially inward shift of a portion of the plastic into the pocket also causes a fissure 40 to develop, thereby dividing the plug into trailing and leading portions 42, 44 in the pocket 12 and remaining on the screw shaft member surface 14, respectively. Fissure 40 is located along pocket edge 22, and similar fissures are produced over pocket edges 23, 23'. In fact, regardless of the pocket bottom land surface shape, fissures are produced over all pocket edges. Some of the melted plastic is forced into these fissures between the interfaces of plug portions to enhance mixing, break up the plug and to carry some of the melted plastic away from the extruder bore wall surface 32 to mitigate the possibility of its being overheated. The melted plastic entering the fissures is replaced by solid plastic as the screw turns to promote additional melting.
When melting plastic in an extruder, it is important that the plastic not be overheated or scorched. Since melted plastic is hotter than the unmelted pellets, the faster and more thoroughly these melted and unmelted portions are mixed, the quicker any excess heat will be absorbed from the melted portion into the unmelted portion. This is conducive to both reducing the possibility of overheating the melted portion and increasing the temperature of the unmelted portion, thereby reducing the time and energy to melt the plastic.
The fissures also accelerate mixing the plastic by allowing part of the melted portion on the outer periphery of the screw to flow radially inwardly to contact part of the lower portion of plastic plug (near the shaft surface 14).
Additional mixing and plasticizing is produced as the screw rotates to the position shown in FIG. 5. Here, under the combined pressure of the forces imposed by the turning screw thread and the radially inward and outward movement of the plastic, relative to the axis of screw rotation, as it travels over moving shaft member surface 14 and bottom land surface 15, the trailing plug portion 42 is compressed against the bore wall 32 while the leading plug portion 44 is forced into another pocket 12. This compresses the previously melted plastic on the outer periphery of plastic plug 42 into a thinner layer while moving some of this melted plastic forwardly to a position over the leading plug portion 44. The unmelted plug portion is urged upwardly to the outer thread periphery to be worked and melted.
As the leading plug portion goes into a pocket, the material already there is forced out and up onto the shaft surface 14 again. All of this radially inward, outward and circumferential movement of the plastic creates a multitude of fissures whose location is constantly shifting in the plastic to promote plasticizing of the unmelted portion and intermixing of the melted and unmelted portions at the fissure interfaces.
Since all screw threads have a lead angle, the plastic is also shifted somewhat in an axial direction 34 as the screw rotates whereby fissure 44 will occur in a slightly different axial location in the plastic plug as it shifts from the position shown in FIG. 4 to the position shown in FIG. 5. Also, the size and shape of the recessed pockets 12, and their position relative to one another, will assist the formation of, and accentuate the shift in, the fissure locations as the plastic moves into and out of the pockets. The alternation between leading and trailing plastic portions 44, 42 being compressed and pressure relieved, relative to each other, and the constantly shifting position of the fissures combine to provide high radial shearing forces of brief duration and to thoroughly mix and plasticize, without overheating it, each pitch length distance along the screw axis as the plastic moves into and out of the pockets. The duration of high shearing forces is a function of screw speed, shaft diameter and circumferential width of the pocket. In FIG. 5, arrows 36', 37, 39 illustrate the various paths taken by the plastic as it travels between the thread edge and extruder bore wall 32' (arrow 37), collects in front of the screw thread (arrow 36') and mixes with the solid plastic particles in fissure 40 (arrow 39).
Some preferred shapes and locations of pockets are shown in FIGS. 6 through 8, although other obvious shapes and modifications thereof have been contemplated which also produce the desired action on the plastic and which are intended to fall within the scope of the appended claims.
The newly produced melted plastic over the trailing plug portion 42, combined with any melt squeezed over by its rise out of the pocket (FIG. 5), is forced into the cracks of the compacted pellets forming the plug to still further contribute to the mixing and plasticizing process. This operation is reversed when the leading portion 44 is compressed (FIG. 4) and the trailing portion 42 is relieved.
As the plastic moves from the rear of the screw in the extruder to the front, the continuous formation of fissures and shearing action at the interfaces thereof, together with a constant pressure to move the plastic radially inward and outward as it passes into and out of the pockets, combines with the heat produced between the plastic working against the extruder bore wall to completely melt the plastic and very thoroughly mix it before it is expelled.
FIGS. 9, 10, 13 and 14 illustrate a different embodiment. Instead of pockets recessed in the screw shaft, a plurality of raised lobes 70 are formed in the shaft surface 14'. As with the recessed pockets, a side wall 24' defines the lobe periphery. In FIG. 9, the shaded portion represents the radially innermost surface (i.e. shaft surface 14') to be consistent with FIGs. 6-8 wherein the shading designates the bottom surface of the pockets. The lobes are not interconnected and gap 72 is maintained between contiguous lobes on the continuous, cylindrical shaft surface 14'. The upper land surface area 73 of the lobes may be either arcuate to be parallel with the screw shaft surface, or planar (FIG. 14) to a parallel with the shaft axis of rotation, as desired. In addition, it is contemplated that the planned view shape of the lobes can be rectangular, quadrangular, triangular or virtually any other geometric shape as with the pockets.
In operation, the compression, pressure relieving and radial shearing action on the plastic occurs in substantially the same manner as the operation described in connection with the pockets. However, since the lobes form a raised upper land surface above the cylindrical shaft, some plastic will move around on the shaft surface through gap 72 between lobes as well as over the upper land surface. Therefore, the intensity of the radially inward and outward shearing action as the plastic moves onto and off the lobe base surfaces will be slightly less than that provided with the recessed pocket embodiment.
Referring to FIG. 11, the screw can be divided into sections to take advantage of the relative intensities of shearing action provided by the lobe and pocket configurations. For purposes of illustration, the screw in the extruder in FIG. 11, has been divided into roughly equal length sections marked 74, 76, 78, to designate plain, lobe and pocket sections, respectively. Generally, the upstream portion of the screw near the plastic inlet in any case has a plain shaft portion without any lobes or pockets since it takes a short period of time for the screw thread to mechanically work the solid pellets, flakes or chips and bring them up to melting temperature before mixing is required.
Further, it is contemplated that the remainder of the screw length can be made up entirely of either the lobe or pocket configurations or both of them in various axial lengths and positions in order to produce the desired degree of mixing at specified positions along the screw length. Either the pockets or lobes could extend for but a portion of the axial length of the threaded shaft as desired.
FIG. 11 illustrates a conventional plastic extruder in which screw 10 is rotatably mounted to operate as previous described. Except in so far as the construction and operation of the above described screw is concerned, the construction and operation of the extruder is conventional. Motor 48 turns screw 10" through a speed reducer 50 and coupling 52. Plastic pellets are held in hopper 54 and introduced through feed throat 56 to the interior of the cylindrical bore of the extruder barrel 58. The diameter of screw thread 16 is also constructed to form a cylindrical peripheral edge profile to fit within the extruder bore. The working length is the axial length of the screw thread. Heating elements 64 are mounted about the external periphery of the extruder barrel to maintain the parts at a uniform temperature and prevent chilling the melted plastic on the bore wall. Melted plastic is forced through a screen pack 60 and out through nozzle 62.
Thus, a new extruder screw has been described which achieves the objects and advantages set forth by continuously subjecting to plastic to radially inward and outward movement and intense shearing action of brief duration all along the shaft length containing the pockets and lobes to thoroughly mix the plastic while simultaneously conveying and melting it before discharging it from the extruder. No volume restricting or a verse thread sections are utilized or required which would slow the speed of extruder operation. | A screw for use in a thermoplastic extruder. A plurality of recessed pockets and/or raised lobes are in the screw shaft and these operate as the shaft is rotated to constantly shift the melted and unmelted portions of the plastic resin radially inwardly and outwardly within a pitch length of the screw inside the extruder to quickly and uniformly mix the plastic into a homogeneous melt. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application 2008-201861, filed on Aug. 5, 2008, the entire contents of which are incorporated herein by reference.
FIELD
The present disclosure relates to a sewing machine and more particularly to so called free motion sewing machine that forms stitches while manually feeding a workpiece cloth.
BACKGROUND
Sewing machines have been known which are capable of executing a so called free motion sewing operation. In a free motion sewing operation, a feed dog for longitudinally feeding a workpiece cloth is inactivated within a bed and a presser foot for applying pressure on the workpiece cloth releases its pressure exerted on the workpiece cloth. The user is allowed to manually feed the workpiece cloth freely under such state. The free motion sewing operation will end up in poor looking stitches if the stitches are not formed at a constant stitch pitch. However, forming stitches at a constant stitch pitch through manual feeding of the workpiece cloth has been a difficult task for inexperienced users.
To address such difficulties, a sewing machine capable of executing the free motion sewing operation at a constant stitch pitch is proposed, for example, in JP-2002-292175 A hereinafter referred to as patent publication 1. The disclosed sewing machine is provided with a distance measuring element which measures the distance of travel of fed workpiece cloth and a needle speed changing element that changes operating speed of the sewing needle based on the measurement. In another example of a sewing machine disclosed in JP 2008-79998 A hereinafter referred to as patent publication 2, an imaging element and a feed amount regulator are provided. Under the disclosed configuration, the feed amount of workpiece cloth is calculated based on the image data captured by the imaging element. The feed amount regulator compares the calculated feed amount with a predetermined stitch pitch and limits the feed amount based on the comparison.
However, the sewing machine disclosed in patent publication 1 requires additional features such as the distance measuring element and the needle speed changing element, whereas the sewing machine disclosed in patent publication 2 requires additional features such as the imaging element and the feed amount regulator. Both sewing machines disadvantageously require complicated configurations.
SUMMARY
One object of the present disclosure is to provide a sewing machine that allows even inexperienced users to form stitches at a constant stitch pitch in free motion sewing in a simple configuration.
In one aspect of the present disclosure there is provided a sewing machine including a needle bar; a sewing needle attached to the lower end of the needle bar; a needle bar drive mechanism that vertically drives the needle bar; a presser foot that is capable of applying releasable pressure on a workpiece cloth and that releases the pressure to allow manual movement and sewing of the workpiece cloth; a regulatory needle that includes a tip and that is capable of assuming a pierced state in which the tip is pierced through the workpiece cloth and a non-pierced state, wherein the regulatory needle is moved along with the workpiece cloth while retaining the pierced state of the tip; a regulatory needle drive unit that vertically drives the regulatory needle between the pierced state and the non-pierced state in coordination with vertical movement of the sewing needle; and a regulatory needle regulator that limits horizontal movement of the regulatory needle in the pierced state so that the horizontal movement does not exceed a predetermined stitch pitch.
According to the above described configuration, the tip of the regulatory needle in the pierced state is allowed to move along with the workpiece cloth and the regulatory needle is driven vertically by the regulatory needle drive unit in coordination with the vertical movement of the sewing needle. The regulatory needle regulator limits the horizontal movement of the regulatory needle in the pierced state so that the amount horizontal movement does not exceed a predetermined stitch pitch. Thus, when the user manually transfers the workpiece cloth in free motion, the movement of the workpiece cloth with the regulatory needle in the pierced state does not and is not allowed to exceed the predetermined stitch pitch. The above configuration allows formation of stitches at a constant stitch pitch and even inexperienced users can readily perform free motion sewing at a constant stitch pitch.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present disclosure will become clear upon reviewing the following description of the illustrative aspects with reference to the accompanying drawings, in which,
FIG. 1 is a front view of a sewing machine according to one exemplary embodiment of the present disclosure with a cover of a sewing machine head removed;
FIG. 2 schematically illustrates a mechanical configuration of the sewing machine;
FIG. 3 is a partial cross sectional front view of a regulatory needle in an upper position;
FIG. 4 is a partial cross sectional front view of a regulatory needle in a lower position;
FIG. 5 is a plan view of a needle plate and a bed;
FIG. 6 is an enlarged view of the main features of the needle plate and a regulatory plate;
FIG. 7 is a cross sectional view taken along line VII-VII of FIG. 6 ;
FIG. 8 is a rear view of the sewing machine with the cover of the sewing machine head removed;
FIG. 9A is a cross sectional view taken along line IX-IX of FIG. 6 showing a lever in a lowered state;
FIG. 9B is a cross sectional view taken along line IX-IX of FIG. 6 showing a lever in a lifted state;
FIGS. 10A to 10D schematically illustrate timing in movement of regulatory needle relative to a sewing needle;
FIG. 11 is a front view of the main features of a second exemplary embodiment;
FIG. 12 is a plan view of a needle guide; and
FIGS. 13A and 13B illustrate partial cross sectional views of cylindrical portions having different inner diameters.
DETAILED DESCRIPTION
A description will be given hereinafter on exemplary embodiments of the present disclosure. Elements that are substantially identical between the exemplary embodiments are identified with identical reference symbols and their descriptions will not be given if once described.
FIGS. 1 to 10 depict a sewing machine according to a first exemplary embodiment. A sewing machine 10 includes a bed 11 , a pillar 12 standing on the right end of bed 11 , an arm 13 extending leftward over bed 11 from the upper end of pillar 12 , and a head 14 defined at the left end of arm 13 . An exterior cover 15 is provided over bed 11 , pillar 12 , arm 13 , and head 14 .
Referring now to FIG. 2 , sewing machine 10 is further provided with a main shaft 16 , a lower shaft 17 , a sewing machine motor 18 , an upper transmission mechanism 19 , a lower transmission mechanism 21 , a needle bar drive mechanism 22 , a needle bar 23 , a sewing needle 24 , a needle plate 25 , and a shuttle 26 . Main shaft 16 extends laterally within arm 13 and is supported rotatably by a bearing not shown. Lower shaft 17 extends laterally within bed 11 and is also supported rotatably by a bearing not shown. Sewing machine motor 18 , upper transmission mechanism 19 , and a lower transmission mechanism 21 are stored within pillar 12 . The rotational drive force generated by sewing machine motor 18 is transmitted to main shaft 16 through a belt 27 provided at upper transmission mechanism 19 , and the rotational drive force of main shaft 16 is in turn transmitted to lower shaft 17 through belt 28 provided at lower transmission mechanism 21 . Rotational drive force of sewing machine motor 18 is thus, transmitted to main shaft 16 through upper rotational transmission mechanism 19 , and from main shaft 16 to lower shaft 17 through lower rotational transmission mechanism 21 . According to the above described configuration, the rotation of sewing machine motor 18 causes the rotation of main shaft 16 and lower shaft 17 .
Needle bar drive mechanism 22 is provided on the left end of main shaft 16 . Needle bar 23 is provided within head 14 of sewing machine 10 and its lower end protrudes downward from cover 15 covering head 14 . Needle bar drive mechanism 22 transforms the rotary movement of main shaft 16 into a vertical movement of needle bar 23 . Needle bar 23 is vertically reciprocated once as main shaft 16 is rotated once. Needle bar 23 has a sewing needle 24 detachably attached to its lower end. Bed 11 has needle plate 25 provided in opposition of head 14 . Within bed 11 below needle plate 25 , shuttle 26 comprising a horizontal shuttle composed of an outer shuttle 26 and an inner shuttle 30 is provided. Shuttle 26 receives detachable attachment of bobbin thread bobbin not shown within inner shuttle 30 . Outer shuttle 29 is driven in rotation by lower shaft 17 . On the upper portion of arm 13 , a thread spool attachment 31 is provided to receive a detachable attachment of a thread spool 32 that provides supply of needle thread. Needle plate 25 has a needle hole 33 defined on it for allowing penetration of sewing needle 24 as can be seen in FIG. 5 .
Referring back to FIG. 1 , head 14 further contains a presser bar 34 . Presser bar 34 is oriented upright relative to needle plate 25 and is vertically movably supported by a sewing machine frame not shown. Presser bar 34 has a presser foot 35 not shown attached to its lower end. Presser foot 35 presses the subject of the sewing operation, which is typically a workpiece cloth not shown, against needle plate 25 . Though not shown in detail, presser foot 35 releases its pressure on the workpiece cloth when sewing in free motion to allow the workpiece cloth to be moved freely by manual transfer.
At the lower front face of head 14 , a start/stop switch 36 is provided for starting or stopping a sewing operation. Depression of start/stop switch 36 causes sewing machine motor 18 to be activated or stopped. Other switches and controls such as a back stitch switch 37 , a needle vertically moving switch 38 , a thread cut switch 39 , and a speed adjustment dial 40 are provided on the front faces of head 14 and arm 13 . Back stitch switch 37 , when operated, reverses the cloth feed direction; whereas needle vertically moving switch 38 alternately transfers sewing needle 24 at an upper needle stop position and a lower needle stop position; thread cut switch 39 activates a needle cut mechanism not shown that cuts the needle thread and bobbin thread at the end of a sewing operation; and speed adjustment dial 40 makes adjustments in sewing speed, in other words, the rotational speed of main shaft 16 .
At the lower end of head 14 , a regulatory needle 41 which penetrates in an out of the workpiece cloth and a regulatory needle driving element 42 which vertically drives regulatory needle 41 are provided so as to be situated at the left side proximity of sewing needle 24 . Regulatory needle driving element 42 comprises a coil 44 and an electromagnetic actuator 43 provided with a regulatory bar 45 . Regulatory bar 45 retains its upper position shown in FIG. 3 by a return spring not shown. Coil 44 , when energized, produces electric magnetism that causes regulatory bar 45 to be driven downward against the bias of return spring. Regulatory needle 41 is provided interchangeably at the lower end of regulatory bar 45 . Thus, when coil 44 is de-energized, regulatory needle 41 retains its upper position, whereas when coil 44 is energized, regulatory needle 41 is moved to a lower position shown in FIG. 4 to penetrate the workpiece cloth. Electromagnetic actuator 43 is supported by a support member 46 which is detachably attached by a fastening screw 47 to a frame 141 secured on the sewing machine frame. Thus, regulatory needle 41 and regulatory needle driving element 42 may be removed from sewing machine 10 , when executing a normal sewing operation, for example.
Regulatory needle 41 comprises an elastically deformable spring wire, for example. Regulatory needle 41 has a sharpened tip to allow penetration in and out of workpiece cloth. The base end of regulatory needle 41 is interchangeably secured to regulatory bar 45 of electromagnetic actuator 43 . To elaborate, the base end of regulatory needle 41 is clamped between a holder 48 mounted at the lower end of regulatory bar 45 and clamp member 49 as can be seen in FIGS. 3 and 4 . Clamp member 49 is screw fastened to holder 48 by a screw not shown and allows replacement of regulatory needle 41 by loosening the fastening screw.
Referring now to FIG. 2 , arm 13 includes a sensor section 51 . Sensor section 51 senses the vertical position of sewing needle 24 through sensing of rotational phase of main shaft 16 . Sensor section 51 comprises a known sensor provided with a plurality of shutters 52 , a photo interrupter 53 and a substrate 54 . Shutters 52 are secured on main shaft 16 and photo interrupter 53 is provided on substrate 54 secured on the sewing machine frame so as to oppose shutters 52 . Though not shown in detail, shutters 52 are each sectoral having a unique angle and provided at different phase positions. The rotational phase of main shaft 16 can be sensed by sensing the unshown edges of shutters 52 by photo interrupter 53 . The vertical position of sewing needle 24 is recognized based on the sensed phase of main shaft 16 . The control circuit not shown, controls the energization and de-energization of coil 44 of electromagnetic actuator 43 based on the incoming electric signals from photo interrupter 53 .
Next, a description will be given on a regulatory needle regulator 60 with reference to FIGS. 3 , 4 , and 5 . Regulatory needle regulator 60 is provided with a regulatory plate 61 which is fitted into a circular recess 251 defined on needle plate 25 so as to be at level, in other words, coplanar with the upper surface of needle plate 25 . As can be seen in FIG. 5 , regulatory plate 61 is disc shaped and is provided with a support shaft 62 at its center. As can be seen in FIGS. 3 , 4 and 7 , support shaft 62 extends downward from the underside of regulatory plate 61 to penetrate a bearing 611 provided at the lower central portion of circular recess 251 , thereby allowing regulatory plate 61 to rotate about support shaft 62 . Regulatory plate 61 is further provided with six holes 631 , 632 , 633 , 634 , 635 , and 636 each having a unique inner diameter defined on the circumference centering on the center of support shaft 62 as can be seen in FIG. 5 . The centers of holes 631 to 636 are disposed at 60 degree angular interval. When regulatory plate 61 assumes the position shown in FIG. 5 , regulator needle 41 is inserted into hole 633 which is in the closest proximity of needle hole 33 . When the workpiece cloth is manually transferred, the tension between sewing needle 24 and regulatory needle 41 tends to be reduced as the distance between needle hole 33 and hole 633 receiving regulatory needle 41 , that is, the distance between sewing needle 24 and regulatory needle 41 is increased. Reduced tension at the workpiece cloth provides grounds for inconsistent stitch pitch and thus, hole 633 that assumes a position to allow penetration of regulatory needle 41 is moved as close as possible to needle hole 33 receiving sewing needle 24 .
Referring now to FIG. 6 , regulatory plate 61 is further provided with six V-shaped notches 641 to 646 on its outer peripheral portion. Notches 641 to 646 are arranged at 60 degree angular interval. On a portion of the inner wall of circular recess 251 defined on needle plate 25 , a protrusion 252 is formed that protrudes radially inward in V-shape. The selective engagement of protrusion 252 with one of notches 641 to 646 determines the positioning of regulatory plate 61 relative to needle plate 25 .
For instance, in FIG. 6 , shows protrusion 252 being engaged with notch 643 . At this instance, hole 633 is located below regulatory needle 41 such that the center of regulatory needle 41 is coincidental with the center of hole 633 .
Next, a description will be given on a hole selector 70 which selects the hole having the desired inner diameter among the six holes 631 to 636 . Referring to FIG. 7 , hole selector 70 comprises a lever 71 for vertically moving regulatory plate 61 , and support shaft 62 , and a support section 72 . The rear end tip of lever 71 slightly protrudes rearward from the rear side surface of bed 11 as can be seen in FIGS. 5 , 7 , and 8 to allow the user to manually operate lever 71 in the vertical direction through this protruding tip. Support section 72 supports the lower end of support shaft 62 so as to be rotatable but axially unmovable. Thus, by lifting lever 71 , the fitting engagement between regulatory plate 61 and circular recess 251 is cancelled to move regulatory plate 61 upward as shown in FIG. 9B . Thus, engagement of protrusion 252 with one of notches 641 to 646 (notch 643 in FIG. 6 ) is cancelled to allow rotation of regulatory plate 61 about support shaft 62 . Then, regulatory plate 61 is rotated to locate one of the six holes 631 to 636 that has the desired inner diameter to be located in a position (in the right side relative to support shaft 62 ) as close as possible to needle hole 33 whereafter lever 71 is lowered to lower regulatory plate 61 back into fitting engagement with circular recess 251 as shown in FIG. 9A . Consequently, protrusion 252 is placed in engagement with one of notches 641 to 646 to determine the rotational positioning of regulatory plate 61 . As described above, the hole through which regulatory needle 41 is inserted is selected from one of the six holes 631 to 636 .
Regulatory plate 61 provided on needle plate 25 may be provided on bed 11 , if found appropriate, depending on the size and shape of needle plate 25 .
The timing in movement of regulatory needle 41 relative to sewing needle 24 will be described based on FIG. 10 . Sewing needle 24 and regulatory needle 41 have been illustrated schematically for simplicity of description. Further, workpiece cloth not shown in the previous figures will be represented as workpiece cloth 100 . Description will be given hereinafter with an assumption that regulatory plate 61 assumes a position in which hole 633 has been selected.
As can be seen in FIG. 10A , when sewing needle 24 is pierced through workpiece cloth 100 , workipiece cloth 100 cannot be moved because it is anchored in place by sewing needle 24 , and thus, regulatory needle 41 is displaced upward away from workpiece cloth 100 . When regulatory needle 41 is in the upper position, regulatory needle 41 assumes the initial position residing on a center line L of hole 633 .
Then, as can be seen in FIG. 10B , as sewing needle 24 is elevated, regulatory needle drive unit 42 drives regulatory needle 41 downward so as to pierce workpiece cloth 100 before sewing needle 24 is lifted above workpiece cloth 100 . Regulatory needle 41 is thus, pierced through workpiece cloth 100 by traveling downward below center line L of hole 633 . Under such state, when sewing needle 24 is moved out of workpiece cloth 100 , workpiece cloth 100 is allowed to be moved within the limitation given by regulatory needle 41 . By piercing regulatory needle 41 through workpiece cloth 100 before sewing needle 24 is lifted above workpiece cloth 100 , regulatory needle 41 can takeover the task of limiting the movement of workpiece cloth 100 from sewing needle 24 .
Then, as can be seen in FIG. 10C , by the time sewing needle 24 is lifted out of workpiece cloth 100 , only regulatory needle 41 is pierced through workpiece cloth 100 . Since regulatory needle 41 is made of elastically deformable material, workpiece cloth 100 can be manually moved freely. Even if work piece cloth 100 is moved in the horizontal direction indicated by arrow A in FIG. 10C , regulatory needle 41 is elastically deformed under the influence of the movement of workpiece cloth 100 to show a bend However, since the tip of regulatory needle 41 is inserted into hole 633 , further movement of regulatory needle 41 can be restricted once the tip of regulatory needle 41 is placed in contact with the inner wall of hole 633 . Thus, workpiece cloth 100 can be moved to the extent of the radius of hole 633 , meaning that the radius of hole 633 defines the stitch pitch. Accordingly, by selecting either of holes 631 , 632 , 634 , 635 , and 636 to replace hole 633 , the distance of movement, in other words, the stitch pitch can be changed.
Then, as can be seen in FIG. 10D , regulatory needle drive unit 42 keeps regulatory needle 41 pierced through workpiece cloth 100 until sewing needle 24 is pierced through workipiece cloth 100 . That is, regulatory needle drive unit 42 moves regulatory needle 41 upward after sewing needle 24 has pierced workpiece cloth 100 . Since movement of workpiece cloth 100 is prohibited by the piercing of sewing needle 24 , workpiece cloth 100 need not be limited in movement by regulatory needle 41 . Regulatory needle 41 being lifted out of workpiece cloth 100 returns, from the bent state, to its original position on center line L of hole 633 by its own elasticity as shown in FIG. 10A .
As described above, regulatory needle 41 stays pierced through workpiece cloth 100 while workpiece cloth 100 is being moved manually. Thus, movement of workpiece cloth 100 can be limited reliably with preciseness.
Next, a description will be given on the operation and effect of the first exemplary embodiment.
Regulatory needle 41 is made of elastically deformable material and thus, can be moved along with workpiece cloth 100 with the tip of regulatory needle 41 pierced through workpiece cloth 100 . The elastic deformation of regulatory needle 41 is limited by hole 633 of regulatory plate 61 , in other words, workpiece cloth 100 is free to move within the radius of hole 633 meaning that the radius of hole 633 represent the stitch pitch According to the above described configuration, the user is allowed to readily execute free motion sewing with constant stitch pitch by merely moving workpiece cloth 100 such that the tip of regulatory needle 41 contacts the inner wall of hole 633 every time workpiece cloth 100 is manually fed.
The above configuration is further advantageous in that stitches with constant stitch pitch can be formed in a simple configuration comprising an elastically deformable regulatory needle 41 and regulatory plate 61 having a hole 633 allowing penetration of regulatory needle 41 .
Regulatory plate 61 is disc shaped and is provided with six holes 631 to 636 having unique inner diameters. One of the six holes having the desired inner diameter is selected by rotating regulatory plate 61 . Thus, constant stitch pitch can be obtained in a simple configuration by a simple operation.
Further, regulatory needle 41 is provided in the proximity of needle hole 33 allowing penetration of sewing needle 24 and thus, the distance between regulatory needle 41 and sewing needle 24 can be reduced. Such configuration minimizes the slack being produced between the regulatory needle 41 and sewing needle 24 when manually moving workpiece cloth 100 to allow the stitches to be formed precisely in constant stitch pitch.
In the first exemplary embodiment, regulatory needle drive unit 42 pierces regulatory needle 41 through workpiece cloth 100 before sewing needle 24 is lifted out of workpiece cloth 100 and stays pierced until sewing needle 24 is pierced through workpiece cloth 100 . Thus, regulatory needle 41 stays pierced through workpiece cloth 100 while workpiece cloth 100 is being manually moved to reliably and precisely prevent movement of workpiece cloth 100 in excess of the predetermined stitch pitch.
Further, regulatory needle drive unit 42 is provided with electromagnetic actuator 43 that vertically moves regulatory needle 41 . Thus, regulatory needle 41 can be vertically moved rapidly and precisely in a simple configuration.
A description will now be given on a second exemplary embodiment of the present disclosure. FIG. 11 shows the portion constituting the main features of the sewing machine according to the second exemplary embodiment.
As can be seen in FIG. 11 , the second exemplary embodiment differs from the first exemplary embodiment in the configuration of the regulatory needle regulator, which is identified in the second exemplary embodiment as regulatory needle regulator 160 . Regulatory needle regulator 160 is provided with a needle guide 161 which is provided with a cylindrical section 162 that covers the entire outer periphery of the base end portion of regulatory needle 41 . Regulatory needle 41 comprises an elastically deformable spring wire as was the case in the first exemplary embodiment. The center of cylindrical section 162 is located with the center of regulatory needle 41 .
Needle guide 161 is provided integrally with a cylindrical head 163 at its upper end. A portion of the side surface of head 163 defines a planar section 164 shown in FIG. 12 . Planar section 164 is placed in abutment with the tip of a later described fastening screw 165 .
Electromagnetic actuator 43 has holder 48 secured on the lower end of regulatory bar 45 as described earlier. Holder 48 is provided with a fitting hole which establishes fitting engagement with head 163 . Needle guide 161 having its head 163 being fitted into the fitting hole of the holder 48 is fastened unfastenably by fastening screw 165 . Planar section 164 of head 163 is provided to avoid contact with fastening screw 165 which may become an impediment to the detachment of needle guide 161 .
Regulatory needle regulator 160 being configured as described above is driven by electromagnetic actuator 43 to move up and down in coordination with the vertical movement of sewing needle 24 as in the first exemplary embodiment.
When workpiece cloth 100 is moved with the downwardly driven regulatory needle 41 pierced through it, regulatory needle 41 bends by elastic deformation as work piece cloth 100 is moved. As the lower end of regulatory needle 41 increases the degree of bend, regulatory needle 41 eventually contacts lower end 166 of the inner wall of cylindrical section 162 . Stated differently, the movement of regulatory needle 41 is limited by the inner wall of cylindrical section 162 . This means that the movement of workpiece cloth 100 is limited to half of the inner diameter of cylindrical section 162 , that is, the radius of cylindrical section 162 . When regulatory needle 41 is lifted out of workpiece cloth 100 , it returns to the initial position which is located with the center of cylindrical section 162 by its own elasticity. As described above, half length of the inner diameter, in other words, the radius of cylindrical section 162 represents the stitch pitch.
Further, as exemplified in FIGS. 13A and 13B , different types of needle guide 161 are provided that vary in the inner diameter of cylindrical portion 162 . Thus, the user is allowed to sew in free motion in the desired stitch pitch by selectively attaching needle guide 161 of the desired size.
The second exemplary embodiment having the above described configuration provides the following operation and effect.
Regulatory needle 41 being elastically deformed by movement of workpiece cloth 100 is limited in movement through contact with the inner wall of cylindrical section 162 of needle guide 161 . Thus, the movement of workpiece cloth in excess of the predetermined stitch pitch can be prohibited by a simple configuration.
The present disclosure is not limited to the above described exemplary embodiments but may be modified or expanded as follows.
In the first and the second exemplary embodiment, electromagnetic actuator 43 for driving regulatory needle 41 has been provided at head 14 to lower regulatory needle 41 to pierce workpiece cloth 100 . In contrast, electromagnetic actuator 43 may be provided within bed 11 and regulatory needle 41 may be configured to protrude upward through the hole such as hole 633 of regulatory plate 61 to pierce workpiece cloth 100 from the underside. In such case, though not shown in detail, a protective element formed in a cap form, for example, may be provided so as to oppose the protruding regulatory needle 41 for user safety and for preventing workpiece cloth 100 from being lifted by the piercing of regulatory needle 41 . The protective element, however, needs to be provided so as to allow the underlying workpiece cloth 100 to move freely.
The count of holes provided on regulatory plate 61 of the first and the second exemplary embodiments is not limited to six, but may be modified as required.
Further, support shaft 62 that supports regulatory plate 61 may be eliminated and the disc shaped regulatory plate 61 may be simply fitted into the circular recess 251 . In such case, regulatory plate 61 can be removed by use of tools such as tweezers.
While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles. | A sewing machine including a needle bar; a sewing needle attached to the lower end of the needle bar; a needle bar drive mechanism vertically driving the needle bar; a presser foot capable of applying releasable pressure on a workpiece cloth and that releases the pressure to allow manual movement and sewing of the workpiece cloth; a regulatory needle including a tip and being capable of assuming a pierced state where the tip is pierced through the workpiece cloth and a non-pierced state, wherein the regulatory needle is moved along with the workpiece cloth while retaining the pierced state of the tip; a regulatory needle drive unit vertically driving the regulatory needle between the pierced state and the non-pierced state in coordination with vertical movement of the sewing needle; and a regulatory needle regulator limiting horizontal movement of the regulatory needle so as not to exceed a predetermined stitch pitch. | 3 |
BACKGROUND OF THE INVENTION
[0001] The invention relates generally to a steam mop, and more particularly to a steam mop including a mechanical water pump that is actuated by the movement of a user to pump water from a water container to a boiler for generating steam to be distributed to a steam pocket applied to a surface to be cleaned.
[0002] Conventional mops have been widely used for cleaning floors. However, conventional mops have not been effective at cleaning dirt in small crevices and floor gaps. In addition, conventional mops require frequent rising since mops can only effectively clean a small surface area at a time.
[0003] Steaming devices used to apply steam to household objects are well known. The uses of the devices vary widely, and may include the application of steam to drapes or other fabrics to ease wrinkles, and the application of steam to objects to assist in cleaning the objects.
[0004] Typical steam devices have a reservoir for storing water that is connected to an electrical water pump with an on/off switch. The exit from the electric water pump is connected to a steam boiler with a heating element to heat the water. The heated water generates steam, which may be directed towards its intended destination through a nozzle which controls the application of the steam. Variation of the shape and size of the nozzle allows for preferred distribution of generated steam to an object to be cleaned. The nozzles may be disconnectable from the steam generator to allow different nozzles to be utilized, based on the object to be steamed. The nozzle may be either closely coupled to the steam generator, or located at a distance from the steam generator, requiring tubing or other steam transfer structures to be interconnected between the steam generator and the discharge nozzle. Typically, it is beneficial to provide suitable connectors between the steam generator and the nozzle to allow either the nozzle to be connected to the steam generator, or to allow the interpositioning of transfer tubes or hoses between the steam generator and the nozzle.
[0005] In general, the nozzles used with the steam cleaners do not have large surface areas and a cloth to absorb the liquid condensate of the steam. In order to increase the cleaning surface area, a flat fabric piece is folded around a flat brush or nozzle. The folded fabric on top of the brush or nozzle is secured by a clip on top of the piece. Often steam injected behind the cloth passes through the cloth at the points the bristles contact on the cloth. This tends to wet the cloth and reduce the cleaning effectiveness of the steam. In addition, the cloth covers must be carefully attached not to cover the front or back of the brush attachment.
[0006] Notwithstanding the wide variety of steam generating appliances available, there exists the need to provide an easy to use steam mop. That will effectively improve the effective steaming surface area of the steam cleaners. It is desirable to provide this device with the ability for a user to clean a larger surface area easily without worrying about wiping up the liquid condensate of the steam when cleaning flooring, furniture and other household items.
SUMMARY OF THE INVENTION
[0007] Generally speaking, in accordance with the invention, a steam mop having a water pump for selectively injecting water from a reservoir to a boiler is provided. The mop includes a housing with an electric boiler and a water pump coupled to a water tank with the pump being actuated by the user's movement to pump water to the boiler for distribution to a steam pocket frame attachment. A fabric steam pocket is mounted on the steam pocket frame to provide a improved cleaning surface.
[0008] The steam pocket frame is connected to the boiler by at least one side arm. In one embodiment, water is stored in a water tank formed as part of the handle. Water is pumped to the boiler only when a user pushes on the handle for generating steam to be fed to the steam pocket frame through the side arm.
[0009] The steam pocket frame is substantially rectangular with a plurality of baffles extending substantially perpendicular to the cleaning surface on both upper and lower surfaces thereof. The steam pocket frame includes a central passageway extending perpendicular to the baffles that has openings between the baffles to direct steam into the space between the baffles and up to the surfaces of a fabric steam pocket mounted on the frame.
[0010] In one embodiment, the steam pocket frame is pivotally connected to one side arm for allowing the frame to be flipped over to provide an additional cleaning surface. In another embodiment, there are two side arms also allowing the frame to be flipped over. This allows the mop to be used backward or forwards and is easy to use by right or left handed users.
[0011] The fabric steam pocket is two layers of fabric joined at three edges with fasteners at the open edge for fastening over the frame, or one layer of fabric wrapped around the frame and Velcro strips on the front or back (or left or right) longitudinal side of the frame for easy installation over the frame. The steam pocket frame is operatively connected to the steam cleaner outlet pipe. When steam is injected into the pocket, the entire surface area of the fabric may be used to steam clean a surface.
[0012] Accordingly, it is an object of the invention to provide a steam mop and steam pocket frame attachment to provide increased steam cleaning surface area.
[0013] Another object of the invention is to provide a steam mop with a mechanical pump that is actuated by the user's movement of pushing the mop forward and pulling backward to clean and does not need a high steam pressure system.
[0014] Another object of the invention is to provide a fabric steam pocket that is easily mounted on a steam pocket frame.
[0015] A further object of the invention is to provide a steam pocket frame attachment with a fabric cover that does not allow steam to escape at points of contact with brush bristles.
[0016] Yet another object of the invention is a fabric steam pocket that can be used for dual side cleaning.
[0017] Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
[0018] The invention accordingly comprises a product possessing the features, properties, and the relation of components which will be exemplified in the product hereinafter described, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a fuller understanding of the invention, reference is made to the following description taken in connection with the accompanying drawing(s), in which:
[0020] FIG. 1 is a perspective view of steam mop having one side arm including a steam pocket frame attachment for receiving a fabric steam pocket constructed and arranged in accordance with the invention;
[0021] FIG. 2 is a front plan view of a housing and assembly for use with the steam mop of FIG. 1 ;
[0022] FIG. 3 is a perspective view of a bellows pump suitable for use with the steam mop of FIG. 1 ;
[0023] FIG. 4 is a plan view of a water container suitable for use with the steam mop and handle shown in FIG. 1 ;
[0024] FIG. 5 is a perspective view of a handle suitable for use with the steam mop of FIG. 1 ;
[0025] FIG. 6A is a top plan view of a steam pocket frame for use with the steam mop of FIG. 1 ;
[0026] FIG. 6B is a plan view in cross-section of the steam pocket frame of FIG. 6A ;
[0027] FIG. 7 is a perspective view of a fabric steam pocket suitable for use with the steam pocket frame attachment of FIG. 11 ;
[0028] FIG. 8 is a perspective view of the mop of FIG. 1 with a fabric steam pocket mounted on the attachment frame;
[0029] FIG. 9 exploded perspective view showing how the steam mop of the type shown in FIG. 1 is assembled;
[0030] FIG. 10 is a perspective view of a steam mop including two side arms constructed and arranged in accordance with another embodiment of the invention;
[0031] FIG. 11 is a perspective view showing a fabric steam pocket mounted onto the steam pocket frame of FIG. 10 ;
[0032] FIG. 12 is an exploded perspective view showing how the steam mop of FIG. 10 is assembled; and
[0033] FIG. 13 is a perspective view of a piston pump suitable for use with the steam mop of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 is a perspective view of a steam mop 10 constructed and arranged in accordance with one embodiment of the invention. Mop 10 includes a steam pocket frame 21 mounted to a housing or main body 16 by a side arm 17 . A water container or tank 14 is mounted to the upper part of housing 16 with a handle 11 and in connected to a boiler 46 by a pump 29 having a one-way outlet valve 37 . A water container cover 19 is closed when handle 11 is installed. Water container 14 also has a handle release button 13 for ease of use to easily detach and attach handle 11 . Any type of mechanical pump or some other means of transporting the water to the boiler may be used with steam mop 10 . Preferably, pump 29 is a mechanical pump, such as a bellows pump or a piston pump, that is actuated by movement of mop 10 by a user pushing and pulling handle 11 .
[0035] Steam pocket frame 21 is rectangular in shape and includes a steam inlet coupling 22 at the side end and at the end of side arm 17 . Steam generated in a steam boiler 46 shown in FIG. 2 dispenses steam into arm 17 and into frame 21 . A rectangular fabric steam pocket 24 is mounted over frame 21 and is attached to the steam inlet coupling 22 side thereof by Velcro strips 66 and 67 as shown in FIG. 7 .
[0036] FIG. 2 is a front plan view of housing 16 of steam mop 10 including boiler 46 with a water hose 41 having a water inlet 38 and a water outlet 39 . Water flows through one-way outlet valve 37 (shown in FIG. 3 ) to water inlet 38 and enters boiler 46 via through water hose 41 . A steam hose 44 with a steam inlet 42 and a steam outlet 43 is coupled to boiler 46 . Water inlet 38 and boiler 46 are connected to a power source by a power cord 47 . Steam generated in boiler 46 exits through steam hose 44 with steam inlet 42 and steam outlet 43 . Conveniently, main body 16 also includes an indicator light 49 to indicate when steam temperature is appropriate for use.
[0037] FIG. 3 is a perspective view of an exemplary embodiment of a pump that can be used with steam mop 10 . Here, a mechanical bellows pump 29 is shown in FIG. 3 as suitable for use with steam mop 10 . Bellows pump 29 includes a pump inlet 29 a and a pump outlet 29 b . Bottom portion 14 b of water container 14 is attached to pump inlet 29 a through a conduit 31 . Arrow A shows the direction of water flow. Pump outlet 29 b is connected to a one-way duck bill inlet valve 33 . Pump inlet 29 a and pump outlet 29 b are connected by a cylindrical flexible tubular bladder 33 with a plurality of creases 34 . Water can only flow in one direction through valve 33 . Pump outlet 29 b is connected to a second one-way duck bill valve 37 in the bottom portion of bellows pump 29 .
[0038] Pump 29 operates when conduit 31 is moved up and down by the movement of user so that distance B increases and decreases. When handle 11 is pulled up and distance B decreases, water fills bellows 34 . Bellows 34 is compressed as handle is pushed, distance B increases and water is ejected from bellows 34 through second duck bill valve 37 in bottom portion 29 a of pump 29 and into water conduit 41 and into boiler 46 . Accordingly, a user may selectively deliver water to boiler 46 by the movement of pushing the mop forward and pulling the mop backward to clean. If there is no movement by the user, water is not delivered to boiler and steam is not generated. Only when the user moves the mop forward and backward will steam be generated and released. Steam mop 10 is designed as a non-pressurized system. For floor cleaning there is no need for high pressure steam. Cleaning is performed by steam distribution to a fabric steam pocket 24 mounted on frame 21 .
[0039] Water container 14 suitable for use with the steam mop 10 is shown in FIG. 4 . Water container 14 has a top portion 14 a and a bottom portion 14 b . Here, top portion 14 a has a cone shaped open top 28 that functions as a funnel for the user to easily fill water into water container 14 . Water container cover 19 shown in FIG. 5 covers cone shaped open top 28 of water container 14 when assembled. A user presses handle release button 13 to disassemble handle 11 from water container 14 for ease of filling container 14 .
[0040] FIG. 5 is a perspective view of handle 11 for use with steam mop 10 . Handle 11 has an adjustable height button 12 and includes at the distal end of water container cover 19 , which connects to water container 14 . Preferably, handle 11 is a telescopic handle.
[0041] FIG. 6A is a top perspective view of a rectangular steam pocket frame 21 including a front wall 51 , a rear wall 52 , a right side wall 53 and a left side wall 54 . A plurality of baffles 58 extends from front wall 51 to rear wall 52 within frame 21 . Baffles 58 are planar in shape and extend perpendicular from the front wall to the back wall of frame 21 . Frame 21 has right side wall 53 with steam inlet coupling 22 connected thereto. Right side wall 53 also connects to arm 17 . Frame 21 has a passageway 61 that extends from right side wall 53 to left side wall 54 perpendicular to baffles 58 . Passageway 61 has a plurality of vents or openings 62 for distributing steam into the spaces between baffles 58 and to a steam pocket mounted thereon. An advantage of steam pocket frame 21 is that steam rises out of upper surface of frame 21 to provide a dry surface with the benefits of steam when cleaning.
[0042] FIG. 6B is a plan view in cross-section of steam pocket frame attachment 21 . The plurality of vents 62 are on both sides of passageway 61 and are parallel to baffles 58 . FIG. 7 shows a top cross-sectional view of steam pocket frame attachment 21 .
[0043] In FIG. 7 , steam pocket 24 is configured to slip over frame 21 . In this respect, it is formed of a first layer 24 a and an opposed second layer 24 b (not shown), each having a rectangular shape with two opposed long edges 24 c and 24 d and two opposed short sides 24 e and 24 f . Long edges 24 c and 24 d and one long side 24 f are stitched to form pocket 24 .
[0044] Straps 66 and 67 are fixed to an open side of steam pocket 24 . In the preferred embodiment, fasteners 66 and 67 are Velcro-type fasteners. Alternatively, straps 66 and 67 may include buttons or snaps. In each case, straps 66 and 67 are placed over frame 21 and secured to hold pocket 24 in place when used to clean a floor or other surface.
[0045] In the illustrated embodiment, steam pocket 24 is a cloth or towel. It may be formed of any suitable fabric such as cotton or a synthetic fabric, such as polyester or polyolefin fiber. Preferably, the fabric of pocket 24 is a microfiber. Most preferably, the microfiber is a synthetic polyester microfiber.
[0046] FIG. 8 shows fabric steam pocket 24 mounted onto the steam pocket frame attachment 21 suitable for use with the steam pocket frame attachment of FIG. 1 . This is also shown by the direction of Arrow C. Steam pocket frame attachment 21 may be rotated as shown by Arrow D so user may use both sides of steam pocket fabric 24 without having to reinstall steam pocket 24 . This extends the time steam pocket 24 may be used without having to rinse and reinstall it.
[0047] FIG. 9 is an exploded perspective view showing how the steam floor mop of the type shown in FIG. 1 is assembled, which is indicated by arrows.
[0048] FIG. 10 is a perspective view of steam floor mop 100 including a steam pocket frame 121 for receiving a fabric steam pocket cover constructed and arranged in accordance with an embodiment of the invention. All elements in FIG. 10 are present and identified by the same reference numerals plus 100. Here, a steam pocket frame 121 is mounted on the distal end of two side arms 117 and 118 coupled to a housing 116 . Steam pocket frame 121 is rectangular in shape and includes a steam inlet coupling 122 at side end. A steam outlet 123 dispenses steam into side arm 117 into a steam pocket frame fabric pocket 124 . Frame 121 also has a left side wall that has a connector 130 that connects arm 118 .
[0049] FIG. 11 is a perspective view of a rectangular fabric steam pocket 124 that shows how rectangular steam pocket fabric 124 is installed on steam pocket frame 121 . Fabric steam pocket 124 is wrapped around the front wall 151 and back wall 152 circumference of steam pocket frame 121 . This is also shown by the direction of Arrow B. Both top side and bottom side of rectangular steam pocket fabric 124 is secured by Velcro-type strip 127 to the front wall 151 or back wall 152 of steam pocket frame 121 .
[0050] In the illustrated embodiment, steam pocket 124 is a cloth or towel. It may be formed of any suitable fabric such as cotton or a synthetic fabric, such as polyester or polyolefin fiber. Preferably, the fabric of steam pocket 124 is a microfiber. Most preferably, the microfiber is a synthetic polyester microfiber.
[0051] Steam inlet coupling 122 and connector 130 attached to steam pocket frame 121 and may be rotated as shown by Arrow B so user may use both sides of steam pocket fabric 124 without having to reinstall steam pocket 124 . This extends the time steam pocket 124 may be used without having to rinse and reinstall it.
[0052] FIG. 12 is an exploded perspective view showing how the steam floor mop of the type shown in FIG. 10 is assembled, which is indicated by arrows.
[0053] FIG. 13 is a perspective view of another exemplary embodiment of a pump that can be used with steam mop 10 . Here, a mechanical piston pump 79 is shown in FIG. 13 as suitable for use with steam mop 10 . Piston pump 79 includes a pump inlet 79 a and a pump outlet 79 b . Bottom portion 14 b of water container 14 is attached to pump inlet 79 a through a conduit 31 . Arrow A shows the direction of water flow. Pump outlet 79 b is connected to a one-way duck bill inlet valve 33 . Pump inlet 79 a and pump outlet 79 b are connected by a sealed movable joint 83 that will allow a piston 82 to move freely inside a cylinder 81 without leaking water in between them. Water can only flow in one direction through valve 33 . Pump outlet 79 b is connected to a second one-way duck bill valve 37 in the bottom portion of piston pump 79 .
[0054] Pump 79 operates when conduit 31 is moved up and down by the movement of user so that distance B increases and decreases. When handle 11 is pulled up and distance B decreases, water fills the volume space in a cylinder 81 . The volume space in cylinder 81 is compressed by piston 82 as handle is pushed, distance B increases and water is ejected from cylinder 81 through second duck bill valve 37 in bottom portion 29 a of pump 29 and into water conduit 41 and into boiler 46 . Accordingly, a user may selectively deliver water to boiler 46 by the movement of pushing the mop forward and pulling the mop backward to clean. If there is no movement by the user, water is not delivered to boiler and steam is not generated. Only when the user moves the mop forward and backward will steam be generated and released. Steam mop 10 is designed as a non-pressurized system. For floor cleaning there is no need for high pressure steam. Cleaning is performed by steam distribution to a fabric steam pocket 24 mounted on frame 21 .
[0055] Steam floor mop 10 and 100 provides many advantages for ease of use because it eliminates the need for an electric water pump and an on/off switch to activate the electric water pump. Here, the user has more control over the amount of water needed to be discharged into the boiler and consequently, how much steam is needed by moving the mop forward and backwards. In addition, steam mop is designed as a low pressure or non-pressurized system so it is safer for the user to use. Further, since the amount of water routed to the boiler is controlled, the boiler can create steam in a short amount of time.
[0056] Steam pocket frame 21 and 121 with fabric steam pocket fabric 24 and 124 in accordance with the invention provide vast improvements over placing a towel onto a bristle attachment for a steam cleaner, respectively. The invention avoids puncture of the cloth by the bristles and provides twice the cleaning surface. Moreover, the fabric cover is easily installed and replaced.
[0057] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above product without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0058] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
[0059] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes of the invention. Accordingly, reference should be made to the appended claims, rather than the foregoing specification, as indicating the scope of the invention. A steam pocket frame attachment with a fabric pocket cover in accordance with the invention provides a vast improvement over placing a towel onto a bristle attachment for a steam cleaned. It avoids puncture of the cloth by the bristles and provide twice the cleaning surface. Moreover, the fabric cover is easily installed and replaced. | A steam mop having a main body with a boiler, a water container, a mechanical water pump between the boiler and container and at least one side arm connecting the boiler steam outlet to a fabric steam pocket frame. The water pump is actuated by movement of the mop when cleaning to send water to the boiler. The steam pocket frame is substantially rectangular with a plurality of baffles to distribute steam disposed substantially perpendicular to a steam channel having openings to distribute steam between the baffles. A replaceable fabric pocket fits snugly over the frame to distribute cleaning steam to the surface to be cleaned. | 5 |
[0001] This is a Continuation-in-Part patent application claiming the benefit of its pending parent with application Ser. No. 10/128,529, filed Apr. 24, 2002.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a friction modifier additive for use in fuels, particularly in gasolines for internal combustion engines. The present invention further relates to new methods for controlling, i.e., reducing or eliminating, combustion chamber deposits in engines while imparting enhanced fuel economy performance.
[0003] Over the years considerable work has been devoted to additives for controlling (preventing or reducing) deposit formation in the fuel induction systems of spark-ignition internal combustion engines. In particular, additives that can effectively control fuel injector deposits, intake valve deposits and combustion chamber deposits represent the focal point of considerable research activities in the field and despite these efforts, further improvements are desired.
[0004] The major fuel-related deposit problem areas for PFI and DIG engines are injectors, intake valves, and the combustion chamber. Additionally, engine friction between piston and cylinder, the valve train, and the fuel pump result in increasing fuel consumption. In DIG engine technology in particular there is a friction related durability issue with the high-pressure pump (up to 1500 psi pumping capacity), which break down due to the inherently low lubricity of gasolines. There is, therefore, a desire in the petroleum industry to produce a fuel suitable for use in both PFI and DIG engines, that can address the engine deposit and frictional requirements outlined above.
[0005] As discussed at some length in U.S. Pat. No. 6,277,158 to McLean, the performance of gasolines and other fuels can be improved through the use of additive technology. For instance, detergents have been used to inhibit the formation of intake system deposits, and thereby improve engine cleanliness and performance. Regulatory mandates have required the introduction of low sulfur fuels, which are known to be less lubricating and raise concerns regarding the durability of fuel pumps and injectors. Sulfur itself is not directly known to be a lubricity modifying agent. However, removal of sulfur by deep hydrotreating is known to also inadvertently remove natural lubricity components of the fuel, such as certain aromatics, carboxylic acids, and esters. Unfortunately, commercial gasoline detergents and dispersants generally show very little friction reducing characteristics until very high concentrations of them are added to the fuel. These high detergent concentrations often reach levels where no-harm effects such as CCD become unacceptable.
[0006] It has been suggested that separate friction modifiers can be added to gasoline to increase fuel economy by reducing engine friction. Fuel friction modifiers would also serve to protect high-pressure fuel pumps and injectors such as those found in DIG engines from wear caused by fuel. Worldwide regulations calling for a steep reduction in fuel sulfur levels may exacerbate this wear problem even further. In selecting suitable components for a combined detergent/friction modifier additive package it is important to ensure a balance of detergent and friction modification properties, and so forth. Ideally, the friction modifier should not adversely affect the deposit control function of the detergent. In addition the additive package should not adversely effect on engine performance. For example, the additive package should not promote valve sticking or cause other performance-reducing problems. To be suitable for commercial use, the friction modifier additive also must pass all no-harm testing required for gasoline performance additives. This is often the biggest hurdle for commercial acceptance. The no-harm testing involves 1) compatibility with gasoline and other additives likely to be in gasoline at a range of temperatures, 2) no increase in IVD and CCD, 3) no valve stick at low temperatures, and 4) no corrosion in the fuel system, cylinders, and crankcase. Developing an additive meeting all these criteria is challenging.
[0007] Most prior friction modifiers for fuels have been derivatives of natural product (plant and animal derived) fatty acids, with only a few purely synthetic products. For example, WO 01/72930 A2 describes a mechanistic proposal for delivery of a fuel born friction modifier to the upper cylinder wall and into the oil sump resulting in upper cylinder/rings and valves lubrication. The friction modifier is packaged with fuel detergent dispersants such as polyetheramines (PEAs), polyisobutene amines (PIBAs), Mannich bases, and succinimides. Fuel friction modifier prior art identified in the WO '930 reference include U.S. Pat. Nos. 2,252,889, 4,185,594, 4,208,190, 4,204,481, and 4,428,182, which all describe use of fuel modifiers in diesel fuel. Chemistries covered by these patents include fatty acid esters, unsaturated dimerized fatty acids, primary aliphatic amines, fatty acid amides of diethanolamine and long-chain aliphatic monocarboxylic acids. Another specific mentioned patent therein is U.S. Pat. No. 4,427,562, which discloses a lubricant oil and fuel friction modifier made by reacting primary alkoxyalkylamines with carboxylic acids or by aminolysis of the appropriate formate ester, and also U.S. Pat. No. 4,729,769.
[0008] U.S. Pat. No. 4,729,769, describes a gasoline carburetor detergent for gasoline compositions derived from reaction products of a C 6 -C 20 fatty acid ester, such as coconut oil, and a mono- or di-hydroxy hydrocarbyl amine, such as diethanolamine, as carburetor detergents. The additive in the '769 patent is described as being useful in any gasoline including leaded and those containing methylcyclopentadienyl manganese tricarbonyl (MMT). The fuel described in the '769 patent may contain other necessary additives such as anti-icers, and corrosion inhibitors.
[0009] U.S. Pat. No. 5,858,029 describes friction reducing additives for fuels and lubricants involving the reaction products of primary etheramines with hydrocarboxylic acids to give hydroxyamides that exhibit friction reduction in fuels and lubricants. Other prior patents describing friction modifiers include U.S. Pat. Nos. 4,617,026 (monocarboxylic acid of ester of a trihydric alcohol, glycerol monooleate as fuels and lubricant friction modifier); 4,789,493, 4,808,196, and 4,867,752 (use of fatty acid formamides); 4,280,916 (use of fatty acid amides); 4,406,803 (use of alkane 1,2-diols in lubricants to improve fuel economy); and 4,512,903 (use of amides from mono- or polyhydroxy substituted aliphatic monocarboxylic acids and amines). U.S. Pat. No. 6,328,771 discloses fuel compositions containing lubricity enhancing salt compositions made by the reaction of certain carboxylic acids with a component that is comprised of a heterocyclic aromatic amine. EP 0 798 364 discloses diesel fuel additives comprising a salt of a carboxylic acid and an aliphatic amine, or an amide obtained by dehydration-condensation between a carboxylic acid and an aliphatic amine.
[0010] EP 0 869 163 A1 describes a method for reducing engine friction by use of ethoxylated amines. In addition, U.S. Pat. No. 4,086,172 (oil soluble hydroxyamines such as “ETHOMEEN 18-12™” formula C 18 H 37 N—(CH 2 CH 2 OH) 2 as lubricant antioxidant); U.S. Pat. No. 4,129,508 (reaction products of succinic acid or anhydride and a polyalkylene glycol or monoether, an organic basic metal, and an alkoxylated amine as a demulsifier); U.S. pat. Nos. 4,231,883; 4,409,000; and 4,836,829, all teach various uses of hydroxyamines in fuels and lubricants.
[0011] U.S. Pat. No. 6,277,158 describes the current practice in the supply of gasoline as generally being to pre-mix the fuel additives into a concentrate in a hydrocarbon solvent base, and then to inject the concentrate into gasoline pipelines used to fill tankers prior to delivery to the customer. To facilitate injection of the concentrate into the gasoline, it is important that the concentrate is in the form of a low viscosity, homogeneous liquid.
[0012] A friction modifier may be added to the gasoline as the lone additive or in combination with a detergent dispersant package that is fully formulated for fuel compatibility at conditions likely to be experienced by the engine. In addition, a need may exist for a detergent/friction modifier additive concentrate for gasoline that provides all of fuel economy enhancement, combustion chamber deposit control and friction reduction. In addition it should be stable over the temperature range at which the concentrate may feasibly be stored, and which does not adversely affect the performance and properties of the finished gasoline or engine in which the gasoline is used, and in particular, does not lead to increased IVD or CCD problems.
SUMMARY OF THE INVENTION
[0013] The present invention provides a method for reducing the formation of CCD in an engine. The method employs the use in the engine of a friction modifier prepared by combining a saturated branched or linear carboxylic acid and an amine, such as ammonia or an alkylated or alkoxylated amine.
[0014] As used herein, the term “alkylated” is generic in that it can mean monoalkylated, or polyalkylated (such as “dialkylated”). The term “amine,” as used in connection with the friction modifier is generic in that it can mean ammonia, monoamine, or polyamine (such as “diamine”).
[0015] In one preferred aspect, the friction modifier comprises branched saturated carboxylic acid salt of a mono- or di-alkylated amine. In another preferred aspect, the friction modifier comprises an alkylamine isostearate. It also will be appreciated that the friction modifier and any detergent package are not necessarily identical materials.
[0016] As used herein, the term “alkoxylated” or “alkoxy” is generic in that it can mean monoalkoxylated, or polyalkoxylated (such as “dialkoxylated”). The term “amine,” as used in connection with the friction modifier, is generic in that it can mean monoamine, or polyamine (such as “diamine”). In one preferred aspect, the friction modifier comprises branched saturated carboxylic acid salt of a mono- or di-alkoxylated amine. In another preferred aspect, the friction modifier comprises an alkoxyamine isostearate or etheramine isostearate.
[0017] As used herein, the terms “alkoxylated amine” and “etheramine” can mean a primary, secondary or tertiary amine that has at least (a) one —OR alkoxy group, where R is an aliphatic hydrocarbon of C 1 -C 28 , or (b) one R—O—R′ ether group where R and R′ are independently aliphatic hydrocarbons of C 1 -C 28 .
[0018] When incorporated into an engine fuel, the friction modifier of the present invention is included in an amount effective such that the engine running on the fuel has significantly reduced formation of combustion chamber deposits.
[0019] In one particular aspect, the present invention utilizes an additive concentrate for use in combustion engine fuels comprising, by weight based on the total weight of the concentrate:
[0020] (a) 0.2 to 50% friction modifier comprising of a branched or linear saturated carboxylic acid salt of ammonia or a mono- or di-alkylated amine or mono- or dialkoxylated amine, which preferably is a liquid or can be solubilized at room temperature and pressure;
[0021] (b) 40 to 99.8% detergent package mainly comprised of a detergent and carrier mix; and
[0022] (c) 0 to 80% solvent.
[0023] In one example of the invention, the friction modifier is n-butylamine isostearate or a branched saturated isomer thereof, or mixtures thereof. In another example, the friction modifier is the salt formed by combining isodecyloxypropylamine with isostearic acid. Also, the friction modifier can be ashless or ash-producing, and in a preferred embodiment is ashless.
[0024] In one aspect, the particular selection of a branched or linear saturated carboxylic acid salt of ammonia or an alkylated or alkoxylated amine, in combination with a detergent package, enables a stable additive concentrate to be formulated having a friction modifier effective to achieve a significant benefit in friction loss, and hence an improvement in fuel economy, yet without leading to an increase in CCD. In one aspect, the CCD is significantly reduced by the present invention.
[0025] It is surprising and unexpected herein that CCD can be reduced without harmful impact in IVD and/or fuel economy.
[0026] In one preferred embodiment, the friction modifier as defined herein comprises a mixture of different monoamine salts having different respective fatty acid moieties with different length backbones and variable degrees of branching. Such mixtures of friction modifier species can further lower the melting point of that additive ingredient, providing a friction modifying component more prone to be in a liquid. The preferred friction modifier is typically a liquid over at least the temperature range of about −20° C. to about +35° C.
[0027] It has been found that the friction modifier comprising a branched or linear saturated carboxylic acid salt of ammonia or an alkylated or alkoxylated amine provides all the benefits explained above, while comparison compounds such as n-butylamine oleate in particular, when used in combination with a detergent, undesirably lead to increases in the incidence of IVD. While not desiring to be bound to a theory, it nonetheless is postulated that provision of a saturated fatty acid moiety in the friction modifier compound in accordance with the present invention helps in not interfering with the desired CCD control mechanisms sought when using fuels modified with the additive concentrate containing the friction modifier and detergent, while imparting the separately desired friction modification functionality and reduced CCD.
[0028] The provision of structural branching in the polyalkylene backbone of the fatty acid moiety of a branched saturated carboxylic acid salt of an alkylated or alkoxylated amine used as the friction modifier in the practice an embodiment of the present invention has been found important to increase the likelihood that the saturated friction modifier additive compound remains fluid and easily miscible with fuels at normal operating temperatures. However, solubilizing agents, for example hydrocarbon solvents such as alcohols or organic acids, may be included if desired or needed to help solubilize a solid form of a friction modifier, such as a linear saturated carboxylic acid, and therefore are not excluded from the scope of the present invention, although the solubilizing agents are not an essential requirement.
[0029] Further, this invention is also directed to methods of increasing fuel efficiency while controlling CCD and IVD deposits in gasoline engines. In another embodiment, the inventive composition of matter is provided as an aftermarket or “top treat” fuel additive composition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The present invention is directed in an embodiment to the reduction in CCD in an engine by administering to the engine a friction modifier prepared by the reaction, mixing or combination of a saturated linear, or more preferably, branched carboxylic acid and ammonia or an alkylated or alkoxylated amine. In one exemplary aspect, the friction modifier is prepared by the reaction, mixing or combination of (i) a saturated carboxylic acid, and (ii) a monoalkylated monoamine, or a dialkylated monoamine, (iii) a monoalkoxylated monoamine, (iv) a dialkoxylated monoamine, or any diamine or polyamine analogue thereof, or a combination or mixture thereof. In one preferred aspect, the saturated branched fatty acid used in the preparation of the friction modifier is an isostearic acid.
[0031] When this friction modifier is used in combination with a detergent package for fuels combusted in engines having intake valves, a remarkable performance enhancement effect is provided combining fuel economy improvements, and reduced CCD without increasing IVD. For instance, saturated and branched or linear carboxylic acid salts of an alkylated or alkoxylated monoamine are friction modifiers found by the present investigators to show especially excellent gasoline fuel economy enhancing properties through, for example, 1) the lowering of the boundary friction coefficient of the thin lubricating oil film on the upper cylinder walls of the engine, and 2) the lowering of IVD and CCD when used in combination with a detergent or deposit inhibitor to levels lower than those of the deposit inhibitor alone. They also may exhibit superior demulse capabilities.
[0032] Friction Modifier
[0033] The friction modifier used in the present invention, in a preferred embodiment, comprises a saturated branched or linear mono-, di- or polycarboxylic acid salt of ammonia or a monoalkylated, dialkylated, polyalkylated or monoalkoxylated, dialkoxylated or alkoxylated amine. In a more preferred embodiment, branching is included in the backbone of the saturated carboxylic acid to enhance compatibility with fuels at low ambient temperatures.
[0034] More specifically, the carboxylic acids useful herein can include, but are not limited to, isostearic, 2-ethyl hexanoic, lauric, palmitic, stearic, decanoic, dodecanoic, undecanoic, myristic, capric, caproic, caprylic, methylvaleric, dimethylvaleric, and isomers and mixtures thereof. In addition, other carboxylic acids useful herein can be alkyl acids in which the alkyl group is cyclic, referred to herein as cyclic carboxylic acids.
[0035] In addition, the carboxylic acid used in the present invention can be a monocarboxylic acid, a dicarboxylic acid, a poly carboxylic acid, or a mixture thereof.
[0036] A non-limiting structural representation of a suitable branched or linear saturated carboxylic acid salt of an alkylated or alkoxylated amine is the following general structural formula I:
[0037] where R 2 and R 3 each independently represents an alkyl group, preferably a C 1 -C 6 alkyl group, and more preferably methyl; j is 1 to 20, preferably 1 to 5; A represents —CH 2 ) x — where x is 4 to 20; with the provisos that each R 3 is substituted for a hydrogen of a backbone carbon atom in A and no more than two R 3 groups are bonded to any given one backbone carbon atom in A; R 4 , R 5 and R 6 each independently represents a hydrocarbyl group, such as an alkyl or alkoxy group, or a hydrogen atom; and q is 1, 2 or 3, and z and y each independently is 0 or 1, with the proviso that q is 3 where z and y each is 0, q is 2 when one of z or y is 1 and the other is 0, and q is 1 when z and y each is 1. In an embodiment, A or R 2 can independently be a cyclic hydrocarbon group.
[0038] In one further embodiment, R 4 and R 5 in structure I each independently represent an aliphatic C 1 -C 8 alkyl or alkoxy group, which can be straight, cyclic, branched, nonsubstituted, or substituted, and with the proviso that any branching or substitution(s) present does not render it incompatible with the modified fuel composition. In one particular embodiment, R 4 and R 5 each independently represents a nonhydroxylated, aliphatic C 1 -C 8 alkyl or alkoxy group. In a further aspect, R 2 and R 3 in structure I each can independently represent an aliphatic C 1 -C 6 alkyl group, which can be straight, branched, cyclic, nonsubstituted, or substituted, and with the proviso that any branching or substitution(s) present does not render it incompatible with the modified fuel composition. An example of a cyclic amine useful herein is piperidine.
[0039] The branched or linear saturated carboxylic acid salt of ammonia or an alkylated or alkoxylated amine used as friction modifiers in this invention can be made, for example, by mixing (i) a branched or linear saturated carboxylic acid, or mixtures thereof, with (ii) a mono- and/or di-alkylated or alkoxylated monoamine, and/or a mono- and/or di-alkylated or alkoxylated polyamine, at an approximately 1:1 molar ratio, and with stirring at temperatures ranging from 25° C. to 75° C., until there is no further temperature change.
[0040] Mixtures of friction modifiers as defined herein having different back bone lengths and variable degrees of branching can be advantageously used as the friction modifier component. Such mixtures can further lower the melting point of the additive ingredient, providing a friction modifying component more prone to be in a liquid state,
[0041] Also, the alkylated amine moiety of the friction modifier compound of structure I can be, for example, a monoalkyl monoamine moiety such as an n-butyl amine moiety, or, alternatively, a dialkyl monoamine moiety such as a di-n-butyl amine moiety.
[0042] Also, the alkoxylated amine moiety of the friction modifier compound of structure I can be, for example,
[0043] Isohexyloxypropylamine
[0044] 2-ethylhexyloxypropylamine
[0045] Octyl/Decyloxypropylamine
[0046] Isodecyloxypropylamine
[0047] Isododecyloxypropylamine
[0048] Isotridecyloxypropylamine
[0049] C 1 - 15 alkyloxypropylamine
[0050] Isodecyloxypropyl-1,3-diaminopropane
[0051] Isododecyloxypropyl-1,3-diaminopropane
[0052] Isotridecyloxypropyl-1,3-diaminopropane
[0053] Isohexyloxypropylamine
[0054] 2-ethylhexyloxypropylaamine
[0055] Octyl/Decyloxypropylamine
[0056] Isodecyloxypropylamine
[0057] Isopropyloxypropylamine
[0058] Tetradecyloxypropylamine
[0059] Dodecyl/tetradecyloxypropylamine
[0060] Tetradecyl/dodecyloxypropylamine
[0061] Octadecyl/hexadecyloxypropylamine
[0062] As an exemplary friction modifier component (a), there is n-butylamine isostearate, which has the general formula: (CH 3 ) 2 CH(CH 2 ) 14 C(O)O − + NH 3 C 4 H 9 .
[0063] N-butylamine isostearate can be used as the friction modifier as well as saturated branched isomers thereof. An exemplary non-limiting structural representation of n-butylamine isostearate is the following structure II:
[0064] The n-butylamine isostearate, as described above, can be made by mixing n-butylamine and isostearic acid at about a 1:1 molar ratio, and stirring at temperatures ranging from 25° C. to 75° C. until there is no further temperature change.
[0065] Another example is isodecyloxypropylamine isostearate. Yet other examples are ammonium isostearate and ammonium stearate.
[0066] The treat level of the friction modifier in the finished gasoline generally will be an amount providing the improved performance and reduced CCD effects, such an in terms of improving fuel efficiency, and so forth, as described herein. For example, a treat level of at least about 5 PTB (pounds per thousand barrels), and more preferably at least about 50 PTB, of the friction modifier can be used for gasolines.
[0067] The friction modifier component (a) can be used as a relatively pure form of branched saturated carboxylic acid salts of an alkylated alkoxylated amine, or optionally in the co-presence of other branched carboxylic acid salts of alkylated or alkoxylated amines having an iodine number less than 10, as long as the latter do not adversely affect the desired performance characteristics of this additive, as identified herein.
[0068] Gasoline Performance Additive (GPA) Package
[0069] A traditional GPA package is generally comprised of a detergent package that mainly comprises a detergent and a carrier mix whose primary purpose is to keep the components parts of the engine free of deposits. Other components present in the GPA package typically include a corrosion inhibitor, a demulsifying agent, antioxidants and solvents. In some cases a marker is added to the GPA package for identification. Thus, the detergent package typically is introduced to the fuel additive concentrate as part of a GPA package, although this is not required.
[0070] Detergent (Deposit Inhibitor) Package
[0071] The detergent or deposit inhibitor used in the detergent package component of an embodiment of the additive concentrate described herein may include any suitable commercially available detergent or deposit inhibitor available for this function. Deposit inhibitors for gasoline, usually referred to as detergents or dispersants, are well known and a variety of compounds can be used. Examples include Mannich bases, polyalkylene amines, and polyalkylene succinimides where the polyalkylene group typically has a number average molecular weight of from 600 to 2000, preferably from 800 to 1400, and polyether amines. A preferred detergent for the additive concentrate of the present invention is a Mannich base detergent.
[0072] The Mannich base detergents suitable for use in the present invention include the reaction products of a high molecular weight alkyl-substituted hydroxyaromatic compound, aldehydes and amines. The alkyl-substituted hydroxyaromatic compound, aldehydes and amines used in making the Mannich reaction products of the present invention may be any such compounds known and applied in the art.
[0073] Suitable Mannich detergents for use in the present invention include those detergents taught in U.S. Pat. Nos. 4,231,759; 5,514,190; 5,634,951; 5,697,988; 5,725,612; and 5,876,468, the disclosures of which are incorporated herein by reference. Suitable Mannich base detergents also include, for example, HiTEC® 4995 and HiTEC® 6410 Detergents and are available from the Ethyl Corporation, Richmond, Va., U.S.A.
[0074] The fuel composition in the present invention can further comprises a material selected from the group consisting of Mannich detergents, polyetheramine detergents, polyisobutylene detergents, succinimide detergents, and imidazoline detergents.
[0075] Carrier
[0076] In a preferred embodiment, the detergents are preferably used with a carrier or induction aid. This carrier typically will be a carrier fluid. Such carriers can be of various types, such as, for example, liquid poly-α-olefin oligomers, mineral oils, liquid poly(oxyalkylene) compounds, polyalkenes, and similar liquid carriers. Mixtures of two or more such carriers can also be employed.
[0077] Optional Solvent
[0078] Among other things, the kinematic viscosity of the additive concentrate can be adjusted (reduced) by solvent addition, if desired or needed. To achieve this, a solvent can be added to the concentrate, such as an aromatic hydrocarbon solvent or an alcohol. Examples include toluene, xylene, tetrahydrofuran, isopropanol isobutylcarbinol, n-butanol, and petroleum hydrocarbon solvents such as solvent naphtha, and the like.
[0079] Fuel Compositions
[0080] The fuel compositions of the present invention may contain supplemental additives in addition to deposit control additives described above. Said supplemental additives include dispersants/detergents, antioxidants, carrier fluids, metal deactivators, dyes, markers, corrosion inhibitors, biocides, antistatic additives, drag reducing agents, demulsifiers, emulsifiers, dehazers, anti-icing additives, antiknock additives, octane enhancers, anti-valve-seat recession additives, lubricity additives, surfactants and combustion improvers. Particularly preferred supplemental additives include methyl cyclopentadienyl manganese tricarbonyl, known as MMT, and or manganese-containing gasoline additives.
[0081] In another aspect, the present invention provides a fuel composition comprising combustible fuel and from 50 to 2500 ppm by weight of an additive combination comprising components (a), (b), and optionally a solvent (c), as described herein.
[0082] The combustible fuel used in the fuel composition of this invention is generally a petroleum hydrocarbon useful as a fuel, e.g., gasoline, for internal combustion engines. Such fuels typically comprise mixtures of hydrocarbons of various types, including straight and branched chain paraffins, olefins, aromatics and naphthenic hydrocarbons, and other liquid hydrocarbonaceous materials suitable for spark ignition gasoline engines.
[0083] These compositions are provided in a number of grades, such as unleaded and leaded gasoline, and are typically derived from petroleum crude oil by conventional refining and blending processes such as straight run distillation, thermal cracking, hydrocracking, catalytic cracking and various reforming processes. Gasoline may be defined as a mixture of liquid hydrocarbons or hydrocarbon-oxygenates having an initial boiling point in the range of about 20 to 60° C. and a final boiling point in the range of about 150 to 230° C., as determined by the ASTM D86 distillation method. The gasoline may contain other combustibles such as alcohol, for example methanol or ethanol.
[0084] The combustible fuels used in formulating the fuel compositions of the present invention preferably include any combustible fuels suitable for use in the operation of gasoline engines such as leaded or unleaded motor gasolines, and so-called reformulated gasolines which typically contain both hydrocarbons of the gasoline boiling range and fuel-soluble oxygenated blending agents (“oxygenates”), such as alcohols, ethers and other suitable oxygen-containing organic compounds. Preferably, the fuel is a mixture of hydrocarbons boiling in the gasoline boiling range. This fuel may consist of straight chain or branch chain paraffins, cycloparaffins, olefins, aromatic hydrocarbons or any mixture of these. The gasoline can be derived from straight run naptha, polymer gasoline, natural gasoline or from catalytically reformed stocks boiling in the range from about 80° to about 450° F. The octane level of the gasoline is not critical and any conventional gasoline may be employed in the practice of this invention.
[0085] Oxygenates suitable for use in the present invention include methanol, ethanol, isopropanol, t-butanol, mixed C 1 to C 5 alcohols, methyl tertiary butyl ether, tertiary amyl methyl ether, ethyl tertiary butyl ether and mixed ethers. Oxygenates, when used, will normally be present in the base fuel in an amount below about 85% by volume, and preferably in an amount that provides an oxygen content in the overall fuel in the range of about 0.5 to about 5 percent by volume.
[0086] The additives used in formulating the preferred fuels of the present invention can be blended into the base fuel individually or in various sub-combinations.
[0087] The friction modifier additive according to the present invention can be used generally in internal combustion engines that burn liquid fuel, especially spark-ignited gasoline engines that are carbureted, port-fuel injected (PFI), and direct injected gasoline (DIG). A preferred embodiment of the present invention comprises a method for controlling engine deposits. This is achieved by introducing into the engine fuel composition a) a spark-ignition fuel and b) a deposit inhibitor package/friction modifier additive as described herein which has been dispersed therein.
EXAMPLES
[0088] The practice and advantages of this invention are demonstrated by the following examples, which are presented for purposes of illustration and not limitation.
[0089] Test Samples Preparation
[0090] For purposes of the following examples, a number of different friction modifiers were tested either as a 5% solution in a 5W30 GF-3 test oil for boundary friction measurements, or in combination with the detergent HiTEC® 6421 for Sequence VI-B fuel economy engine tests and IVD and CCD measurements. HiTEC® 6421 Gasoline Performance Additive (GPA) is commercially available from Ethyl Corporation, Richmond, Va., U.S.A. For the Sequence VI-B engine fuel economy testing described in the examples below, the friction modifier/GPA combinations were formulated to contain (a) 50 PTB friction modifier, and (b) 80.9 PTB of HiTEC® 6421 GPA as the detergent source.
[0091] An example of a friction modifier (FM) additive representing the present invention is n-butylamine salt of Century 1101 V, which is a mixture of branched saturated fatty acids derived from vegetable oil. This salt is referred to as FM-1. A second example (FM-2) of the inventive salt is the n-butylamine salt of Century 1101P, which is a mixture of branched saturated fatty acids derived from pine oil. A third example of the salt of the present invention is FM-3, the isostearic acid salt of n-butylamine salt. Also useful as acids in the present invention are the materials obtained from the hydrogenation of animal-based sources of fatty acids and/or oligomers. As a comparison, n-butylamine oleate, which is outside the scope of the present invention, instead was used in the same wt % proportion in place of n-butylamine isostearate to demonstrate the CCD control superiority of the invention. The mixture of branched saturated fatty acids was obtained from Arizona Chemical under the generic product name Century 1101.
[0092] Comparative example FM-4 was the ammonium salts of mono-unsaturated oleic acid/iso-linoleic acid mix (37% and 46%, respectively, remainder is stearic acid). This is available as Century® MO-5N from Arizona Chemical.
[0093] CCD measurements were carried out on a Ford 2.3 L engine according to a modified version of the ASTM procedures to compare the FM-1, FM-2 and FM-3 additives. CCD levels from the combustion of fuels containing 80.9 PTB of the Mannich detergent (and carrier fluid) supplied as HiTEC® 6421 GPA, with 50 PTB friction modifier FM-1, and, separately, with 50 PTB FM-2 and FM-3, were measured. The results are summarized in Table 1.
TABLE 1 Combustion Chamber Deposit Additive Formulation (CCD) in mg Mannich Detergent (A) 1613 (A) + FM-1 (invention) 1443 (A) + FM-2 (invention) 1460 (A) + FM-3 (invention) 1416 (A) + FM-4 (comparative) 1721
[0094] The results are also illustrated in Table 1, which shows the significantly better CCD control and deposit reduction achieved with the fuel composition containing the n-butylamine salts of the saturated carboxylic acids (FM-1, FM-2 and FM-3) and detergent combination, as compared to the fuel compositions containing the unsaturated additives (FM-4) combined with the same type of detergent.
[0095] The invention also indicates that both n-butylamine isostearate of the invention and n-butylamine oleate of the prior art function as friction modifiers for gasoline, but that the use of fuel additives containing both a detergent and the n-butylamine isostearate results in decreased occurrence of CCD, while the use of fuel additives containing the detergent in combination with n-butylamine oleate results in an undesirable increase in the occurrence of CCD.
[0096] It is to be understood that the reactants and components referred to by chemical name anywhere in the specification or claims hereof, whether referred to in the singular or plural, are identified as they exist prior to coming into contact with another substance referred to by chemical name or chemical type (e.g., base fuel, solvent, etc.). It matters not what chemical changes, transformations and/or reactions, if any, take place in the resulting mixture or solution or reaction medium as such changes, transformations and/or reactions are the natural result of bringing the specified reactants and/or components together under the conditions called for pursuant to this disclosure. Thus the reactants and components are identified as ingredients to be brought together either in performing a desired chemical reaction (such as a Mannich condensation reaction) or in forming a desired composition (such as an additive concentrate or additized fuel blend). It will also be recognized that the additive components can be added or blended into or with the base fuels individually per se and/or as components used in forming preformed additive combinations and/or sub-combinations. Accordingly, even though the claims hereinafter may refer to substances, components and/or ingredients in the present tense (“comprises”, “is”, etc.), the reference is to the substance, components or ingredient as it existed at the time just before it was first blended or mixed with one or more other substances, components and/or ingredients in accordance with the present disclosure. The fact that the substance, components or ingredient may have lost its original identity through a chemical reaction or transformation during the course of such blending or mixing operations is thus wholly immaterial for an accurate understanding and appreciation of this disclosure and the claims thereof.
[0097] As used herein the term “fuel-soluble” or “gasoline-soluble” means that the substance under discussion should be sufficiently soluble at 20° C. in the base fuel selected for use to reach at least the minimum concentration required to enable the substance to serve its intended function. Preferably, the substance will have a substantially greater solubility in the base fuel than this. However, the substance need not dissolve in the base fuel in all proportions.
[0098] At numerous places throughout this specification, reference has been made to a 20 number of U.S. Patents. All such cited documents are expressly incorporated in full into this disclosure as if fully set forth herein.
[0099] This invention is susceptible to considerable variation in its practice. Therefore the foregoing description is not intended to limit, and should not be construed as limiting, the invention to the particular exemplifications presented hereinabove. Rather, what is intended to be covered is as set forth in the ensuing claims and the equivalents thereof permitted as a matter of law. | A method for reducing the formation of combustion chamber deposits in an engine using a friction modifier for combustible fuels is provided. The friction modifier is prepared by combining a saturated carboxylic acid and an alkylated or alkoxylated amine. The particular selection of friction modifier enables a stable additive concentrate to be formulated providing a significant decrease in CCD without increasing the incidence of IVD deposits in combustion engines running on a fuel modified with the additive concentrate. | 2 |
RELATED APPLICATIONS
[0001] This patent application is a continuation of prior application Ser. No. 09/819,243, filed on Mar. 28, 2001, which claimed the benefit of provisional patent Application No. 60/192,751, filed on Mar. 28, 2000.
BACKGROUND OF THE INVENTION
[0002] The invention relates to draining bodily fluid contained in the liner of a liner-type medical suction apparatus.
[0003] Medical suction systems are used in hospital environments and particularly during various surgical procedures to drain and store bodily fluid from a patient. In general, medical suction systems are used in conjunction with a vacuum source which enables the bodily fluid to be drained from the patient.
[0004] One type of medical suction system used to drain and contain fluid from a patient is an apparatus including a disposable bag-like liner and a cover secured to the liner. Such liners are thin-walled pliable plastic members. The cover typically includes a patient port for receiving the fluid from a patient and a vacuum port for establishing a vacuum within the liner. The vacuum draws fluid from the patient through the patient port for collection in the liner.
[0005] It has become important in environments such as hospitals to eliminate the handling of and thus reduce personnel exposure to bodily fluids. Hospitals typically dispose of the bodily fluid contained in a liner-type medical suction apparatus in various ways. Bodily fluid can be poured from the liner through a port in the cover down the hospital sink and into the sewer system, can be incinerated as a liquid or solid, or can be disposed of at an approved hazardous waste site. Since the liner is in the form of a pliable bag filled with liquid, special disposal handling is required in order to prevent puncturing or bursting due to contact with sharp objects.
SUMMARY OF THE INVENTION
[0006] The invention provides improved methods and apparatus for removing body fluids from a liner-type medical suction apparatus to eliminate the potential for a person handling the apparatus to come into contact with the fluid being drained.
[0007] Specifically, the invention provides for methods of draining bodily fluid from a liner that is drained of potentially hazardous fluid without contact with the fluid. The liner is drained in conjunction with a drainage device. Various types of drainage devices can be employed to drain the liner.
[0008] More particularly, the invention provides a method for draining a liner-type medical suction apparatus, the liner-type medical suction apparatus including a liner, a liner interior filled with fluid, a cover, and a port in the cover. The method includes providing a drainage device, the drainage device including a conduit and a cradle. The method also includes positioning the cover of the liner-type medical suction apparatus within the cradle of the drainage device with the liner-type suction apparatus inverted, causing the conduit to communicate with the liner interior through the port, and draining the fluid from the liner interior through the conduit.
[0009] The invention also provides another method for draining a liner-type medical suction apparatus, the liner-type medical suction apparatus including a liner, a liner interior filled with fluid, a cover, and a port in the cover. The method includes providing a drainage device, the drainage device including a movable support member and a conduit. The method also includes positioning the liner-type medical suction apparatus in a substantially upright position within the support member, attaching the conduit to the port, and moving the support member to cause the liner-type medical suction apparatus to move from the substantially upright position to a position in which the fluid flows out of the liner interior into the conduit.
[0010] The invention also provides a medical apparatus including a liner-type medical suction apparatus. The liner-type medical suction apparatus includes a liner, a liner interior for containing fluid, a cover, a port in the cover, and a pre-attached tube coupled to the port and extending into the liner interior. The medical apparatus includes a drainage device including a housing. The medical apparatus also includes a conduit including a first end coupled to the drainage device housing and a second end coupleable to the port so that fluid in the liner interior can flow through the pre-attached tube and the conduit to the drainage device.
[0011] The invention also provides another device for draining a liner-type medical suction apparatus, the liner-type medical suction apparatus including a liner, a liner interior filled with fluid, a cover, and a port in the cover. The device includes a drainage device housing and a cradle coupled to the drainage device housing, the cradle being adapted to support the cover of the liner-type medical suction apparatus when the liner-type medical suction apparatus is in an inverted position. The device also includes a breakout pipe including a first end coupled to the cradle and a second end for communication with the liner interior. The breakout pipe is movable upwardly between a storage position in which the second end is stored substantially within the cradle and a drainage position in which the second end is in communication with the liner interior through the cover.
[0012] The invention also provides still another device for draining a liner-type medical suction apparatus, the liner-type medical suction apparatus including a liner, a liner interior, a cover, and a port in the cover. The device includes a drainage device housing, a drain coupled to the drainage device housing, and a conduit including a first end coupled to the drain and a second end adapted for attachment to the port. The device also includes a support member coupled to the drainage device housing and adapted to support the liner-type medical suction apparatus. The support member is movable between a loading position in which the liner-type medical suction apparatus is in a substantially upright position and a drainage position in which the liner-type medical suction apparatus is in a position in which the fluid flows through the conduit to the drain.
[0013] Other features and advantages of the invention will become apparent to those of ordinary skill in the art upon review of the following description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a front view of a liner-type medical suction apparatus.
[0015] [0015]FIG. 2 is a sectional view of the apparatus and one method for draining the liner.
[0016] [0016]FIG. 3 is a sectional view of the apparatus and a second method for draining the liner.
[0017] [0017]FIGS. 4 and 5 are sectional views of the apparatus and a third method for draining the liner.
[0018] [0018]FIG. 6 is a sectional view of the apparatus and a fourth method for draining the liner.
[0019] [0019]FIG. 7 is a sectional view of the apparatus and a fifth method for draining the liner.
[0020] [0020]FIG. 8 is a perspective view of a liner and sixth method for draining the liner.
[0021] [0021]FIG. 9 is a front view of a seventh method for draining the liner.
[0022] Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
DETAILED DESCRIPTION OF THE INVENTION
[0023] With reference to FIG. 1, there is shown a liner-type medical suction apparatus 10 . The apparatus 10 includes a cover 12 and a liner 14 suitably attached to the cover 12 . The liner 14 is a thin-walled bag having an interior 16 adapted to hold the fluid drained from a patient. The liner 14 is preferably fabricated from a plastic such as ultra low density polyethylene, however, other materials can be used as desired.
[0024] The cover 12 includes a patient port 18 , a suction port 20 , and other access ports as desired. A patient conduit is connectable to the patient port 18 to enable communication between the patient and the interior 16 of the liner 14 . A suction conduit is connectable to the suction port 20 to enable communication between the interior 16 of the liner 14 and a suction source, such as a hospital suction system.
[0025] To drain fluid from a patient, the patient and suction conduits are respectively secured to the patient and suction ports 18 and 20 . The liner 14 is supported by a stand or by a rigid outer container or canister (not shown), and fluid is drained from a patient as is conventionally known.
[0026] When it is desired to drain the fluid contained in the liner 14 , one of the seven methods described herein can be employed to drain the fluid contents from the interior 16 of the liner 14 while eliminating any contact with the fluid by the person handling the apparatus 10 .
[0027] Turning now to FIG. 2, there is shown the liner-type medical suction apparatus 10 . To drain the fluid contents of the interior 16 of the liner 14 , a conduit 22 is positioned in the interior 16 of the liner 14 , such as through an open port 24 in the cover 12 . One end 26 of the conduit 22 is positioned in the interior 16 of the liner 14 and the other end 28 is in communication with a drainage device 30 which evacuates the fluid from the interior 16 of the liner 14 . To support the apparatus during drainage, the apparatus 10 can be hung from a stand or hung from a bracket secured to a wall.
[0028] With reference to FIG. 3, a second method for draining the apparatus 10 is shown. In this embodiment, a tube 32 is pre-attached to the inside of the cover 12 and hangs down into the interior 16 of the liner 14 . To drain the liner 14 , the end 26 of the conduit 22 is secured to the open port 24 on the cover 12 and the second end 28 is secured to the drainage device 30 , such as was described above.
[0029] Turning now to FIGS. 4 and 5, a third method for draining the liner 14 is shown. With this method, the cover 12 includes a flapper-style valve 34 positioned in a port 36 . To drain the fluid from the liner 14 , the apparatus 10 is inverted with respect to a drainage device 38 and the cover 12 is positioned in a cradle 40 of the drainage device 38 . Preferably, the drainage device 38 creates a negative pressure or suction force within the cradle 40 to hold the apparatus 10 in place. The drainage device 38 includes a breakout pipe 42 that is movable vertically. After the cover 12 has been positioned in the cradle 40 , the pipe 42 is actuated such that it moves upwardly toward the valve 34 . Further upward movement of the pipe 42 pivots the valve 34 to enable fluid to escape the liner 14 through the pipe 42 as is shown by the arrow in FIG. 5. After drainage, the pipe 42 is actuated downwardly, the valve 34 returns to its normally closed position and the apparatus 10 can be removed from the cradle 40 . One suitable construction for the pipe 42 is disclosed in U.S. patent application Ser. No. 09/239,842, titled “Method and Apparatus for Removing and Disposing of Body Fluids,” filed Jan. 29, 1999, the entire contents of which is incorporated herein by reference.
[0030] A fourth method for draining the liner is shown in FIG. 6. In this embodiment, the cover 12 includes a breakaway portion 44 . Preferably, the breakaway portion 44 is a frangible part of the cover 12 . To drain the fluid from the liner 14 , the apparatus 10 is inverted with respect to the drainage device 38 , the cover 12 is positioned in the cradle 40 , and drainage device 38 creates a suction force within the cradle 40 to hold the apparatus 10 in place. After the cover 12 has been positioned in the cradle 40 , the pipe 42 is actuated upwardly toward the portion 44 . Further upward movement of the pipe 42 breaks the breakaway portion 44 allowing fluid to drain from the interior 16 of the liner 14 through the pipe 42 . After drainage, the pipe 42 is actuated downwardly and the apparatus 10 can be removed from the cradle 40 .
[0031] As shown in FIG. 7, a fifth method is depicted for draining the liner 14 . In this method, the cover 12 includes a port 46 that is normally occluded with a plug 48 . To drain the fluid from the liner 14 , the apparatus 10 is inverted with respect to the drainage device 38 , the cover 12 is positioned in the cradle 40 , and the drainage device 38 creates a suction force within the cradle 40 to hold the apparatus 10 in place. After the cover 12 has been positioned in the cradle 40 , the pipe 42 is actuated upwardly toward the plug 48 . Further upward movement of the pipe 42 dislodges the plug 48 from the port 46 allowing fluid to drain from the interior 16 of the liner 14 through the pipe 42 . After drainage, the pipe 42 is actuated downwardly and the apparatus 10 can be removed from the cradle 40 .
[0032] Turning now to FIG. 8, a sixth method is shown for draining the liner 14 . In this embodiment, the liner 14 includes a nipple portion 50 on the bottom of the liner 14 . To drain the contents of the liner 14 , the nipple portion 50 is severed or punctured allowing fluid to drain from the interior 16 of the liner 14 .
[0033] In addition to the cover structures shown in FIGS. 4 - 8 , other cover structures may be employed. While the structures disclosed in U.S. patent application Ser. No. 09/239,842 are generally shown as being incorporated into the bottom of a medical suction apparatus, those structures may also be incorporated into the cover of a liner-type medical suction apparatus.
[0034] With reference to FIG. 9, a seventh method for draining the liner 14 is shown. In this embodiment, a drainage device 52 includes a pivotable swing arm 54 that rotates about a pivot point 56 . To drain the liner 14 , the apparatus 10 is positioned in the swing arm 54 with the swing arm 54 in a first position, shown in phantom in FIG. 9. One end 58 of a conduit 60 is secured to a port on the cover 12 and the second end 62 of the conduit 60 is secured to the drainage device 52 . The swing arm 54 is then pivoted to a second position as shown in solid lines in FIG. 9 and the contents of the liner 14 drained. The second position may be a substantially horizontal position as shown in FIG. 9, or the second position may be any position that allows as much fluid as possible to drain out of the liner 14 . After drainage is completed, the swing arm 54 is returned to its first position and the apparatus 10 can be removed from the swing arm 54 .
[0035] The embodiments of the drainage device shown herein can operate using various methods to drain the liner such as a venturi action, a pumping action, or the like. One example of a drainage device is the Eductor Fluid Management System available from Deknatel or Bemis Manufacturing Company. However, it should be noted that other drainage devices can be utilized and the invention herein is not limited to use of the Eductor Fluid Management System to drain the liner-type medical suction apparatuses shown herein.
[0036] Various features and advantages of the invention are set forth in the following claims. | A method and apparatus for draining a liner-type medical suction apparatus. The method includes the acts of positioning the liner-type medical suction apparatus relative to a drainage device including a conduit, causing the conduit to communicate with the liner interior, and draining the fluid from the liner interior through the conduit. The apparatus includes a support member adapted to support the liner-type medical suction apparatus and a drainage device housing adjacent to the support member. The device also includes a conduit including a first end coupled to the drainage device housing and a second end for communication with the liner interior. | 0 |
FIELD OF THE INVENTION
[0001]
[0002] The present invention provides new compounds of formula I as positive allosteric modulators of metabotropic receptors—subtype 5 (“mGluR5”) which are useful for the treatment or prevention of central nervous system disorders such as for example: cognitive decline, both positive and negative symptoms in schizophrenia as well as other disorders in which the mGluR5 subtype of glutamate metabotropic receptor is involved. The invention is also directed to pharmaceutical compounds and compositions in the prevention or treatment of such diseases in which mGluR5 is involved.
BACKGROUND OF THE INVENTION
[0003] Glutamate, the major amino-acid transmitter in the mammalian central nervous system (CNS), mediates excitatory synaptic neurotransmission through the activation of ionotropic glutamate receptors receptor-channels (iGluRs, namely NMDA, AMPA and kainate) and metabotropic glutamate receptors (mGluRs). iGluRs are responsible for fast excitatory transmission (Nakanishi S et al., (1998) Brain Res. Rev., 26:230-235) while mGluRs have a more modulatory role that contributes to the fine-tuning of synaptic efficacy. Glutamate performs numerous physiological functions such as long-term potentiation (LTP), a process believed to underlie learning and memory but also cardiovascular regulation, sensory perception, and the development of synaptic plasticity. In addition, glutamate plays an important role in the patho-physiology of different neurological and psychiatric diseases, especially when an imbalance in glutamatergic neurotransmission occurs.
[0004] The mGluRs are seven-transmembrane G protein-coupled receptors. The eight members of the family are classified into three groups (Groups I, II & III) according to their sequence homology and pharmacological properties (Schoepp D D et al. (1999) Neuropharmacology, 38:1431-1476). Activation of mGluRs lead to a large variety of intracellular responses and activation of different transductional cascades. Among mGluR members, the mGluR5 subtype is of high interest for counterbalancing the deficit or excesses of neurotransmission in neuropsychatric diseases. mGluR5 belongs to Group I and its activation initiates cellular responses through G-protein mediated mechanisms. mGluR5 is coupled to phospholipase C and stimulates phosphoinositide hydrolysis and intracellular calcium mobilization.
[0005] mGluR5 proteins have been demonstrated to be localized in post-synaptic elements adjacent to the post-synaptic density (Lujan R et al. (1996) Eur. J. Neurosci., 8:1488-500; Lujan R et al. (1997) J. Chem. Neuroanat., 13:219-41) and are rarely detected in the pre-synaptic elements (Romano C et al. (1995) J. Comp. Neurol., 355:455-69). mGluR5 receptors can therefore modify the post-synaptic responses to neurotransmitter or regulate neurotransmitter release.
[0006] In the CNS, mGluR5 receptors are abundant mainly throughout the cortex, hippocampus, caudate-putamen and nucleus accumbens. As these brain areas have been shown to be involved in emotion, motivational processes and in numerous aspects of cognitive function, mGluR5 modulators are predicted to be of therapeutic interest.
[0007] A variety of potential clinical indications have been suggested to be targets for the development of subtype selective mGluR modulators. These include epilepsy, neuropathic and inflammatory pain, numerous psychiatric disorders (eg anxiety, depression, schizophrenia and related psychotic disorders), movement disorders (eg Parkinson disease), neuroprotection (stroke and head injury), migraine and addiction/drug dependency (for reviews, see Bordi F and Ugolini A. (1999) Prog. Neurobiol., 59:55-79; Brauner-Osborne H et al. (2000) J. Med. Chem., 43:2609-45; Spooren W et al. (2003) Behay. Pharmacol., 14:257-77; Marino M J and Conn P J. (2006) Curr. Opin. Pharmacol., 6: 98-102)
[0008] The hypothesis of hypofunction of the glutamatergic system as reflected by NMDA receptor hypofunction as a putative cause of schizophrenia has received increasing support over the past few years (Carlsson A et al. (2001) Annu. Rev. Pharmacol. Toxicol., 41:237-260 for a review; Goff D C and Coyle J T (2001) Am. J. Psychiatry, 158:1367-1377). Evidence implicating dysfunction of glutamatergic neurotransmission is supported by the finding that antagonists of the NMDA subtypes of glutamate receptor can reproduce the full range of symptoms as well as the physiologic manifestation of schizophrenia such as hypofrontality, impaired prepulse inhibition and enhanced subcortical dopamine release. In addition, clinical studies have suggested that mGluR5 allele frequency is associated with schizophrenia among certain cohorts (Devon R S et al. (2001) Mol. Psychiatry., 6:311-4) and that an increase in mGluR5 message has been found in cortical pyramidal cells layers of schizophrenic brain (Ohnuma T et al. (1998) Brain Res. Mol. Brain. Res., 56:207-17).
[0009] The involvement of mGluR5 in neurological and psychiatric disorders is supported by evidence showing that in vivo activation of group I mGluRs induces a potentiation of NMDA receptor function in a variety of brain regions mainly through the activation of mGluR5 receptors (Awad H. et al. (2000) J. Neurosci., 20:7871-7879; Mannaioni G. et al. (2001) Neuroscience., 21:5925-34; Pisani A et al. (2001) Neuroscience, 106:579-87; Benquet P. et al (2002) J. Neurosci., 22:9679-86).
[0010] The role of glutamate in memory processes also has been firmly established during the past decade (Martin S. J. et al. (2000) Annu. Rev. Neurosci., 23:649-711; Baudry M. and Lynch G. (2001) Neurobiol. Learn. Mem., 76:284-297). The use of mGluR5 null mutant mice have strongly supported a role of mGluR5 in learning and memory. These mice show a selective loss in two tasks of spatial learning and memory, and reduced CA1 LTP (Lu et al. (1997) J. Neurosci., 17:5196-5205; Jia Z. et al. (2001) Physiol. Behay., 73:793-802; Schulz B et al. (2001) Neuropharmacology, 41:1-7; Rodrigues et al. (2002) J. Neurosci., 22:5219-5229).
[0011] The finding that mGluR5 is responsible for the potentiation of NMDA receptor mediated currents raises the possibility that agonists of this receptor could be useful as cognitive-enhancing agents, but also as novel antipsychotic agents that act by selectively enhancing NMDA receptor function.
[0012] The activation of NMDARs could potentiate hypofunctional NMDARs in neuronal circuitry relevant to schizophrenia. Recent in vivo data strongly suggest that mGluR5 activation may be a novel and efficacious approach to treat cognitive decline and both positive and negative symptoms in schizophrenia (Kinney G G et al. (2003) J. Pharmacol. Exp. Ther., 306(1):116-123; Lindsley et al. (2006) Curr. Top. Med. Chem. 6:771-785).
[0013] mGluR5 receptor is therefore being considered as a potential drug target for treatment of psychiatric and neurological disorders including treatable diseases in this connection are anxiety disorders, attentional disorders, eating disorders, mood disorders, psychotic disorders, cognitive disorders, personality disorders and substance-related disorders.
[0014] Most of the current modulators of mGluR5 function have been developed as structural analogues of glutamate, quisqualate or phenylglycine (Schoepp D D et al. (1999) Neuropharmacology, 38:1431-1476) and it has been very challenging to develop in vivo active and selective mGluR5 modulators acting at the glutamate binding site. A new avenue for developing selective modulators is to identify molecules that act through allosteric mechanisms, modulating the receptor by binding to site different from the highly conserved orthosteric binding site.
[0015] Positive allosteric modulators of mGluRs have emerged recently as novel pharmacological entities offering this attractive alternative. This type of molecule has been discovered for mGluR1, mGluR2, mGluR4, mGluR5, mGluR7 and mGluR8 (Knoflach F. et al. (2001) Proc. Natl. Acad. Sci. USA., 98:13402-13407; Johnson K et al. (2002) Neuropharmacology, 43:291; O'Brien J. A. et al. (2003) Mol. Pharmacol., 64:731-40; Johnson M. P. et al. (2003) J. Med. Chem., 46:3189-92; Marino M. J. et al. (2003) Proc. Natl. Acad. Sci. USA., 100:13668-73; Mitsukawa K. et al. (2005) Proc Natl Acad Sci USA 102(51):18712-7; Wilson J. et al. (2005) Neuropharmacology 49:278; for a review see Mutel V. (2002) Expert Opin. Ther. Patents, 12:1-8; Kew J. N. (2004) Pharmacol. Ther., 104(3):233-44; Johnson M. P. et al. (2004) Biochem. Soc. Trans., 32:881-7; recently Ritzen A., Mathiesen, J. M., and Thomsen C. (2005) Basic Clin. Pharmacol. Toxicol. 97:202-13). DFB and related molecules were described as in vitro mGluR5 positive allosteric modulators but with low potency (O'Brien J A et al. (2003) Mol. Pharmacol., 64:731-40). Benzamide derivatives have been patented (WO 2004/087048; O'Brien JA (2004) J. Pharmacol. Exp. Ther., 309:568-77) and recently aminopyrazole derivatives have been disclosed as mGluR5 positive allosteric modulators (Lindsley et al. (2004) J. Med. Chem., 47:5825-8; WO 2005/087048). Among aminopyrazole derivatives, CDPPB has shown in vivo activity antipsychotic-like effects in rat behavioral models (Kinney G G et al. (2005) J. Pharmacol. Exp. Ther., 313:199-206). Recently, intracerebroventricular application of DFB has been shown to result in a marked improvement in spatial alternation retention when it was tested 24 h after training, suggesting that the enhancement of intrinsic mGluR5 activity immediately during a critical period for memory consolidation have a positive impact on long-term memory retention in rats (Balschun D., Zuschratter W. and Wetzel W. (2006) Neuroscience 142:691-702). These reports are consistent with the hypothesis that allosteric potentiation of mGluR5 may provide a novel approach for development of antipsychotic or cognitive enhancers agents. Recently two novel series of positive allosteric modulators of mGluR5 receptors have been disclosed (WO05044797A1, WO06048771A1).
[0016] The compounds of the invention demonstrate advantageous properties over compounds of the prior art. Improvements have been observed in one or more of the following characteristics of the compounds of the invention: the potency on the target, the selectivity for the target, the solubility, the bioavailability, the brain penetration, and the activity in behavioural models of psychiatric and neurological disorders.
[0017] The present invention relates to a method of treating or preventing a condition in a mammal, including a human, the treatment or prevention of which is affected or facilitated by the neuromodulatory effect of mGluR5 positive allosteric modulators.
DETAILED DESCRIPTION OF THE INVENTION
[0018] According to the present invention, there are provided new compounds of the general formula I
[0000]
Or pharmaceutically acceptable salts, hydrates or solvates of such compounds
Wherein
[0000]
W represents (C 5 -C 7 )cycloalkyl, (C 3 -C 7 )heterocycloalkyl, (C 3 -C 7 )heterocycloalkyl-(C 1 -C 3 )alkyl or (C 3 -C 7 )heterocycloalkenyl ring;
R 1 and R 2 represent independently hydrogen, —(C 1 -C 6 )alkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, arylalkyl, heteroarylalkyl, hydroxy, amino, aminoalkyl, hydroxyalkyl, —(C 1 -C 6 )alkoxy or R 1 and R 2 together can form a (C 3 -C 7 )cycloalkyl ring, a carbonyl bond C═O or a carbon double bond;
P and Q are each independently selected and denote a cycloalkyl, a heterocycloalkyl, an aryl or heteroaryl group of formula
[0000]
R 3 , R 4 , R 5 , R 6 , and R 7 independently are hydrogen, halogen, —NO 2 , —(C 1 -C 6 )alkyl, —(C 3 -C 6 )cycloalkyl, —(C 3 -C 7 )cycloalkylalkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heteroaryl, heteroarylalkyl, arylalkyl, aryl, —OR 8 , —NR 8 R 9 , —C(═NR 10 )NR 8 R 9 , —NR 8 COR 9 , NR 8 CO 2 R 9 , NR 8 SO 2 R 9 , —NR 10 CONR 8 R 9 , —SR 8 , —S(═O)R 8 , —S(═O) 2 R 8 , —S(═O) 2 NR 8 R 9 , —C(═O)R 8 , —C(═O)—O—R 8 , —C(═O)NR 8 R 9 , —C(═NR 8 )R 9 , or C(═NOR 8 )R 9 substituents; wherein optionally two substituents are combined to the intervening atoms to form a bicyclic heterocycloalkyl, aryl or heteroaryl ring; wherein each ring is optionally further substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —O—(—C 1 -C 3 )alkylaryl, —O—(C 1 -C 3 )alkylheteroaryl, —N((—C 0 -C 6 )alkyl)((C 0 -C 3 )alkylaryl) or —N((C 0 -C 6 )alkyl)((C 0 -C 3 -)alkylheteroaryl) groups;
R 8 , R 9 , R 10 each independently is hydrogen, (C 1 -C 6 )alkyl, (C 3 -C 6 )cycloalkyl, (C 3 -C 7 )cycloalkylalkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heterocycloalkyl, heteroaryl, heteroarylalkyl, arylalkyl or aryl; any of which is optionally substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —N(C 0 -C 6 -alkyl) 2 , —N((C 0 -C 6 )alkyl)((C 3 -C 7 -)cycloalkyl) or —N((C 0 -C 6 )alkyl)(aryl) substituents;
D, E, F, G and H represent independently —C(R 3 )═, —C(R 3 )═C(R 4 )—, —C(═O)—, —C(═S)—, —O—, —N═, —N(R 3 )— or —S—;
A is hydrogen, (C 1 -C 6 )alkyl, (C 3 -C 6 )cycloalkyl, (C 3 -C 7 )cycloalkylalkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heterocycloalkyl, heteroaryl, heteroarylalkyl, arylalkyl or aryl; any of which is optionally substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —N(C 0 -C 6 -alkyl) 2 , —N((C 0 -C 6 )alkyl)((C 3 -C 7 -)cycloalkyl) or —N((C 0 -C 6 )alkyl)(aryl) substituents;
B represents a single bond, —C(═O)—(C 0 -C 2 )alkyl-, —C(═O)—(C 2 -C 6 )alkenyl-, —C(═O)—(C 2 -C 6 )alkynyl-, —C(═O)—O—, —C(═O)NR 8 —(C 0 -C 2 )alkyl-, —C(═NR 8 )NR 9 —S(═O)—(C 0 -C 2 )alkyl-, —S(═O) 2 —(C 0 -C 2 )alkyl-, —S(═O) 2 NR 8 —(C 0 -C 2 )alkyl-, C(═NR 8 )—(C 0 -C 2 )alkyl-, —C(═NOR 8 )—(C 0 -C 2 )alkyl- or —C(═NOR 8 )NR 9 —(C 0 -C 2 )alkyl-;
R 8 and R 9 , independently are as defined above; Any N may be an N-oxide.
[0030] The present invention includes both possible stereoisomers and includes not only racemic compounds but the individual enantiomers as well.
[0031] For the avoidance of doubt it is to be understood that in this specification “(C 1 -C 6 )” means a carbon group having 1, 2, 3, 4, 5 or 6 carbon atoms. “(C 0 -C 6 )” means a carbon group having 0, 1, 2, 3, 4, 5 or 6 carbon atoms.
[0032] In this specification “C” means a carbon atom.
[0033] In the above definition, the term “(C 1 -C 6 )alkyl” includes group such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, pentyl, isopentyl, neopentyl, tert-pentyl, hexyl or the like.
[0034] “(C 2 -C 6 )alkenyl” includes group such as ethenyl, 1-propenyl, allyl, isopropenyl, 1-butenyl, 3-butenyl, 4-pentenyl and the like.
[0035] “(C 2 -C 6 )alkynyl” includes group such as ethynyl, propynyl, butynyl, pentynyl and the like.
[0036] “Halogen” includes atoms such as fluorine, chlorine, bromine and iodine.
[0037] “Cycloalkyl” refers to an optionally substituted carbocycle containing no heteroatoms, includes mono-, bi-, and tricyclic saturated carbocycles, as well as fused ring systems. Such fused ring systems can include on ring that is partially or fully unsaturated such as a benzene ring to form fused ring systems such as benzo fused carbocycles. Cycloalkyl includes such fused ring systems as spirofused ring systems. Examples of cycloalkyl include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, decahydronaphthalene, adamantane, indanyl, fluorenyl, 1,2,3,4-tetrahydronaphthalene and the like.
[0038] “Heterocycloalkyl” refers to an optionally substituted carbocycle containing at least one heteroatom selected independently from O, N, S. It includes mono-, bi-, and tricyclic saturated carbocycles, as well as fused ring systems. Such fused ring systems can include one ring that is partially or fully unsaturated such as a benzene ring to form fused ring systems such as benzo fused carbocycles. Examples of heterocycloalkyl include piperidine, piperazine, morpholine, tetrahydrothiophene, indoline, isoquinoline and the like.
[0039] “Aryl” includes (C 6 -C 10 )aryl group such as phenyl, 1-naphtyl, 2-naphtyl and the like.
[0040] “Arylalkyl” includes (C 6 -C 10 )aryl-(C 1 -C 3 )alkyl group such as benzyl group, 1-phenylethyl group, 2-phenylethyl group, 1-phenylpropyl group, 2-phenylpropyl group, 3-phenylpropyl group, 1-naphtylmethyl group, 2-naphtylmethyl group or the like.
[0041] “Heteroaryl” includes 5-10 membered heterocyclic group containing 1 to 4 heteroatoms selected from oxygen, nitrogen or sulphur to form a ring such as furyl (furan ring), benzofuranyl (benzofuran ring), thienyl (thiophene ring), benzothiophenyl (benzothiophene ring), pyrrolyl (pyrrole ring), imidazolyl (imidazole ring), pyrazolyl (pyrazole ring), thiazolyl (thiazole ring), isothiazolyl (isothiazole ring), triazolyl (triazole ring), tetrazolyl (tetrazole ring), pyridil (pyridine ring), pyrazynyl (pyrazine ring), pyrimidinyl (pyrimidine ring), pyridazinyl (pyridazine ring), indolyl (indole ring), isoindolyl (isoindole ring), benzoimidazolyl (benzimidazole ring), purinyl group (purine ring), quinolyl (quinoline ring), phtalazinyl (phtalazine ring), naphtyridinyl (naphtyridine ring), quinoxalinyl (quinoxaline ring), cinnolyl (cinnoline ring), pteridinyl (pteridine ring), oxazolyl (oxazole ring), isoxazolyl (isoxazole ring), benzoxazolyl (benzoxazole ring), benzothiazolyly (benzothiaziole ring), furazanyl (furazan ring) and the like.
[0042] “Heteroarylalkyl” includes heteroaryl-(C 1 -C 3 -alkyl) group, wherein examples of heteroaryl are the same as those illustrated in the above definition, such as 2-furylmethyl group, 3-furylmethyl group, 2-thienylmethyl group, 3-thienylmethyl group, 1-imidazolylmethyl group, 2-imidazolylmethyl group, 2-thiazolylmethyl group, 2-pyridylmethyl group, 3-pyridylmethyl group, 1-quinolylmethyl group or the like.
[0043] “Solvate” refers to a complex of variable stoechiometry formed by a solute (e.g. a compound of formula I) and a solvent. The solvent is a pharmaceutically acceptable solvent as water preferably; such solvent may not interfere with the biological activity of the solute.
[0044] “Optionally” means that the subsequently described event(s) may or may not occur, and includes both event(s), which occur, and events that do not occur.
[0045] The term “substituted” refers to substitution with the named substituent or substituents, multiple degrees of substitution being allowed unless otherwise stated.
[0046] Preferred compounds of the present invention are compounds of formula I-A depicted below
[0000]
[0000] Or pharmaceutically acceptable salts, hydrates or solvates of such compounds
Wherein
[0000]
R 1 and R 2 represent independently hydrogen, —(C 1 -C 6 )alkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, arylalkyl, heteroarylalkyl, hydroxy, amino, aminoalkyl, hydroxyalkyl, —(C 1 -C 6 )alkoxy or R 1 and R 2 together can form a (C 3 -C 7 )cycloalkyl ring, a carbonyl bond C═O or a carbon double bond;
P and Q are each independently selected and denote a cycloalkyl, a heterocycloalkyl, an aryl or heteroaryl group of formula
[0000]
R 3 , R 4 , R 5 , R 6 , and R 7 independently are hydrogen, halogen, —NO 2 , —(C 1 -C 6 )alkyl, —(C 3 -C 6 )cycloalkyl, —(C 3 -C 7 )cycloalkylalkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heteroaryl, heteroarylalkyl, arylalkyl, aryl, —OR 8 , —NR 8 R 9 , —C(═NR 10 )NR 8 R 9 , —NR 8 COR 9 , NR 8 CO 2 R 9 , NR 8 SO 2 R 9 , —NR 10 CONR 8 R 9 , —SR 8 , —S(═O)R 8 , —S(═O) 2 R 8 , —S(═O) 2 NR 8 R 9 , —C(═O)R 8 , —C(═O)—O—R 8 , —C(═O)NR 8 R 9 , —C(═NR 8 )R 9 , or C(═NOR 8 )R 9 substituents; wherein optionally two substituents are combined to the intervening atoms to form a bicyclic heterocycloalkyl, aryl or heteroaryl ring; wherein each ring is optionally further substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —O—(—C 1 -C 3 )alkylaryl, —O—(C 1 -C 3 )alkylheteroaryl, —N((—C 0 -C 6 )alkyl)((C 0 -C 3 )alkylaryl) or —N((C 0 -C 6 )alkyl)((C 0 -C 3 -)alkylheteroaryl) groups;
R 8 , R 9 , R 10 each independently is hydrogen, (C 1 -C 6 )alkyl, (C 3 -C 6 )cycloalkyl, (C 3 -C 7 )cycloalkylalkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heterocycloalkyl, heteroaryl, heteroarylalkyl, arylalkyl or aryl; any of which is optionally substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —N(C 0 -C 6 -alkyl) 2 , —N((C 0 -C 6 )alkyl)((C 3 -C 7 -)cycloalkyl) or —N((C 0 -C 6 )alkyl)(aryl) substituents;
D, E, F, G and H represent independently —C(R 3 )═, —C(R 3 )═C(R 4 )—, —C(═O)—, —C(═S)—, —O—, —N═, —N(R 3 )— or —S—;
A is hydrogen, (C 1 -C 6 )alkyl, (C 3 -C 6 )cycloalkyl, (C 3 -C 7 )cycloalkylalkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heterocycloalkyl, heteroaryl, heteroarylalkyl, arylalkyl or aryl; any of which is optionally substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —N(C 0 -C 6 -alkyl) 2 , —N((C 0 -C 6 )alkyl)((C 3 -C 7 -)cycloalkyl) or —N((C 0 -C 6 )alkyl)(aryl) substituents;
B represents a single bond, —C(═O)—(C 0 -C 2 )alkyl-, —C(═O)—(C 2 -C 6 )alkenyl-, —C(═O)—(C 2 -C 6 )alkynyl-, —C(═O)—O—, —C(═O)NR 8 —(C 0 -C 2 )alkyl-, —C(═NR 8 )NR 9 —S(═O)—(C 0 -C 2 )alkyl-, —S(═O) 2 —(C 0 -C 2 )alkyl-, —S(═O) 2 NR 8 —(C 0 -C 2 )alkyl-, C(═NR 8 )—(C 0 -C 2 )alkyl-, —C(═NOR 8 )—(C 0 -C 2 )alkyl- or —C(═NOR 8 )NR 9 —(C 0 -C 2 )alkyl-;
R 8 and R 9 , independently are as defined above;
J represents a single bond, C(R i 0(R 12 ), —O—, —N(R 11 )— or —S—;
R 11 , R 12 independently are hydrogen, —(C 1 -C 6 )alkyl, —(C 3 -C 6 )cycloalkyl, —(C 3 -C 7 )cycloalkylalkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, halo(C 1 -C 6 )alkyl, heteroaryl, heteroarylalkyl, arylalkyl or aryl; any of which is optionally substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O(C 0 -C 6 )alkyl, —O(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(hetero aryl), —N((C 0 -C 6 )alkyl)((C 0 -C 6 )alkyl), —N((C 0 -C 6 )alkyl)((C 3 -C 7 )cycloalkyl) or —N((C 0 -C 6 )alkyl)(aryl) substituents; Any N may be an N-oxide.
[0058] The present invention includes both possible stereoisomers and includes not only racemic compounds but the individual enantiomers as well.
[0059] More preferred compounds of the present invention are compounds of formula I-B
[0000]
[0000] Or pharmaceutically acceptable salts, hydrates or solvates of such compounds
Wherein
[0000]
P and Q are each independently selected and denote a cycloalkyl, a heterocycloalkyl, an aryl or heteroaryl group of formula
[0000]
R 3 , R 4 , R 5 , R 6 , and R 7 independently are hydrogen, halogen, —NO 2 , —(C 1 -C 6 )alkyl, —(C 3 -C 6 )cycloalkyl, —(C 3 -C 7 )cycloalkylalkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heteroaryl, heteroarylalkyl, arylalkyl, aryl, —OR 8 , —NR 8 R 9 , —C(═NR 10 )NR 8 R 9 , —NR 8 COR 9 , NR 8 CO 2 R 9 , NR 8 SO 2 R 9 , —NR 10 CONR 8 R 9 , —SR 8 , —S(═O)R 8 , —S(═O) 2 R 8 , —S(═O) 2 NR 8 R 9 , —C(═O)R 8 , —C(═O)—O—R 8 , —C(═O)NR 8 R 9 , —C(═NR 8 )R 9 , or C(═NOR 8 )R 9 substituents; wherein optionally two substituents are combined to the intervening atoms to form a bicyclic heterocycloalkyl, aryl or heteroaryl ring; wherein each ring is optionally further substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —O—(—C 1 -C 3 )alkylaryl, —O—(C 1 -C 3 )alkylheteroaryl, —N((—C 0 -C 6 )alkyl)((C 0 -C 3 )alkylaryl) or —N((C 0 -C 6 )alkyl)((C 0 -C 3 -)alkylheteroaryl) groups;
R 8 , R 9 , R 10 each independently is hydrogen, —(C 1 -C 6 )alkyl, —(C 3 -C 6 )cycloalkyl, —(C 3 -C 7 )cycloalkylalkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, halo-(C 1 -C 6 )alkyl, heterocycloalkyl, heteroaryl, heteroarylalkyl, arylalkyl or aryl; any of which is optionally substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O—(C 0 -C 6 )alkyl, —O—(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —N(C 0 -C 6 -alkyl) 2 , —N((C 0 -C 6 )alkyl)((C 3 -C 7 -)cycloalkyl) or —N((C 0 -C 6 )alkyl)(aryl) substituents;
D, E, F, G and H represent independently —C(R 3 )═, —C(R 3 )═C(R 4 )—, —C(═O)—, —C(═S)—, —O—, —N═, —N(R 3 )— or —S—;
J represents a single bond, —C(R 11 )(R 12 ), —O—, —N(R 11 )— or —S—;
R 11 , R 12 independently are hydrogen, —(C 1 -C 6 )alkyl, —(C 3 -C 6 )cycloalkyl, —(C 3 -C 7 )cycloalkylalkyl, —(C 2 -C 6 )alkenyl, —(C 2 -C 6 )alkynyl, halo (C 1 -C 6 ) alkyl, heteroaryl, heteroarylalkyl, arylalkyl or aryl; any of which is optionally substituted with 1-5 independent halogen, —CN, —(C 1 -C 6 )alkyl, —O(C 0 -C 6 )alkyl, —O(C 3 -C 7 )cycloalkylalkyl, —O(aryl), —O(heteroaryl), —N((C 0 -C 6 )alkyl)((C 0 -C 6 )alkyl), —N((C 0 -C 6 )alkyl)((C 3 -C 7 )cycloalkyl) or —N((C 0 -C 6 )alkyl)(aryl) substituents; Any N may be an N-oxide.
[0067] The present invention includes both possible stereoisomers and includes not only racemic compounds but the individual enantiomers as well.
[0068] Specifically preferred compounds are:
(4-Fluoro-phenyl)-{(S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidin-1-yl}-methanone (6-Fluoro-pyridin-3-yl)-{(S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidin-1-yl}-methanone (4-Fluoro-phenyl)-{(S)-3-[4-(4-fluorophenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone (6-Fluoro-pyridin-3-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone (2-Fluoro-pyridin-4-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone (3-Fluoro-pyridin-4-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone (S)-(3-(4-(4-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(5-methyl-isoxazol-4-yl)-methanone (S)-(4-Fluoro-phenyl)(3-(4-(pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone (S)-(3,4-Difluoro-phenyl)(3-(4-(pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone (S)-(4-Fluoro-phenyl)(3-(4-(5-fluoro-pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone (S)-(4-Fluoro-phenyl)(3-(4-(2-fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)-methanone (S)-(3-(4-(2-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(6-fluoro-pyridin-3-yl)-methanone (S)-(3-(4-(2-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(2-fluoro-pyridin-4-yl)-methanone (S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(4-fluoro-phenyl)-methanone (S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(6-fluoro-pyridin-3-yl)-methanone (S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(2-fluoro-pyridin-4-yl)-methanone.
[0085] The present invention relates to the pharmaceutically acceptable acid addition salts of compounds of the formula I or pharmaceutically acceptable carriers or excipients.
[0086] The present invention relates to a method of treating or preventing a condition in a mammal, including a human, the treatment or prevention of which is affected or facilitated by the neuromodulatory effect of mGluR5 allosteric modulators and particularly positive allosteric modulators.
[0087] The present invention relates to a method useful for treating or preventing peripheral and central nervous system disorders selected from the group consisting of tolerance or dependence, anxiety, depression, psychiatric disease such as psychosis, inflammatory or neuropathic pain, memory impairment, Alzheimer's disease, ischemia, drug abuse and addiction.
[0088] The present invention relates to pharmaceutical compositions which provide from about 0.01 to 1000 mg of the active ingredient per unit dose. The compositions may be administered by any suitable route: for example orally in the form of capsules or tablets, parenterally in the form of solutions for injection, topically in the form of onguents or lotions, ocularly in the form of eye-lotion, rectally in the form of suppositories.
[0089] The pharmaceutical formulations of the invention may be prepared by conventional methods in the art; the nature of the pharmaceutical composition employed will depend on the desired route of administration. The total daily dose usually ranges from about 0.05-2000 mg.
Methods of Synthesis
[0090] Compounds of general formula I may be prepared by methods known in the art of organic synthesis as set forth in part by the following synthesis schemes. In all of the schemes described below, it is well understood that protecting groups for sensitive or reactive groups are employed where necessary in accordance with general principles of chemistry. Protecting groups are manipulated according to standard methods of organic synthesis (Green T. W. and Wuts P. G. M. (1991) Protecting Groups in Organic Synthesis , John Wiley et Sons). These groups are removed at a convenient stage of the compound synthesis using methods that are readily apparent to those skilled in the art. The selection of process as well as the reaction conditions and order of their execution shall be consistent with the preparation of compounds of formula I.
[0091] The compound of formula I may be represented as a mixture of enantiomers, which may be resolved into the individual pure R- or S-enantiomers. If for instance, a particular enantiomer of the compound of formula I is desired, it may be prepared by asymmetric synthesis, or by derivation with a chiral auxiliary, where the resulting diastereomeric mixture is separated and the auxiliary group cleaved to provide the pure desired enantiomers. Alternatively, where the molecule contains a basic functional group such as amino, or an acidic functional group such as carboxyl, this resolution may be conveniently performed by fractional crystallization from various solvents, of the salts of the compounds of formula I with optical active acid or by other methods known in the literature, e.g. chiral column chromatography.
[0092] Resolution of the final product, an intermediate or a starting material may be performed by any suitable method known in the art as described by Eliel E. L., Wilen S. H. and Mander L. N. (1984) Stereochemistry of Organic Compounds , Wiley-Interscience.
[0093] Many of the heterocyclic compounds of formula I can be prepared using synthetic routes well known in the art (Katrizky A. R. and. Rees C. W. (1984) Comprehensive Heterocyclic Chemistry , Pergamon Press).
[0094] The product from the reaction can be isolated and purified employing standard techniques, such as extraction, chromatography, crystallization, distillation, and the like.
[0095] The compounds of formula I-A may be prepared according to the synthetic sequences illustrated in the Schemes 1 and 2.
Wherein
[0000]
P and Q each independently is aryl or heteroaryl as described above
B represents —C(═O)—C 0 -C 2 -alkyl-; —S(═O) 2 —C 0 -C 2 -alkyl-.
J is CH2 and A, R1 and R2 are H,
[0000]
[0099] The precursor N-protected primary amide can be prepared using methods readily apparent to those skilled in the art, starting from N-protected-piperidine-3-carboxylic acid.
[0100] The precursor α-bromo-ketone derivatives described above are prepared according to synthetic routes well known in the art.
[0101] In the Scheme 1, PG is an amino protecting group such as Benzyloxycarbonyl, Ethoxycarbonyl, Benzyl and the like.
[0102] Thus, a primary amide (for example, (S)-3-Carbamoyl-piperidine-1-carboxylic acid benzyl ester) is reacted with an α-bromo-ketone derivative under neutral or basic conditions such as triethylamine, diisopropyl-ethylamine and the like, in a suitable solvent (e.g. N-methylpyrrolidone (NMP), dimethylformamide (DMF), xylene and the like) or without solvent, but simply mixing the primary amide and the α-bromo-ketone. The reaction typically proceeds by allowing the reaction temperature to warm slowly from ambient temperature to a temperature range of 100° C. up to 150° C. inclusive, for a time in the range of about 1 hour up to 48 hours inclusive. The reaction may be conducted under conventional heating (using an oil bath) or under microwaves heating. The reaction may be conducted in an open vessel or in a sealed tube.
[0103] As shown in the Scheme 1, protecting groups PG are removed using standard methods.
[0104] In the Scheme 1, B is as defined above, X is halogen or —OH. For example, in the case where X is halogen, the piperidine derivative is reacted with an aryl or heteroaryl acyl chloride using methods that are readily apparent to those skilled in the art. The reaction may be promoted by a base such as triethylamine, diisopropylamine, pyridine in a suitable solvent (e.g. tetrahydrofuran, dichloromethane). The reaction typically proceeds by allowing the reaction temperature to warm slowly from 0° C. up to ambient temperature for a time in the range of about 4 up to 12 hours. In the case where X is —OH, the coupling reaction may be promoted by coupling agents known in the art of organic synthesis such as EDCI (1-(3-Dimethylaminopropyl)-3-ethylcarbodiimide), DCC (N,N′-Dicyclohexyl-carbodiimide) or by polymer-supported coupling agents such as polymer-supported carbodiimide (PS-DCC, ex Argonaut Technologies), in the presence of a suitable base such as triethylamine, diisopropyl-ethylamine, in a suitable solvent (e.g. tetrahydrofuran, dichloromethane, N,N-dimethylformamide, dioxane). Typically, a co-catalyst such as HOBT (1-Hydroxy-benzotriazole), HOAT (1-Hydroxy-7-azabenzotriazole) and the like may also be present in the reaction mixture. The reaction typically proceeds at ambient temperature for a time in the range of about 2 hours up to 24 hours.
[0000]
[0105] As an alternative synthetic route to obtain these derivatives, the pathway described in the Scheme 2 can be used. Thus, a primary amide like (S)-Piperidine-3-carboxylic acid amide (which can be easily prepared using methods that are readily apparent to those skilled in the art, starting from piperidine-3-carboxylic acid) can be reacted with an aryl or heteroaryl acyl chloride using methods that are readily apparent to those skilled in the art. The reaction may be promoted by a base such as triethylamine, diisopropylamine, pyridine in a suitable solvent (e.g. tetrahydrofuran, dichloromethane). The reaction typically proceeds by allowing the reaction temperature to warm slowly from 0° C. up to ambient temperature for a time in the range of about 4 up to 12 hours. Alternatively, in the case where X is —OH, the coupling reaction may be promoted by coupling agents known in the art of organic synthesis such as EDCI (1-(3-Dimethylaminopropyl)-3-ethylcarbodiimide), DCC(N,N′-Dicyclohexyl-carbodiimide) or by polymer-supported coupling agents such as polymer-supported carbodiimide (PS-DCC, ex Argonaut Technologies), in the presence of a suitable base such as triethylamine, diisopropyl-ethylamine, in a suitable solvent (e.g. tetrahydrofuran, dichloromethane, N,N-dimethylformamide, dioxane). Typically, a co-catalyst such as HOBT (1-Hydroxy-benzotriazole), HOAT (1-Hydroxy-7-azabenzotriazole) and the like may also be present in the reaction mixture. The reaction typically proceeds at ambient temperature for a time in the range of about 2 hours up to 24 hours.
[0106] The cyclization step can be performed then as described above and in Scheme 1.
[0107] The compounds of Formula I which are basic in nature can form a wide variety of different pharmaceutically acceptable salts with various inorganic and organic acids. These salts are readily prepared by treating the base compounds with a substantially equivalent amount of the chosen mineral or organic acid in a suitable organic solvent such as methanol, ethanol or isopropanol (see Stahl P. H., Wermuth C. G., Handbook of Pharmaceuticals Salts, Properties, Selection and Use , Wiley, 2002).
[0108] The following non-limiting examples are intended to illustrate the invention. The physical data given for the compounds exemplified is consistent with the assigned structure of those compounds.
EXAMPLES
[0109] Unless otherwise noted, all starting materials were obtained from commercial suppliers and used without further purification.
[0110] Specifically, the following abbreviation may be used in the examples and throughout the specification.
[0000]
g (grams)
rt (room temperature)
mg (milligrams)
MeOH (methanol)
mL (millilitres)
μl (microliters)
Hz (Hertz)
M (molar)
LCMS (Liquid Chromatography
Mass Spectrum)
MHz (megahertz)
HPLC (High Pressure Liquid
Chromatography)
mmol (millimoles)
NMR (Nuclear Magnetic Resonance)
min (minutes)
1H (proton)
AcOEt (ethyl acetate)
Na 2 SO 4 (sodium sulphate)
K 2 CO 3 (potassium carbonate)
MgSO 4 (magnesium sulphate)
CDCl 3 (deuteriated chloroform)
HOBT (1-hydroxybenzotriazole)
EDCI•HCl (1-
RT (Retention Time)
3(Dimethylaminopropyl)-3-
ethylcarbodiimide, hydrochloride)
EtOH (ethyl alcohol)
NaOH (sodium hydroxide)
% (percent)
h (hour)
DCM (dichloromethane)
HCl (hydrochloric acid)
DIEA (diisopropyl ethyl amine)
n-BuLi (n-butyllithium)
Mp (melting point)
THF (tetrahydrofuran)
[0111] All references to brine refer to a saturated aqueous solution of NaCl. Unless otherwise indicated, all temperatures are expressed in ° C. (degrees Centigrade). All reactions are conducted under an inert atmosphere at room temperature unless otherwise noted.
[0112] 1 H NMR spectra were recorded on a Brucker 500 MHz or on a Brucker 300 MHz. Chemical shifts are expressed in parts of million (ppm, 8 units). Coupling constants are in units of hertz (Hz) Splitting patterns describe apparent multiplicities and are designated as s (singlet), d (doublet), t (triplet), q (quadruplet), q (quintuplet), m (multiplet).
[0113] LCMS were recorded under the following conditions:
[0000] Method A) Waters Alliance 2795 HT Micromass ZQ. Column Waters XTerra MS C18 (50×4.6 mm, 2.5 μm). Flow rate 1 ml/min Mobile phase: A phase=water/CH 3 CN 95/5+0.05% TFA, B phase=water/CH 3 CN=5/95+0.05% TFA. 0-1 min (A: 95%, B: 5%), 1-4 min (A: 0%, B: 100%), 4-6 min (A: 0%, B: 100%), 6-6.1 min (A: 95%, B: 5%). T=35° C.; UV detection: Waters Photodiode array 996, 200-400 nm.
Method B) Waters Alliance 2795 HT Micromass ZQ. Column Waters Symmetry C18 (75×4.6 mm, 3.5 μm). Flow rate 1.5 ml/min. Mobile phase: A phase=water/CH 3 CN 95/5+0.05% TFA, B phase=water/CH 3 CN=5/95+0.05% TFA. 0-0.5 min (A: 95%, B: 5%), 0.5-7 min (A: 0%, B: 100%), 7-8 min (A: 0%, B: 100%), 8-8.1 min (A: 95%, B: 5%). T=35° C.; UV detection: Waters Photodiode array 996, 200-400 nm.
Method C) Waters Alliance 2795 HT Micromass ZQ. Column Waters Atlantis C18 (75×4.6 mm, 3.0 μm). Flow rate 1.5 ml/min. Mobile phase: A phase=water/CH 3 CN 95/5+0.05% TFA, B phase=water/CH 3 CN=5/95+0.05% TFA. 0-0.5 min (A: 95%, B: 5%), 5.5 min (A: 0%, B: 100%), 5.5-8 min (A: 0%, B: 100%), 8.1 min (A: 95%, B: 5%). T=35° C.; UV detection: Waters Photodiode array 996, 200-400 nm.
Method D): HPLC system Waters Acquity, Micromass ZQ2000 Single quadrupole (Waters). Column 2.1*50 mm stainless steel packed with 1.7 μm Acquity HPLC-BEH; flow rate 0.50 ml/min; mobile phase: A phase=water/acetonitrile 95/5+0.05% TFA, B phase=water/acetonitrile 5/95+0.05% TFA. 0-0.1 min (A: 95%, B: 5%), 1.6 min (A: 0%, B: 100%), 1.6-1.9 min (A: 0%, B: 100%), 2.4 min (A: 95%, B: 5%); UV detection wavelength 254 nm.
Method E): Pump 1525 u (Waters), 2777 Sample Manager, Micromass ZQ2000 Single quadrupole (Waters); PDA detector: 2996 (Waters). Column: Acquity HPLC-BEH C18 50×2.1 mm×1.7 um; flow rate 0.25 ml/min splitting ratio MS:waste/1:4; mobile phase: A phase=water/acetonitrile 95/5+0.1% TFA, B phase=water/acetonitrile 5/95+0.1% TFA. 0-1.0 min (A: 98%, B: 2%), 1.0-5.0 min (A: 0%, B: 100%), 5.0-9.0 min (A: 0%, B: 100%), 9.1-12 min (A: 98%, B: 2%); UV detection wavelength 254 nm; Injection volume: 54
Method F) Waters Alliance 2795 HT Micromass ZQ. Column Waters Symmetry C18 (75×4.6 mm, 3.5 μm). Flow rate 1.5 ml/min. Mobile phase: A phase=water/CH 3 CN 95/5+0.05% TFA, B phase=water/CH 3 CN=5/95+0.05% TFA. 0-0.5 min (A: 95%, B: 5%), 0.5-7 min (A: 0%, B: 100%), 7-8 min (A: 0%, B: 100%), 8-8.1 min (A: 95%, B: 5%). T=35° C.; UV detection: Waters Photodiode array 996, 200-400 nm.
Method G) Waters Alliance 2795 HT Micromass ZQ. Column Waters Symmetry C18 (75×4.6 mm, 3.5 μm). Flow rate 1.5 ml/min. Mobile phase: A phase=water/CH 3 CN 95/5+0.05% TFA, B phase=water/CH 3 CN=5/95+0.05% TFA. 0-0.1 min (A: 95%, B: 5%), 6 min (A: 0%, B: 100%), 6-8 min (A: 0%, B: 100%), 8.1 min (A: 95%, B: 5%). T=35° C.; UV detection: Waters Photodiode array 996, 200-400 nm.
Method H): HPLC system: Waters Acquity, MS detector: Waters ZQ2000. Column: Acquity HPLC-BEH C18 50×2.1 mm×1.7 um; flow rate 0.6 ml/min; mobile phase: A phase=water/acetonitrile 95/5+0.1% TFA, B phase=water/acetonitrile 5/95+0.1% TFA. 0-0.25 min (A: 98%, B: 2%), 3.30 min (A: 0%, B: 100%), 3.3-4.0 min (A: 0%, B: 100%), 4.1 min (A: 98%, B: 2%); UV detection wavelength 254 nm; Injection volume: 14
Method I): HPLC system: Waters Acquity, MS detector: Waters ZQ2000. Column: Acquity HPLC-BEH C18 50×2.1 mm×1.7 um; flow rate 0.4 ml/min; mobile phase: A phase=water/acetonitrile 95/5+0.1% formic acid, B phase=water/acetonitrile 5/95+0.1% formic acid. 0-0.5 min (A: 98%, B: 2%), 1.5 min (A: 90%, B: 10%), 5.0 min (A: 70%, B: 30%), 7.0 min (A: 0%, B: 100%), 7.0-8.0 min (A: 0%, B: 100%), 8.1 min (A: 98%, B: 2%), 9.5 min (A: 98%, B: 2%); UV detection wavelength 254 nm; Injection volume: 14
[0114] All mass spectra were taken under electrospray ionisation (ESI) methods.
[0115] Most of the reactions were monitored by thin-layer chromatography on 0.25 mm Macherey-Nagel silica gel plates (60E-2254), visualized with UV light. Flash column chromatography was performed on silica gel (220-440 mesh, Fluka).
[0116] Melting point determination was performed on a Buchi B-540 apparatus.
Example 1
(4-Fluoro-phenyl)-{(S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0117]
1 (A) (S)-3-Carbamoyl-piperidine-1-carboxylic acid tert-butyl ester
[0118] A solution of carbonyl-diimidazole (2.97 g, 18.3 mmol) in 50 mL of acetonitrile was added dropwise to a solution of (S)—N-Boc-nipecotic acid (4 g, 17.4 mmol) in acetonitrile (70 mL). After stirring at room temperature for 10 min, conc. NH 4 OH (aq.) (100 mL) was added and stiffing was maintained for 1 h. The solvent was removed, the crude residue was dissolved in ethyl acetate and washed subsequently with citric acid (aq.), with water and then with brine. The organic layer was dried over sodium sulphate and evaporated under reduced pressure to afford (S)-3-Carbamoyl-piperidine-1-carboxylic acid tert-butyl ester, that was used for the next step without further purification.
[0119] Yield: quantitative; LCMS (RT): 3.31 min (Method F); MS (ES+) gave m/z: 229.0.
1(B) (S)-Piperidine-3-carboxylic acid amide hydrochloride
[0120] To a solution of (S)-3-carbamoyl-piperidine-1-carboxylic acid tert-butyl ester (2 g, 8.77 mmol), in dichloromethane (20 mL), 9 mL of 4N HCl (dioxane solution) were added at 0° C. and the reaction mixture was allowed to warm at room temperature and stirred for 20 h. The solvent was evaporated under reduced pressure to give the title compound as a white solid, which was used for the next step without further purification.
[0121] Yield: quantitative; LCMS (RT): 0.76 min (Method C); MS (ES+) gave m/z: 128.9.
1(C) (S)-1-(4-Fluoro-benzoyl)-piperidine-3-carboxylic acid amide
[0122] To a suspension of (S)-piperidine-3-carboxylic acid amide hydrochloride (8.77 mmol) in dry dichloromethane (10 mL), triethylamine (1.5 mL, 20 mmol) and 4-fluorobenzoyl chloride (1.1 mL, 9 mmol) were added dropwise at 0° C. The reaction mixture was allowed to warm at room temperature and stirred under nitrogen atmosphere for 24 h. The solution was then treated with 0.2N NaOH (10 mL) and the phases were separated. The organic layer was washed with water (5 mL), with 0.2M HCl and with brine (5 mL), then was dried over Na 2 SO 4 and evaporated under reduced pressure. The crude was purified by flash chromatography (silica gel, eluent gradient: from petroleum ether/ethyl acetate 100:0 to petroleum ether/ethyl acetate 0:100) to give 220 mg of the title compound.
[0123] Yield: 10%; LCMS (RT): 2.89 min (Method B); MS (ES+) gave m/z: 251.09.
1(D) 4-Fluoro-1H-pyrrole-2-carboxylic acid methoxy-methyl-amide
[0124] A mixture of 4-fluoro-1H-pyrrole-2-carboxylic acid (500 mg, 3.8 mmol), O,N-Dimethyl-hydroxylamine hydrochloride (451 mg, 4.65 mmol), HOBT (891 mg, 5.812 mmol), EDC (1.110 g, 5.8 mmol) and TEA (2.174 ml, 15.5 mmol) in DCM (30 ml) was stirred at room temperature for 20 h. The solvent was evaporated under vacuum, the residue was partitioned between 5% NaHCO 3 (aq) and ethyl acetate. The organic phase was separated, dried over Na 2 SO 4 and concentrated under vacuum. The crude was purified by flash chromatography (silica gel cartridge, eluent: ethyl acetate/petroleum ether 1:1) to give 555 mg of white solid.
[0125] Yield: 83%, LC-MS (RT): 1.02 min (Method D), MS (ES+) gave m/z: 173.0.
1(E) 4-Fluoro-1-(toluene-4-sulfonyl)-1H-pyrrole-2-carboxylic acid methoxy-methyl-amide
[0126] NaH (60% in mineral oil, 56 mg, 1.40 mmol) was added to a stirred solution of 4-fluoro-1H-pyrrole-2-carboxylic acid methoxy-methyl-amide (201 mg, 1.17 mmol) under nitrogen at room temperature. After 10 min, tosyl chloride (311 mg, 1.64 mmol) was added and the mixture was stirred for 1 h. NH 4 Cl sat (aq) was added and the mixture was extracted with ethyl acetate. The organic phase was washed with brine, dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent: ethyl acetate/petroleum ether 1:3) to give 300 mg of white solid.
[0127] Yield: 79%; LC-MS (RT): 1.43 min (Method D), MS (ES+) gave m/z: 326.9.
1(F) 1-[4-Fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-ethanone
[0128] A solution of methylmagnesiumbromide (3M sol THF, 0.443 ml, 1.33 mmol) was added to a stirred solution of 4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrole-2-carboxylic acid methoxy-methyl-amide (288 mg, 0.88 mmol) in dry THF (2 ml) at ±12° C., under nitrogen. The mixture was stirred for 30 min at room temperature, then another portion of methylmagnesium bromide (3M sol THF, 0.443 ml, 1.33 mmol) was added. After 30 min, 0.5M HCl was added dropwise and the mixture was extracted twice with diethyl ether. The organic phase was dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent: ethyl acetate/petroleum ether 1:5) to give 210 mg of white solid.
[0129] Yield: 85%; %; LC-MS (RT): 1.48 min (Method D), MS (ES+) gave m/z: 282.0.
1(G) 2-Bromo-1-[4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-ethanone
[0130] A mixture of 1-[4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-ethanone (50 mg, 0.178 mmol), pyridinium tribromide (63 mg, 0.196 mmol), HBr (48%, 0.076 ml) and glacial acetic acid (3.5 ml) was stirred at room temperature for 20 h. Volatiles were evaporated and the crude was purified by flash chromatography (silica gel cartridge, eluent: ethyl acetate/petroleum ether 1:9) to give 30 mg of viscous oil.
[0131] Yield: 47%; LCMS (RT): 5.9 min (Method D): MS (ES+) gave m/z: 359.9, 361.9.
1(H) (4-Fluoro-phenyl)-((S)-3-{4-[4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-oxazol-2-yl}-piperidin-1-yl)-methanone
[0132] 2-Bromo-1-[4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-ethanone (120 mg, 0.333 mmol) and (S)-1-(4-fluoro-benzoyl)-piperidine-3-carboxylic acid amide (92 mg, 0.367 mmol), prepared as described in Example 1(C), were dissolved in dichloromethane (2 ml), the solvent was evaporated and the residue was heated at 125° C. for 6 h. After cooling to room temperature, 5 ml of acetonitrile were added and the mixture was treated with 2 eq of triethylamine and 0.5 eq of 4-fluoro-benzoylchloride. After 30 min, the solvent was evaporated and the crude was purified by flash chromatography (silica gel cartridge, eluent:
ethyl acetate/petroleum ether 1:2) to give 43 mg of title compound.
[0134] Yield: 25%, LC-MS (RT): 1.73 min (Method D), MS (ES+) gave m/z: 511.8.
1(I) (4-Fluoro-phenyl)-{(S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0135] A solution of TBAF (1M THF, 0.276 ml, 0.276 mmol) was added to a stirred solution of (4-fluoro-phenyl)-((S)-3-{4-[4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-oxazol-2-yl}-piperidin-1-yl)-methanone (47 mg, 0.092 mmol) in THF (4 ml).
[0136] The mixture was heated at reflux for 5 min, the solvent was evaporated and the residue was partitioned between diethyl ether and water. The organic phase was separated and washed with 1N HCl and brine, dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent: ethyl acetate/petroleum ether 1:1) to give 21 mg of title compound.
[0137] Yield: 64%; mp=136° C.; LCMS (RT): 2.22 min (Method E); MS (ES+) gave m/z: 358.1 (MH+).
[0138] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 10.68 (s br, 1H); 8.04 (s, 1H); 7.46 (dd, 2H); 7.24 (dd, 2H); 6.62 (m, 1H); 6.17 (m, 1H); 4.21 (m, 1H); 3.80 (m, 1H); 3.36 (dd, 1H); 3.21 (ddd, 1H); 3.11 (ddd, 1H); 2.19 (m, 1H); 1.96-1.76 (m, 2H); 1.61 (m, 1H).
Example 2
(6-Fluoro-pyridin-3-yl)-{(S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0139]
2(A) (S)-3-Carbamoyl-piperidine-1-carboxylic acid benzyl ester
[0140] Benzyl chloroformate (0.210 ml, 1.498 mmol) was added dropwise to a stirred solution of (S)-piperidine-3-carboxylic acid amide hydrochloride (234 mg, 1.427 mmol), prepared as described in Example 1(B), and triethylamine (0.5 ml, 3.567 mmol) in a mixture of dioxane (5 ml) and water (1 ml) at room temperature. After 30 min, the solvent was evaporated and the residue was dissolved in dichloromethane and washed with 1M K 2 CO 3 (aq). The organic phase was dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent: dichloromethane/methanol 20:1.5) to give 330 mg of white solid.
[0141] Yield: 88%; LCMS (RT): 3.4 min (Method A): MS (ES+) gave m/z: 263.1.
2(B) (S)-3-{4-[4-Fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-oxazol-2-yl}-piperidine-1-carboxylic acid benzyl ester
[0142] 2-Bromo-1-[4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-ethanone (409 mg, 1.136 mmol), prepared as described in Example 1(G), and (S)-3-carbamoyl-piperidine-1-carboxylic acid benzyl ester (330 mg, 1.259 mmol), prepared as described in Example 2(A), were dissolved in dichloromethane (10 ml); the solvent was evaporated and the residue was heated at 125° C. for 6 h. The mixture was cooled to room temperature and dissolved in acetonitrile, then 0.244 ml of triethylamine and 0.073 ml of benzyl chloroformate were added. After stiffing for 15 min, the solvent was evaporated, the residue was partitioned between dichloromethane and 1M K 2 CO 3 (aq). The organic phase was separated, dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent: ethyl acetate/petroleum ether 1:3) to give 230 mg of title compound.
[0143] Yield: 39%; LCMS (RT): 4.9 min (Method A): MS (ES+) gave m/z: 524.0.
2(C) (S)-3-[4-(4-Fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidine-1-carboxylic acid benzyl ester
[0144] TBAF (1M sol. THF, 1.317 ml, 1.317 mmol) was added to a stirred solution of (S)-3-{4-[4-fluoro-1-(toluene-4-sulfonyl)-1H-pyrrol-2-yl]-oxazol-2-yl}-piperidine-1-carboxylic acid benzyl ester (230 mg, 0.439 mmol) in THF (15 ml). The mixture was heated at reflux for 2 min, the solvent was evaporated and the residue was partitioned between diethyl ether and 1N HCl. The organic phase was separated, washed with brine, dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent:
ethyl acetate/petroleum ether 2:3) to give 136 mg of title compound.
[0146] Yield: 84%; LC-MS (RT): 1.63 min (Method D), MS (ES+) gave m/z: 369.9.
2(D) (S)-3-[4-(4-Fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidine
[0147] Pd/C (10%, 14 mg) was added to a stirred solution of (S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidine-1-carboxylic acid benzyl ester (136 mg, 0.368 mmol) and ammonium formate (114 mg, 1.84 mmol) in MeOH (14 ml). The mixture was heated at reflux for 5 min, cooled to room temperature and the catalyst was filtered off. The solution was concentrated, the residue was dissolved in DCM and washed with a solution of brine/1N K 2 CO 3 1/1. The organic phase was dried over Na 2 SO 4 and concentrated to give 78 mg of beige solid.
[0148] Yield: 90%; LC-MS (RT): 0.91 min (Method D), MS (ES+) gave m/z: 236.0.
2(E) (6-Fluoro-pyridin-3-yl)-{(S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0149] A mixture of 6-fluoro-nicotinic acid (45 mg, 0.323 mmol), EDC (92 mg, 4.484 mmol), HOAT (66 mg, 0.484 mmol) and triethylamine (0.136 ml, 0.968 mmol) in dichloromethane (5 ml) was stirred for 30 min at room temperature; then a solution of (S)-3-[4-(4-fluoro-1H-pyrrol-2-yl)-oxazol-2-yl]-piperidine (76 mg, 0.323 mmol) in dichloromethane (5 ml) was added. After 22 h, the solvent was evaporated, the residue was partitioned between ethyl acetate and 5% NaHCO 3 (aq); the organic phase was separated, washed with brine, dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent: ethyl acetate/petroleum ether 2:1) to give 54 mg of pink solid.
[0150] Yield: 47%; mp=123° C.; [α D ]=+104.0° (MeOH, c=1.000); LCMS (RT): 1.98 min (Method E); MS (ES+) gave m/z: 359.1 (MH+).
[0151] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 10.68 (s br, 1H); 8.30 (m, 1H); 8.04 (s, 1H); 8.01 (ddd, 1H); 7.21 (ddd, 1H); 6.62 (m, 1H); 6.16 (m, 1H); 4.20 (m, 1H); 3.78 (m, 1H); 3.42 (dd, 1H); 3.28 (ddd, 1H); 3.15 (ddd, 1H); 2.19 (m, 1H); 2.00-1.77 (m, 2H); 1.65 (m, 1H).
Example 3
(4-Fluoro-phenyl)-{(S)-3-[4-(4-fluorophenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0152]
[0153] A solution of (S)-1-(4-fluoro-benzoyl)-piperidine-3-carboxylic acid amide (1.8 g, 7.19 mmol), prepared as described in Example 1(C), and 4-fluorophenacyl bromide (625 mg, 2.88 mmol) in dry N-methyl-2-pyrrolidinone (10 mL) was heated at 100° C. for 14 h. The reaction mixture was cooled to room temperature, ethyl acetate was added and the organic layer was washed sequentially with water (twice) and with brine (twice). The organics were dried over sodium sulphate and evaporated under reduced pressure to afford a crude oil that was purified by flash chromatography (silica gel, eluent: petroleum ether/ethyl acetate 7:3). 350 mg of (4-fluoro-phenyl)-{(S)-3-[4-(4-fluorophenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone were obtained as a yellow solid.
[0154] Yield: 33%; [α D ]=+92.64° (c=0.9, CH 3 OH); LCMS (RT): 3.26 min (Method H); MS (ES+) gave m/z: 369.1 (MH+).
[0155] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.34 (s, 1H) 7.74-7.81 (m, 2H) 7.41-7.49 (m, 2H) 7.17-7.26 (m, 4H) 4.19 (dd, 1H) 3.77 (ddd, 1H) 3.45 (dd, 1H) 3.27 (ddd, 1H) 3.08-3.20 (m, 1H) 2.16-2.27 (m, 1H) 1.77-2.01 (m, 2H) 1.54-1.68 (m, 1H).
Example 4
(6-Fluoro-pyridin-3-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0156]
4(A) (S)-3-[4-(4-Fluoro-phenyl)-oxazol-2-yl]-piperidine-1-carboxylic acid benzyl ester
[0157] A solution of 4-fluorophenacyl bromide (217 mg, 1.0 mmol) and (S)-3-carbamoyl-piperidine-1-carboxylic acid benzyl ester (500 mg, 1.9 mmol), prepared as described in Example 2(A), in dry N-methyl-2-pyrrolidinone (5 mL) was heated at 150° C. for 3 h, under nitrogen atmosphere. The reaction mixture was cooled to room temperature, ethyl acetate was added and the organic layer was washed sequentially with water (twice), 0.2M NaOH (aq.), 0.2M HCl (aq.) and with brine (twice). The organics were dried over sodium sulphate and evaporated under reduced pressure to afford a crude oil that was purified by passing it through a silica gel cartridge (eluent gradient: from hexane to hexane/ethyl acetate 8:2). 132 mg of (S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidine-1-carboxylic acid benzyl ester were obtained as a pale yellow oil that solidified on standing.
[0158] Yield: 35%; LCMS (RT): 6.7 min (Method F): MS (ES+) gave m/z: 381.0.
4(B) (S)-3-[4-(4-Fluoro-phenyl)-oxazol-2-yl]-piperidine
[0159] Pd/C (10%, 20 mg) was added to a solution of (S)-3-[4-(4-fluoro-phenyl)-oxazol-2yl]-piperidine-1-carboxylic acid benzyl ester (105 mg, 0.276 mmol) and 1N HCl (276 uL) in EtOH (25 ml). The mixture was hydrogenated at 25 psi at room temperature for 2 h, the catalyst was filtered off and the filtrate was evaporated under reduced pressure. The crude residue was dissolved in MeOH and loaded onto a SCX cartridge. After elution with EtOH and then MeOH, the title compound was recovered pure by eluting with 2% NH 3 in MeOH. (S)-3-[4-(4-Fluoro-phenyl)-oxazol-2-yl]-piperidine (55 mg) was obtained as a pale oil.
[0160] Yield: 81%; LCMS (RT): 2.9 min (Method F): MS (ES+) gave m/z: 247.0.
4(C) (6-Fluoro-pyridin-3-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0161] A mixture of 6-fluoro-nicotinic acid (37 mg, 0.26 mmol), EDC (58 mg, 0.3 mmol), HOAT (41 mg, 0.3 mmol) in dichloromethane (10 ml) was stirred for 10 min at room temperature; then a solution of (S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidine (55 mg, 0.22 mmol) in dichloromethane (5 ml) was added. After stiffing for 2 h at room temperature, the solvent was evaporated, the residue was partitioned between ethyl acetate and 0.2M NaOH (aq); the organic phase was separated, washed with water, dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent gradient: from ethyl acetate/hexane 1:9 to ethyl acetate/hexane 6:4) to give 67 mg of pink solid.
[0162] Yield: 83%; [α D ]=+105° (c=0.5, MeOH); LCMS (RT): 2.91 min (Method H); MS (ES+) gave m/z: 370.1 (MH+).
[0163] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.38 (s, 1H) 8.27-8.31 (m, 1H) 8.01 (td, 1H) 7.74-7.81 (m, 2H) 7.18-7.27 (m, 3H) 4.18 (br. s., 1H) 3.76 (br. s., 1H) 3.49 (dd, 1H) 3.33 (ddd, 1H) 3.14-3.24 (m, 1H) 2.16-2.26 (m, 1H) 1.77-2.02 (m, 2H) 1.57-1.72 (m, 1H).
Example 5
(2-Fluoro-pyridin-4-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0164]
[0165] (2-Fluoro-pyridin-4-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone was prepared following the same procedure described in Example 4(C), starting from (S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidine, prepared as described in Example 4(B), and using 2-fluoro-pyridine-4-carboxylic acid as the acid of choice.
[0166] Yield: 100% (pale gum); LCMS (RT): 2.93 min (Method H); MS (ES+) gave m/z: 370.1 (MH+).
[0167] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.38 (s, 1H) 8.29-8.35 (m, 1H) 7.73-7.84 (m, 2H) 7.32 (ddd, 1H) 7.18-7.28 (m, 2H) 7.12-7.17 (m, 1H) 4.13 (br. s., 1H) 3.69 (br. s., 1H) 3.47 (dd, 1H) 3.26-3.38 (m, 1H) 3.20 (ddd, 1H) 2.14-2.25 (m, 1H) 1.76-2.01 (m, 2H) 1.52-1.73 (m, 1H).
Example 6
(3-Fluoro-pyridin-4-yl)-{(S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidin-1-yl}-methanone
[0168]
[0169] A mixture of 3-fluoro-isonicotinic acid (34 mg, 0.24 mmol), EDC (69 mg, 0.36 mmol), HOBT (37 mg, 0.24 mmol) and triethylamine (84 uL, 0.6 mmol) in dioxane (5 ml) was stirred for 30 min at room temperature; then a solution of (S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidine (68 mg, 0.275 mmol), prepared as described in Example 4(B), in dioxane (5 ml) was added. After stirring for 6 h at room temperature, the solvent was evaporated, the residue was partitioned between ethyl acetate and citric acid (aq.); the organic phase was separated, washed with 1N NaOH, dried over Na 2 SO 4 and concentrated under reduced pressure. The crude was purified by flash chromatography (silica gel, eluent gradient: from ethyl acetate/petroleum ether 3:7 to ethyl acetate/petroleum ether 1:1) to give 58 mg of pale yellow gummy solid.
[0170] Yield: 83%; [α D ]=+93.6° (c=1.05, MeOH); LCMS (RT): 2.73 min (Method H); MS (ES+) gave m/z: 370.2 (MH+).
[0171] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.64 (s, 1H) 8.51 (dd, 1H) 8.38 (br. s., 1H) 7.78 (br. s., 2H) 7.43 (t, 1H) 7.15-7.29 (m, 2H) 4.51 (br. s., 1H) 4.04 (br. s., 1H) 3.30-3.55 (m, 2H) 3.11-3.28 (m, 1H) 2.15-2.28 (m, 1H) 1.78-2.02 (m, 2H) 1.47-1.70 (m, 1H).
Example 7
(S)-(3-(4-(4-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(5-methyl-isoxazol-4-yl)-methanone
[0172]
[0173] A mixture of 5-methylisoxazole-4-carboxylic acid (32 mg, 0.25 mmol), EDC (48 mg, 0.25 mmol), HOAT (34 mg, 0.25 mmol) in dioxane (5 ml) was stirred for 30 min at room temperature; then a solution of (S)-3-[4-(4-fluoro-phenyl)-oxazol-2-yl]-piperidine (41 mg, 0.167 mmol) in dioxane (5 ml) was added. After stiffing overnight at room temperature, the solvent was evaporated, the residue was partitioned between ethyl acetate and 5% citric acid (aq.); the organic phase was separated, dried over Na 2 SO 4 and concentrated. The crude was purified by flash chromatography (silica gel cartridge, eluent gradient: from petroleum ether to ethyl acetate/petroleum ether 1:1) to give 31 mg of gummy white solid.
[0174] Yield: 52%; LCMS (RT): 2.91 min (Method H); MS (ES+) gave m/z: 356.1 (MH+).
[0175] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.57 (s, 1H) 8.38 (s, 1H) 7.73-7.81 (m, 2H) 7.18-7.26 (m, 2H) 4.20 (dd, 1H) 3.78 (dt, 1H) 3.49 (dd, 1H) 3.32 (ddd, 1H) 3.10-3.21 (m, 1H) 2.45 (s, 3H) 2.14-2.28 (m, 1H) 1.90-2.02 (m, 1H) 1.77-1.90 (m, 1H) 1.53-1.72 (m, 1H).
Example 8
(S)-(4-Fluoro-phenyl)(3-(4-(pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone
[0176]
[0177] A solution of (S)-1-(4-fluoro-benzoyl)-piperidine-3-carboxylic acid amide (0.2 g, 0.8 mmol), prepared as described in Example 1(C), and 2-(bromoacetyl)-pyridine hydrobromide (90 mg, 0.32 mmol) in dry N-methyl-2-pyrrolidinone (2.5 mL) was heated at 100° C. for 5 h. The reaction mixture was cooled to room temperature, ethyl acetate was added and the organic layer was washed sequentially with water (twice) and with brine (twice). The organics were dried over sodium sulphate and evaporated under reduced pressure to afford a crude oil that was purified by flash chromatography: after 3 successive column chromatography purifications (silica gel, eluent: DCM/MeOH/NH 4 OH 98:2:0.2), 18 mg of (S)-(4-Fluoro-phenyl)(3-(4-(pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone were obtained as a brown oil.
[0178] Yield: 16%; LCMS (RT): 1.99 min (Method H); MS (ES+) gave m/z: 352.2 (MH+). 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.57 (ddd, 1H) 8.43 (s, 1H) 7.77-7.88 (m, 2H) 7.43-7.50 (m, 2H) 7.28-7.33 (m, 1H) 7.19-7.27 (m, 2H) 4.21 (dd, 1H) 3.78 (dd, 1H) 3.46 (dd, 1H) 3.13-3.35 (m, 2H) 2.15-2.28 (m, 1H) 1.78-2.01 (m, 2H) 1.52-1.70 (m, 1H).
Example 9
(S)-(3,4-Difluoro-phenyl)(3-(4-(pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone
[0179]
9(A) (S)-1-(3,4-Difluoro-benzoyl)-piperidine-3-carboxylic acid amide
[0180] To a suspension of (S)-piperidine-3-carboxylic acid amide hydrochloride (2.3 g, 14 mmol), prepared as described in Example 1(B), in dry dichloromethane (50 mL), triethylamine (4.9 mL, 35 mmol) and 3,4-difluorobenzoyl chloride (1.93 mL, 15.4 mmol) were added dropwise at 0° C. The reaction mixture was allowed to warm at room temperature and stirred under nitrogen atmosphere for 14 h. The solution was washed with 5% citric acid (aq.), with 1N NaOH, then with brine and the organic layer was dried over Na 2 SO 4 and evaporated under reduced pressure. The crude was purified by trituration from DCM/hexane 1:1 to give 2.5 g of (S)-1-(3,4-difluoro-benzoyl)-piperidine-3-carboxylic acid amide.
[0181] Yield: 67%; LCMS (RT): 3.1 min (Method F); MS (ES+) gave m/z: 269.0.
9(B) (S)-(3,4-Difluoro-phenyl)(3-(4-(pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone
[0182] A solution of (S)-1-(3,4-difluoro-benzoyl)-piperidine-3-carboxylic acid amide (0.214 g, 0.8 mmol) and 2-(bromoacetyl)-pyridine hydrobromide (90 mg, 0.32 mmol) in dry N-methyl-2-pyrrolidinone (3 mL) was heated at 110° C. for 7 h. The reaction mixture was cooled to room temperature, ethyl acetate was added and the organic layer was washed sequentially with water (twice) and with brine (twice). The organics were dried over sodium sulphate and evaporated under reduced pressure to afford a crude oil that was purified by flash chromatography (silica gel, eluent gradient: from DCM/MeOH/NH 4 OH 99:1:0.1 to DCM/MeOH/NH 4 OH 98:2:0.2). The solid that was recovered from this purification was purified again by flash chromatography (silica gel, eluent: DCM/MeOH/NH 4 OH 99:1:0.1) to afford 8.5 mg of (S)-(3,4-difluoro-phenyl)(3-(4-(pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone, obtained as a yellow gummy solid.
[0183] Yield: 7%; LCMS (RT): 4.44 min (Method I); MS (ES+) gave m/z: 370.4 (MH+).
[0184] 1 H-NMR (CDCl 3 , 328K), δ (ppm): 8.59 (ddd, 1H) 8.17 (s, 1H) 7.85 (ddd, 1H) 7.73 (ddd, 1H) 7.29-7.34 (m, 1H) 7.16-7.25 (m, 3H) 4.29-4.39 (m, 1H) 3.93-4.03 (m, 1H) 3.53 (dd, 1H) 3.27 (ddd, 1H) 3.07-3.18 (m, 1H) 1.83-2.06 (m, 2H) 1.68 (br. s., 1H).
Example 10
(S)-(4-Fluoro-phenyl)(3-(4-(5-fluoro-pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone
[0185]
10(A) 5-Fluoro-pyridine-2-carbonitrile
[0186] A solution of 2-bromo-5-fluoro-pyridine (5.0 g, 28.4 mmol), CuCN (2.01 g, 22.5 mmol) and NaCN (1.14 g, 23.2 mmol) in dry DMF (50 ml) was refluxed for 9 h. The reaction mixture was allowed to cool down to room temperature and a solution of 2% K 2 CO 3 (aq.) was added. Ethyl acetate was added and the phases were separated. The organic layer was dried over sodium sulphate and evaporated under reduced pressure to give a crude solid that was triturated from hexane.
[0187] Yield: 50%; LCMS (RT): 2.5 min (Method G); MS (ES+) gave m/z: 122.9 (MH+).
10(B) 1-(5-Fluoro-pyridin-2-yl)-ethanone
[0188] To a solution of 5-fluoro-pyridine-2-carbonitrile (2.6 g, 21.31 mmol) in dry THF (50 ml), cooled at ±20° C., under nitrogen atmosphere, methylmagnesium bromide (3M solution in diethyl ether, 7.1 ml, 21.31 mmol) was added dropwise. After stiffing overnight at ±20° C., the reaction mixture was slowly allowed to warm to room temperature, and then a saturated solution of NH 4 Cl (aq.) was added to adjust the pH to 2. Ethyl acetate was added and the phases were separated. Evaporation of the solvent gave a crude solid that was purified through a silica gel cartridge (eluent: DCM/petroleum ether 1:1). The solid that was recovered from this purification was purified again by flash chromatography (silica gel, eluent: diethyl ether/petroleum ether 1:9) to afford 1 g of 1-(5-fluoro-pyridin-2-yl)-ethanone.
[0189] Yield: 34%; LCMS (RT): 3.4 min (Method F); MS (ES+) gave m/z: 140.0 (MH+).
10(C) 2-Bromo-1-(5-fluoro-pyridin-2-yl)-ethanone hydrobromide
[0190] To a solution of 1-(5-fluoro-pyridin-2-yl)-ethanone (200 mg, 1.439 mmol) in 33% HBr in acetic acid (0.7 ml), cooled at 0° C., a suspension of pyridinium tribromide (665 mg, 1.87 mmol) in acetic acid (14 ml) was added. After stiffing at room temperature for 3.5 h, 50 ml of diethyl ether were added and the reaction mixture was kept overnight at ±4° C. in the refrigerator. The pale yellow solid that precipitated out was filtered (218 mg). LC-MS analysis showed that the yellow solid is pure 2-bromo-1-(5-fluoro-pyridin-2-yl)-ethanone hydrobromide. The filtrate was evaporated under reduced pressure and the crude solid was then triturated from petroleum ether to give another 280 mg of pure 2-bromo-1-(5-fluoro-pyridin-2-yl)-ethanone hydrobromide.
[0191] Yield: quantitative; LCMS (RT): 4.6 min (Method F); MS (ES+) gave m/z: 218.0 and 220.0 (MH+).
10(D) (S)-(4-Fluoro-phenyl)(3-(4-(5-fluoro-pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone
[0192] A solution of (S)-1-(4-fluoro-benzoyl)-piperidine-3-carboxylic acid amide (0.35 g, 1.4 mmol), prepared as described in Example 1(C), and 2-bromo-1-(5-fluoro-pyridin-2-yl)-ethanone hydrobromide (218 mg, 1.0 mmol) in dry N-methyl-2-pyrrolidinone (5 mL) was heated at 150° C. for 3 h. The reaction mixture was cooled to room temperature, ethyl acetate was added and the organic layer was washed sequentially with water (twice), with 0.2N NaOH (aq.) and with brine (twice). The organics were dried over sodium sulphate and evaporated under reduced pressure to afford a crude oil that was purified by preparative HPLC. The solid that was recovered from this purification was dissolved in ethyl acetate, treated with 0.5N NaOH, and the phases were separated. The organic layer was dried over sodium sulphate and evaporated under reduced pressure to give 7 mg of (S)-(4-fluoro-phenyl)(3-(4-(5-fluoro-pyridin-2-yl)-oxazol-2-yl)-piperidin-1-yl)-methanone.
[0193] Yield: 2%; LCMS (RT): 2.79 min (Method H); MS (ES+) gave m/z: 370.1 (MH+).
[0194] 1 H-NMR (CDCl 3 ), δ (ppm): 8.44 (d, 1H) 8.06-8.15 (m, 1H) 7.80-7.91 (m, 1H) 7.39-7.49 (m, 4H) 7.05-7.14 (m, 2H) 4.01 (br. s., 1H) 3.44 (br. s., 1H) 3.14-3.25 (m, 1H) 3.11 (br. s., 1H) 2.27-2.35 (m, 1H) 1.83-2.06 (m, 2H) 1.68 (br. s., 1H).
Example 11
(S)-(4-Fluoro-phenyl)(3-(4-(2-fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)-methanone
[0195]
[0196] A solution of (S)-1-(4-fluoro-benzoyl)-piperidine-3-carboxylic acid amide (0.161 g, 0.645 mmol), prepared as described in Example 1(C), and 2-fluorophenacyl bromide (100 mg, 0.461 mmol) in dry N-methyl-2-pyrrolidinone (5 mL) was heated at 150° C. for 6 h. The reaction mixture was cooled to room temperature, ethyl acetate was added and the organic layer was washed sequentially with water (twice) and with brine (twice). The organics were dried over sodium sulphate and evaporated under reduced pressure to afford a crude oil that was purified by flash chromatography (silica gel, eluent: ethyl acetate/petroleum ether 1:2). 25 mg of (S)-(4-fluoro-phenyl)(3-(4-(2-fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)-methanone were obtained as a colourless gummy solid.
[0197] Yield: 15%; LCMS (RT): 3.32 min (Method H); MS (ES+) gave m/z: 369.3 (MH+).
[0198] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.23 (d, 1H) 7.95 (ddd, 1H) 7.19-7.49 (m, 7H) 4.09-4.33 (m, 1H) 3.77 (ddd, 1H) 3.47 (dd, 1H) 3.14-3.32 (m, 2H) 2.17-2.28 (m, 1H) 1.78-2.02 (m, 2H) 1.54-1.71 (m, 1H).
Example 12
(S)-(3-(4-(2-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(6-fluoro-pyridin-3-yl)-methanone
[0199]
12(A) (S)-3-[4-(2-Fluoro-phenyl)-oxazol-2-yl]-piperidine
[0200] The compound was prepared following the procedures described in Examples 4(A) and 4(B), starting from (S)-3-carbamoyl-piperidine-1-carboxylic acid benzyl ester, prepared as described in Example 2(A), and 2-fluorophenacyl bromide.
[0201] Yield: 11%; LCMS (RT): 3.2 min (Method F); MS (ES+) gave m/z: 247.2 (MH+).
12(B) (S)-(3-(4-(2-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(6-fluoro-pyridin-3-yl)-methanone
[0202] The compound was prepared following the same procedure described in Example 6, starting from (S)-344-(2-fluoro-phenyl)-oxazol-2-A-piperidine and using 6-fluoronicotinic acid as the acid of choice. Purification was performed by flash chromatography (silica gel, eluent: ethyl acetate/petroleum ether 1:1).
[0203] Yield: 51%; LCMS (RT): 2.37 min (Method H); MS (ES+) gave m/z: 370.2 (MH+).
[0204] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.30 (ddd, 1H) 8.24 (d, 1H) 8.01 (ddd, 1H) 7.91-7.98 (m, 1H) 7.19-7.42 (m, 4H) 4.10-4.31 (m, 1H) 3.67-3.84 (m, 1H) 3.51 (dd, 1H) 3.18-3.40 (m, 2H) 2.18-2.28 (m, 1H) 1.78-2.03 (m, 2H) 1.58-1.73 (m, 1H).
Example 13
(S)-(3-(4-(2-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(2-fluoro-pyridin-4-yl)-methanone
[0205]
[0206] (S)-(3-(4-(2-Fluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(2-fluoro-pyridin-4-yl)-methanone was prepared following the same procedure described in Example 6, starting from (S)-3-[4-(2-fluoro-phenyl)-oxazol-2-yl]-piperidine, prepared as described in Example 12(A), and using 2-fluoroisonicotinic acid as the acid of choice. Purification was performed by flash chromatography (silica gel, eluent: ethyl acetate/petroleum ether 4:6).
[0207] Yield: 73%; [α D ]=+96.15° (c=0.65, MeOH); LCMS (RT): 3.03 min (Method H); MS (ES+) gave m/z: 370.3 (MH+).
[0208] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.32 (d, 1H), 8.24 (d, 1H), 7.90-7.98 (m, 1H), 7.24-7.42 (m, 4H), 7.12-7.16 (m, 1H), 4.11 (br. s., 1H), 3.70 (br. s., 1H), 3.51 (dd, 1H), 3.19-3.38 (m, 2H), 2.17-2.27 (m, 1H), 1.78-2.03 (m, 2H), 1.58-1.72 (m, 1H).
Example 14
(S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(4-fluoro-phenyl)-methanone
[0209]
[0210] (S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(4-fluoro-phenyl)-methanone was prepared following the same procedure described in Example 11, starting from (S)-1-(4-fluoro-benzoyl)-piperidine-3-carboxylic acid amide, prepared as described in Example 1(C), and 2-bromo-2′,4′-difluoro-acetophenone.
[0211] Purification was performed by flash chromatography (silica gel, eluent: ethyl acetate/petroleum ether 2:8).
[0212] Yield: 24%; [α d ]=+93° (c=0.66, MeOH); LCMS (RT): 3.44 min (Method H); MS (ES+) gave m/z: 387.3 (MH+).
[0213] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.23 (d, 1H), 7.96 (td, 1H), 7.41-7.49 (m, 2H), 7.13-7.30 (m, 4H), 4.20 (d, 1H), 3.77 (d, 1H), 3.46 (dd, 1H), 3.13-3.32 (m, 2H), 2.16-2.27 (m, 1H), 1.77-2.01 (m, 2H), 1.54-1.70 (m, 1H).
Example 15
(S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(6-fluoro-pyridin-3-yl)-methanone
[0214]
15(A) (S)-3-[4-(2,4-Difluoro-phenyl)-oxazol-2-yl]-piperidine
[0215] The compound was prepared following the procedures described in Examples 4(A) and 4(B), starting from (S)-3-carbamoyl-piperidine-1-carboxylic acid benzyl ester, prepared as described in Example 2(A), and 2-bromo-2′,4′-difluoroacetophenone.
[0216] Yield: 7%; LCMS (RT): 3.4 min (Method F); MS (ES+) gave m/z: 265.1 (MH+).
15(B) (S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(6-fluoro-pyridin-3-yl)-methanone
[0217] (S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(6-fluoro-pyridin-3-yl)-methanone was prepared following the same procedure described in Example 6, starting from (S)-3-[4-(2,4-difluoro-phenyl)-oxazol-2-yl]-piperidine and using 6-fluoronicotinic acid as the acid of choice. Purification was performed by flash chromatography (silica gel, eluent: ethyl acetate/petroleum ether 1:1). The solid that was recovered from this purification was purified again by preparative HPLC to give the pure title compound.
[0218] Yield: 48%; LCMS (RT): 2.45 min (Method H); MS (ES+) gave m/z: 388.1 (MH+).
[0219] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.30 (d, 1H), 8.23 (d, 1H), 7.91-8.04 (m, 2H), 7.12-7.31 (m, 3H), 4.20 (br. s., 1H), 3.76 (br. s., 1H), 3.51 (dd, 1H), 3.18-3.40 (m, 2H), 2.14-2.28 (m, 1H), 1.77-2.03 (m, 2H), 1.54-1.74 (m, 1H).
Example 16
(S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(2-fluoro-pyridin-4-yl)-methanone
[0220]
[0221] (S)-(3-(4-(2,4-Difluoro-phenyl)-oxazol-2-yl)-piperidin-1-yl)(2-fluoro-pyridin-4-yl)-methanone was prepared following the same procedure described in Example 6, starting from (S)-3-[4-(2,4-difluoro-phenyl)-oxazol-2-yl]-piperidine, prepared as described in Example 15(A), and using 2-fluoroisonicotinic acid as the acid of choice. Purification was performed by flash chromatography (silica gel, eluent: ethyl acetate/petroleum ether 1:1).
[0222] Yield: 92%; [α D ]=+82.5° (c=0.7, MeOH); LCMS (RT): 3.08 min (Method H); MS (ES+) gave m/z: 388.2 (MH+).
[0223] 1 H-NMR (DMSO-d 6 , 353K), δ (ppm): 8.30-8.34 (m, 1H), 8.24 (d, 1H), 7.90-8.04 (m, 1H), 7.23-7.34 (m, 2H), 7.12-7.20 (m, 2H), 4.12 (br. s., 1H), 3.68 (br. s., 1H), 3.49 (dd, 1H), 3.19-3.40 (m, 2H), 2.16-2.28 (m, 1H), 1.77-2.02 (m, 2H), 1.57-1.73 (m, 1H).
Pharmacology
[0224] The compounds provided in the present invention are positive allosteric modulators of mGluR5. As such, these compounds do not appear to bind to the orthosteric glutamate recognition site, and do not activate the mGluR5 by themselves. Instead, the response of mGluR5 to a concentration of glutamate or mGluR5 agonist is increased when compounds of Formula I are present. Compounds of Formula I are expected to have their effect at mGluR5 by virtue of their ability to enhance the function of the receptor.
Example A
mGluR5 Assay on Rat Cultured Cortical Astrocytes
[0225] Under exposure to growth factors (basic fibroblast growth factor, epidermal growth factor), rat cultured astrocytes express group I-Gq coupled mGluR transcripts, namely mGluR5, but none of the splice variants of mGluR1, and as a consequence, a functional expression of mGluR5 receptors (Miller et al. (1995) J. Neurosci. 15:6103-9): The stimulation of mGluR5 receptors with selective agonist CHPG and the full blockade of the glutamate-induced phosphoinositide (PI) hydrolysis and subsequent intracellular calcium mobilization with specific antagonist as MPEP confirm the unique expression of mGluR5 receptors in this preparation.
[0226] This preparation was established and used in order to assess the properties of the compounds of the present invention to increase the Ca 2+ mobilization-induced by glutamate without showing any significant activity when applied in the absence of glutamate.
Primary Cortical Astrocytes Culture:
[0227] Primary glial cultures were prepared from cortices of Sprague-Dawley 16 to 19 days old embryos using a modification of methods described by Mc Carthy and de Vellis (1980) J. Cell Biol. 85:890-902 and Miller et al. (1995) J. Neurosci. 15 (9):6103-9. The cortices were dissected and then dissociated by trituration in a sterile buffer containing 5.36 mM KCl, 0.44 mM NaHCO 3 , 4.17 mM KH 2 PO 4 , 137 mM NaCl, 0.34 mM NaH 2 PO 4 , 1 g/L glucose. The resulting cell homogenate was plated onto poly-D-lysine precoated T175 flasks (BIOCOAT, Becton Dickinson Biosciences, Erembodegem, Belgium) in Dubelcco's Modified Eagle's Medium (D-MEM GlutaMAX™ I, Invitrogen, Basel, Switzerland) buffered with 25 mM HEPES and 22.7 mM NaHCO 3 , and supplemented with 4.5 g/L glucose, 1 mM pyruvate and 15% fetal bovine serum (FBS, Invitrogen, Basel, Switzerland), penicillin and streptomycin and incubated at 37° C. with 5% CO 2 . For subsequent seeding, the FBS supplementation was reduced to 10%. After 12 days, cells were subplated by trypsinisation onto poly-D-lysine precoated 384-well plates at a density of 20.000 cells per well in culture buffer.
Ca 2+ Mobilization Assay Using Rat Cortical Astrocytes:
[0228] After one day of incubation, cells were washed with assay buffer containing: 142 mM NaCl, 6 mM KCl, 1 mM Mg 2 SO 4 , 1 mM CaCl 2 , 20 mM HEPES, 1 g/L glucose, 0.125 mM sulfinpyrazone, pH 7.4. After 60 min of loading with 4 μM Fluo-4 (TefLabs, Austin, Tex.), the cells were washed three times with 50 μl of PBS Buffer and resuspended in 45 μl of assay Buffer. The plates were then transferred to a Fluorometric Imaging Plate Reader (FLIPR, Molecular Devices, Sunnyvale, Calif.) for the assessment of intracellular calcium flux. After monitoring the baseline fluorescence for 10 s, a solution containing 101.1M of representative compound of the present invention diluted in Assay Buffer (15 μl of 4× dilutions) was added to the cell plate in the absence or in the presence of 300 nM of glutamate. Under these experimental conditions, this concentration induces less than 20% of the maximal response of glutamate and was the concentration used to detect the positive allosteric modulator properties of the compounds from the present invention. The final DMSO concentration in the assay was 0.3%. In each experiment, fluorescence was then monitored as a function of time for 3 minutes and the data analyzed using Microsoft Excel and GraphPad Prism. Each data point was also measured two times.
[0229] The effect of the compounds of the present invention are performed on primary cortical mGluR5-expressing cell cultures in the absence or in the presence of 300 nM glutamate. Data are expressed as the percentage of maximal response observed with 30 μM glutamate applied to the cells. Each bar graph is the mean and S.E.M of duplicate data points and is representative of three independent experiments
[0230] The compounds of this application have EC 50 values in the range of less than 10 μM. Example # 1 has EC 50 value of less than 1 μM.
[0231] The results in Example A demonstrate that the compounds described in the present invention do not have an effect per se on mGluR5. Instead, when compounds are added together with an mGluR5 agonist such as glutamate, the effect measured is significantly potentiated compared to the effect of the agonist alone at the same concentration. This data indicates that the compounds of the present invention are positive allosteric modulators of mGluR5 receptors in native preparations.
Example B
mGluR5 Assay on HEK-Expressing Rat mGluR5
Cell Culture
[0232] Positive functional expression of HEK-293 cells stably expressing rat mGluR5 receptor was determined by measuring intracellular Ca 2+ changes using a Fluorometric Imaging Plate Reader (FLIPR, Molecular Devices, Sunnyvale, Calif.) in response to glutamate or selective known mGluR5 agonists and antagonists. Rat mGluR5RT-PCR products in HEK-293 cells were sequenced and found 100% identical to rat mGluR5Genbank reference sequence (NM — 017012). HEK-293 cells expressing rmGluR5 were maintained in media containing DMEM, dialyzed Fetal Bovine Serum (10%), Glutamax™ (2 mM), Penicillin (100 units/ml), Streptomycin (100 μg/ml), Geneticin (100 μg/ml) and Hygromycin-B (40 μg/ml) at 37° C./5% CO 2 .
Fluorescent Cell Based-Ca 2+ Mobilization Assay
[0233] After one day of incubation, cells were washed with assay buffer containing: 142 mM NaCl, 6 mM KCl, 1 mM Mg 2 SO 4 , 1 mM CaCl 2 , 20 mM HEPES, 1 g/L glucose, 0.125 mM sulfinpyrazone, pH 7.4. After 60 min of loading with 4 uM Fluo-4 (TefLabs, Austin, Tex.), the cells were washed three times with 50 μl of PBS Buffer and resuspended in 45 μl of assay Buffer. The plates were then transferred to a Fluorometric Imaging Plate Reader (FLIPR, Molecular Devices, Sunnyvale, Calif.) for the assessment of intracellular calcium flux. After monitoring the baseline fluorescence for 10 seconds, increasing concentrations of representative compound (from 0.01 to 60 μM) of the present invention diluted in Assay Buffer (15 μl of 4× dilutions) was added to the cell. The final DMSO concentration in the assay was 0.3%. In each experiment, fluorescence was then monitored as a function of time for 3 minutes and the data analyzed using Microsoft Excel and GraphPad Prism. Each data point was also measured two times.
[0234] Under these experimental conditions, this HEK-rat mGluR5 cell line is able to directly detect positive allosteric modulators without the need of co-addition of glutamate or mGluR5 agonist. Thus, DFB, CPPHA and CDPPB, published reference positive allosteric modulators that are inactive in rat cortical astrocytes culture in the absence of added glutamate (Liu et al (2006) Eur. J. Pharmacol. 536:262-268; Zhang et al (2005); J. Pharmacol. Exp. Ther. 315:1212-1219) are activating, in this system, rat mGluR5 receptors.
[0235] The concentration-response curves of representative compounds of the present invention were generated using the Prism GraphPad software (Graph Pad Inc, San Diego, USA). The curves were fitted to a four-parameter logistic equation:
[0000] ( Y =Bottom+(Top-Bottom)/(1+10̂((Log EC 50− X )*Hill Slope)
[0000] allowing determination of EC 50 values.
[0236] The Table 1 below represents the mean EC 50 obtained from at least three independent experiments of selected molecules performed in duplicate.
[0000]
TABLE 1
EXAMPLE #
Ca 2+ Flux*
1
++
2
++
3
++
4
++
5
++
6
++
7
++
8
++
9
++
10
++
11
++
12
++
13
++
14
++
15
+
16
++
*Table legend:
+: 1 μM < EC 50 < 10 μM
++: EC 50 < 1 μM
Example C
mGluR5 Binding Assay
[0237] Activity of compounds of the invention was examined following a radioligand binding technique using whole rat brain and tritiated 2-methyl-6-(phenylethynyl)-pyridine ([ 3 H]-MPEP) as a ligand following similar methods than those described in Gasparini et al. (2002) Bioorg. Med. Chem. Lett. 12:407-409 and in Anderson et al. (2002) J. Pharmacol. Exp. Ther. 303 (3) 1044-1051.
Membrane Preparation:
[0238] Cortices were dissected out from brains of 200-300 g Sprague-Dawley rats (Charles River Laboratories, L'Arbresle, France). Tissues were homogenized in 10 volumes (vol/wt) of ice-cold 50 mM Hepes-NaOH (pH 7.4) using a Polytron disrupter (Kinematica AG, Luzern, Switzerland) and centrifuged for 30 min at 40,000 g. (4° C.). The supernatant was discarded and the pellet washed twice by resuspension in 10 volumes 50 mM HEPES-NaOH. Membranes were then collected by centrifugation and washed before final resuspension in 10 volumes of 20 mM HEPES-NaOH, pH 7.4. Protein concentration was determined by the Bradford method (Bio-Rad protein assay, Reinach, Switzerland) with bovine serum albumin as standard.
[ 3 H]-MPEP Binding Experiments:
[0239] Membranes were thawed and resuspended in binding buffer containing 20 mM HEPES-NaOH, 3 mM MgCl 2 , 3 mM CaCl 2 , 100 mM NaCl, pH 7.4. Competition studies were carried out by incubating for 1 h at 4° C.: 3 nM [ 3 H]-MPEP (39 Ci/mmol, Tocris, Cookson Ltd, Bristol, U.K.), 50 μg membrane and a concentration range of 0.003 nM-30 μM of compounds, for a total reaction volume of 300 μl. The non-specific binding was defined using 30 μM MPEP. Reaction was terminated by rapid filtration over glass-fiber filter plates (Unifilter 96-well GF/B filter plates, Perkin-Elmer, Schwerzenbach, Switzerland) using 4×400 μl ice cold buffer using cell harvester (Filtermate, Perkin-Elmer, Downers Grove, USA). Radioactivity was determined by liquid scintillation spectrometry using a 96-well plate reader (TopCount, Perkin-Elmer, Downers Grove, USA).
Data Analysis:
[0240] The inhibition curves were generated using the Prism GraphPad program (Graph Pad Software Inc, San Diego, USA). IC 50 determinations were made from data obtained from 8 point-concentration response curves using a non linear regression analysis. The mean of IC 50 obtained from at least three independent experiments of selected molecules performed in duplicate were calculated.
[0241] The compounds of this application have IC 50 values in the range of less than 30 μM. Example # 1 has IC 50 value of less than 10 μM.
[0242] The results shown in Examples A, B and C demonstrate that the compounds described in the present invention are positive allosteric modulators of rat mGluR5 receptors. These compounds are active in native systems and are able to inhibit the binding of the prototype mGluR5 allosteric modulator [ 3 H]-MPEP known to bind remotely from the glutamate binding site into the transmembrane domains of mGluR5 receptors (Malherbe et al (2003) Mol. Pharmacol. 64(4):823-32).
[0243] Thus, the positive allosteric modulators provided in the present invention are expected to increase the effectiveness of glutamate or mGluR5 agonists at mGluR5 receptor. Therefore, these positive allosteric modulators are expected to be useful for treatment of various neurological and psychiatric disorders associated with glutamate dysfunction described to be treated herein and others that can be treated by such positive allosteric modulators.
[0244] The compounds of the present invention are allosteric modulators of mGluR5 receptors, they are useful for the production of medications, especially for the prevention or treatment of central nervous system disorders as well as other disorders modulated by this receptor.
[0245] The compounds of the invention can be administered either alone, or in combination with other pharmaceutical agents effective in the treatment of conditions mentioned above.
Formulation Examples
[0246] Typical examples of recipes for the formulation of the invention are as follows:
[0247] 1) Tablets
[0000]
Compound of the example 1
5 to 50
mg
Di-calcium phosphate
20
mg
Lactose
30
mg
Talcum
10
mg
Magnesium stearate
5
mg
Potato starch
ad 200
mg
[0248] In this example, the compound of the example 1 can be replaced by the same amount of any of the described examples 1 to 16.
[0249] 2) Suspension
[0250] An aqueous suspension is prepared for oral administration so that each 1 milliliter contains 1 to 5 mg of one of the described example, 50 mg of sodium carboxymethyl cellulose, 1 mg of sodium benzoate, 500 mg of sorbitol and water ad 1 ml.
[0251] 3) Injectable
[0252] A parenteral composition is prepared by stirring 1.5% by weight of active ingredient of the invention in 10% by volume propylene glycol and water.
[0253] 4) Ointment
[0000]
Compound of the example 1
5 to 1000
mg
Stearyl alcohol
3
g
Lanoline
5
g
White petroleum
15
g
Water
ad 100
g
[0254] In this example, the compound 1 can be replaced by the same amount of any of the described examples 1 to 16.
[0255] Reasonable variations are not to be regarded as a departure from the scope of the invention. It will be obvious that the thus described invention may be varied in many ways by those skilled in the art. | The present invention provides new compounds of formula I, wherein P, A, W, B, Q, R1 and R2 are defined as in formula I; invention compounds are positive allosteric modulators of metabotropic receptors—subtype 5 (“mGluR5”) which are useful for the treatment or prevention of central nervous system disorders such as for example: cognitive decline, both positive and negative symptoms in schizophrenia as well as other disorders in which the mGluR5 subtype of glutamate metabotropic receptor is involved. | 2 |
RELATED APPLICATIONS
This Application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/537,595 filed Jan. 20, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention herein relates to forming models of subsurface earth formations based on data obtained from wells being drilled in those formations.
2. Description of the Related Art
With increased competition in the energy market, oil companies face a daunting task of improving accuracy while reducing cycle time. Technologies in horizontal drilling, real time monitoring, and reservoir modeling have advanced significantly during the last few years. There are still, however, conceptual gaps in knowledge of the actual subsurface structure in well plans by geoscientists and engineers for a well to be drilled.
Typically, the well plan is an earth model based on best available information from surveys, well logs and other reservoir techniques. The interest is to locate a well at particular locations in a formation of interest for optimum production. A considerable number of wells currently being drilled are drilled horizontally through a formation or reservoir of hydrocarbon interest. The objective in such a well is for the well base to have a suitable length or exposure of extent, usually expressed in terms of reservoir feet, in the formation.
In the event that the actual subsurface formations or stratigraphy differ from the well plan, the well bore may be located in the reservoir at a position where less reservoir feet of extent in the reservoir are obtained than were planned. In some instances, even with sophisticated well plans, the actual subsurface formation may differ sufficiently from the plan model so that the well bore does not contact the reservoir of interest for any significant extent.
There have been techniques for forming revised or updated models based on well data. However, so far as is known, conventional techniques to form revised or updated models have taken days or weeks. Thus, the revised data or well model was not available until long after drilling operations had passed the proper location for corrections to be made in steering of the drill bit to better locate the well in the reservoir of interest.
SUMMARY OF INVENTION
Briefly, the present invention provides an earth model incorporating up-to-the-minute knowledge derived from geology, seismic, drilling, and engineering data. The present invention utilizes Logging-While-Drilling (LWD) or Measuring-While-Drilling (MWD) data directly from the drilling rig as a well is being drilled.
An earth model is formed in real time during drilling of a well by incorporating up-to-the-minute knowledge derived from geology, seismic, drilling, and engineering data. Logging-While-Drilling (LWD) or Measuring-While-Drilling (MWD) data are directly from the drilling rig as the well is drilled. The LWD or MWD data are sent to visualization centers and compared with other data such as existing geological models, the proposed well plan and present interpretation of the subsurface stratigraphy. When the real time data from the well indicates a different stratigraphy than the well model, revised models are formed based on the newly acquired well data. The present invention thus enables experts to analyze unexpected results and update the geological model within minutes of penetration of a formation during drilling. Well drilling efficiency is improved in real time, and an “on-the-spot” road map is provided to steer the drill bit based on the newly developed map for maximal reservoir contact and drilling accuracy.
To better understand the characteristics of the invention, the description herein is attached, as an integral part of the same, with drawings to illustrate, but not limited to that, described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be obtained when the detailed description set forth below is reviewed in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic diagram, taken partly in cross-section, of an illustrative example of a conventional prior art well measuring while drilling system for gathering data to be processed.
FIG. 2 is a block diagram of data processing steps according to the present invention.
FIG. 3 is an example plot of data formed according to the present invention showing process results in the form of an updated model of formation stratigraphy.
FIG. 4 is an example plot of a three-dimensional model of a subsurface tar mat or body in a field containing hydrocarbon production reserves.
FIGS. 5 and 6 are example plots formed according to the present invention of subsurface formations and the location of a well bore in the area of the tar body shown in the model of FIG. 4 .
FIG. 7 is another example plot of formation stratigraphy formed according to the present invention.
FIG. 8 is another example plot of data results obtained according to the present invention.
FIG. 9 is another example result of formation stratigraphy formed according to the present invention.
To better understand the invention, we shall carry out the detailed description of some of the modalities of the same, shown in the drawings with illustrative but not limited purposes, attached to the description herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, FIG. 1 illustrates an example of a prior art measurement-while-drilling (MWD) system S for gathering data about subsurface formations during drilling. The system S may be one of several commercially available types used during drilling operations at a wellsite to gather data. Once the data has been obtained, it is then available for processing in a manner to be set forth according to the present invention. The system S includes as a part of the drilling rig a downhole subassembly 10 that moves within a borehole 14 behind a drill bit 12 at a lower end of a drill string 16 during drilling of the borehole 14 . As shown in FIG. 1 , the drill bit 12 and the borehole 14 have transitioned from an initial vertical direction to a generally horizontal path into subsurface earth formations 18 . The downhole subassembly 10 is preferably positioned as close as practical to the drill bit 12 .
The drill bit 12 may be rotated in several ways during drilling operations. The drill bit 12 may be rotated by a downhole motor which may be contained in a downhole subassembly 10 . The drill bit 12 may also be driven by rotating the drill string 16 by a surface prime mover 26 to drill the borehole 14 in the earth formations 18 . For simplicity, the prime mover and other components of the surface drilling rig are not shown. The downhole assembly 10 contains various sensors and devices of the conventional type for gathering data during drilling operations. If desired, a conventional logging-while-drilling or LWD system may be used in place of the MWD system 10 .
Data from the downhole subassembly 10 are telemetered by a downhole telemetry system (not shown) in the downhole subassembly 10 to an uphole telemetry and data processing system D. The uplink data telemetry path is indicated by a phantom or broken line 22 . Data from the downhole subassembly 10 are received by the uphole telemetry and data processing system D and recorded in a suitable data memory 30 including a data records unit 32 and a data input unit 34 as functions of borehole depth.
A preprocessing unit 36 and a processor computer 38 receive and process the data of interest such that the parameters of interest are recorded and displayed in the desired manner which is usually a plot of the parameters of interest as a function of depth within the borehole at which they are determined. The telemetry system utilized in the present invention may be of several conventional, commercially available types, including either MWD or LWD well telemetry systems. It should also be understood that there are several commercially available well telemetry systems which are capable of providing well data about formation parameters of interest derived from well drilling as the well is being drilled that may be used for gathering data. Once the data are gathered, they are available for processing according to the present invention.
The preprocessing unit 36 and processor computer 38 also receive input data from the data memory input element 34 which are telemetered downhole by a downlink telemetry path denoted by the broken line 24 to the downhole subassembly 10 . The use of a two-way communication system is especially useful in changing reference data such as offset well data or even sensor response model data during the actual drilling operation. The system 10 also includes a surface depth measurement system, such as a depth measure wheel and associated circuitry 28 . A depth measurement system (not shown) also is typically included in the downhole subassembly 10 which enable a downhole computer to more accurately correlate or compute various sensor measurements and parameters of interest to their respective depths or true locations within the borehole 14 at which such measurements are made.
The MWD data from the downhole subassembly 10 are recorded as functions of borehole depth in the data memory 30 . Once recorded, the MWD data measurements are transferred as needed into the preprocessing unit 36 and processor computer 38 of the system D. The MWD data measurements are subjected to conventional preprocessing in the preprocessing unit 36 and then transferred to a computer 38 . The processed data measurements in computer 38 are then available for processing according to the present invention in a manner to be set forth below.
The processed MWD data measurement obtained while drilling may, if desired, be transmitted by satellite or other suitable telemetry link for processing according to the present invention by a computer located at an office or other facility which is considerably distant from the area of the well being drilled or logged. The processed MWD data results may also be processed according to the present invention in the computer 38 at the drilling site. The results from processing, whether at a distant computer or at the computer 38 , are then available in real time during well operations for analysis on a suitable display or plotter, such as plotter 40 at the well site. Processed results obtained by telemetry at computers spaced from the well site are also available during real time on suitable displays and plotters.
The computer at the office located away from the well can be a mainframe computer of any conventional type of suitable processing capacity such as those available from International Business Machines (IBM) of Armonk, N.Y. or other source. Other digital processors, however, may be used, such as a laptop computer, or any other suitable processing apparatus both at the well site and the central office.
In any case, the processor of the computer 38 at the well site, or the computer at the other office, accesses the MWD data measurements to undertake the logic of the present invention, which may be executed by a processor as a series of computer-executable instructions. The instructions may be contained on a data storage device 42 with a computer readable medium, such as a computer diskette shown in FIG. 1 having a computer usable medium stored thereon. Or, the instructions may be stored in memory of the computer 38 , or on magnetic tape, conventional hard disk drive, electronic read-only memory, optical storage device, or other appropriate data storage device.
A flow chart F of FIG. 2 herein illustrates the structure of the logic of the present invention as embodied in computer program software. Those skilled in the art will appreciate that the flow charts illustrate the structures of computer program code elements that function according to this invention. Manifestly, the invention is practiced in its essential embodiment by a machine component that renders the program code elements in a form that instructs a digital processing apparatus (that is, a computer) to perform a sequence of function steps corresponding to those shown.
It is important to note that, while the present invention has been, and will continue to be, described in the context of a fully functional computer system, those skilled in the art will appreciate that the present invention is capable of being distributed as a program product in a variety of forms, and that the present invention applies equally regardless of the particular type of signal-bearing media utilized to actually carry out the distribution. Examples of signal-bearing media include: recordable-type media, such as floppy disks, hard disk drives, and CD ROMs, and transmission-type media such as digital and analog communication links.
With reference to FIG. 2 , there is depicted a high-level logic flowchart illustrating a method according to the present invention of forming models of subsurface earth formations through which well drilling operations are proceeding in a well bore. The method of the present invention performed in the computer 38 can be implemented utilizing the computer program steps of FIG. 6 stored in memory 42 and executable by system processor of computer 38 and also the data resulting from the other steps of FIG. 2 not implemented by the computer 38 . Such data is furnished to computer 38 through any suitable form of computer data input device.
As shown in the flow chart F, several existing estimates of the subsurface formations and their location, in the form of one or more of: proposed well plan data 50 , existing geological model data 52 and a current interpretation 54 of the well being drilled are available for comparison and use during according to the present invention.
The proposed well plan data 50 represents a planned or estimated well trajectory through subsurface earth formations in three-dimensional space before drilling of the well in question actually begins. The existing geological model data 52 is continually updated during the process of the present invention. The existing geological model data 52 contains at any time during processing according to the present invention the most recent three-dimensional model of geological attributes processing results at the present moment in time during a drilling operation. The current interpretation data 54 is also continuously updated during the process of the present invention. The current interpretation data 54 , at any time during the process of the present invention, contains the most recent geological and geophysical interpretation at that time of a subsurface reservoir of interest.
The existing estimates are stored in either the data records 32 or other suitable data memory associated with the computer 38 . Real time telemetry data from in the form of logging data (such as one or more of gamma ray, ROP or resistivity logs) obtained while drilling from the downhole assembly 10 are obtained. The real time telemetry data are available in real time as indicated at 56 after suitable processing according to the process steps depicted schematically in the flow chart F. As previously noted, such processing may occur well after transmission from the well to a central processing facility, or in the computer 38 .
As indicated at step 58 in flow chart F, the real time data 56 are compared in real time (as the well is being drilled) with one or more sets of existing element data 50 , 52 and 54 . The comparison is performed to see if one or more geological indications of interest might differ from some indicator, measurement or parameter of the existing estimates stored as data as indicated at 50 , 52 and 54 , or from some earlier measurement or indication. For example, a geological markers interpretation based on real time well logs from the system S might indicate that a reservoir boundary is either shallower or deeper than a previous estimate.
It is thus important to note that the process of the present invention incorporates real time logging-while-drilling data and real time structure interpretation into the comparison process. In the event that the results of the comparison step 58 indicate no significant variation or difference in the real-time telemetry data from the well bore and the existing estimates, the process of the present invention updates the current interpretation data 54 . Processing according to the present invention then continues sampling with the telemetry data from the downhole subassembly 10 as drilling progresses. As new data are obtained, they are processed in the foregoing manner and subjected to the comparison step 58 .
In the event, however, that the results of comparison step 58 indicate that there is a difference sufficient in magnitude or effect between the well being drilled and the existing estimates, the process of the present invention proceeds to generate or morph a new geological model of the well according to the latest understanding obtained from the well telemetry. If the real time data indicates a different scenario from the current model, then a new interpretation and structure grids are generated or morphed during a process step 60 .
Thus, once a geological marker interpretation changes, those changes are incorporated into the data. The structure grids are in effect re-gridded in real time to provide up-to-date structure grids. As a result of step 60 , the structure grids which make up the stratigraphic framework in the existing geological model 52 are no longer current. During step 62 , the newly updated structure grids are exchanged and substituted in place of those previously in the existing geological model 52 . The old grids are thus exchanged and replaced by the updated grids. However, the original geological relationship established at the outset is maintained. This is done while allowing a new model as indicated at step 66 to be made based on the updated structure grids.
Usually when a new stratigraphic framework is formed, existing reservoir attributes are erased or deleted. With the present invention, those files which contain the existing reservoir attributes are retained and migrated into their revised or updated locations during the step 66 . The results of step 66 are then stored and retained as the current interpretation 54 . The previously calculated reservoir attributes are thus migrated in real time to their spatially up-to-date locations. A new real-time structure model of the well is thus generated as the well is being drilled.
An important feature of the present invention is the speed at which the decision-making process and new model generating or morphing takes place. According to the present invention, it is possible to generate or morph a revised geological model in minutes based on the real-time telemetry data.
The methodology of morphing or forming a new model according to the present invention occurs during a process step 66 . Processing during step 66 has two processing phases: a stratigraphic framework phase; and a reservoir attributes migration phase, and a display phase.
Processing during step 66 assumes the uncertainty of the reservoir of interest for the well in progress lies mostly on the absolute location of the layers in the subsurface formation stratigraphy. The relative stratigraphic positions tend not to vary drastically within the length of a well bore. Generally, a 100% structurally up-to-date and 90+% stratigraphically sound continuity may be applied to most carbonate reservoirs. The reservoir attributes migration phase of step 66 morphs the attributes from the current geological model into the real-time structure model to obtain an updated model according to the present invention. Also during step 66 , the display 40 is provided with the processing results to form output displays of the types shown in FIGS. 3-8 . The processed results are also used, as has been previously mentioned, to update either or both of the current interpretation data 52 and the geological model 54 .
FIG. 3 is an example display of stratigraphic data illustrating by way of comparison a cross-section from an original model at 100 and an original stratigraphic slice at 102 . FIG. 3 also contains at 104 a new model cross-section and a stratigraphic slice 106 at a new location based on data processed from MWD data obtained according to the present invention.
FIG. 4 is a display of a three-dimensional model of data from the same area as FIG. 3 , and formed by conventional techniques in a computer. As can be seen, FIG. 4 shows a significant tar mat 108 known to be present in a field containing significant hydrocarbon reserves. This large and complicated tar body 108 has impeded a pressure difference (over 1000 psi) which has been built up by a ring of injector wells on one side of the mat to support oil production wells on an opposite side of the tar mat. A tunnel well with a mother bore and two laterals were planned to drill across the tar mat to provide the much needed reservoir pressure support. The techniques of the present invention were important to the successful drilling of the multi-lateral well.
As will be discussed below, the existing structural grids in the area of body 108 were updated using the latest well control and these grids were then utilized to “morph” the tar, porosity and permeability attributes to fit the current structural interpretation. This allowed for extremely accurate well planning of the mother bore and both laterals across the tar mat. This accuracy was required to ensure that the cased “heel” section of the horizontal well was placed in the “tar-free” area or the injector well side of the tar mat and the “toes” of all three horizontals placed also in the “tar-free” area on the opposite of the tar mat from the injector wells. Upon perforation the fluids were to flow from the high-pressure injector well side to the low-pressure opposite side oil producers.
FIG. 5 is an example vertical cross-section plot of a subsurface structure in the same area as FIGS. 3 and 4 , showing a wellbore at 110 from a mother bore 111 to be drilled horizontally out of the tar barrier or mat 108 . A semi-transparent surface 114 is the current real time interpretation of the structure formed according to the present invention. The tar geobody 108 extends in the display of FIG. 5 from a lower area 108 a to an upper area 108 b , and is based on an old interpretation. As can be seen, the location of tar 108 does not conform with the real time interpretation 114 . The tar 108 is shown in the display of FIG. 5 to be a lot deeper than the real-time interpretation 114 .
In FIG. 6 , an area 120 indicates a revised location formed according to the present invention of the tar geobody shown at 108 in FIGS. 4 and 5 . It is to be noted that the tar body 120 has been pulled up structurally and now is conforming with the current structure grid 114 shown in both FIGS. 5 and 6 . Further, as indicated at 122 , the well bore 110 has drilled out of the up-to-date location of tar barrier 120 provided by the present-invention to meet the well drilling objective of drilling for reservoir pressure support, as previously mentioned.
FIG. 7 is another example of formation stratigraphy formed according to the present invention from data in the field from which the displays of FIGS. 3 , 4 , 5 and 6 were formed. In FIG. 7 , the trajectories of five highly complicated and long-reaching lateral wells or laterals 124 a , 126 a , 128 a , 130 a and 132 a of a well originating from the mother bore 111 are shown. Also shown in FIG. 7 along each of the lateral wells is a vertical model 124 b , 126 b , 128 b , 130 b and 132 b , respectively, formed according to the present invention, displaying an attribute of interest, such as porosity, for the various formations along the path of such lateral wells. The present invention thus provides real time displays of attributes along the paths of the various lateral wells. Up-to-date displays of an attribute (e.g. porosity) according to the present invention guide the drill bit to reach best reservoir rock.
FIG. 8 is another example of three lateral wells 134 a , 136 a and 138 a from the well bore 111 formed utilizing the present invention from data in the same area discussed above. Reference numerals 134 b , 136 b and 138 b indicate the formation attributes along the paths of the respective wellbores, 134 a , 136 a and 138 a . These on-the-spot attributes can be compared and calibrated exactly with real time data 56 .
FIG. 9 is another example data display of results obtained according to the present invention at a location from an existing geological model. An area 144 displays permeability as obtained from the existing geological model 62 . An area 146 displays oil saturation obtained from the simulation model, and an area 148 is a display of interval velocity obtained from seismic data in the existing geological model 62 . Reference numeral 150 designates the current-drilling wellbore, and a tar geobody is indicated at 152 . As discussed above, the objective of drilling the well 150 is to stay away from the tar 152 (a non-reservoir feature). Therefore, accurately knowing during drilling where the tar 152 is located proves to be a key factor on the well success. Area 154 in FIG. 9 is the location of tar body after data processing according to the present invention. It can be seen that the present invention provides a real time road map for drilling to avoid undesirable obstacles in the earth formation, or to steer an optimum path in or through them.
The speed at which the processing occurs is an important factor for the model update in order to guide expensive geosteering and drilling. Conventional methods take a much longer time when a drill bit has passed the position indicated by the geological model. A conventional update according to methods presently known to applicants typically takes a long time (e.g., days or weeks). As a result, the drill bit has moved significantly away from the reservoir of interest before this fact could be determined. Drilling operations are expensive, and unnecessary drilling makes drilling more expensive. Due to the lack of adequate or accurate data from prior processes, guiding of the drill bit window was done in the absence of accurate information about the drill bit location with respect to the formation of interest.
With the present invention, it is thus possible to plan, drill and control in real-time or geosteer a well during drilling at thousands of feet below the earth's surface. As the well is being drilled and new data about drilling progress is learned along the way in real-time, the new interpretations are incorporated into the earth model to guide the continuous drilling. As has been mentioned, conventional methods take significant time to update the model as compared to the drilling speed. The end result of conventional methods is that of multi-million dollar costs for a well being drilled and based on decisions obtained from use of an outdated model or data.
The process of the present invention provides a real-time earth model to quantitatively not qualitatively, guide and control the geosteering or drilling operations. The present invention thus provides a real time earth model, which greatly enhances reservoir geologists' ability to accurately visualize, predict, geosteer, and monitor the placement of wells.
The invention has been sufficiently described so that a person with average knowledge in the matter may reproduce and obtain the results mentioned in the invention herein Nonetheless, any skilled person in the field of technique, subject of the invention herein, may carry out modifications not described in the request herein, to apply these modifications to a determined structure, or in the manufacturing process of the same, requires the claimed matter in the following claims; such structures shall be covered within the scope of the invention.
It should be noted and understood that there can be improvements and modifications made of the present invention described in detail above without departing from the spirit or scope of the invention as set forth in the accompanying claims. | An earth model is formed in real time during drilling of a well by incorporating up-to-the-minute knowledge derived from geology, seismic, drilling, and engineering data. The process of forming the model utilizes Logging-While-Drilling (LWD) or Measuring-While-Drilling (MWD) data directly from the drilling rig as the well is drilled. The LWD or MWD data is sent to visualization centers and compared with other data such as existing geological models, the proposed well plan and present interpretation of the subsurface stratigraphy. The results of the comparison enable experts to analyze anomalous results and update the geological model within minutes of penetration of a formation during drilling. Well drilling efficiency is improved, and an “on-the-spot” road map is provided for maximal reservoir contact and pinpoint accuracy. | 4 |
[0001] This application is a division of U.S. Non-Provisional patent application Ser. No. 11/430,178, filed May 9, 2006 in the U.S. Patent and Trademark Office, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to diagnostic test strips for testing biological fluids. More specifically, the present invention relates to an apparatus and method for storing and dispensing diagnostic test strips.
[0004] 2. Background of the Invention
[0005] Diagnostic test strips are used to measure analyte concentrations in biological fluids. For example, diagnostic test strips are often used by diabetic patients to monitor blood glucose levels.
[0006] To preserve their integrity, diagnostic test strips must be maintained in appropriate environmental conditions. That is, the test strips should be maintained at appropriate humidity levels, and should remain free of foreign substances. Furthermore, to avoid contamination by oils or foreign substances, test strips should not be handled prior to use.
[0007] Thus, to preserve test strips, they are typically maintained in a storage vial or the like. In order to use the test strip, a user must reach into the vial, and retrieve a single test strip. However, many users, such as diabetic patients, have impaired vision or physical dexterity. Such users may find it difficult to retrieve a single test strip from a storage vial. Further, users may accidentally touch multiple test strips while reaching into the storage vial to withdraw a test strip, and potentially contaminate the unused test strips.
[0008] Accordingly, there is a need for an apparatus for storing diagnostic test strips in appropriate environmental conditions, and for conveniently dispensing the test strips one at a time.
SUMMARY OF THE INVENTION
[0009] An object of the present invention is to address at least the above problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an object of the present invention is to provide an apparatus for storing a plurality of test strips and for dispensing the test strips one at a time.
[0010] According to one embodiment of the present invention, the above and other objects are achieved by an apparatus for storing and dispensing a test strip which comprises a container configured to store a stack of test strips, a roller disposed in the container, the roller adapted to contact one test strip of the stack of test strips, and an actuator for actuating the roller to dispense the one test strip from the container.
[0011] According to another embodiment of the present invention, an apparatus for storing and dispensing a test strip comprises a container configured to store a stack of test strips, a lid connected to the container by a living hinge, and a linkage assembly operatively connected to the lid. The linkage assembly is adapted to contact one test strip of the stack of test strips so that when the lid is opened, a test strip is dispensed.
[0012] According to yet another embodiment of the present invention, an apparatus for storing and dispensing test strips comprises a container configured to store a stack of test strips, a spring disposed in the container, the spring adapted to contact one test strip of the stack of test strips, and an actuator for actuating the spring to dispense the one test strip from the container.
[0013] According to still another embodiment of the present invention, an apparatus for storing and dispensing test strips comprises means for storing a stack of test strips, means for contacting one test strip of the stack of test strips, and means for actuating the contacting means to dispense the contacted test strip.
[0014] According to a still further embodiment of present invention, a method of storing and dispensing test strips comprises the steps of arranging a plurality of test strips to form a stack of test strips, storing the plurality of test strips in a storage container, urging the stack of test strips toward a dispensing position, engaging the stack of test strips with an engaging member, actuating the engaging member to dispense the contacted test strip, and urging the remaining test strips toward the dispensing position so that another test strip is placed into a dispensing position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above and other objects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
[0016] FIG. 1 is a perspective view of a storage vial for storing and dispensing test strips, according to a first exemplary embodiment of the present invention;
[0017] FIG. 2 is a front view of the storage vial shown in FIG. 1 ;
[0018] FIG. 3 is a top view of the storage vial shown in FIG. 1 ;
[0019] FIG. 4 is a sectional view taken along the line 4 - 4 in FIG. 3 ;
[0020] FIG. 5 is a sectional view taken along the line 5 - 5 in FIG. 3 ;
[0021] FIG. 6 is a partially cut-away perspective view of the storage vial shown in FIG. 1 , with a test strip partially dispensed;
[0022] FIG. 7 is a perspective view of the storage vial shown in FIG. 1 , with a motor for operating the dispenser;
[0023] FIG. 8 is a perspective view of a storage vial for storing and dispensing test strips according to a second exemplary embodiment of the present invention;
[0024] FIG. 9 is a top view of the storage vial shown in FIG. 8 ;
[0025] FIG. 10 is a sectional view taken along the line 10 - 10 in FIG. 9 ;
[0026] FIG. 11 is a sectional view taken along the line 11 - 11 in FIG. 9 ;
[0027] FIG. 12 is an enlarged sectional view of certain elements of the storage vial shown in FIG. 8 ;
[0028] FIG. 13 is a sectional view of a storage vial for storing and dispensing test strips according to a third exemplary embodiment of the present invention;
[0029] FIG. 14 is another sectional view of the storage vial shown in FIG. 13 ;
[0030] FIG. 15 is a cut-away perspective view of a storage vial for storing and dispensing test strips according to a fourth exemplary embodiment of the present invention;
[0031] FIG. 16 is an enlarged view of certain elements of the storage vial shown in FIG. 15 ;
[0032] FIG. 17 is a sectional view of the storage vial shown in FIG. 15 , with a partially dispensed test strip;
[0033] FIG. 18 is a cut-away perspective view of a storage vial for storing and dispensing test strips according to a fifth exemplary embodiment of the present invention;
[0034] FIG. 19 is a cut-away perspective view of the storage vial shown in FIG. 18 , with a partially dispensed test strip;
[0035] FIG. 20 is a perspective view of a linkage member of the storage vial shown in FIG. 18 ;
[0036] FIG. 21 is a sectional view of a storage vial for storing and dispensing test strips according to a sixth exemplary embodiment of the present invention;
[0037] FIG. 22 is a sectional view of a storage vial for storing and dispensing test strips according to a seventh exemplary embodiment of the present invention;
[0038] FIG. 23 is a perspective view of a storage vial for storing and dispensing test strips according to a eighth exemplary embodiment of the present invention; and
[0039] FIG. 24 is perspective view of a cartridge of the storage vial shown in FIG. 23 .
[0040] Throughout the drawings, the same reference numerals will be understood to refer to the same elements, features and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0041] The matters defined in the description such as detailed construction and elements are provided to assist in a comprehensive understanding of the embodiments of the invention. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. Also, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
First Exemplary Embodiment
[0042] Referring to FIGS. 1-7 , a storage vial 100 for storing and dispensing test strips according to a first exemplary embodiment of the present invention includes a storage container 102 configured to store a stack of test strips 104 , a strip roller 106 rotatably disposed in the container, and a thumbwheel 108 rotatably disposed in the container. The strip roller 106 contacts one test strip 142 of the stack of test strips 104 . The thumbwheel 108 operates the strip roller 106 so that when the thumbwheel 108 is rotated, the strip roller 106 rotates to dispense the test strip 142 in contact with the strip roller 106 .
[0043] The storage container 102 includes a lower body portion 110 and a top wall 112 mounted in the lower body portion 110 . The lower body portion 110 of the storage container 102 is generally rectangular and forms a cavity 123 which is configured to store a stack of test strips 104 . A test strip supporting wall 116 extends upwardly from the bottom wall 118 of the container. The test strip supporting wall 116 is tall enough to provide support for the stack of test strips 104 loaded in the storage container 102 . The test strip supporting wall 116 may end short of the strip roller 106 so that it does not interfere with the strip roller 106 . Alternatively, the test strip supporting wall may extend to the bottom surface of the top wall 112 of the storage container 102 , and have an elongated slot to provide clearance for installation and operation of the strip roller 106 (refer to element 331 in FIG. 14 ).
[0044] The storage container 102 may be formed of a desiccant entrained polymer to regulate the specific relative humidity inside the container. U.S. Pat. No. 5,911,937, which is hereby incorporated by reference in its entirety, discloses one suitable desiccant entrained polymer. Alternatively, the storage container 102 may be formed of a polymer with an insert-molded desiccant, or a desiccant may be placed in the cavity 123 .
[0045] The top wall 112 of the storage container 102 is preferably formed separately from the remainder of the storage container 102 for easier manufacturing and assembly. After the test strips 104 are loaded into the storage container 102 , the top wall 112 may be fixed to the storage container 102 by ultrasonic welding, by an adhesive, by mechanical engagement (such as a snap-fit), or by any other suitable method known to those skilled in the art. The top wall 112 of the storage container 102 forms a dispensing slot 120 through which test strips are dispensed. The top surface 122 of the top wall 112 may bear indicia 136 (such as an arrow) for indicating the direction to rotate the thumbwheel 108 to dispense a test strip. A first supporting member 124 extends from the bottom surface 126 of the top wall 112 to rotatably support the strip roller 106 , as will be discussed in detail below. A second supporting member 128 also extends from the bottom surface of the top wall 112 . The thumbwheel 108 is rotatably supported by the second supporting member 128 , and the thumbwheel 108 extends through a second slot through the top wall 112 of the storage container 102 . A downwardly extending test strip supporting wall may be located adjacent to the test strip dispensing slot 120 to support and guide test strips into the dispensing slot 120 while they are being dispensed (refer to element 831 in FIG. 14 ).
[0046] The storage container 102 may be provided with a lid 138 to prevent humidity and other environmental contaminants from entering the storage container 102 . The lid 138 may be a separate component, but preferably the lid 138 is connected to the storage container 102 by a hinge 140 . In the illustrated embodiment, the lid 138 is formed integrally with the lower body portion 110 of the storage container 102 so that it is connected to the storage container 121 by a living hinge 140 . The lid 138 preferably forms a substantially hermetic seal with the lower body portion 110 of the storage container 102 . Such seals are known to those skilled in the art, and therefore, a detailed description of the seal will be omitted for conciseness. Also, for convenience of explanation, the lid is only shown in some of the drawings.
[0047] A biasing element 132 , such as a compression spring or a leaf spring, urges the stack of test strips 104 stored in the storage container 102 into contact with the strip roller 106 . A platform 134 may be disposed between the biasing element 132 and the stack of test strips 104 to uniformly distribute the force generated by the biasing element 132 along the length of the stack of test strips 104 . If the test strips are sufficiently rigid, however, the biasing element 132 may directly contact the test strips.
[0048] The strip roller 106 is rotatably supported by the first supporting member 124 , which extends downwardly from the top wall 112 of the storage container 102 . The strip roller 106 contacts one of the test strips 142 in the stack of test strips 104 . In the illustrated embodiment, ( FIG. 4 ), the strip roller 106 engages the right-most test strip 142 . Preferably, the strip roller 106 engages the test strip in the upper portion of the test strip. The outer circumferential surface 144 of the strip roller 106 should have a sufficient coefficient of friction to frictionally engage and dispense a test strip. For example, the strip roller 106 may be formed of rubber bonded to a metal or molded plastic roller insert. A strip roller gear 146 is located on one side of the strip roller 106 .
[0049] A thumbwheel 108 is rotatably supported by the second supporting member 128 . A plurality of gear teeth 148 are located around the outer circumference of the thumbwheel 108 , and the gear teeth 148 on the thumbwheel 108 engage the strip roller gear 146 . The gear teeth 148 also provide friction to allow a user to more conveniently operate the thumbwheel 108 with a thumb, a finger, or the like.
[0050] Alternatively, as illustrated in FIG. 7 , the storage container 102 may be used in a fully automated test strip dispenser. In this case, the automated test strip dispenser is provided with a motor 150 with a pinion gear 152 , and the storage container 102 is disposed in the automated test strip dispenser so that the pinion gear 152 engages the thumbwheel 108 . The automated test strip dispenser can, if desired, be combined with a blood glucose meter that reads the test strips 104 .
[0051] Furthermore, a locking member 154 , such as a ratchet or pawl, may be disposed on the storage container 102 to engage the thumbwheel 108 . The locking member 154 allows the thumbwheel 108 to rotate in one direction (that is, a dispensing direction), but prevents the thumbwheel 108 from rotating in the opposite direction.
[0052] The method of using the storage vial for storing and dispensing test strips according to the first exemplary embodiment of the invention will now be described. Initially, the strip roller 106 and the thumbwheel 108 are assembled to the first and second supporting members 124 , 128 , respectively, on the top wall 112 of the storage container 102 . A stack of test strips 104 is loaded into the lower body portion 110 of the storage container 102 so that the stack of test strips 104 is disposed between the platform 132 and the test strip supporting wall 130 . The biasing element 132 is installed in the cavity 123 between the platform 132 and the opposite wall of the storage container. The top wall 112 , with the strip roller 106 and the thumbwheel 108 installed, is then assembled to the lower body of the storage container 102 . The lid 138 is placed on the storage container 102 to form a substantially hermetic seal. The storage vial 100 may now be stored, and the stack of test strips 104 will be protected from environmental hazards, such as moisture. Typically, these steps will be performed by a manufacturer, rather than an end user of the storage vial.
[0053] To dispense a test strip, a user opens the lid 138 to expose the thumbwheel 108 and the strip dispensing slot 120 . The user then rotates the thumbwheel 108 in the dispensing direction by manipulating the thumbwheel 108 , with the user's fingers or the like. Upon rotation of the thumbwheel 108 , the thumbwheel 108 transmits the rotational force to the strip roller 106 through the gear teeth 148 on the thumbwheel 108 and the strip roller gear 146 . Therefore, the strip roller 106 rotates. The strip roller 106 contacts one test strip 142 of the stack of test strips 104 , and through frictional force generated between the strip roller 106 and the contacted test strip 142 , dispenses the contacted test strip 142 through the test strip dispensing slot 120 . The thumbwheel 108 may be rotated so that the test strip 142 is completely dispensed out of the storage container 102 , or the test strip 142 may be partially dispensed from the storage container 102 to expose the test strip so that a user may grasp the exposed test strip 142 to completely withdraw the test strip and use the test strip.
[0054] Once the test strip is completely dispensed from the storage container 102 , the biasing element 132 urges the remaining test strips in the stack of test strips 104 toward the strip roller 106 so that a new test strip is placed into contact with the strip roller 106 . Thus, to dispense another test strip, the user rotates the thumbwheel 108 again. After dispensing the desired number of test strips, the user may then replace the lid on the storage container 102 to store the remaining test strips for future use.
[0055] After all of the stored test strips stored in the storage container 102 have been dispensed, the storage vial 100 may be discarded, or may be returned to the manufacturer for recycling. Alternatively, the storage container 102 may be adapted to be reusable (e.g., by making the top wall 112 removable from the lower body portion 110 ).
Second Exemplary Embodiment
[0056] Referring to FIGS. 8-12 , a storage vial 200 for storing and dispensing test strips according to a second exemplary embodiment of the present invention includes a storage container 202 configured to store a stack of test strips 204 , a strip roller 206 rotatably disposed in the storage container 202 , and a pushbutton 208 disposed in the container. The strip roller 206 contacts one test strip 226 of the stack of test strips 204 . The pushbutton 208 is connected with the strip roller 206 by a gear train 230 so that when the pushbutton 208 is pushed, the strip roller 206 rotates to dispense the test strip 226 in contact with the strip roller.
[0057] The storage container 202 includes a lower body portion 210 and a top wall 212 mounted in the lower body portion 210 . The lower body portion 210 of the storage container 202 is configured substantially the same as the lower body portion 110 of the storage container 100 of the first exemplary embodiment of the invention. Accordingly, a detailed description of the lower body portion 210 will not be repeated.
[0058] The top wall 212 of the storage container 202 has a test strip dispensing slot 216 through which test strips are dispensed. A first supporting member 218 extends from the bottom surface 220 of the top wall 212 to rotatably support the strip roller 206 , as will be discussed in detail below. A second supporting member 222 extends from the bottom surface 220 of the top wall 212 to rotatably support an intermediate gear 232 .
[0059] The pushbutton 208 has a first end 234 and a second end 236 . The first end 234 of the pushbutton 208 extends through a slot located in the top wall 212 of the storage container 202 so that it may be manipulated by a user. The second end 236 of the pushbutton 208 is disposed inside the cavity 214 of the storage container 202 . A rack gear 238 is formed along the length of the pushbutton 208 near the second end 236 of the pushbutton 208 .
[0060] The pushbutton is movable between a resting position (illustrated in FIG. 10 , for example) and a dispensing position. A biasing element 240 , such as an extension spring, is disposed between the top wall 212 and the pushbutton 208 . The biasing element 240 urges the pushbutton 208 toward the resting position.
[0061] The pushbutton 208 has at least one track 242 located on one side of the pushbutton, and may have tracks located on both sides of the pushbutton 208 . The tracks 242 are configured to guide the movement of the pushbutton 208 so that when the pushbutton 208 is pressed to dispense a test strip, the rack gear 238 on the pushbutton 208 engages the intermediate gear 232 . When the pushbutton 208 is released, the tracks 242 are configured to cause the rack gear 238 to disengage from the intermediate gear 232 . Therefore, the pushbutton 208 may be restored from the dispensing position to the resting position without rotating the intermediate gear 238 .
[0062] The intermediate gear 232 is rotatably disposed on the second supporting member 222 which extends downwardly from the bottom surface 220 of the top wall 212 of the storage container 202 . The intermediate gear 232 is disposed between the rack gear 238 on the pushbutton 208 and the strip roller gear 228 on the strip roller 206 to operatively connect the gears and form a gear train 230 .
[0063] The strip roller 206 is rotatably supported by the first supporting member 218 , which extends downwardly from bottom surface 220 of the top wall 212 of the storage container 202 . The strip roller 206 is generally configured the same as the strip roller 106 of the first exemplary embodiment of the present invention. Accordingly, a detailed description of the strip roller 206 will not be repeated.
[0064] The method of using the storage vial 200 for storing and dispensing test strips according to the second exemplary embodiment of the invention will now be described. Initially, the strip roller 206 , the pushbutton 208 , the biasing element 240 , and the intermediate gear 232 are assembled to the top wall 212 of the storage container 202 . A stack of test strips 204 is loaded into the lower body portion 210 of the storage container 202 so that the stack of test strips 204 is disposed between the platform 246 (and the biasing element 232 ) and the test strip supporting wall 224 . The top wall 212 , with the installed components, is then assembled to the lower body portion 210 of the storage container 202 so that the strip roller 206 engages one test strip 226 of the stack of test strips 226 . The lid 224 may then be closed, and the stack of test strips may be stored as long as desired.
[0065] To dispense a test strip, a user opens the lid 224 , and pushes the pushbutton 208 to move the pushbutton 208 from a resting position to a dispensing position. Initially, the tracks 242 on the pushbutton 208 cause the rack gear 238 to engage the intermediate gear 232 . Consequently, movement of the pushbutton 208 causes the rack gear 238 to rotate the intermediate gear 232 . The rotation of the intermediate gear 232 rotates the strip roller gear 228 and causes the strip roller 206 to dispense the test strip 226 which the strip roller 206 contacts. The pushbutton 208 may be configured to completely dispense the test strip 226 out of the storage container 202 , or the test strip 226 may be partially dispensed from the storage container 202 to expose the test strip so that a user may grasp the exposed test strip 226 to completely withdraw the test strip from the storage container 202 .
[0066] After the test strip 226 has been dispensed, the biasing element 244 urges the platform 246 and the stack of test strips 204 against the test strip supporting wall 248 so that a new test strip may be dispensed.
[0067] When a user releases the pushbutton 108 , the configuration of the tracks 242 on the pushbutton cause the pushbutton 208 , along with the rack gear 238 , to move away from and disengage the intermediate gear 232 . Therefore, the pushbutton 208 may be returned to the resting position without rotating the intermediate and strip roller gears 232 , 228 in a reverse direction.
Third Exemplary Embodiment
[0068] Referring to FIGS. 13-14 , a storage vial 300 for storing and dispensing test strips according to a third exemplary embodiment of the present invention includes a storage container 302 configured to store a stack of test strips, a strip roller 306 rotatably disposed in the storage container 302 , and a pushbutton 308 disposed in the storage container 302 . The strip roller 306 contacts one test strip of the stack of test strips. The pushbutton 308 is connected with the strip roller 306 by a gear train so that when the pushbutton 308 is pushed, the strip roller 306 rotates to dispense the test strip in contact with the strip roller 306 .
[0069] The storage container 302 of the third exemplary embodiment of the present invention is generally the same as the storage container 202 of the second exemplary embodiment of the present invention, except for the configuration of the intermediate gear 316 of the gear train and the pushbutton 308 .
[0070] In this embodiment of the invention, the pushbutton 308 does not have tracks for engaging and disengaging the rack gear from the intermediate gear 316 . Instead, the pushbutton 308 has extended guide pins (not shown) which are disposed in and guided by pushbutton guide tracks 310 disposed on the inner surface of the outer wall of the lower body portion 304 of the storage container 302 . The guide tracks 310 are generally parallel to the edge of the lower body portion so that the pushbutton member moves substantially straight into and out of the storage container 302 .
[0071] The intermediate gear 316 of this embodiment of the invention is not supported by a supporting member which extends from the top wall of the storage container. Instead, the intermediate gear 316 has extended shaft portions (not shown) which are disposed in and guided by a pair of intermediate gear guide tracks 312 formed on the inner surface of the outer wall of the lower body portion 304 of the storage container 302 . Accordingly, the intermediate gear 316 is free to move linearly along the length of the intermediate gear guide tracks 312 .
[0072] The method of using the storage vial 300 for storing and dispensing test strips according to the third exemplary embodiment of the invention will now be described. Initially, the storage vial 300 is loaded with a stack of test strips and assembled in substantially the same manner described above.
[0073] To dispense a test strip, a user pushes the pushbutton 308 to move the pushbutton 308 from a resting position to a dispensing position. Initially, a rack gear on the pushbutton 308 engages the intermediate gear 316 , and the intermediate gear 316 moves linearly toward the lower end 314 of the intermediate gear guide tracks 312 . Upon reaching the lower end 314 of the intermediate gear guide tracks 312 , the guide tracks 312 prevent the intermediate gear 316 from any further linear movement. Accordingly, further movement of the pushbutton 308 causes the rack gear on the pushbutton 308 to rotate the intermediate gear 316 . The rotation of the intermediate gear 316 rotates a strip roller gear and causes the strip roller 306 to dispense a test strip. The pushbutton 308 may be configured to completely dispense a test strip, or a test strip may be partially dispensed from the storage container 302 to expose the test strip so that a user may grasp the exposed test strip to completely withdraw the test strip from the storage container 302 .
[0074] When a user releases the pushbutton 308 , a biasing element urges the pushbutton 308 from the dispensing position back to the resting position. During the initial movement of the pushbutton 308 toward the resting position, the intermediate gear 316 translates along the intermediate gear guide tracks 312 to move toward the upper end of the guide tracks. When the intermediate gear 316 moves far enough, it disengages the strip roller gear. Therefore, the pushbutton 308 may be returned to the resting position without rotating the strip roller gear in a reverse direction.
Fourth Exemplary Embodiment
[0075] Referring to FIGS. 15-17 , a storage vial 400 for storing and dispensing test strips according to a fourth exemplary embodiment of the present invention includes a storage container 402 configured to store a stack of test strips 404 , a lid 406 connected to the storage container by a hinge 408 , and a linkage assembly 410 operatively connected to the lid 406 . When the lid 406 is opened, the linkage assembly 410 engages one test strip 412 of the stack of test strips 404 and dispenses the test strip 412 .
[0076] The storage container 402 has a generally rectangular lower body portion 414 and forms a cavity 416 which is configured to store a stack of test strips 404 . The storage container 402 is formed of any suitable material, as previously discussed.
[0077] The storage vial 400 is provided with a lid 406 to prevent humidity and other environmental contaminants from entering the storage container. The lid 406 is connected to the storage vial by a hinge 408 . In the illustrated embodiment, the lid 406 is formed integrally with the lower body portion of the storage container so that it is connected by a living hinge 408 . Any type of hinge arrangement may be used, however. The lid 406 preferably forms a hermetic seal with the lower body portion 414 of the storage container 402 .
[0078] The linkage assembly 410 includes a first arm member 418 connected to the lid 406 , a second arm member 420 connected to the first arm member 418 by a living hinge 428 , and a third arm member 422 connected to the second arm member 420 by a living hinge 428 . The first arm member 418 is a generally V-shaped member. The two legs of the V-shaped member form, in the illustrated embodiment, an obtuse angle with respect to one another. The first arm member 418 is attached to the lid 406 by heat staking, by ultrasonic welding, by mechanical attachment, or by any other suitable method known to those skilled in the art.
[0079] The second arm member 420 joins the first and third arm members 418 , 422 by living hinges 428 at both ends of the second arm. The use of living hinges provide certain benefits, such as lower manufacturing costs, but it should be understood that the arms also may be joined by other types of hinges.
[0080] The third arm member 422 has guide members 430 , such as guide pins, which are disposed in and configured to travel in rails located in the side wall of the lower body portion 414 of the storage container 402 . The third arm member 422 has a lower contacting member 426 which is configured to contact the lower edge of one test strip 412 of the stack of test strips 404 . In particular, in the illustrated embodiment, the third arm member 422 contacts the lower edge of the right-most test strip 412 .
[0081] As illustrated, one set of first, second, and third arm members is provided at the front side of the storage container 402 . For stability, a second set of first, second, and third arm members, which is substantially identical to the first set of first, second, and third arm members, may be located at the back side of the storage container 402 .
[0082] The method of using the storage vial 400 for storing and dispensing test strips according to the fourth exemplary embodiment of the invention will now be described. Initially, the lid 406 is opened, a stack of test strips 404 is loaded into the container between a platform 432 and the outer wall 434 of the storage container 402 , and the lid 406 is closed. With the lid 406 closed, the linkage assembly 410 is placed into a resting position. In the resting position, the third arm member 422 is located at the bottom of the storage container, and the lower contacting member 426 is located underneath the bottom edge of the right-most test strip 412 .
[0083] To dispense a test strip, a user opens the lid 406 of the storage container 402 . The opening of the lid 406 causes the first arm member 418 to rotate up and out of the storage container. The second and third arm members 420 , 422 , which are connected to the first arm member 418 , are also raised. The third arm member 422 travels substantially vertically up due to the cooperation of the guide member 430 and the guide rails and is raised up to a dispensing position. Since the lower contacting member 426 of the third arm member 422 is located under a test strip 412 , it raises and dispenses the test strip 412 . Once the third arm member 422 reaches the dispensing position, a user may grasp the test strip and remove the dispensed test strip 412 . The first, second, and third arm members 418 , 420 , and 422 may be configured to completely dispense the test strip 412 out of the storage container 402 , or the test strip 412 may be partially dispensed from the storage container 402 to expose the test strip so that a user may grasp the exposed test strip 412 to completely withdraw the test strip from the storage container 402 and use the test strip.
[0084] After the test strip 412 has been dispensed, a user may then close the lid 406 . Closing the lid 406 causes the linkage assembly 410 to return to its resting position. When the linkage assembly 410 , and the third arm member 422 in particular, reaches the resting position, the biasing element 436 urges the stack of test strips 404 toward the outer wall 434 so that a new test strip is placed over the lower contacting member 426 of the new test strip. Consequently, the storage vial 400 is ready to dispense another test strip.
Fifth Exemplary Embodiment
[0085] Referring to FIGS. 18-20 , a storage vial 500 for storing and dispensing test strips according to a fifth exemplary embodiment of the present invention includes a storage container 502 configured to store a stack of test strips, a lid 504 connected to the storage container 502 by a hinge 506 , and a linkage assembly 508 operatively connected to the lid 504 . When the lid 504 is opened, the linkage assembly 508 engages one test strip 510 of the stack of test strips and dispenses the test strip.
[0086] The storage container 502 and lid 504 of this embodiment is generally configured the same as the storage container 402 and lid 404 of the fourth exemplary embodiment.
[0087] The linkage assembly 508 includes at least one slider arm 512 , at least one first linkage member 514 , and at least one second linkage member 516 . In the illustrated embodiment, a pair of slider arms 512 , a pair of first linkage members 514 , and a pair of second linkage members 516 are provided to increase the stability and reliability of the linkage assembly.
[0088] First ends 518 of the slider arms 512 are pivotably connected to the lid 504 . Second ends 520 of the slider arms 512 are pivotably connected to the first linkage members 514 . Each of the slider arms 512 has a slot 522 that engages a guide boss 536 disposed on the storage container 502 .
[0089] First ends 524 of the first linkage members 514 are pivotably connected to the second ends 520 of the slider arms 512 , and second ends 526 of the first linkage members 514 are pivotably connected to the second linkage members 516 .
[0090] The second linkage members 516 have guide members 528 , such as guide pins, which are disposed in and configured to travel in guide rails located in the side walls of the storage container 502 . The first ends 530 of the second linkage members 516 are connected to the second ends 526 of the first linkage members 514 . A lower contacting member 534 is disposed between the second ends 532 of the second linkage members 516 . The lower contacting member contacts one test strip 510 so that the test strip 510 is dispensed when the lid 504 is opened.
[0091] The method of using the storage vial 500 for storing and dispensing test strips according to the fifth exemplary embodiment of the invention will now be described. Initially, the lid 504 is opened, a stack of test strips is loaded into the storage container 502 , and the lid 504 is closed. With the lid 504 closed, the linkage assembly 508 is placed into a resting position. In the resting position, the second linkage members 516 are located at the bottom of the storage container 502 , and the lower contacting member 534 is located underneath the lower edge of the bottom edge of the right-most test strip 510 .
[0092] To dispense a test strip, a user opens the lid 504 of the storage container 502 . The opening of the lid 504 causes the slider arms 512 to rotate up and out of the storage container 502 . The slider arms 512 are guided by cooperation of the guide bosses 536 and the slots in the slider arms 512 along a predetermined path. The second ends 520 of the slider arms 512 pull the first linkage members 514 , which, in turn, pull the second linkage members 516 . The second linkage members 516 travel substantially vertically up insider the storage container 502 due to the cooperation of the guide members 528 and guide rails and is raised up to a dispensing position. Since the lower contacting member 534 is located under a test strip, it raises and dispenses the test strip. Once the second linkage members 516 reach the dispensing position, a user may grasp the test strip and remove the dispensed test strip. The slider arms 512 and the first and second linkage members 514 , 516 may be configured to completely dispense a test strip out of the storage container 502 , or the test strip may be partially dispensed from the storage container 502 to expose the test strip so that a user may grasp the exposed test strip to completely withdraw the test strip from the storage container and use the test strip.
[0093] After the test strip has been dispensed, a user may then close the lid 504 . Closing the lid 504 causes the linkage assembly 508 to return to its resting position. When the linkage assembly 508 , and the second linkage members 516 in particular, reach the resting position, a biasing element urges the stack of test strips towards the side wall of the storage container 502 so that a new test strip is placed over the lower contacting member. Consequently, the storage container 502 is ready to dispense another test strip.
Sixth Exemplary Embodiment
[0094] Referring to FIG. 21 , a storage vial 600 for storing and dispensing test strips according to a sixth exemplary embodiment of the present invention includes a storage container 602 configured to store a stack of test strips, a spiral pusher spring 604 , and a thumbwheel 606 connected to the spiral pusher spring 604 by a gear train 628 so that rotation of the thumbwheel 606 causes the spring to dispense one test strip of the stack of test strips.
[0095] The storage container 602 is generally rectangular and forms a cavity 612 which is configured to receive a cartridge 610 for storing a stack of test strips. The storage container 602 may be formed of any suitable material, as previously discussed.
[0096] The storage vial 600 is provided with a lid 608 to prevent humidity and other environmental contaminants from entering the storage container 602 . The lid 608 may be connected to the storage vial by any suitable type of hinge, such as a living hinge.
[0097] A cartridge 610 is inserted into the cavity in the storage container 602 . The spiral pusher spring 604 and the associated gear train 628 are disposed in the cartridge 610 . The cavity 612 in the cartridge 610 is configured to hold a stack of test strips, and a platform, as well as a biasing element, are located in the cavity to urge the stack of elements toward one wall of the cartridge 610 . The cartridge 610 may be removable from the storage container 602 or permanently affixed thereto.
[0098] The spiral pusher spring 604 is wound around a cylindrical spring drum 614 . A first end 616 of the spiral pusher spring 604 is disposed in a guide track 618 formed in the cartridge 610 . A second end 620 of the spiral pusher spring 604 is fixed to the cylindrical spring drum 614 . The first end 616 of the spiral pusher spring 604 is configured to contact the edge of a test strip. Accordingly, when the spring drum 614 is rotated, the first end 616 of the spiral pusher spring 604 is extended and moves along the guide track 618 to dispense a test strip.
[0099] In the illustrated embodiment, the gear train 628 comprises a thumbwheel driving gear 606 , a first idler gear 622 , a second idler gear 624 , and a spring drum driving gear 626 . The thumbwheel driving gear 606 is partially exposed to the outside of the storage container 602 so that a user may manipulate the thumbwheel 606 . The first and second idler gears 622 , 624 engage the thumbwheel 606 , and transmit a rotational force generated by the thumbwheel 606 to the spring drum driving gear 626 . The gear train 628 may be configured with any desired gear ratios.
[0100] The method of using the storage vial 600 for storing and dispensing test strips according to the sixth exemplary embodiment of the invention will now be described. Initially, a stack of test strips is loaded into the cartridge 610 , the spiral pusher spring 604 is retracted into an initial resting position, and the cartridge is inserted into the storage container 602 . In the resting position, the spiral pusher spring 604 is retracted so that the end of the spring is located at the bottom of the storage container 602 and is underneath the lower edge of one edge of a test strip.
[0101] To dispense a test strip, a user rotates the exposed thumbwheel 606 in a dispensing direction. The rotational force of the thumbwheel 606 is transmitted to the spiral pusher spring 604 through the gear train 628 . The spiral pusher spring 604 is extended and dispenses the test strip. The thumbwheel 606 may be rotated so that the test strip is completely dispensed out of the storage container 602 , or the test strip may be partially dispensed from the storage container 602 to expose the test strip so that a user may grasp the exposed test strip to completely withdraw the test strip and use the test strip.
[0102] After the test strip has been dispensed, a user may then rotate the thumbwheel 606 in an opposite direction to the dispensing direction to return the spiral pusher spring 604 to its resting position. Alternatively, the inherent spring force of the spiral pusher spring 604 may cause it to return to its resting position automatically. When the spiral pusher spring 604 reaches the resting position, the biasing element urges the stack of test strips towards the spiral spring so that a new test strip is placed over the end of the pusher spring. Consequently, the storage container 602 is ready to dispense another test strip.
Seventh Exemplary Embodiment
[0103] Referring to FIG. 22 , a storage vial 700 for storing and dispensing test strips according to a seventh exemplary embodiment of the present invention includes a storage container 702 configured to store a stack of test strips, a spring 704 configured to contact one test strip of the stack of test strips, a rack 706 connected to the spring 704 , a pinion 708 engaging the rack 706 , and a thumbwheel 710 engaging the pinion 708 so that rotation of the thumbwheel 710 displaces the rack 706 and causes the spring 704 to dispense the contacted test strip.
[0104] The storage container 702 and lid of this embodiment is generally configured the same as the storage container 702 and lid of the sixth exemplary embodiment.
[0105] A cartridge 712 is inserted into a cavity 714 in the storage container 702 502 . The cartridge 712 has a cavity which is configured to hold a stack of test strips, and a platform, as well as a biasing element, are located in the cartridge 712 to urge the stack of test strips toward one wall of the cartridge 712 . The cartridge 712 may be removable from the storage container 602 or permanently affixed thereto.
[0106] The spring 704 is disposed in a guide track 722 formed in the cartridge 712 . A first end 716 of the spring 704 is guided by the guide track 722 and is configured to contact the edge of a test strip. A second end 718 of the spring 704 is fixed to the rack 706 .
[0107] The rack 706 is linearly movable within the storage container 702 . The rack 706 has a rack gear 720 located on one side of the rack.
[0108] A pinion gear 708 is rotatably disposed on the cartridge 712 , and engages the rack gear 720 .
[0109] The thumbwheel 710 is also rotatable disposed on the cartridge 712 , and engages the pinion gear 708 . Accordingly, when the thumbwheel 710 is rotated, the pinion gear 708 rotates, and the rack 706 translates linearly. Thus, the first end of the attached spring 704 is moved along the guide track 722 .
[0110] The method of using the storage vial for storing and dispensing test strips according to the seventh exemplary embodiment of the invention will now be described. Initially, a stack of test strips is loaded into the cartridge 712 , the pusher spring 704 and rack 706 are placed into an initial resting position, and the cartridge is inserted into the storage container 702 . In the resting position, the rack 706 and pusher spring 704 are retracted so that the end of the spring 704 is located at the bottom of the storage container 702 and is underneath the lower edge of one edge of a test strip.
[0111] To dispense a test strip, a user rotates the exposed thumbwheel 710 in a dispensing direction. The rotational force of the thumbwheel 710 is transmitted to the pinion 708 gear, and the pinion gear 708 engages the rack 706 gear to translate the rotational force of the pinion gear 708 into linear movement of the rack 706 . The linear movement of the rack 706 extends the pusher spring 704 , and dispenses the test strip. The thumbwheel 710 may be rotated so that the test strip is completely dispensed out of the storage container 702 , or the test strip may be partially dispensed from the storage container 702 to expose the test strip so that a user may grasp the exposed test strip to completely withdraw the test strip and use the test strip.
[0112] After the test strip has been dispensed, a user may then rotate the thumbwheel 710 in an opposite direction to the dispensing direction to return the pusher spring 704 to its resting position. Alternatively, the pusher spring can return to its resting position automatically. When the pusher spring 704 reaches the resting position, the biasing element urges the stack of test strips towards the pusher spring 704 so that a new test strip is placed over the end of the pusher spring 704 . Consequently, the storage container 702 is ready to dispense another test strip.
Eighth Exemplary Embodiment
[0113] Referring to FIGS. 23-24 , a storage vial 800 for storing and dispensing test strips according to an eighth exemplary embodiment of the present invention includes a storage container 802 configured to store a stack of test strips rack, a spring 804 configured to contact one test strip of the stack of test strips, and a lever arm 806 that pivots about a pivot point 808 . A first end 810 of the lever arm 806 is connected to the spring 804 to drive the spring 804 so that pivoting of the lever causes the spring 804 to dispense the contacted test strip.
[0114] The storage container 802 and lid (not shown) of this embodiment is generally configured the same as the storage container 602 and lid 608 of the sixth exemplary embodiment.
[0115] A cartridge 814 is inserted into a cavity in the storage container 802 . A cavity in the cartridge 814 is configured to hold a stack of test strips, and a platform, as well as a biasing element, are located in the cavity to urge the stack of test strips toward one wall of the cartridge. The cartridge 814 may be removable from the storage container 802 or permanently affixed thereto.
[0116] The spring 804 is disposed in a guide track 818 formed by the cartridge and 814 . The first end 820 of the spring 804 is guided by the guide track 818 and is configured to contact the edge of a test strip 816 . A second end 822 of the spring 804 is fixed to a first end 810 of the lever arm 806 .
[0117] The lever arm 806 is pivotably disposed about a pivot point 808 on the cartridge. The second end 824 of the lever arm 806 extends above the top end of the cartridge so that a user may manipulate the lever arm 806 .
[0118] The method of using the storage vial 800 for storing and dispensing test strips according to the eighth exemplary embodiment of the invention will now be described. Initially, a stack of test strips is loaded into the cartridge 814 , the lever arm 806 and the pusher spring 804 are placed into an initial resting position, and the cartridge is inserted into the storage container 802 . In the resting position, the lever arm 806 is pivoted to one side of the storage container 802 , and the pusher spring 804 is retracted so that the end of the spring 804 is located at the bottom of the storage container 802 and is underneath the lower edge of one edge of a test strip.
[0119] To dispense a test strip, a user presses the lever arm 806 to pivot the lever arm 806 . The pivoting of the lever arm 806 causes the pusher spring 804 to extend along the guide track, and dispenses the test strip. The lever arm 806 is pivoted far enough for a user to grasp the test strip and remove the dispensed test strip.
[0120] After removing the test strip, a user may then pivot the lever arm 806 back to its initial resting position. Alternatively, the lever arm may return to its resting position automatically. When the lever arm 806 reaches the resting position, the biasing element urges the stack of test strips towards the pusher spring 804 so that a new test strip is placed over the end of the pusher spring 804 . Consequently, the storage container 802 is ready to dispense another test strip.
[0121] While various embodiments have 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. | An apparatus for storing and dispensing a test strip includes a container configured to store a stack of test strips. The container maintains appropriate environmental conditions, such as humidity, for storing the test strips. An engaging member is disposed in the container and is adapted to contact one test strip of the stack of test strips. An actuator actuates the engaging member to dispense the one test strip from the container. Since one test strip is dispensed at a time, the remaining test strips are not handled by the user. Accordingly, the unused test strips remain free of contaminants such as naturally occurring oils on the user's hand. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a filed of manufacturing micro-channel chips, particularly to the structure and the integration of micro-components of the micro-channel chip system.
2. Description of the Related Art
A micro-channel chip is a main technique for the laboratory on a chip. In the same way as computation chips, the reliable integration is an important part to decide whether the laboratory on a chip can be applied to various laboratory researches and habitual medical inspections, such as life science, chemistry and physics. As the high-scale integrated circuit (IC) benefits from the photoetching technique, so problems of high-scale integrated micro-fluidic circuits (IFC) related to the integration, costs, stability and adaptability can be solved if micro-components of the micro-fluidic circuit, namely micro-channel circuit, are like IC to be formed by photoetching.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a micro-channel chip which allows multiple micro-components of the micro-channel chip, such as micro-pumps, micro-valves, unicellular or multicelluar experimental units, gas exchange units, to be photoetched and formed at one time and further applies the industrialized printing technique to attain multi-layered and high-integrated micro-channel chips with low cost manufacturing.
To attain the above objective, the present invention provides a solution as follows:
An important dynamic component of a micro-channel chip focuses on a micro-pump integration design, which includes two gas control channels, a liquid inlet channel, a liquid outlet channel, a piston channel, and a micro-pump which includes two micro-valves and a plurality of micro-channels. One of the gas control channels communicates with one end of the piston channel and communicates with the two micro-valves and the liquid inlet channel respectively via the micro-channels. The other one of the gas control channels communicates with the two micro-valves and the liquid outlet channel respectively via the micro-channels. The other end of the piston channel communicates with one of the micro-valves via the micro-channels.
The micro-channels are gradually narrowed.
The micro-pump is characterized in that such structure can be designed within an area of one square millimeter on the chip and can be designed into a smaller dimension according to demand to attain the high density of integration.
The micro-pump is characterized in that the digital gas pressure operated by a driving pump can be controlled to lessen from three channels to two channels, thereby simplifying the order sequence of control signals.
The micro-pump is characterized in that such structure possesses a high fault-tolerant recovery function, which does not need to be pre-input at time of initialization and attains a strong capability of resisting the bubble block while operating. The restoring procedure of the pump is effective and easy to operate.
The micro-pump is characterized in that such design is a single-layered geometrical space structure on the planar surface and is extraneous to the physical material of the chip. The adoption of other materials like plastic materials which are likely to be manufactured in industrialization (printing manufacture) as the chip basic material does not affect the achievement of its functions. Therefore, the structure can be applied to the chip with other materials, such as glass, silicon sheets, and composite materials like plastic materials.
The aforesaid features of the micro-pump design allow the design to be compatible with multiple micro-components formed by photoetching, such as micro-pumps, micro-valves, unicellular or multicelluar experimental units, and gas exchange units and to attain an integration of the multi-functional chip on a designed planar surface via an integrated design.
The aforesaid integrated chips on the planar surface can be connected with each other through a middle chip with holes in order to develop the design of integration or other functions on a direction of the normal line (the third dimension) of the planar surface of the chip.
The aforesaid single-layered design can be directly applied to industrialized printing production. By the middle layer with holes, the multi-layered high-scale integrated chips can be made. The multi-layered chips can be industrially printed in amass production as well.
According to the above structure, the new micro-pump of the micro-channel chip and the aforesaid micro-components can execute a single-layered or multi-layered high-density integration on hard materials, such as glass and silicon sheets, and can also set at a high-density integration on other elastic materials like plastic materials and execute a printing production, thereby fulfilling the high-scale integrated micro-channel chip with industrialization and low cost manufacturing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a -1 c are schematic views showing a designed micro-pump within one square millimeter, and the micro-pump is formed by one-time glass etching. The black area of the mask design (a) shows the etching area, and the blue grid in the figure shows the area of one square millimeter (the side length of the small grid is 100 millimeters); (b) shows the situation after the one-time glass etching; and (c) shows that the micro-fluid (orange) is pushed by the pump and goes from the lower vertical channel pump to the left horizontal channel while operating.
FIGS. 2 a -2 d are schematic views showing the initialization of the pump. The liquid in the empty micro-channel system (a) can enter (shown in the red mark in (b)) from the inlet passage (the input channel in a lower place of the figure); the redundant liquid of the gas control channels (GC 1 ,GC 2 ) is pushed into the liquid channel (c) while imparting the adequate gas pressure until the gas and liquid interface reaches JC 1 or JC 2 (d);
FIGS. 3 a -3 f are schematic views showing the driving principle on which the pump is based under the digital gas pressure control; the circulation of the pump is driven by the two-channel digital command (yellow numbers in the figure); after the initialization of the pump (a, 0s), a loading process is conducted firstly (b, 1 s, red arrows; c, 3 s), then the liquid enters the piston via JC 2 , and thence the liquid inside the piston is pushed into the outlet channel (d, 8 s, red arrows; e, 9 s) when 7s pump proceeds the outputting stage; and thereafter back to the initialization stage (f, 13 s);
FIG. 4 is a schematic view showing a measurement of the output efficiency of the pump, where the liquid output by the pump enters a vertical tube for being measured;
FIG. 5 is a schematic view showing a calculated result of the output of the pump, where the relationship between the output of the pump bulk and the press head is shown;
FIG. 6 is a schematic view showing the pump in a real chip;
FIG. 7 is a schematic view showing a unicellular chip structure formed by one-time photoetching;
FIG. 8 is a schematic view showing a multicelluar chip structure formed by one-time photoetching;
FIG. 9 is a schematic view showing a gas exchange chip structure formed by one-time photoetching;
FIGS. 10 a -10 b are schematic views showing the chip structure of the valve-piston-valve pump formed by one-time photoetching;
FIG. 11 is a schematic view showing a technique of manufacturing the low-cost chip by printing technique (this figure is cited from Micromech. Microeng. 21 (2011);
FIG. 12 is a schematic view showing a glass chip integrated into 529 pumps on a glass of 6 cm side length via the one-time etching technique;
FIGS. 13 a -13 b are schematic views showing the integration of the multi-layered chips, where two chips are integrated via the chip with holes; and
FIG. 14 is a schematic view showing the industrialized production of multi-layered high-integration micro-channel chips.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. The Integration Design of the Micro-Pump
Referring to FIG. 1 a , in order to design the micro-pump into a micro-component which is smaller, more stable to operation and easier to attain the high integration, the present invention has the following features: A. The integral design is disposed within a square area of 1 mm 2 to facilitate an easy arrangement in the design, and the dimension can reach the standard of integration smaller than the millimeter; B. the piston and the inlet valve (valve 1 ) are integrated to allow the inlet valve and the piston to use the same gas pressure signal, thereby decreasing the burden of the control signal and further lessening the space where the design occupies; C. Two square channels (JC 1 ,JC 2 ) of 100 millimeters are adopted between every channel for connecting, and such channel having the aspect ratio (length-width ratio) of 1:1 can simplify the structure and make the operation more reliable to facilitate the fault treatment and restoring step, whereby the design itself increases the capability of resisting the bubble block as well.
By using the mask shown in FIG. 1 a to execute the photoetching process, micro-channel systems communicated with each other can be obtained ( FIG. 1 b ). The joints between these channels are defined as holes far smaller than the channels themselves. Liquid can flow through the hole but the gas and liquid interface cannot travel through the hole within a certain range of pressure difference due to the force of the surface tension, thereby attaining a function of blocking switches. The hole in the figure is denoted by the letter “M”. While the liquid is full as shown the red part in FIG. 1 c , the liquid occupies the liquid channel, and the gas occupies the gas channel under the preservation of the strong gas pressure. The gas channel is used to control and drive the gas, and the liquid channel is the passage where the fluid travels and where the fluid is driven to generate the press head.
2. Working Principle of the Micro-Pump
Due to the requirement of integration, the design of the micro-valve utilizes the space thoroughly, and the channels are tightly connected. Such a dense design does not affect the normal operation of the pump. FIGS. 2 a -2 d show the initialization process before the pump is operated. The advantage of the pump is that the pump does not need to be filled in advance, and liquid ( FIG. 2 b ) can be directly poured into the hollow channel system ( FIG. 2 a ) of the pump via the inlet channel (input). After imparting the initializing gas pressure, the gas and liquid interface is pushed by the gas pressure ( FIG. 2 c ) to the joints of JC 1 and JC 2 ( FIG. 2 d ), thereby fulfilling the initialization of the pump.
After the initialization, the pump can be driven by a command sequence of a digital gas pressure and operated. First, the initial gas pressure at the two control channels (GC 1 and GC 2 ) are set at 1 (1 denotes the high gas pressure, 0 denotes the low gas pressure, shown in FIG. 3 a ). The GC 1 is switched to 0 and the valve of GC 1 is opened, whereby liquid flows into a piston channel ( FIG. 3 b ). When the piston channel is filled with the liquid ( FIG. 3 c ), the pressure of GC 1 is switched to 1, and the pressure of GC 2 is switched to 0, thereby attaining the close state of GC 1 valve and the open state of GC 2 valve. Accordingly, the liquid in the piston channel can only pass the valve 2 and enter the outlet channel under the gas pressure and cannot go back to the inlet channel ( FIG. 3 d ). After the liquid in the piston is all output to the outlet channel ( FIG. 3 e ), GC 2 is set at 1, and the outlet valve is closed ( FIG. 3 f ), thereby becoming the initializing state. Such operation is circulated and repeated to allow the pump to activate and make the liquid in the inlet channel go into the outlet channel. The important part is that the piston channel is much longer than the valve channel, and the completion of the close of the valve of the high pressure chamber is much earlier than the piston driving action, whereby the same high-pressure device can fulfill a dual-function which closes the valve of GC 1 firstly and thereafter makes the liquid in the driving piston go into the outlet channel.
3. Performance Test of the Micro-Valve
FIG. 4 shows the output performance of a micro-valve, wherein the pump is able to output the pure water to the height of 40 mm, and the efficiency of the bulk output is measured ( FIG. 5 ). Under the maintenance of bulk output at the velocity of 0.5-0.7 nl/s, the press head can reach to about 300 Pa.
4. Compatibility of Integrating the Micro-Valve and Other Micro-Components
FIG. 6 is an appearance of a glass chip of the micro-valve, wherein the entire structure exists on a planar surface between two glass. Because other micro-components, such as the unicellular experimental unit ( FIG. 7 ), the multicelluar experimental unit ( FIG. 8 ), the gas exchange unit ( FIG. 9 ) and the micro-valve ( FIG. 10 ), can use the same technique and can be made on a same mask, thereby fulfilling the same chip integration having chip micro-components with different functions. The appearance of the made chip is similar to the appearance of FIG. 6 , and various structures are able to exist between the two glass.
5. Industrialized Production of the Integrated Chip
Because the space structure of the micro-channels can be rolled by using the rolling sleeve (in a convex-concave design) with a micro-channel pattern ( FIG. 11 ), it especially adapted to the micro-components with the single-layered and simple design. Therefore, the top and bottom glass as shown in FIG. 6 can be replaced by other printable rolled materials, such as plastic materials, thereby executing the industrialized production and manufacturing the chip with very low cost.
6. Multi-Layered Integration Method of the Chip
Taking the space reserved between the pumps into consideration, an interstice of 1 mm can be set between the pumps. Therefore, more than 500 independent micro-valves ( FIG. 12 ) can be integrated on the single-layered planar chip of 50×50 mm (plus a square chip with a margin of 60×60). If a middle layer is utilized to execute the top-bottom communication ( FIGS. 13 a -13 b ), the top and bottom micro-channels, which can be gas channel or the liquid channel, are integrated together to become a dual-layered chip structure. By this method, more layers can be superimposed to attain the multi-layered chips to solve the problem of the integration of solid multi-layered chips. As aforesaid, such multi-layered chips can execute a mass production by using the industrial printing method, as shown in FIG. 14 . | A micro-channel chip comprises two gas control channels, a liquid inlet channel, a liquid outlet channel, a piston channel, and a micro pump including two micro-valves and a plurality of micro-channels. One of the gas control channels communicates with one end of the piston channel and communicates with the two micro-valves and the liquid inlet channel respectively via the micro-channels. The other one of the gas control channels communicates with the two micro-valves and the liquid outlet channel respectively via the micro-channels. The other end of the piston channel communicates with one of the micro-valves via the micro-channels. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to the construction for a heddle frame which includes top and bottom frame slats, each of which has a heddle rod integral therewith, or attached thereto, which supports heddles in the frame. The heddles include central thread eyes in which the individual warp yarn ends are held during shedding operations on the loom. The heddles are typically constructed of metal and are attached to the heddle rod by means of U-shaped slots in which the heddle rod is received.
The majority of the high-speed weaving machines, in use presently in the textile industry, provides for a 12 mm. space for each harness frame. Each frame in the set of frames is actuated by levers and cams all in side by side relationship. One or more of fixed nose guides on each frame, having a thickness essentially equal to the 12 mm. pitch between the center lines of the frames, serve to keep the thinner (generally 9 mm.) harness slats from clashing together.
Manufacturers of high-speed weaving machines recognize that the stroke of the shed opening could be reduced and the weaving machine speed increased if the pitch of the harness frames could be reduced to 10 mm. or less. Unfortunately, the currently popular asymmetrical riveted rod construction is not practical from clearance and strength standpoints when all dimensions of the slats are simply reduced.
A typical slat in use currently is shown in U.S. Pat. No. 4,633,916, issued Jan. 6, 1987 to John L. Rast and owned by the assignee of the present application. The slat disclosed in this patent greatly reduced the weight of the heddle frames and thereby led to increases in the weaving machine speeds because of the reduced weight. However, the problem arises that the asymmetrical slat disclosed in this patent still requires a greater pitch due to clearance and strength limitations, than a symmetrical slat according to the present invention.
Accordingly, an important object of the present invention is to provide a heddle frame assembly having a heddle slat which can be reduced in thickness without weakening the structure of the frame.
It is another object of the invention to provide a heddle frame slat which has a heddle support bar that is symmetrical.
It is still another important object of the invention to provide a heddle with symmetrical U-shaped open ends for engaging the heddle bar and avoiding accidental disengagement therefrom.
SUMMARY OF THE INVENTION
The above objects are accomplished according to the present invention by providing a heddle frame assembly for a loom which utilizes a frame slat at the top and bottom of a generally hollow rectangular nature having along one of its longitudinal edges, either integral therewith or attached thereto, a heddle bar for supporting heddles. The vertical longitudinal axis of the slat extends also through the axis of the heddle support bar so as to produce a completely symmetrical frame slat.
Extending from each side of the heddle support bar are opposed heddle support surfaces which are wear-resistant and adapted to engage hook portions of the heddle. The invention also includes a heddle having a U-shaped open end with two extending arms terminating in inwardly converging hooks for engaging outwardly diverging heddle support surfaces of said heddle bar for retaining the heddles on said bar.
BRIEF DESCRIPTION OF THE DRAWINGS
The construction designed to carry out the invention will hereinafter be described, together with other features thereof.
The invention will be more readily understood from a reading of the following specification, and by reference to the accompanying drawings forming a part thereof, wherein examples of the invention are shown, and wherein:
FIG. 1 is a front elevation illustrating a heddle frame assembly for a loom having frame slats and heddles constructed according to the instant invention;
FIG. 2 is a sectional view taken along lines 2--2 of FIG. 1;
FIG. 3 is a perspective view of the upper slat shown in FIG. 2;
FIG. 4 is a partial sectional view similar to that shown in FIG. 2, illustrating a second embodiment of the heddle bar construction of the invention;
FIG. 5 is a sectional view similar to FIG. 4 illustrating a third embodiment of the heddle bar of the invention;
FIG. 6 is a sectional view similar to FIG. 4 showing a fourth embodiment of a heddle bar according to the invention;
FIG. 7 is a sectional view of a fifth embodiment of the heddle bar according to the invention; and
FIG. 8 is an elevation view of the heddle of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a vertically reciprocating heddle frame assembly on a weaving machine which holds the warp ends and raises and lowers the warp ends during shedding. Since the structural and operational features of weaving machines are well known, only so much of the weaving machine and heddle frame assembly is illustrated as is necessary for an understanding of the present invention.
Referring now to FIGS. 1, 2, and 3 of the drawings, a heddle frame is designed generally as 10 in FIG. 1 and includes top frame slat 12 and bottom frame slat 14, which are identical in construction. The frame assembly also includes side frame members 16 which connect the top and bottom slats and maintains them in a parallel spaced position. Each of the top and bottom slats also includes a heddle support bar 30 and the frame assembly comprises a plurality of open-ended heddles 18 which extend between the heddle bars of the heddle frame assembly.
As pointed out above, each of the frame slats are identical and FIGS. 2 and 3, while showing the construction of the top frame slat and its relationship with the open end heddle, is intended to illustrate the frame slats used in the top and the bottom of the heddle frame assembly seen in FIG. 1. Referring now more particularly to FIGS. 2 and 3 wherein is shown top slat 12 which comprises a rectangular portion 20. Rectangular portion 20 comprises a cap outer 22 constructed of a pultrusion of resin reinforced by carbon fiber for adding rigidity and strength to the frame slat. A lower inner reinforcing pultrusion 24 is provided at the opposite longitudinal edge of the frame slat for stiffening and reinforcing the slat. In this embodiment, the front wall 26, composed of sheet steel or other rigid material, bridges the space between cap 22 and the lower pultrusion 24 and is bonded to both 22 and 24 by an epoxy glue or the like as may be suitable to the material selected.
A rear wall 28 also bridges the space between the cap 22 and lower pultrusion 24 of the frame slat. Interposed between cap 22 and lower pultrusion 24 and front wall 26 and rear wall 28 is a filler 29 which may be comprised of foam or a nylon honeycomb structure such as that illustrated in U.S. Pat. No. 4,633,916, identified above. The filler material is lightweight in construction yet renders the slat rigid in use.
The front and rear walls 26 and 28 extend beyond the lower edge of the slat to form a heddle support bar 30. The heddle support bar comprises J-shaped extensions 32 and 34 of each of the front and rear walls. The walls 26 and 28 are bonded together at 31 by means of spot welding, adhesive, or the like. Fitted within the J-shaped extensions 32 and 34 are angled front wear-resistant heddle support element 36 and rear wear-resistant heddle support element 38, respectively. Support elements 36 and 38 are securely retained within the U-shaped portions of the wall extensions by means of thermoplastic glue or interference fit but can be replaced whenever they wear out. A vertical plane extending along the longitudinal axis of slat 12 also extends to the longitudinal axis of the heddle support bar 30 as seen in FIG. 2.
Disposed on heddle support bar 30 is a plurality of open-end heddles 18 which are typically constructed of metal and include central thread eyes through which individual warp yarns are drawn and held during shedding on the weaving machine. Each end of heddle 18 is provided with a U-shaped opening 40. U-shaped opening 40 comprises vertically extending front arm 42 and rear arm 44 which terminate at their free ends in front hook 46 and rear hook 48. As seen in FIG. 2, the heddle supporting surface of the front and rear wear-resistant heddle supports 36 and 38 are angled so that their heddle supporting surfaces extend in planes which intersect each other and which also intersect the longitudinal vertical plane taken through the longitudinal axis of the slat and the heddle support bar. The planes of supports 36 and 38 diverge from the vertical plane towards the rectangular portion of the slat. The surfaces of hooks 46 and 48 where they contact the heddle supports 36 and 38 extends in planes which intersect each other and which intersect the vertical plane taken through the slat 12. This surface mates with the heddle support surfaces so that a downward force applied to heddle 18 causes hooks 46 and 48 to be cammed towards the vertical plane so as to retain the heddle on the heddle bar and to avoid accidental disengagement of the heddle therefrom.
It is to be noted that the thickness of slat 12 can be greatly reduced from what was possible with the prior art slat because of the symmetrical construction of the slat and the heddles herein. A thickness of 6.6 mm. for the slat has been found to be adequate to permit a 9 mm. pitch of the weaving machine. As pointed out above, this enables the manufacturer of the weaving machine to produce machines which will permit greater operating speeds thereof.
Referring now to FIG. 4 where a second embodiment of the heddle support bar is shown. In this embodiment, the heddle support bar is formed from the folded ends of walls 26 and 28 into a heddle support bar 50 which has a front heddle support surface 52 and a rear heddle support surface 54. Support surfaces 52 and 54 in this embodiment are hardened to make them wear resistant at the point where the hooks of the heddles 18 come into contact with them. In this embodiment, the surfaces of 52 and 54 lie in planes that intersect with each other and with the vertical plane extending through the vertical axis of the slat. The planes of surfaces 52 and 54 diverge in the direction of the slat rectangular portion and converge to intersect the vertical plane passing through the vertical axis of the slat at a point between the free end of the heddle bar and the point of contact with the heddle itself. In this embodiment, the same heddle disclosed in FIG. 2 and shown in FIG. 8 is used and its hook surfaces conform with the surfaces of 52 and 54.
Reference now is had to FIG. 5 wherein a third embodiment of the slat is illustrated. In this embodiment, walls 26 and 28 terminate adjacent to the pultrusion 24 and heddle support bar 56 is formed of an extruded T-shaped piece of aluminum to which are bonded wear-resistant front heddle support 60 and rear heddle support 62. The leg of the vertical bar of the T-shaped extruded aluminum foot 57 is connected to slat 12 by means of a rivet or the like 59 it being understood that a plurality of rivets would be extending through the vertical leg of the T and the walls 26 and 28 all along the longitudinal edge of the slat and that the vertical leg of the T would extend into a groove or notch within pultrusion 24 in this embodiment. In this embodiment, heddle support surfaces 60 and 62 are wear-resistant and are bonded or glued to the surface of foot 57 by appropriate means. The support surfaces 60 and 62 lie in planes that intersect each other and that intersect a vertical plane extending longitudinally of the slat through the vertical axis of the slat and the vertical axis of foot 57 so as to intersect the vertical plane at a point which is closer to the end of bar 56 than it is to where such surfaces contact the hooks of heddle 18.
Referring now to FIG. 6 wherein a fourth embodiment of the invention is illustrated. In this embodiment, heddle support bar 64 comprises an extruded aluminum extension bar foot 67 which is extruded integrally with walls 26 and 28. In this embodiment, the heddle support bar foot 67 is square and has attached to it a U-shaped heddle support composed of wear-resistant surfaces 70 and 72 which are cut at an angle for supporting the heddle hooks 46 and 48. Surfaces 70 and 72 lie in planes which intersect the longitudinal vertical plane of the slat at a point between the end of the heddle bar 64 and the point the heddle hooks contact said heddle supporting surfaces 70 and 72.
Referring now to FIG. 7 wherein a fifth embodiment of the heddle support bar is illustrated. In this embodiment, heddle support bar 74 comprises an extension 76 of the slat and a foot 77 which is T-shaped and integral with walls 26 and 28 of the slat. Walls 26 and 28 and T-extension 76 and 77 are all integrally extruded from aluminum. Disposed on the upper surfaces of foot 77 are front heddle support 78 and rear heddle support 80. The front and rear heddle supports are composed of a wear-resistant, case hardened metal which is bonded or spot welded to the foot 77. The surfaces of support 78 and 80 lie in planes which intersect each other and also the vertical plane extending along the vertical axis of heddle support bar 74 and slat 12 at a point which is closer to the free end of the heddle support bar than the point at which the heddle contacts the support surfaces.
Referring now to FIG. 8 wherein the heddle of the invention is illustrated. Heddle 18, as shown, has an open end 40 on each end of the heddle and arms 42 and 44 which terminate in hooks 46 and 48 for engaging the heddle bars of the invention.
While several embodiments of the invention have been described using specific terms, such description is for illustrative purposes, and it is to be understood that changes and variations may be made therein without departing from the spirit and the scope of the following claims. | A heddle frame assembly for a weaving machine comprising elongated top and bottom slats supported at each end by side members. Each of the top and bottom slats includes a symmetrically depending heddle support bar at one of its edges. The heddle support bar includes opposed heddle support surfaces which lie in intersecting planes which intersect with a vertical plane taken through the longitudinal axis of the slat at a point which is between said heddle support surface and the free end of the heddle bar. | 3 |
FIELD OF THE INVENTION
The present invention relates to the fabrication of an optical waveguide device for tapping out a small amount of power from a light signal guided in a planar waveguide. The invention discloses a compact and low-loss optical structure that taps light out with low excess loss. The response of the optical tap structure can also be substantially independent of the wavelength and the polarization of the light signal.
BACKGROUND OF THE INVENTION
The manipulation of input and output light signals to and from optical fiber transmission lines generally requires that the signals be processed in some fashion, examples of which might include amplification, power splitting or the addition and/or dropping of signals. With the persistent trend towards miniaturization and integration, the optical circuits which best serve these processing functions are more and more being integrated on optical chips as a single module. The resulting optical circuits, which carry channel waveguides as their fundamental light-guiding elements, are generally referred to as planar lightwave circuits or PLCs. Current planar waveguide technology typically prepares a PLC by depositing a sequence of three glass films (lower cladding, core and upper cladding) on a rigid planar substrate and utilizing photolithography to pattern the required waveguide and component designs into the core layer. The refractive index of the core composition is chosen to be larger than those of the cladding layers to ensure good optical confinement within the core waveguides.
In optical networks it is necessary to monitor the level of the propagating light signal at several points in the system. As more and more functions are integrated in photonic lightwave circuits, integrated tapping devices, tapping a small fraction of the light, are needed to monitor the signal power. Although Y-branching circuits with equal power division are fundamental building blocks for optical signal processing devices, any asymmetric adaptation of this form with a branching angle large enough to achieve compactness is unable to tap out a sufficient power fraction for many applications. An optical tap representing the current art typically comprises a pair of side-by-side channel waveguides, or directional couplers, in which structure the light signal in one waveguide is evanescently coupled to the other waveguide. The fraction of light tapped-out (tap efficiency) is controlled by the distance between the two waveguides and the by the length along which they couple. Unfortunately, the optical response of a directional coupler in general depends strongly both on the polarization and wavelength of the light signal to be tapped, a characteristic that is undesirable for a versatile optical network component.
Two types of integrated optical taps have been proposed that are both polarization independent and wavelength insensitive. FIG. 1 illustrates the optical tap proposed by Henry et al. (U.S. Pat. No. 5,539,850). The invention comprises two directional couplers 101 and 102 in series in which the second coupler 102 compensates for the wavelength and polarization dependencies of the first coupler 101 . The light signal is input at port 103 and most of it exits at port 104 , while a small amount is tapped off to port 105 . This design, however, has several disadvantages. For example, the size of such a coupler cascade is large (typically a few mms), and it also possesses an inherent loss mechanism due to light dumped from port 106 of the device. A different design for a compact integrated tap has been disclosed by Adar et al. (U.S. Pat. No. 5,276,746) and is illustrated in FIG. 2 . It utilizes the guide-interaction properties of an X waveguide crossing to tap out a low level (−20 dB to −60 dB) signal. Light signal is input in port 201 , passes through the X-crossing 202 and most of the light exits at port 203 while a small amount of power is tapped off to port 204 . Due to symmetry, light can also be input at port 205 , in which case most of the light exits at port 204 and a small amount will be tapped off to port 203 . This design is also polarization independent, but the signal power fraction that can be tapped out using a crossing angle large enough to achieve device compactness is (as is the case for the Y-junction) insufficient for many applications. Moreover, the low index contrast between the cladding and the waveguide core materials, combined with the large crossing angle (>10 degrees), results in a low tap efficiency.
The mechanism of light transfer between the arms of a pair of intersecting waveguides is, at least for small crossing angles, qualitatively similar to that of a directional (i.e. evanescent) coupler with variable inter-guide separation. At the X-branch geometric crossover between two guides A and B, the incoming optical field (say in branch A) can be pictured as the sum of equal-amplitude symmetric and antisymmetric component fields in the two incoming branches. Where they begin to interact on approach to the junction, these two component fields will in general develop different velocities (and possibly different rates of attenuation). In the output branches the two fields (minus their radiative and absorption losses) can be recombined taking their relative phase shifts into account. A phase shift of π/2, for example, would cause light to be wholly transferred from A to B. More generally the degree of transfer from A to B at any point of the crossover will depend on the phase difference accumulated to that point and, for small crossing angles (with a large interaction length) the light power may alternate back and forth several times before emerging from the crossing. The final degree of transfer therefore depends on the total phase difference accumulated over the entire crossover region. In this simple picture (see, for example, Bergmann et al., Applied Optics 23, 3000-3003 (1984)) the fractional power transferred between the waveguides is approximately periodic in the reciprocal of the crossing angle θ with a period that depends sensitively on the magnitude of the guide refractive index contrast Δn=n(core)−n(cladding) in the crossing regime. As a result of this sensitivity, most of the current applications of waveguide crossing structures are in the field of optical switches, and are based on the use of an external (electro-optic, magneto-optic, acousto-optic or thermo-optic) stimulus to modulate Δn in the region of the crossing.
At crossing angles larger than a degree or two the periodicity in 1/θ ceases and the power-fraction transferred from the signal waveguide to the tap waveguide decreases rapidly to extremely small values at larger crossing angles. Unfortunately, this is the angular region of relevance for the formation of compact waveguide-crossing taps.
SUMMARY OF THE INVENTION
The present invention demonstrates a manner in which the X-geometry of the simple waveguide crossing can be modified to greatly increase the fractional power tapped out in the angular regime appropriate for use with compact taps. Significantly, this same modification does not increase the loss (or fractional power transfer from channeled to radiative modes) associated with the tap.
The invention is directed to an integrated optical tap comprising an input waveguide, a tap waveguide, and an output waveguide, all meeting at a common junction. The input waveguide carries a light signal, from which the tap waveguide carries away a small amount of power, while another, an output waveguide, also originating from the junction, carries away most of the power. Another, a ‘blind’, waveguide may originate from the junction positioned on the opposite side of the input waveguide from the tap waveguide. The offset between the center axes of the tap waveguide and the blind waveguide can be adjusted to increase both the magnitude of the tapped power and a ‘figure of merit’ defined by the ratio of tapped-out power to scattering (radiative) loss. A taper may be added near the intersection of any two waveguides near the junction to increase further the fractional power tapped out and to decrease scattering losses. The response of an optical tap of this kind is substantially independent of the wavelength and the polarization of the light signal propagating in the waveguide.
In accordance with one aspect of the present invention, an optical tap is provided that includes an input waveguide having a first width for receiving an optical signal and a tap waveguide having a second width. The tap waveguide is coupled to the input waveguide in a junction region. An output waveguide, which has a third width, is coupled to the input waveguide in the junction region defined by the intersection of the input and tap waveguides. The input waveguide, tap waveguide and output waveguide respectively have input, tap and output longitudinal, centrally disposed optical axes. The input and tap axes define a first acute angle therebetween and the input and output axes define a second acute angle therebetween. A tapping ratio is defined by a ratio of optical output power from the tap waveguide to optical output power from the output waveguide. The tapping ratio is determined at least in part by the first, second and third widths and the first and second angles. The first, second and third widths and the first and second angles have values selected to produce a specified tapping ratio.
In accordance with another aspect of the invention, the second acute angle is nonzero and the input axis and the output axis intersect in the junction region at a point offset from an intersection between the tap axis and the input axis in the junction region.
In accordance with another aspect of the invention, at least one of the first, second and third widths differ from the other widths.
In accordance with another aspect of the invention, the first, second and third widths are substantially equal to one another.
In accordance with another aspect of the invention, the selected values of the first, second and third widths and the first and second angles are further selected to enhance a tapping figure of merit defined by a ratio of tap efficiency to scattering loss.
In accordance with another aspect of the invention, the junction region includes at least one tapered waveguide section.
In accordance with another aspect of the invention, the optical tap also includes at least one power transfer enhancing (PTE) waveguide having a fourth width and a PTE longitudinal, centrally disposed optical axis. The PTE waveguide is coupled to the input waveguide in the junction region. The PTE waveguide couples therethrough substantially none of the optical signal. The PTE axis and the input axis define a third acute angle therebetween.
In accordance with another aspect of the invention, the PTE axis and the output axis are nonparallel.
In accordance with another aspect of the invention, the PTE axis and the input axis intersect at a point offset from the intersection of the tap axis and the input axis.
In accordance with another aspect of the invention, an optical tap is provided that includes an input waveguide having a first width for receiving an optical signal and a tap waveguide having a second width. The tap waveguide is coupled to the input waveguide in a junction region. An output waveguide, which has a third width, is coupled to the input waveguide in the junction region defined by the intersection of the input and tap waveguides. The input waveguide, tap waveguide and output waveguide respectively have input, tap and output longitudinal, centrally disposed optical axes. The input and tap axes define a first acute angle therebetween. The input and output axes define a second acute angle therebetween. The junction region includes at least one tapered waveguide section.
In accordance with another aspect of the invention, a method is provided for tapping a desired portion of optical power from an optical signal. The method begins by providing an optical tap that includes an input waveguide having a first width for receiving an optical signal, a tap waveguide having a second width and being coupled to the input waveguide in a junction region, and an output waveguide having a third width and being coupled to the input waveguide in the junction region defined by the intersection of the input and tap waveguides. The input waveguide, tap waveguide and output waveguide respectively have input, tap and output longitudinal, centrally disposed optical axes. The input and tap axes define a first acute angle therebetween and the input and output axes define a second acute angle therebetween. The method continues by directing the optical signal though the input waveguide of the optical tap. Values for each of the first, second and third widths and the first and second angles are selected to produce a specified tapping ratio that gives rise to the desired portion of optical power at an output of the tap waveguide. The tapping ratio defines a ratio of optical output power directed through a tap waveguide to optical output power directed through an output waveguide.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 Schematic of a prior art optical tap comprising two cascaded directional couplers.
FIG. 2 Schematic of a prior art optical tap comprising a waveguide crossing.
FIG. 3 Schematic of a waveguide configuration that defines the geometry of the optical waveguide tap of the present invention.
FIG. 4 Schematic of a waveguide configuration of FIG. 1 with the addition of a blind waveguide.
FIG. 5 Schematic of a waveguide configuration of FIG. 2 where the input and output waveguides are aligned.
FIG. 6 A plot of the fractional power tapped T and the fractional power L lost by scattering out of the guide channels as a function of offset distance for one specific embodiment of the invention with angles α 1 and α 2 of FIG. 5 both equal to 8 degrees.
FIG. 7 A plot of tap efficiency and loss as functions of reciprocal angle 1/α for
an embodiment of the invention where angles α 1 and α 2 of FIG. 5 are both equal to α.
FIG. 8 Schematic of an embellishment of the optical tap configuration of a) FIG. 4 and b ) FIG. 3 showing the addition of triangular tapers positioned to enhance tap performance.
FIG. 9 Schematic of an embellishment of the optical tap configuration of FIG. 4 showing the addition of a four triangular tapers with pairwise parallel edges, positioned to enhance tap performance.
FIG. 10 Schematic of an embellishment of the optical tap configuration of FIG. 4 showing the addition of a single triangular taper positioned to enhance tap performance.
FIG. 11 A plot of tap efficiency and loss as a function of taper thickness H for an embodiment of the invention including one taper.
FIG. 12 A plot of tap efficiency and loss as a function of wavelength for incoming light signals with TE and TM polarization, using a specific embodiment of the invention including a taper.
FIG. 13. a Schematic cross-sectional top view of an integrated optical tap monitor.
FIG. 13. b Schematic cross-sectional side view of an integrated optical tap monitor.
DETAILED DESCRIPTION
It is worthy to note that any reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Embodiment 1 of the invention is a waveguide structure as shown in FIG. 3 . The structure comprises an input waveguide 301 of width w s1 , a tap waveguide 302 of width w t , and an output waveguide 303 of width w s2 . The three waveguides meet at a junction 304 . We denote the acute angle enclosed by the input and the tap waveguides by α, and the acute angle enclosed by the input and the output waveguides by β. The operation of the tap is as follows. A light signal is input at the input port 305 , propagates through waveguides 301 and 303 , and most of the signal power is transmitted to the output port 307 . In the junction region 304 , some of the signal power is transferred into the tap waveguide and travels to the tap port 306 .
Embodiment 2 of the invention is a waveguide structure as shown in FIG. 4 . The structure consists of input, tap and output waveguides 401 , 402 and 403 , with widths w s1 , w t1 , and w s2 , respectively, as in the previous embodiment. We add a blind waveguide 404 of width w t2 to the optical tap to improve its performance. The blind waveguide is a waveguide section which couples substantially zero portion of the light signal. The blind waveguide preferably ends in a non-reflecting waveguide termination 408 so that light is not reflected from the optical tap structure should there be a light signal propagating from tap port 406 or from the output port 407 . The acute angle enclosed by the input and the tap waveguides is denoted by α 1 , the acute angle enclosed by the input and the blind waveguides is denoted by α 2 , while the acute angle enclosed by the input and the output waveguides is denoted by β. The light signal enters the optical tap structure at input port 405 , propagates through waveguide 401 , and most of the signal power is transmitted to the output port 407 . In the junction region 409 , some of the signal is transferred into the tap waveguide and travels to the tap port 406 . The blind waveguide aids in optimal power transfer to the tap waveguide by turning the signal wavefront towards it.
Embodiment 3 of the invention is a waveguide structure as shown in FIG. 5 . This embodiment is a specific case of Embodiment 2, where the angle β is zero. In this case the blind and tap waveguides 502 and 504 are parallel to each other. The center axis of the blind waveguide 504 can be offset with respect to the center axis of the tap waveguide 502 to achieve optimal power transfer to the tap waveguide. The offset dimension is defined as the distance between the intersection 510 of the center axes of the input and tap waveguides and the intersection 511 of the center axes of the input and blind waveguides. The offset can take either positive or negative values, depending on whether the intersection 510 is closer or farther away than intersection 511 to the input port 505 . Therefore if the offset is positive, as is the case in FIG. 5 , the device is effectively shorter than with zero offset. More generally, a deviation of the angular ratio α 1 /α 2 from unity can be added to the offset as a second optimization variable.
Embodiment 4 of the invention is a specific case of Embodiment 3, where the angles α 1 and α 2 are both equal to α. The optical tap is constructed from a set of channel waveguides made of a doped silica glass of refractive index of 1.45177 embedded in a silica cladding material with a refractive index of 1.444 at 1.55 μm. The width of all waveguides is the same: w s1 =w t1 =w s2 =w t2 =3 μm and the angle α=8°. Working throughout at a vacuum light wavelength of 1.55 μm, we calculate the tap efficiency T and the scattering loss L as a function of the waveguide offset using the two-dimensional beam propagation method (see for example, C.L. Xu et al., Journal of Lightwave Technology, 12, 1926-1931 (1994)). The quantities T and L are expressed in dimensionless form as a fraction of the power P i into the input port in the form
T=P t /P l ; L=[P l −P t −P o ]/P i ;
where P i and P o are respectively the powers exiting through the tap and output ports. These quantities are plotted in FIG. 6 as a function of the waveguide offset. At zero offset, where the optical tap structure is similar to a common X waveguide crossing, the tap efficiency is below 0.01%. However, if we set the waveguide offset to +30 μm, the tap efficiency increases to 5.8%. Although the tap efficiency improves by a large factor, the scattering loss does not change significantly even after the introduction of a large offset.
The response of this optical tap structure cannot be described in terms of simple coupled-mode theory as has been done for simple waveguide crossings in the prior art. To demonstrate this, in FIG. 7 we plot the tap efficiency and the scattering losses as functions of the inverse angle 1/α, for 3 μm wide waveguides with zero offset. While, for large values of 1/α (small angles), the functional form of the tapped power is sinusoidal as predicted by coupled-mode theory, for 1/α<0.15, this periodicity clearly breaks down. In the region of larger angles, where compact optical taps are possible, the tapped power in FIG. 7 is seen to be extremely small. However, in this same regime, the tapped power is a strong function of the offset between the tap and the blind waveguides, as exemplified in FIG. 6 . In this regime the physical behavior of the optical tap is more appropriately described by taking into account the full set of local guided and radiation modes. As the guided light in the input waveguide enters the junction region, the mode will couple to a large set of radiation modes in addition to the guided modes existing there. At the far end of the junction, both local guided and radiation modes combine to couple to the guided modes in the tap and the output waveguides. Finally, they also couple to radiation modes, causing the observed scattering losses.
Embodiment 5 of the invention is illustrated in FIG. 8 a . The optical tap consists of the waveguide structure in Embodiment 2, with input, tap, output and blind waveguides 801 , 802 , 803 and 804 , respectively. To improve the performance of the optical tap, we add a set of triangular tapers 806 , 807 , 808 , and 809 near the waveguide junction 805 . The taper can be made of the same core material as the waveguides. Tapers 806 and 808 assist in redirecting a portion of the light traveling in the input waveguide 801 into the tap waveguide 802 by turning the wavefront of the light signal towards the tap waveguide. At the same time, by effectively increasing the overall width of the waveguides near the junction, the tap enables the accommodation of more guided modes in the primary coupling regime and thus reduces scattering losses. The dimensions of the taper can be appropriately designed such that scattering losses are minimized while maintaining relatively high tap efficiency. Nothing in this embodiment is intended to imply that the geometric shape of the taper be restricted to the linear or straight edge triangular form depicted in FIG. 8 . The taper can have any other functional shape without departing significantly from the spirit of the invention.
The optical tap of Embodiment 1 can also be modified in the same manner by adding tapers near the junction to improve its performance as illustrated in FIG. 8 b .
Embodiment 6 of the invention is illustrated in FIG. 9 . This embodiment is a specific case of Embodiment 5, where each of the four tapers is a triangle and the two sides 901 and 902 , as well as the two sides 903 and 904 are parallel.
Embodiment 7 of the invention is illustrated in FIG. 10 . The optical tap is a specific case of Embodiment 5, where only the taper between the input and the tap waveguides has nonzero dimensions. The taper is a triangle 1001 bounded by sides 1002 , 1003 and 1004 near the junction 1005 . We denote the angle enclosed by the input waveguide and the tap waveguide by 2φ. The dimensions of the taper can be defined with reference to FIG. 10 by the angle φ+γ enclosed by the sides 1002 and 1003 (with −φ<γ<φ being a measure of the deviation of the taper from isosceles triangular form γ=0), and by the length H of the angular bisector of the obtuse angle opposite side 1002 .
Embodiment 8 is a specific case of Embodiment 7, where the waveguides and the taper are constructed using the material system of Embodiment 4 with the same waveguide widths, waveguide offset and angles. We plot the response of the optical tap against H with γ=−1° in FIG. 11 . As H is increased from 0 to H=1.4 μm, the tap efficiency doubles from 5.8% to 9.4%, while at the same time the scattering loss decreases from 4.1% to 2.5%. As a cumulative measure of optimizing the waveguide offset and the taper, a figure of merit for the optical tap, defined as the ratio of the tap efficiency to the scattering loss, increased from 0.01%/4.1%≈0.0024 to 9.4%/2.5%=3.76, or more than three orders of magnitude.
Embodiment 9 of the invention is a specific case of Embodiment 7, with the following parameters. The material system is the same as in Embodiment 4, while the waveguide widths are w s1 =w s2 =5, w t1 =w t2 =3 μm, the angles are α 1 =α 2 =10°, β=8°, and γ=0°, the waveguide offset is +12 μm, and the height of the taper is H=1 μm. We plot the response of the optical tap as a function of wavelength both for TE and TM polarization of the incoming light signal in FIG. 12 . The tap efficiency is substantially independent of wavelength in a large 200 nm wavelength range. Moreover, the response is also substantially independent of the polarization of the light signal. The difference between the tap efficiencies for TE and TM polarizations is about 0.1 dB across the entire wavelength range sampled, which is sufficiently small for most purposes.
Embodiment 10 of the invention is an integrated optical tap monitor illustrated in FIG. 13 . The monitor first comprises an optical tap 1301 of Embodiment 5. FIG. 13. a is a schematic cross-sectional top view of the integrated optical tap monitor in the plane of the optical tap structure 1301 . With reference to FIG. 13. a , the optical tap comprises an input waveguide 1302 , an output waveguide 1304 , a blind waveguide 1305 , and a tap waveguide 1303 ending in a waveguide termination 1308 . FIG. 13. b is a schematic cross-sectional side view of the integrated optical tap monitor in the plane defined by the axis of the tap waveguide 1303 . With reference to FIG. 13. b , the waveguides of the optical tap are enclosed by a lower cladding 1309 and an upper cladding 1310 . The monitor further comprises a turning mirror 1311 created by first etching a wedge-like opening 1312 through the upper and lower claddings 1309 and 1310 and through the tap waveguide 1303 . The opening 1312 has a first facet 1313 that vertically terminates the tap waveguide 1303 in the waveguide termination 1308 as well as a second facet 1314 , angled at about 45 degrees from the plane of the waveguides. On the second facet 1314 metal comprising the turning mirror 1311 is deposited to make it reflecting. The monitor further comprises a photodiode 1315 that is mounted above the turning mirror 1311 . The light signal enters the input port 1306 , and most of the signal travels to output port 1307 . Some of the light is tapped of by the optical tap into the tap waveguide 1303 and this tapped light signal travels to the waveguide termination 1308 . The tapped light signal encounters the metallized turning mirror 1311 , which reflects the signal out of the plane of the optical tap 1301 toward the photodiode 1315 , where the tapped light signal is collected and detected. | An optical tap is provided that includes an input waveguide having a first width for receiving an optical signal and a tap waveguide having a second width. The tap waveguide is coupled to the input waveguide in a junction region. An output waveguide, which has a third width, is coupled to the input waveguide in the junction region defined by the intersection of the input and tap waveguides. The input waveguide, tap waveguide and output waveguide respectively have input, tap and output longitudinal, centrally disposed optical axes. The input and tap axes define a first acute angle therebetween and the input and output axes define a second acute angle therebetween. A tapping ratio is defined by a ratio of optical output power from the tap waveguide to optical output power from the output waveguide. The tapping ratio is determined at least in part by the first, second and third widths and the first and second angles. The first, second and third widths and the first and second angles have values selected to produce a specified tapping ratio. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. application Ser. No. 09/862,973, filed on May 22, 2001, which claims priority from U.S. Provisional Application Ser. No. 60/206,050, filed May 22, 2000, both of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to cooling engine exhaust manifolds and related components, and more particularly to controlling the temperature of engine exhaust components and the exhaust gasses flowing through them.
BACKGROUND
[0003] The exhaust gasses flowing through an exhaust gas manifold of an internal combustion engine are typically very hot, and the exhaust manifold itself may reach very high surface temperatures. To keep the outer surface temperature of the exhaust manifold down for safety reasons, some exhaust manifolds are water cooled, meaning that they contain inner passages through which cooling water flows during engine operation or that they are placed within jackets with cooling water flowing directly across the outer surface of the manifold. Indeed, there are some regulations requiring that exhaust manifolds be provided with cooling jackets for particular applications, such as for marine vessel inspections.
SUMMARY
[0004] In one aspect, the invention features a cooling jacket having internal passages for flowing water or other coolant through the jacket to moderate jacket temperature. The jacket attaches to the engine cylinder head to enclose and cool the exhaust manifold of the engine, thereby moderating the temperature of the exhaust gas flowing through the manifold and blocking the outer surface of the manifold from unwanted contact with nearby objects or personnel. As the coolant flows through internal passages in the manifold rather than through or across the exhaust manifold, the coolant never comes into contact with the manifold itself. Manifold cooling is achieved via radiant and convective heat transfer to the jacket when an air gap is provided between the outer surfaces of the manifold and the inner surfaces of the cooling jacket, or by conduction through an insulating material placed between the manifold and jacket. Among the various aspects of the invention are the cooling jacket so described, engines equipped with such cooling jackets, and methods of cooling engine exhaust manifolds by incorporating such jackets.
[0005] In some embodiments the cooling jacket defines a coolant inlet and a coolant outlet that are both separate from the exhaust stream. In some other cases, particularly applicable to marine engines, for example, coolant enters the jacket through a separate inlet but then joins the exhaust flow as the exhaust leaves the manifold, thereby further reducing exhaust gas temperature.
[0006] In another aspect, the invention features a liquid-cooled turbocharger disposed between a liquid-cooled exhaust manifold and a liquid-cooled exhaust elbow, such that manifold cooling fluid flowing to the elbow flows through and cools the housing containing the turbocharger. Preferably, for marine applications, for instance, the cooling fluid is injected into the exhaust stream downstream of the turbocharger, such as in the elbow. In some cases, the manifold cooling fluid flows through the exhaust manifold itself. In some other cases, the fluid cools the manifold by flowing through a channel within a jacket that surrounds the manifold, as discussed above.
[0007] In some embodiments, the manifold houses an exhaust conversion catalyst. The exhaust conversion catalyst is arranged within the exhaust stream, such that the exhaust flows through the catalyst, and is isolated from the liquid coolant, which flows around the catalyst. For example, a coolant passage can extend along opposite sides of the catalyst. Preferably, the flow of liquid coolant joins the flow of exhaust downstream of the catalyst. In some embodiments, an insulating blanket is placed between the catalyst and the manifold housing to help to insulate the hot catalyst from the surrounding housing, thereby promoting exhaust conversion and avoiding excessive external surface temperatures. The blanket can, in some cases, also help to protect fragile catalysts from shock damage.
[0008] In another aspect of the invention, a liquid-cooled exhaust manifold houses an exhaust conversion catalyst arranged within the exhaust stream, such that the exhaust flows through the catalyst, and is isolated from the liquid coolant, which flows around the catalyst. The manifold is adapted to receive and join separate flows of exhaust gas and direct them through the catalyst. The manifold can include a one-piece housing, preferably of cast metal, forming the internal exhaust flow passages and cavity for receiving the catalyst.
[0009] In some embodiments, the housing includes an exhaust elbow defining an elbow passage for liquid coolant arranged to align with a coolant passage. The exhaust manifold can include a sealed exhaust conduit for conducting a flow of exhaust from the exhaust manifold through the housing with the catalyst being sized and configured to span a portion of the exhaust conduit. In some embodiments, the cooling jacket can be configured to merge exhaust flows from a plurality of combustion cylinders.
[0010] Some aspects of the invention can provide for the ready modification of engines to comply with exhaust manifold cooling requirements, without having to modify the exhaust manifold to either provide for internal cooling or withstand prolonged surface contact with a desired coolant. Furthermore, the temperature of the exhaust gas within the manifold can be maintained at a higher temperature than with normally cooled manifolds, given a maximum allowable exposed surface temperature, enabling more complete intra-manifold combustion and improving overall emissions. Among other advantages, some aspects of the invention help to maintain high exhaust temperatures, such as to promote exhaust catalytic conversion, for example, without producing undesirably high external surface temperatures.
[0011] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0012] FIGS. 1A and 1B are front and back perspective views, respectively, of an exhaust manifold cooling jacket.
[0013] FIG. 2 is a side view of the cooling jacket, viewed from the side adjacent the engine.
[0014] FIG. 3 is an end view of the cooling jacket.
[0015] FIGS. 4 and 5 are cross-sectional views, taken along lines 4 - 4 and 5 - 5 , respectively, in FIG. 2 .
[0016] FIG. 6 is a cross-sectional view, taken along line 6 - 6 in FIG. 3 .
[0017] FIG. 7 is a perspective view of a mounting plate for the cooling jacket.
[0018] FIGS. 8A and 8B are front and back perspective views, respectively, of an exhaust elbow.
[0019] FIG. 9 is an end view of the exhaust elbow, as looking toward the cooling jacket.
[0020] FIG. 10 is a side view of the exhaust elbow.
[0021] FIGS. 11 and 12 are cross-sectional views, taken along lines 11 - 11 and 12 - 12 , respectively, in FIG. 9 .
[0022] FIG. 13 is a cross-sectional view, taken along line 13 - 13 in FIG. 10 .
[0023] FIG. 14 is a perspective view of a liquid-cooled exhaust manifold sized to house a catalytic conversion element.
[0024] FIGS. 15 and 16 are end and side views, respectively, of the manifold of FIG. 14 .
[0025] FIGS. 17 and 18 are cross-sectional views, taken along lines 17 - 17 and 18 - 18 , respectively, in FIG. 16 .
[0026] FIG. 19 is a cross-sectional view, taken along line 19 - 19 in FIG. 18 .
[0027] FIG. 20 is a top view of a liquid-cooled exhaust system including a manifold, turbocharger, and injection elbow.
[0028] FIG. 21 is an exploded perspective view of the exhaust system of FIG. 20 .
[0029] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0030] Referring first to FIGS. 1A and 1B , cooling jacket 20 is sand or investment cast in a shape designed to form an interior cavity 22 sized to fit about an engine exhaust manifold (not shown) when the cooling jacket is mounted against the engine head. In this embodiment, the jacket includes a mounting boss 24 and associated exhaust port 26 through which exhaust gas flows from the manifold to a downstream exhaust elbow (shown in FIGS. 8A through 13 ). Accordingly, boss 24 features mounting holes 28 through which fasteners from the exhaust elbow extend into threaded bosses on the exhaust manifold, sandwiching the cooling jacket 20 between the manifold and elbow and sealing the exhaust passage. If desired, the cooling jacket may also be mounted securely to the engine cylinder head by appropriate lugs and fasteners (not shown).
[0031] Referring also to FIGS. 2-6 , cooling jacket 20 is cast to define an internal cooling passage or cavity 30 in hydraulic communication with a coolant inlet 32 , which is attached to a pressurized coolant source (not shown) for circulating coolant through the cooling jacket. From passage 30 , the coolant exits the cooling jacket through ports 34 in boss 24 and flows into the exhaust elbow, where it is blended with the exhaust gas. Alternatively, a separate coolant exit port (not shown) may be provided for returning the coolant to its source.
[0032] As shown in FIG. 3 , in this embodiment an air gap 31 is formed between the inner surface of the cooling jacket and the outer surface 33 of the exhaust manifold (shown in dashed outline). Alternatively, an appropriate insulating material, such as glass fiber (not shown), may be packed into this gap and provide insulation against heat conduction between the exhaust manifold and cooling jacket.
[0033] Cooling jacket 20 may be cast of any material suitable to the intended environment. For marine applications employing salt water as coolant, a salt resistant aluminum alloy is appropriate. If the cooling jacket is to be mounted directly against a cast iron engine head, or if very high temperatures are anticipated, cast iron may be more appropriate. If aluminum is used and exiting exhaust gas temperatures are high or the exhaust gas is particularly corrosive to aluminum, an iron sleeve may be provided through exhaust port 26 .
[0034] To completely enclose the exhaust manifold, a backing plate 36 may be employed as shown in FIG. 3 , and illustrated in FIG. 7 . The backing plate is made of flat metal stock, with appropriate exhaust ports placed to align with the exhaust ports of the engine cylinder head. Backing plate 36 is positioned as if it were an exhaust manifold gasket, between the cylinder head and manifold, with the manifold fasteners securing the backing plate in place. The outer edges of the backing plate engage the rim of the cooling jacket, such that there is no appreciable convective air flow through the cooling jacket.
[0035] Referring now to FIGS. 8A and 8B , exhaust elbow 38 is adapted to mount on boss 24 of cooling jacket 20 (see FIG. 1A ) via an appropriate mounting flange 40 . Exhaust inlet 42 aligns with exhaust port 26 of the cooling jacket ( FIG. 1A ), and appropriately positioned coolant inlets 44 align with the coolant outlet ports 34 of the cooling jacket ( FIG. 1A ), such that both the exhaust gasses and coolant enters exhaust elbow 38 separately. At its downstream end 46 , the exhaust elbow is coupled to the remainder of the exhaust system (not shown) in typical fashion.
[0036] Referring to FIGS. 9-13 , from mounting flange 40 and inlet 42 the exhaust gas flows straight through the exhaust elbow along a central exhaust passage 49 to an exhaust outlet 48 . The coolant flows through coolant passage 50 to the downstream end 46 of the exhaust elbow, where it exits the exhaust elbow at outlets 52 and joins the flow of exhaust gas. Coolant passage 50 is not completely annular at either end of the exhaust tube, due to the structural ribs required between the inner and outer portions of the exhaust elbow.
[0037] Referring next to FIGS. 14-16 , liquid-cooled manifold 54 is produced as a one-piece casting and is designed to merge the exhaust flows from three separate combustion cylinders (not shown) entering the manifold through three respective inlets 56 . The merged exhaust flows exit the manifold through exit 58 , after having passed through a catalytic conversion element contained within the manifold (discussed further below). Cooling liquid (e.g., fresh water or sea water) enters the manifold through port 60 and exits through port 62 .
[0038] As shown in FIGS. 17-19 , the manifold housing defines coolant passages 64 extending about the internal exhaust cavity 66 , for circulating liquid coolant through the manifold to control manifold housing surface temperature. Shown disposed within the housing just upstream of exhaust exit 58 in FIG. 17 is a catalytic conversion element 68 surrounded by an insulator 70 . Element 68 is a cylindrical, porous material designed to promote combustion of combustible exhaust gasses. Such materials are well known in the art of exhaust system design, and a suitable material is available from Allied Signal as their part number 38972. Element 68 has a reasonable porosity and size, at 600 cells per square inch, 3.0 inches in diameter and 2.6 inches in length, to perform its intended function without creating excessive exhaust back pressure. Insulator 70 is a rolled sheet of vermiculite, having a nominal uncrushed thickness of about 5 millimeters. Together, catalytic conversion element 68 and insulator 70 completely span exhaust exit 58 , such that all exhaust gas entering manifold 54 is forced to flow through element 68 before exiting the manifold. By disposing the conversion catalyst within the manifold itself, relatively close to the exhaust source, the high temperatures developed by secondary combustion are safely contained within a liquid-cooled housing so as to not present any exposed high temperature surfaces. As shown in FIG. 17 , a major length of catalytic element 68 is substantially surrounded by coolant passage 64 .
[0039] Although not specifically illustrated, it should be understood from the above disclosure that another advantageous arrangement is to house an appropriately sized catalytic conversion element, such as element 68 , within a manifold not adapted to circulate cooling fluid, and then surrounding the manifold with a secondary cooling jacket such as that shown in FIGS. 1-6 . It should also be understood that manifold 54 may be modified to provide the coolant exit coaxially with the exhaust exit, such that the exiting coolant flows directly into an injection elbow or other downstream exhaust component.
[0040] Referring now to FIGS. 20 and 21 , liquid-cooled exhaust system 72 includes a liquid-cooled exhaust manifold 74 , a liquid-cooled turbocharger 76 , and a coolant injection elbow 78 . The individual exhaust system components are shown separated in FIG. 21 . Manifold 74 is configured to receive the exhaust from a bank of six combustion cylinders through exhaust inlets 80 , and a flow of coolant through coolant inlet 82 . From manifold 74 , both the combined exhaust stream and the liquid coolant pass directly into the housing of turbocharger 76 through ports 84 and 86 , respectively. The passed coolant helps to control the surface temperature of turbocharger 76 , which uses kinetic flow energy from the exhaust gas to boost the pressure of intake air for combustion in the associated engine. Turbocharger 76 accepts atmospheric air through intake 88 and supplies pressurized air to the engine via air outlet 90 . From turbocharger 76 , both the exhaust stream and the liquid coolant flow directly into injection elbow 78 , through ports 92 and 94 , respectively. In elbow 78 the coolant is injected into the stream of exhaust to further cool the exhaust. The placement of turbocharger 76 immediately downstream of manifold 74 , before the exhaust stream has experienced substantial flow losses, promotes turbocharging efficiency. In addition, flowing the coolant through the turbocharger helps to maintain desirable external turbocharger housing surface temperatures in systems employing downstream water injection, such as for marine applications. It should be understood from the above disclosure that any of the three components shown in FIG. 21 may be equipped with an internal catalytic conversion element, such as element 68 of FIG. 17 , and that manifold 74 may be replaced with a standard manifold without internal coolant channels but rather surrounded by a cooled jacket such as the one shown in FIGS. 1-6 .
[0041] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, a single manifold/jacket assembly may replace the standard exhaust manifold and contain both internal exhaust passages and internal coolant passages, with an internal air space between the coolant passages and exhaust passages such that many of the benefits of the invention are achieved. Because of direct exposure to high temperature exhaust gasses, however, such a combination version would be limited to particular materials, such as cast iron or steel. Accordingly, other embodiments are within the scope of the following claims. | An exhaust manifold cooling jacket has internal passages for the circulation of liquid coolant and encloses an exhaust manifold such that a gap is created between the exhaust manifold and cooling jacket. Flowing coolant through the jacket regulates outer jacket temperature while enabling high intra-manifold exhaust gas temperatures for thorough intra-manifold combustion and improved emissions. In some applications, a liquid-cooled exhaust system includes a turbocharger disposed between manifold and elbow, with liquid coolant flowing from manifold to elbow through the turbocharger. Another liquid-cooled exhaust manifold contains an internal exhaust combustion catalyst wrapped in an insulating blanket. In some marine applications, seawater or fresh water coolant is discharged into the exhaust gas stream at an attached exhaust elbow. | 5 |
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 60/659,991 filed Mar. 7, 2005, entitled SKI BOOT ATTACHMENTS.
FIELD OF THE INVENTION
This invention relates to detachable soles for ankle and foot coverings, which afford easier walking for individuals wearing ankle and foot coverings, and more particularly, but not by way of limitation, to attachments that easily attach and detach to the bottoms of ski boots, and to the bottom of an orthopedic device affixed to an individual's ankle and foot.
BACKGROUND
Walking in orthopedic devices or ski boots is an awkward endeavor at best. Attachments that fit onto the bottom of ski boots and orthopedic devices have been proposed in the prior art. However, each proposed solution has drawbacks, which fail to provide: an overall solution to ease the process of walking in ski boots or orthopedic devices when encountering changes in the walking terrain; and a convenient, compact configuration for storing the attachment when not in use.
As such, challenges remain and a need persists for improvements in methods and apparatuses for use in enhancing the walking experience of individuals wearing ski boots or orthopedic devices.
BRIEF SUMMARY OF THE INVENTION
In accordance with preferred embodiments, a combination including: an ankle and foot covering; a detachable sole configured for attachment to and detachment from the ankle and foot covering; a detachable sole storage rack configured for attachment to the ankle and foot covering and for receipt of the detachable sole, when the detachable sole is detached from the ankle and foot covering; and methods of making and using the combination are provided.
In a preferred embodiment, the detachable sole includes at least a chassis that provides a baffled support matrix interposed between top and bottom chassis portions, and more preferably the chassis includes a hinge interposed between a heel chassis portion and a toe chassis portion, in which said heel and toe chassis portions each comprise baffled support matrices interposed between top and bottom chassis portions to form the chassis.
Preferably, the toe chassis portion is overmolded with a toe tread portion to form a first sole portion, and the heel chassis portion is overmolded with a heel tread portion to form a second sole portion, and the hinge includes at least one hinge knuckle and a pair of hinge pins. Preferably, each hinge knuckle provides a pair of hinge pin apertures, and the hinge pins are configured for sliding engagement with the hinge pin apertures.
The detachable sole further preferably includes an attachment hoop that communicates with a heel chassis, and a latch attached to the attachment hoop, such that upon a positioning of the latch adjacent a latch region of the ankle and foot covering and latching the latch, the detachable sole is attached to the ankle and foot covering. Preferably, the attachment hoop is attached to the heel chassis portion by a latch pin. The heel chassis portion preferably provides a latch pin mounting aperture, which includes an inner diameter configured to provide an interference fit between the latch pin and the mounting aperture, when the latch pin engages the inner diameter of the latch pin mounting aperture.
In a preferred embodiment, the latch is preferably an over-center latch that includes at least a latch block with a latch body engagement feature and a latch door engagement feature, a latch body configured for engagement with the latch block, and a latch door configured for engagement with the latch body and latch block.
A preferred embodiment of the present intention further includes a plurality of side caps configured to prevent encroachment of debris from entering the baffled support matrices of the toe and heel chassis portions, and mounting studs provided by the detachable sole storage rack to confine the detachable sole in proper alignment with the detachable sole storage rack, wherein the detachable sole is detached from the ankle and foot covering. In addition to the mounting studs, the detachable sole storage rack further preferably provides a strap used to secure the detachable sole to the detachable sole rack when storing the detachable sole.
These and various other features and advantages that characterize the claimed invention will be apparent upon reading the following detailed description and upon review of the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top perspective view of an embodiment of an inventive detachable sole.
FIG. 2 shows a top perspective view of an alternate embodiment of the inventive detachable sole.
FIG. 3 is a bottom perspective view of tread portions of the inventive detachable sole of FIG. 2 .
FIG. 4 is an exploded perspective view of the inventive detachable sole of FIG. 1 .
FIG. 5 is an exploded perspective view of the inventive detachable sole of FIG. 2 .
FIG. 6 shows a side elevational view of an alternative embodiment of the inventive detachable sole secure to an ankle and foot covering.
FIG. 7 illustrates a side elevational view of the inventive detachable sole of FIG. 2 secure to an alternate ankle and foot covering.
FIG. 8 is a side elevational view of the inventive detachable sole of FIG. 2 shown in a collapsed configuration ready for storage.
FIG. 9 is a rear elevational view of the inventive detachable sole of FIG. 2 shown in a collapsed configuration ready for storage.
FIG. 10 is a first side elevational view of an inventive detachable sole storage rack configured for interaction with the inventive detachable sole of FIG. 2 .
FIG. 11 is a second side elevational view of the inventive detachable sole storage rack of FIG. 10 .
FIG. 12 is a partial cutaway rear elevational view of the inventive detachable sole storage rack of FIG. 10 .
FIG. 13 is a side elevational view of the inventive detachable sole storage rack of FIG. 10 attached to the alternate ankle and foot covering of FIG. 7 .
FIG. 14 is a side elevational view of the inventive combination of the present invention.
FIG. 15 is a flow diagram of the method of making the inventive detachable sole of FIG. 2 .
FIG. 16 is flow diagram of a method of using the inventive combination of FIG. 14 .
DETAILED DESCRIPTION
Reference will now be made in detail to one or more examples of the invention depicted in the figures. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a different embodiment. Other modifications and variations to the described embodiments are also contemplated within the scope and spirit of the invention.
Referring to the drawings, FIG. 1 shows an inventive detachable sole 100 that includes a tread portion 102 , which includes a toe confinement portion 104 , attached to a chassis 106 . In a preferred embodiment, the tread portion 102 is attached to the chassis 106 through the use of an overmold process. However, alternate techniques may be used for the attachment of the tread portion 102 to the chassis 106 , such as through the employment of adhesive material, or by sonically welding the components together.
In a preferred embodiment, the chassis 106 is formed from glass filled polypropylene compound, in which the compound contains between 10-30% glass by volume, and preferably 20% glass by volume, and the tread portion 102 preferably formed from a quasi pliable polymer such as the thermoplastic elastimer resin (TPE), or a polyurethane.
FIG. 1 further shows the inventive detachable sole 100 further includes an attachment hoop 108 , which is preferably formed from nickel plated steel, but may be formed from alternate materials such as a carbon filed compound, or stainless steel. In a preferred embodiment, the attachment hoop 108 supports a latch 110 , that is preferably an over-center latch. The latch 110 accommodates attachment of the detachable sole 100 to a plurality of ankle and foot coverings.
Turning to FIG. 2 , shown therein is an alternate preferred embodiment of the inventive detachable sole 120 . In contrast to the detachable sole 100 (of FIG. 1 ), the detachable sole 120 includes a first sole portion 122 and a second sole portion 124 secured together by a hinge portion 126 . Additionally, the attachment hoop 108 (of FIG. 1 ) of the detachable sole 100 differs from an attachment hoop 128 of the inventive detachable sole 120 . The attachment hoop 128 provides two portions, a latch attachment portion 130 and a heel chassis attachment portion 132 hinged to the latch attachment portion 130 . It is noted however that the inventive detachable sole 120 and the inventive detachable sole 100 share the latch 110 in common.
FIG. 3 shows the first sole portion 122 includes a toe tread portion 133 , and the second sole portion 124 includes a heel tread portion 134 . As with the tread portion 102 (of FIG. 1 ), the toe and heel tread portions 133 , 134 are preferably attached through the use of an overmold process. FIG. 3 further shows that the first sole portion 122 includes a side cap 136 , and the second sole portion 124 includes a side cap 138 . It will be understood that a tread pattern 140 of the toe tread portion 133 , and a tread pattern 142 of the heel tread portion 134 represent preferred tread patterns, and do not impose limitations on the present invention. Those skilled in the art understand that alternate tread patterns may be utilized, and slip resistance mechanisms such as studs (similar to studs used on studded snow tires) may be incorporated within tread patterns 140 and 142 , which fall within the scope of the present invention.
The exploded perspective views of the inventive detachable soles 100 and 120 of FIG. 4 and FIG. 5 respectively may be best viewed in concert to provide an enhanced understanding of the commonalities and differences between the inventive detachable soles 100 and 120 .
FIG. 4 shows chassis 106 includes a baffled support matrix 144 interposed between a top chassis portion 146 and a bottom chassis portion 148 . FIG. 5 shows that the first sole portion 122 includes a toe chassis portion 150 constructed with a baffled support matrix 152 interposed between a top chassis portion 154 and a bottom chassis portion 156 . The second sole portion 124 includes a heel chassis portion 158 constructed with a baffled support matrix 160 interposed between a top chassis portion 162 and a bottom chassis portion 164 .
FIG. 4 shows the inventive detachable sole 100 includes a right side cap 166 and a left side cap 168 . When the side caps 166 and 168 are attached to the baffled support matrix 144 , debris is prevented from entering a plurality of cavities 170 . It is noted that the plurality of cavities 170 collectively form the baffling members of the baffled support matrix 144 . In addition to the side caps 136 and 138 (of FIG. 3 ), FIG. 5 further shows the inventive detachable sole 120 includes a pair of the left side caps 172 and 174 , which are provided to preclude entry of debris into the baffled support matrix 152 .
The hinge portion 126 , as shown by FIG. 5 , includes a plurality of hinge knuckles 176 , and a pair of hinge pins 178 . Each hinge knuckle 176 provides a pair of hinge pin apertures 180 , and each hinge pin 178 is configured for sliding engagement within the hinge pin apertures 180 . To accommodate each hinge knuckle 176 , the toe chassis portion 150 , and the heel chassis portion 158 each provide a plurality of hinge pin confinement portions 182 , wherein each hinge pin confinement portions provides a passageway 184 sized to snugly accommodate each hinge pin 178 in mating contact. Interposed between each hinge pin confinement portions 182 are hinge knuckle reception cavities 186 . Each hinge knuckle reception cavities 186 of the toe chassis portion 150 is positioned to align directly across from a corresponding hinge knuckle reception cavity 186 of the heel chassis portion 158 .
When each the toe and heel chassis portions, 150 , 158 are outlined for mating with the hinge portion 126 , each of the plurality of hinge knuckles are deposited within the hinge knuckle reception cavities 186 , and each hinge pin is encouraged through the respective passageways 184 of the toe and heel chassis portions 150 , 158 to combine the first sole portion 122 with the second sole portion 124 to form the inventive detachable sole 120 .
As can be seen in FIG. 4 , the chassis 106 includes a plurality of overmold interface cavities 188 , which have been found useful in enhancing an ability of the tread portion 102 to adhere to the chassis 106 . Preferably, during an overmold process, a selected polymer used in forming the tread portion 102 is forced through each of the overmold interface cavities 188 , and reflowed together to form a continuous surface 190 adjacent to top chassis portion 146 . The continuous surface 190 provides a bridge-way between the chassis 106 and the toe confinement portion 104 . A quasi pliable polymer such as the thermoplastic elastimer resin (TPE), or a polyurethane is preferable for use in forming the tread portion 102 , the continuous surface 190 , and the toe confinement portion 104 because the selection of a quasi pliable polymer accommodates various toe configurations of a mating ankle and foot covering, such as a ski boot 220 (of FIG. 7 ). In a preferred embodiment, the quasi pliable polymer continuous surface 190 , and the toe confinement portion 104 have been found useful in holding the inventive detachable sole 120 under tension when attached to the ski boot 220 . However, as those skilled in the art will recognize, alternate methods of providing a tensile load to the detachable sole 120 to aid in maintaining a snug fit between the ski boot 220 and the inventive detachable sole 120 may be provided, without deviation from the scope and spirit of the present invention, for example, through use of a spring configuration.
The latch 110 of FIG. 4 , which in a preferred embodiment is an over-center latch 110 that includes three primary components: a latch block 192 , a latch body 194 , and a latch door 196 . The latch block 192 provides a latch body engagement feature 198 , a latch door engagement feature 200 , and an attachment hoop attachment feature 202 . The latch body 194 provides a plurality of tension adjustment members 204 (one shown in cutaway view), an over-center pivot feature 206 , and a catch receptacle 208 .
In a preferred embodiment, the latch body engagement feature 198 of the latch block 192 is slid into engagement with a selected one of the plurality of tension adjustment members 204 . Because the plurality of tension adjustment members 204 extend along a length 210 of the latch body 194 , the selection of a specific tension adjustment member 204 determines a holding force imparted by the attachment hoop 108 on the chassis 106 , which determines how tightly the inventive detachable sole 100 is secured adjacent a mating ankle and foot covering, such as orthopedic device 218 (of FIG. 6 ).
The latch door 196 is configured for engagement with the latch block 192 and the latch body 194 . The latch body provides a plurality of latch block support channels 212 , a latch door catch 214 , and a pivot detent 216 . Once the selection has been made for the particular tension adjustment member 204 , and the latch body engagement feature 198 has been slid onto the selected tension adjustment member 204 , a position of the latch block 192 relative to the catch receptacle 208 can be determined. When the relative position of the latch block 192 to the catch receptacle 208 has been determined, a specific latch block support channel 212 is selected by rotating the latch door catch 214 about the pivot detent 216 to engage the latch door engagement feature 200 with the catch receptacle 208 . Once positioned, the latch door 196 mitigates a buildup of ice and snow around the interface of the latch body engagement feature 198 and the selected tension adjustment member 204 .
FIGS. 6 and 7 each show an example of a use for the inventive detachable sole 120 . The applied use of the inventive detachable sole 120 depicted by FIG. 6 resides within the medical arts. The inventive detachable sole 120 , provides an enhanced walking ability for an individual wearing an orthopedic device such as a cast 218 . The enhanced walking ability provided for an individual wearing the cast 218 results from the concave shape 222 of the inventive detachable sole 120 , and the preferred tread patterns 140 and 142 , respectively of the first sole portion 122 and the second sole portion 124 .
The applied use of the inventive detachable sole 120 depicted by FIG. 7 resides within the sports equipment arts. The inventive detachable sole 120 , provides an enhanced walking ability for an individual wearing, for example an Alpine type ski boot, such as 220 . The enhanced walking ability provided for an individual wearing the ski boot 220 results from the concave shape 222 of the inventive detachable sole 120 , the preferred tread patterns 140 and 142 , respectively of the first sole portion 122 and the second sole portion 124 , the toe confinement portion 104 , and the adjustability features of the over-center latch 110 .
FIG. 8 provides a best view of a chassis stabilization member 224 , which extends from the proximal end 226 of the heel chassis portion 158 , while FIG. 9 provides a best view of a chassis stabilization aperture 228 . The chassis stabilization aperture 228 is configured to accommodate penetration of the chassis stabilization member 224 when the heel chassis portion 158 is folded into alignment with the toe chassis portion 150 . FIG. 9 further shows the inclusion of a pair of retention stud apertures 230 . The retention stud apertures 230 accommodate penetration of a pair of respective chassis retention studs 232 of FIGS. 10 and 11 .
It will be noted that FIG. 8 shows the inventive detachable sole 120 to be in a partially folded position. It will be understood that the depiction of the inventive detachable sole 120 in a partially folded position was provided to enhance an understanding of the present invention and does not impose any limitations on the present invention. In a preferred embodiment, in a fully folded position, the first sole portion 122 aligns with the second sole portion 124 in a substantially flat continuous manner.
Turning to FIGS. 10 and 11 , a left side elevational view of a storage rack 234 is provided by FIG. 10 , and a right side elevational view of the storage rack 234 is provided by FIG. 11 . The storage rack 234 includes a main body portion 236 with a concave surface 238 , configured for mating conformance with the toe tread portion 133 (of FIG. 8 ). A hook adjustment portion 240 projects from a proximal end 242 of the main body portion 236 . The hook adjustment portion 240 supports and accommodates a hook attachment member 244 . The hook attachment member 244 is useful for attachment of the inventive detachable sole 120 to an ankle and foot covering such as the ski boot 220 of FIG. 7 .
In a preferred embodiment, the hook adjustment portion 240 provides for an adjustment, in a vertical direction (as shown by FIG. 11 ), of the hook attachment member 244 to accommodate varying sizes of ski boots, or orthopedic devices. The storage rack 234 further includes a chassis support shelf 246 extending from a proximal end 247 of the main body portion 236 . The chassis support shelf 246 provides a support member for the chassis retention studs 232 . The chassis retention studs 232 interact with the retention stud apertures 230 (of FIG. 9 ) to position the toe tread portion 133 adjacent the main body portion 236 . FIG. 11 further shows a main body support 248 extending from a mid-portion 250 of the main body portion 236 .
FIG. 11 further shows a strap support member 252 projecting from the proximal end 242 of the main body portion 236 . A garment confinement slot 254 is formed between the hook adjustment portion 240 and said strap support member 252 . With the inventive detachable sole 120 attached to a ski boot, such as ski boot 220 (of FIG. 7 ), the garment confinement slot 254 accommodates placement of a garment portion, such as a pant leg of the pair of ski pants (not shown). To secure the inventive detachable sole 120 to the ski boot 220 (as shown in FIG. 7 ), a strap pin 256 is attached to a distal end 258 of the strap support member 252 , and a strap 260 attached to the strap pin 256 . The strap 260 interacts with the over-center latch 110 to confine the toe tread portion 133 adjacent the main body portion 236 .
FIG. 12 is provided to enhance an understanding of a preferred configuration of the hook attachment member 244 relative to the hook adjustment portion 240 . In a preferred embodiment the hook attachment member 244 is formed from stainless spring steel, however those skilled in the art will understand that alternate materials and configurations may provide substitute design choices for the hook attachment member 244 , and still remain within the scope and spirit of the present intention.
FIG. 13 provides an elevational view of a preferred embodiment configuration of the storage rack 234 attached to ski boot 220 , while FIG. 14 serves to shows the configuration of FIG. 13 with the addition of the inventive detachable sole 120 of the present invention. By viewing FIG. 14 it will be noted that the storage rack 234 , when attached to the ski boot 220 , provides for convenient storage of the inventive detachable sole 120 , when the inventive detachable sole 120 is detached from the ski boot 220 , for example during periods of time in which an individual is engaged in skiing down a slope.
Flowchart 300 of FIG. 15 shows method steps of a process of making an inventive detachable sole (such as 120 ). The process commences at start step 302 and continues at process step 304 . At process step 304 , a toe chassis portion (such as 150 ) is formed, and at process step 306 a toe tread portion (such as 133 ) is overmolded onto the toe chassis. At process step 308 , a heel chassis (such as 158 ) is formed and at process step 310 a heel tread portion (such as 134 ) is overmolded onto the heel chassis.
At process step 312 , a first sole portion (such as 122 ) is aligned to a second sole portion (such as 124 ). With the first and second sole portions aligned, at process step 314 , a process of installing a hinge portion (such as 126 ) is commenced by disposing each of a plurality of hinge knuckles (such as 176 ) within corresponding knuckle reception cavities (such as 186 ). At process step 316 , a first of a pair of hinge pins (such as 178 ) is slid into its final position to secure the hinge knuckle to the first sole portion, and at process step 318 the second of the pair of hinge pins is slid into position to secure the hinge knuckle to the second sole portion.
At process step 320 , side caps (such as 136 , 138 , 172 , and 174 ) are attached to each of the first and second sole portions. The attachment of the side caps mitigates encroachment of debris from migrating into each of the plurality of cavities (such as 170 ), which collectively form baffling members of a baffled support matrix (such as 144 ). At process step 322 , an attachment hoop (such as 128 ) is attached to the second sole portion, and at process step 324 a latch block (such as 192 ) is snapped onto the attachment hoop.
At process step 326 , a latch body engagement feature (such as 198 ), is slid onto a pre-selected tension adjustment member (such as 204 ), provided by a latch body (such as 194 ). At process step 328 , a pre-selected latch body support channel (such as 212 ) of a latch door (such as 196 ) engages a latch door engagement feature (such as 200 ) of the latch block. At process step 330 , a latch door catch (such as 214 ) is snapped into an interference fit with a catch receptacle (such as 208 ) of the latch body, and the process concludes at end process step 332 .
Flowchart 400 of FIG. 16 shows method steps of a process of using an inventive detachable sole (such as 120 ). The process commences at start step 402 and continues at process step 404 . At process step 404 , a detachable sole storage rack (such as 234 ), is attached to a ski boot (such as 220 ). At process step 406 , a toe of a ski boot is placed into a toe confinement portion (such as 104 ) of a first sole portion (such as 122 ). At process 408 , a heel of the ski boot is placed in mating contact with a second sole portion (such as 124 ). At process step 410 , an attachment hoop (such as 128 ) is pulled into a confinement position adjacent the ski boot, and at process step 412 an over-center latch (such as 110 ) is engaged to secure the detachable sole to the ski boot.
At process step 414 , the over-center latch is released to detach the detachable sole from the ski boot. At process step 416 , a top chassis portion (such as 162 ) of the second sole portion is folded into mating contact with a top chassis portion (such as 154 ) of the first sole portion. At process step 418 , the attachment hoop is folded to position the over-center latch into mating contact with a heel tread portion (such as 134 ) of the second sole portion. At process step 420 , a pair of retention stud apertures (such as 230 ), are slid into confining engagement with a pair of chassis retention studs (such as 232 ). At process step 422 , a toe tread portion (such as 133 ) of the first sole portion is aligned adjacent a main body portion (such as 236 ) of the detachable sole storage rack.
A latch body (such as 194 ) of the over-center latch is lashed with a strap (such as 260 ) to the detachable storage rack at process step 424 . At process step 426 , the strap is tightened to confine the toe tread portion of the first sole portion adjacent the main body portion of the detachable storage rack and the process concludes at end process step 428 .
With respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes may be made which will readily suggest themselves to those skilled in the art and which are encompassed by the appended claims. | A combination and methods of making and using the combination are disclosed. Preferably the combination includes at least: an ankle and foot covering; a detachable sole detachably attached to the ankle and foot covering; and a detachable sole storage rack attached to the ankle and foot covering for use in storing the detachable sole when detached from the ankle and foot covering. The detachable sole preferably includes at least: heel and toe chassis portions each formed from a baffled support matrix and overmolded with tread portions; and an over-center latch coupled to an attachment hoop. The over-center latch preferably incorporates adjustment features to accommodate varying sizes of the ankle and foot coverings. Upon latching of a properly adjusted over-center latch adjacent the ankle and foot covering, a holding force transmitted through the attachment hoop secures the detachable sole adjacent the ankle and foot covering. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a wearing part. More particularly the invention relates to a cutting insert made of hard metal and comprising a multi-layered coating of hard material having at least one layer that is an oxide layer, and which is employed in metal cutting work.
A wearing part of the type generally described above is disclosed in German Auslegeschrift 22 53 745, in which the inner layer adjoining the basic, hard, metal body is composed of one or a plurality of carbides and/or nitrides of the elements Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Si and/or B, and the outer layer is composed of one or a plurality of highly wear-resistant deposits of alumina and/or zirconia.
The disclosed wearing part is disadvantageous to the extent that cracks may form in the top layers of pure oxide and the oxide layers exhibit in many cases insufficient adhesive strength and, consequently, peel off. The friability of the oxide layer increases strongly as the thickness of the layer is increased and causes a highly disadvantageous change in the structure, so that as a practical matter, such layers on such wearing parts are limited to a comparatively very low thickness of only a few micrometers, i.e., a thicker layer does not bring any additional advantages. This, in turn, decisively limits the wear life of such wearing parts, such as, for example, of reversible cutting attachments for metal cutting.
German Offenlegungsschrift 23 17 447, which represents an application of addition or improvement to the above-mentioned German Auslegescrift 22 53 745, specifies a wearing part having an outer top layer which is composed of one or a plurality of deposits of ceramic oxides, and, in addition to the oxides disclosed in the main patent lists, oxides of the elements Si, B, Ca, Mg, Ti and/or Hf, generally including in the application also the formation of mixed oxides. No special mention is made of any individual mixed oxides.
To the extent to which experience has been gained with individual embodiments in practical application, the occurrence of cracks and the adhesive strength of the top oxide layers is not satisfactory in any of these cases.
A composite body preferably comprising a basic body made of hard metal is known from German Auslegeschrift 28 51 584, in which one or a plurality of layers composed of one or a plurality of carbides and/or nitrides of the elements Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Si and B are arranged on the basic body, and on which one or a plurality of layers, there is arranged one or a plurality of layers composed of a mixture of at least one oxide and at least one nitride and/or at least one oxynitride of the elements Cr, Al, Ca, Mg, Th, Sc, Y, La, Ti, Hf, V, Nb, Ta; with the nitrogen content of the outermost layer being in a range of from about 0.1 to about 30 atom-%, and preferably in a range of from about 0.2 to about 15 atom-%. The single example specifies the following structure of the layer on hard metal: TiC, 4 μm+Al 2 O 2 .8 N 0 .2, 2-3 μm.
Primarily hard-metal wearing parts are known and in practical commerical use in which the outer layer is composed of a relatively large number of alternating layers of Ti(C,N) and Al 2 (O,N) 3 . Such wearing parts are within the scope of German Auslegeschrift 29 17 348. However, with such composite bodies, the resistance to wear which can be achieved is not satisfactory for many cases of application. Furthermore, the excessive number of individual layers--the single example of German Auslegeschrift 29 17 348 specifies 38 individual layers--is not economical in terms of manufacture.
Therefore, it is the object of the present invention to provide a wearing part, in particular a cutting insert made of hard metal for metal cutting, which has a multi-layered coating of hard material, in which at least one layer is an oxide layer and which has an improved resistance to wear and which exhibits enhanced adhesive strength with respect to the hard material coating as compared to known wearing parts.
BRIEF STATEMENT OF THE INVENTION
In accordance with the invention, there is provided a wearing part comprising a basic body, a coating applied directly to the basic body or to a backing provided on the basic body and which coating consists in each case of one or a plurality of layers of oxycarbides and/or oxycarbon nitrides and/or oxynitrides and/or oxyborides and/or oxyboron nitrides and/or oxyboron carbon nitrides of the elements Ti, Zr, Hf, B, Si, Al and having an oxygen content in a range of from about 0.1 to about 5% by weight, alternating in each case with one or a plurality of layers of aluminum-boron mixed oxides having a boron content in a range of from about 0.01 to about 1% by weight.
As compared to known wearing parts provided wth multi-layered coatings, the wearing part of the invention exhibits significantly increased resistance to wear, as well as an excellent adhesive strength of the hard-material coating, resulting in a substantially prolonged useful life. These unexpectedly good properties are achieved by incorporating boron in the alumina layers combined with the incorporation of oxygen proportions in the intermediate layers of oxycarbide, oxycarbon nitride, oxynitride, oxyboride, oxyboron nitride and oxyboron carbon nitride. In particular, it is totally surprising that only the simultaneous incorporation of the oxygen proportions in the intermediate layers and of the boron in the alumina layers effects a substantial increase in the resistance to wear. This fact is supported by the examples set forth hereinbelow.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the invention it is important that the oxygen and boron contents of the individual layers be maintained within the specified limits. The influence of the oxygen is practically no longer noticeable if it is below about 0.1% by weight. With oxygen contents exceeding the specified range, the hardness of the intermediate layers drops rapidly and no longer effects any increase in the resistance to wear of the layer structure according to the invention. Likewise, only a boron content in the alumina within the limits according to the invention will lead to an abrupt increase in the resistance to wear. Actually, it was not to be expected that the addition of boron to alumina would result in an increase of the resistance to wear to begin with, since pure boron is very soft and totally unsuitable as a layer protecting against wear. In addition, a boron content within the limits mentioned generates less dust in the coating booth when the aluminum-boron mixed oxide layer is deposited, which means it effects less dust also on the surface of the material being coated, which in turn, causes fewer flaws in the layer and leads to more uniform layers.
In certain cases of application, it is useful to provide a backing layer between the basic body and the coating according to the invention. The backing has a single or multi-layer structure preferably composed of one or a plurality of carbides, nitrides, carbon nitrides, borides or boron nitrides of the elements of Groups IV to VI of the Periodic System.
Furthermore, it is advantageous in certain cases of application to apply to the basic body of hard metal or to the backing layer one single layer of titanium oxycarbon nitride and/or titanium oxynitride with a layer thickness of from about 0.05 to about 1 μm and to subsequently apply thereto one single aluminum-boron mixed oxide layer with a layer thickness of from about 2 to about 10 μm.
According to a particularly preferred embodiment of the invention, the basic body of hard metal or the backing layer is provided with a coating consisting of a layer of titanium oxycarbon nitride and/or titanium oxynitride with a layer thickness of from about 0.1 to about 1 μm, to which there are subsequently applied from 2 to 8 aluminum-boron mixed oxide layers, each layer having a thickness of from about 0.3 to about 2 μm, in each case alternating with from 1 to 7 layers of titanium oxycarbon nitride and/or titanium oxynitride, each layer having a thickness from about 0.05 to about 0.5 μm. The titanium oxycarbon nitride and/or titanium oxynitride layers have an oxygen content of preferably from about 0.5 to about 3% by weight, whereas the aluminum-boron mixed oxide layers have a boron content preferably in the range of from about 0.2 to about 2% by weight.
As compared to a layer structure which, according to the invention, contains only one aluminum-boron mixed oxide layer, it is in particular the multi-layered structure of the invention which further increases the toughness of the coating and, as well, exhibits excellent adhesive strength of the individual layers, thus leading to an unexpected increase in resistance to wear under impact stressing of the wearing part.
A particularly preferred backing layer comprises the following layer sequence disposed on a basic body of hard metal; titanium carbide and/or titanium carbon nitride and/or titanium nitride with a total layer thickness of from about 1 to about 10 μm.
Furthermore, it may be advantageous if the aluminum-boron mixed oxides partially contain titanium, zirconium, hafnium, niobium, chromium and/or magnesium oxides. In addition, the mixed oxides also may have a nitrogen content of from about 0.2 to about 4 atom-%.
The wearing part according to the invention is preferably coated with the hard material by using the CVD-process, that is the chemical vapor deposition process, whereby the chemical composition of the individual layers is fixed by adjusting the mixing ratios of the reaction gases accordingly.
Another preferred process for producing the wearing part of the present invention comprises producing the individual layers with the respective chemical compositions both by depositing according to the CVD-process, that is the chemical vapor deposition process, and interdiffusion between adjacent layers.
In particular, the oxygen proportions may be incorporated in the layers of oxycarbide, oxycarbon nitride, oxynitride, oxyboron nitride, oxyboride and/or oxyboron carbon nitride both by adjusting the composition of the gas mixture accordingly, which mixture may contain, for example, CO 2 , steam, air, O 2 or other oxidizing gases, and interdiffusion from the adjacent aluminum-boron mixed oxide layers. The interdiffusion may be carried out, for example, by a temperature treatment between or after the individual coating steps at a temperature above the coating temperature, or during the application of the aluminum-boron mixed oxide layers by increasing the supply of oxygen in the gas mixture.
THE EXAMPLES
In order to illustrate the present invention more fully, the following illustrative examples are set forth. It is to be understood that the examples are illustrative and not limitative.
EXAMPLE 1
Coatings in five different variations of layer structure as specified in the following Table were applied to reversible cutting plates made of hard metal of grade of grade U10T and having a composition of 6% Co, 5% TiC, 5% (TaC+NbC), 84% WC, conforming to ISO application group M10 and form SPGN 120308 EN. In accordance with the coating process employed, the reversible cutting plates were cleaned, installed in the coating chamber of a prototype plant of applicant, heated to the coating temperature under protective gas and coated under the coating conditions specified in the following Table.
Variations 4 and 5 were provided with a layer structure according to the invention. These variations were compared in a machining or cutting test with the variations 1 to 3 all of which had a layer structure different from that of the present invention and in one case a known layer structure.
All variations comprised a backing consisting of 2 μm titanium carbide followed by 2 μm titanium carbon nitride (with approximately 40% TiC and 60% TiN proportions). Nitrogen was used as the carrier gas for variations 1 to 4, which means that the layer of alumina or aluminum-boron mixed oxides contained about 3 atom-% nitrogen. For variation 5, the aluminum-boron mixed oxide layer was free of nitrogen.
__________________________________________________________________________Layer structures: Al--B mixed oxide with 0.1% by wt.VariationTiC 1. Ti(C, N) 2. Ti(C, N) Ti(C, N, O) Al.sub.2 O.sub.3 boron__________________________________________________________________________1 about 2 μm about 2 μm about 0.4 μm -- 2.5-3.5 μm --2 about 2 μm about 2 μm about 0.4 μm -- -- about 3 μm3 2 μm 2 μm -- about 0.4 μm about 3 μm --4 2 μm 2 μm -- about 0.4 μm -- about 3 μm5 2 μm 2 μm -- about 0.4 μm -- about 3 μm Coating conditions:Gas pressure in all cases; atmospheric pressure (about 1 bar absolute)TiC-layer 1. Ti(C, N)-layerGas mixture: 84 vol % H.sub.2 81 8 vol % H.sub.2 3.2 vol % TiCl.sub.4 3.2 vol % TiCl.sub.4 12.8 vol % CH.sub.4 10 vol % N.sub.2Duration: 17 minutes 25 minutesTemperature 1040° C. 1040° C.2. Ti(C, N)-layer Ti(C, N, O)-layerGas mixture: 66 vol % H.sub.2 65.95 vol % H.sub.2 3 vol % TiCl.sub.4 3 vol % TiCl.sub.4 16 vol % N.sub.2 16 vol % N.sub.2 11 vol % Ar 4 vol % CH.sub.4 4 vol % CH.sub.4 11 vol % Ar 0.05 vol % CO.sub.2Duration: 16 minutes 16 minutesTemperature: 1060° C. 1060° C.Al.sub.2 O.sub.3 -layer or Al--B mixed oxide layer:Gas mixture with nitrogen: Gas mixture without nitrogen:(variations 1-4) (variation 5)13.25 vol % H.sub.2 13.25 vol % H.sub.258 vol % N.sub.2 81 vol % Ar23 vol % Ar 1.6 vol % AlCl.sub.31.6 vol % AlCl.sub.34 vol % CO.sub.2 4 vol % CO.sub.2.BHorizBrace.Variations 2, 4 and 5 0.15 vol % BCl.sub.3Variations 1 and 3 0 vol % BCl.sub.3 and 13.4 vol % H.sub.2Duration: 160 minutesTemperature: 1060° C.__________________________________________________________________________
Cutting test
Turning tests were carried out on 2 shafts made of different materials under different cutting conditions using the coated reversible cutting plates with an HDP 7225 tool:
1. Material: structural steel, material No. 1.1231
Composition:
0.72% C
0.28% Si
0.79% Mn
0.015% P
0.011% S,
balance Fe, refined to 1000 N/mm 2
Cutting rate: v=180 m/min
Feed rate: s=0.42 mm/revolution
Cutting depth: a=2 mm
2. Material: gray (cast) iron
Recommended composition values:
3-3.5% C
0.4-0.8% Si
0.2-0.5% Mn, balance Fe
Hardness: 215 HB
Cutting rate: v=80 m/min
Feed rate: s=0.28 mm/revolution
Cutting depth: a=2 mm
The wear mark width v B of the flank wear was measured in each case after a turning time of 5 minutes.
______________________________________ Turning of structural steel: end of wear life Turning of cast iron:Variation after turning v.sub.B after 5 minutes______________________________________1 18 minutes 0.16 mm2 18.5 minutes 0.17 mm3 17.5 minutes 0.18 mm4 23 minutes 0.11 mm5 24.5 minutes 0.10 mm______________________________________
The wear life was ended for all variations due to cratering.
A comparison between the wear results shows that a noticeable increase in the resistance to wear is achieved only with the layer structures of variations 4 and 5 according to the invention (where a boron proportion is present in the alumina layer simultaneously with an oxygen proportion in the Ti(C,N)-layer) as compared to variation 1, which approximately has the layer structure of a material currently available on the market. On the other hand, the alternative incorporation of boron in the alumina layer (variation 2) or of oxygen in the Ti(C,N)-layer yields no significant increase in the wear resistance as compared to variation 1.
The comparison between variations 4 and 5 shows that a defined proportion of nitrogen in the aluminum-boron mixed oxide layer, which is formed, for example, if nitrogen is used as the carrier gas in the coating process, has an only insignificant influence on the resistance to wear values.
EXAMPLE 2
In contrast to EXAMPLE 1, the single-layered Al 2 O 3 or aluminum-boron mixed oxide layer is replaced by 4 layers which are connected to each other via 3 intermediate Ti(C,N)-layers or 3 Ti(C,N,O)-layers, respectively.
Argon was the carrier gas used for variations 1 to 4, which means that the aluminum-boron mixed oxide layer was free of nitrogen.
In connection with variation 5, the mixed-oxide layer contained 3 atom-% nitrogen, because N 2 was used as the carrier gas.
__________________________________________________________________________Layer structures Al--B-mixed Ti(C, N, O) oxide with Inter- 1. 2. with abt. 0.1% by wt. mediateVariationTiC Ti(C, N) Ti(C, N) 1 wt. % O Al.sub.2 O.sub.3 boron layers__________________________________________________________________________1 2 μm 2 μm 0.5 μm -- 4 × 0.8 μm -- 3 × 0.2 μm Ti(C, N)2 2 μm 2 μm 0.5 μm -- -- 4.0 × 0.9 μm 3 × 0.2 μm Ti(C, N)3 2 μm 2 μm -- 0.3 μm 4 × 0.8 μm 3 × 0.15 μm Ti(C, N, O)4 2 μm 2 μm -- 0.3 μm -- 4.0 × 0.9 μm 3 × 0.15 μm Ti(C, N, O)5 2 μm 2 μm -- 0.3 μm -- 4.0 × 0.7 μm 3 × 0.15 μm (Ti(C, N, O)) Coating conditions:Gas pressure in all cases: atmospheric pressure (about 1 bar absolute)TiC-layer 1. Ti(C, N)-layerGas mixture: 84 vol % H.sub.2 81.8 vol % H.sub.2 3.2 vol % TiCl.sub.4 3,2 vol % TiCl.sub.4 12.8 vol % CH.sub.4 10 vol % N.sub.2 5 vol % CH.sub.4Duration: 17 minutes 25 minutesTemperature: 1040° C. 1040° C.2. Ti(C, N)-layer Ti(C, N, O)-layerGas mixture: 66 vol % H.sub.2 65.95 vol % H.sub.2 3 vol % TiCl.sub.4 3 vol % TiCl.sub.4 16 vol % N.sub.2 16 vol % N.sub.2 11 vol % Ar 11 vol % Ar 4 vol % CH.sub.4 4 vol % CH.sub.4 0.05 vol % CO.sub.2Duration: 16 minutes 16 minutesTemperature: 1060° C. 1060° C.Al.sub.2 O.sub.3 -layers or aluminum-boron mixed oxide layersGas mixture with nitrogen: Gas mixture without nitrogen:(variation 5) (variations 1-4)13.25 vol % H.sub.2 13.25 vol % H.sub.258 vol % N.sub.2 81 vol % N.sub.223 vol % Ar 1.6 vol % AlCl.sub.31.6 vol % AlCl.sub.3 4 vol % CO.sub.24 vol % CO.sub.2.BHorizBrace.Variations 2, 4 and 5 0.15 vol % BCl.sub.3Variations 1 and 3 0 vol % BCl.sub.3 and 13.4 vol % H.sub.2Duration: 40 minutes/layerTemperature: 1060° C.__________________________________________________________________________
Ti(C,N)-intermediate layers
Coating temperature and gas composition as specified for 2nd Ti(C,N)-layer
Duration: 8 minutes/layer
Ti(C,N,O)-intermediate layers
Coating temperature and gas composition as specified above.
Duration: 8 minutes/layer
Cutting test
Turning tests were carried out with the coated reversible cutting plates using a shaft made of structural steel and cutting conditions as specified in EXAMPLE 1.
______________________________________ End of useful (wear)Variation life after:______________________________________1 26 minutes2 25.5 minutes3 27 minutes4 36 minutes5 33 minutes______________________________________
The end of the useful life was caused in each case by the limit of still-acceptable cratering.
The comparison between EXAMPLES 1 and 2 shows that as compared to the single-layer structure according to EXAMPLE 1, a further increase in the resistance to wear can be achieved under the given cutting conditions and with an about equal total layer thickness with the multi-layer structure of the alumina and aluminum-boron mixed oxide layers as defined in EXAMPLE 2. The increase in the resistance to wear in the layer structure according to the invention (variations 4 and 5) in significantly higher than the one with the layer structure according to variations 1 to 3.
EXAMPLE 3
A layer of Ti(C 0 .6,N 0 .4) was deposited as backing layer on reversible cutting plates of the same type as specified in EXAMPLE 1, and a TiN-layer was then applied (deposited) to said backing. Additional layers were applied in 2 variations; variation 2 represents the layer structure according to the invention. In contrast to the preceding EXAMPLES, the coating process was carried out at underpressure. The wear resistances of the individual variations were compared again in a cutting test.
______________________________________Layer structure:Variation 1: 2 μm Ti(C.sub.0.6, N.sub.0.4) 1.5 μm TiN 1.5 μm Al.sub.2 O.sub.3 0.5 μm TiN 1.5 μm Al.sub.2 O.sub.3Variation 2: 2 μm Ti(C.sub.0.6, N.sub.0.4) 1 μm TiN abt. 0.5 μm Ti(N, B, O) 1.5 μm aluminum-boron mixed oxide 0.5 μm Ti(N, B, O) 1.5 μm aluminum-boron mixed oxideCoating conditions:Ti(C.sub.0.6, N.sub.0.4)-layer: Temperature: 1020° C. Pressure: ##STR1##Gas mixture: 83 vol % H.sub.2 8 vol % N.sub.2 4 vol % CH.sub.4 5 vol % TiCl.sub.4Duration: 130 minutesTiN-layer: Temperature: 1020° C. Pressure: ##STR2##Gas mixture: 65 vol % H.sub.2 32 vol % N.sub.2 7 vol % TiCl.sub.4Duration: Variation 1: 93 minutes Variation 2: 62 minutesTi(N, B, O)-layers: Temperature: 1020° C. Pressure: ##STR3##Gas mixture: 60.8 vol % H.sub.2 27 vol % N.sub.2 5 vol % BCl.sub.3 7 vol % TiCl.sub.4 0.2 vol % CO.sub.2Duration: 35 minutesAl.sub.2 O.sub.3 -layers: Temperature: 1020° C. Pressure: ##STR4##Gas mixture: 76.8 vol % H.sub.2 4.0 vol % CO.sub.2 16 vol % CO 3.2 vol % AlCl.sub.3Duration: 180 minutes/layerAluminum-boron Temperature: 1020° C.mixed oxide layers Pressure: ##STR5##Gas mixture: 76.5 vol % H.sub.2 4.0 vol % CO.sub.2 16 vol % CO 3.2 vol % AlCl.sub.3 0.3 vol % BCl.sub.3Duration: 180 minutes/layer______________________________________
Turning tests were carried out with the coated cutting plates on structural steel under the cutting conditions specified in EXAMPLE 1 and turning tests on gray (cast) iron under the following cutting conditions:
Material: Gray cast iron--composition as defined in EXAMPLE 1
Hardness: 205 HB
Cutting rate v: 80 m/min
Feed rate s: 0.28 mm/revolution
Cutting depth a: 2 mm
______________________________________ Structural steel: Gray (cast) iron: End of useful life Wear mark width v.sub.BVariation after: after 10 minutes:______________________________________1 21 minutes 0.28 mm2 28 minutes 0.15 mm______________________________________
The comparison between EXAMPLE 1 and EXAMPLES 2 and 3 shows that no significant difference exists with respect to the quality of the wear parts with the different coatings irrespective of whether said parts were coated at atmospheric pressure or in the under pressure.
EXAMPLE 4
A multi-layer structure was applied directly to the hard metal of reversible cutting plates (of the same type as in the preceding EXAMPLES) without a backing layer; the plates were coated under pressure (variation 2). The layer structure was compared with a multi-layer coating structure different from the one of the invention, but also applied without using a backing (variation 1).
______________________________________Layer structure:Variation 1: Variation 2:0.5 μm Ti(C.sub.0.6, N.sub.0.4) 0.5 μm Ti(C, N, O)0.8 μm Al.sub.2 O.sub.3 0.8 μm aluminum-boron mixed oxide0.3 μm Ti(C, N) 0.2 μm Ti(C, N, O)0.8 μm Al.sub.2 O.sub.3 0.8 μm aluminum-boron mixed oxide0.3 μm Ti(C, N) 0.2 μm Ti(C, N, O)0.8 μm Al.sub.2 O.sub.3 0.8 μm aluminum-boron mixed oxide0.3 μm Ti(C, N) 0.2 μm Ti(C, N, O)0.8 μm Al.sub.2 O.sub.3 0.8 μm aluminum-boron mixed oxide0.3 μm Ti(C, N) 0.2 μm Ti(C, N, O)0.8 μm Al.sub.2 O.sub.3 0.8 μm aluminum-boron mixed oxideOxygen content of the Ti(C, N, O)-layers of variation 2 about2% by weight.Coating conditions:Ti(C.sub.0.6, N.sub.0.4)-layers:Gas mixture: 83 vol % H.sub.2 8 vol % N.sub.2 4 vol % CH.sub.4 5 vol % TiCl.sub.4Temperature: 1020° C. Duration: backing (layer): 32 minutesPressure: 5 k Pa intermediate layers: ##STR6## 20 min/layerTi(C, N, O)-layers:Gas mixture: 82.9 vol % H.sub.2 8 vol % N.sub.2 4 vol % CH.sub.4 5 vol % TiCl.sub.4 0.1 vol % CO.sub.2Temperature: 1020° C.Pressure: ##STR7##Duration: backing (layer): 45 minutes intermediate layers: l8 minutes/layerAl.sub.2 O.sub.3 -layers:Gas mixture: 25 vol % H.sub.2 6 vol % CO.sub.2 66 vol % Ar 3 vol % AlCl.sub.3Temperature: 1020° C.Pressure: ##STR8##Duration: 65 minutes/layerAluminum-boron layers (mixed oxide layers):Gas mixture vol % H.sub.2 6 vol % CO.sub.2 65.6 vol % Ar 3 vol % AlCl.sub.3 0.4 vol % BCl.sub.3Temperature: 1020° C.Pressure: ##STR9##Duration: 65 minutes/layer______________________________________
Cutting test
Turning tests were carried out on a structural steel shaft (0.6% C, strength 750 N/mm 2 ) under the following cutting conditions:
Cutting rate v=200 m/min
Feed rate s=0.41 mm/revolution
Cutting depth a=2 mm
The end of the useful life was caused for both variations by cratering. For variation 1, the end of the useful life was reached after 32 minutes, and for the variation according to the invention (variation 2) after 41 minutes.
In the EXAMPLES, the basic body was composed of hard metal. However, the present invention is not limited to basic bodies made of hard metal. The layer structure according to the invention leads to an unexpectedly high increase in the resistance to wear also with other basic body materials such as, for example, high-speed tool steel, stellite or other heat-resistant alloys. Likewise, the invention is not limited to tools used in metal cutting, but also covers tools for noncutting working, such as drawing dies and the like, as well as tools which are mainly subjected to eroding wear, for example, rock drills. | There is disclosed a wearing part comprising a basic body, a coating applied directly to the basic body or to a backing provided on the basic body and which coating consists of one or a plurality of layers of oxycarbides and/or oxynitrides and/or oxyborides and/or oxyboron nitrides and/or oxyboron carbon nitrides of the elements Ti, Zr, Hf, B, Si and Al and having an oxygen content in a range of from about 0.1 to about 5% by weight, alternating in each case with one or a plurality of layers of aluminum-boron mixed oxides having a boron content in a range of from about 0.01 to about 1% by weight. Compared to previously known wearing parts provided with multi-layer coatings a wearing part in accordance with the present invention exhibits significantly increased resistance to wear, as well as excellent adhesive strength, with respect to the hard-material coating, thus resulting in a substantially prolonged useful life. | 2 |
FIELD OF THE INVENTION
The present invention relates to a power component.
BACKGROUND INFORMATION
Power components having an actuator which is adjacent to a measuring element are already known in the form of SENSEFET transistors.
SUMMARY OF THE INVENTION
In contrast, the power component of the present invention has the advantage that it ensures safe and reliable operation even with high currents through the actuator as well as protection against the risk of failure.
In SmartPower components such as SENSEFET transistors in particular (in DMOS design, for example) or in IGBT transistors having an integrated sense element, a reliable protection is ensured against overvoltange and breakdowns between the sense cell and adjacent DMOS cell. In particular when employed as a high-side switch, critical operating conditions such as, for example ground and/or battery separation, ISO pulses (interference pulses from the supply system) or with inductive loads or cable inductances can be withstood without risk of failure of the power component. Moreover, it has proven to be advantageous that there is no adverse effect on the current detection by the sense element in normal operation as a consequence of the arrangement provided. Moreover, the arrangement can be integrated monolithically.
If the arrangement prevents an activation of existing parasitic bipolar transistors, for example, by preventing the buildup of the base potential, then the danger of a second breakdown with subsequent fusing is prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a SENSEFET transistor in cross-section.
FIG. 2 shows a first exemplary embodiment.
FIG. 3 shows a second exemplary embodiment.
FIG. 4 shows a third exemplary embodiment.
FIG. 5 a shows a fourth exemplary embodiment.
FIG. 5 b shows a fifth exemplary embodiment.
DETAILED DESCRIPTION
FIG. 1 shows a transistor having a sense element, in cross-section. A weakly n-doped semiconductor layer is arranged on a p-doped substrate 1 . Weakly p-doped regions 3 are arranged in semiconductor layer 2 , the p-doped regions being separated from each other by regions of semiconductor layer 2 . A strongly p-doped region 4 is arranged in the center of each of regions 3 , the p-doped region extending from the surface of the semiconductor component to a depth in which region 4 is always directly in contact with semiconductor layer 2 . Strongly n-doped regions 5 are incorporated in the margins of strongly p-doped regions 4 , each of strongly n-doped regions 5 extending somewhat into weakly p-doped region 3 at the edge of each of the strongly p-doped regions 4 . A weakly p-doped region 30 is 25 also incorporated in semiconductor layer 2 by analogy to region 5 . By analogy to region 4 , a strongly p-doped region 40 is incorporated in weakly p-doped region 30 ; by analogy to strongly n-doped regions 5 , strongly n-doped region 29 is incorporated in strongly p-doped region 40 . Gate electrodes 6 , insulated from the semiconductor layer by an insulating layer, are arranged above the regions of semiconductor layer 2 which extend to the surface of the semiconductor component. Gate electrodes 6 are electrically connected with each other and can be electrically contacted via gate terminal 11 . Strongly n-doped regions 5 and strongly p-doped regions 4 are electrically connected with each other and can be jointly electrically contacted via source/load terminal 10 . Regions 40 and 29 are also electrically connected and can be electrically contacted via sense terminal 12 . Oxide layers and necessary metallic coatings on the surface of the semiconductor component are not shown in FIG. 1 for reasons of simplicity of presentation. If the component of FIG. 1 is designed as a DMOS power transistor, a strongly n-doped drain region, for example, is incorporated in weakly n-doped semiconductor layer 2 . This drain region is not shown in FIG. 1 . This drain region can be electrically contacted via a front drain terminal which is also not illustrated and in addition to load terminal 10 , gate terminal 11 and sense terminal 12 , represents the fourth terminal of a SENSEFET transistor.
The p-region 3 , p-region 30 and the region of semiconductor layer 2 lying between the two p-regions form a parasitic PMOS transistor. At a gate potential which is lower than the potential at sense terminal 12 , this parasitic PMOS transistor has a threshold voltage between source terminal 10 and sense terminal 12 which is, for example, 4 volts. If region 30 which represents the source region of the PMOS transistor is then in contact with a potential which is at least 4 volts higher than the potential of the p-region, a parasitic p channel is activated in semiconductor layer 2 . The parasitic PMOS transistor shifts current into region 3 of the adjacent DMOS cell which functions simultaneously as the base of a vertical npn bipolar transistor. This parasitic npn transistor is formed by regions 5 , 3 / 4 and semiconductor layer 2 . In normal operating conditions, switching through this parasitic npn bipolar transistor by a short-circuit between the strongly n-doped region 5 and strongly p-doped region 4 is effectively prevented. The current of the parasitic PMOS transistor, however, allows the potential to build up in the base region of the parasitic bipolar transistor so that the npn bipolar transistor is activated and there exists the danger of a second breakdown with fusion.
FIG. 2 shows a SENSEFET transistor 41 , 42 , a sense element 41 and an actuator 42 which, for example, is also constructed using DMOS technology. The gate electrodes of sense element 41 and actuator 42 are connected with a control circuit 47 which in turn is connected to the power supply via both ground terminal 45 and voltage source 46 .
Voltage source 46 is also connected to the drain terminals of the sense element and actuator. An analysis circuit 49 is connected between ground 45 and the source terminal of sense element 41 . An inductive load 50 is connected between source terminal 10 of actuator 42 and ground 45 . A protective diode 48 is connected between source terminal 10 of actuator 42 and the source terminal of sense element 41 , the negative pole of the protective diode being connected to source terminal 10 of actuator 42 .
(Externally controllable) control circuit 47 controls the current through actuator 42 . Analysis circuit 49 evaluates the current through sense element 41 which functions as a current detection element. Depending on the application, analysis circuit 49 is connected to other electronic circuits or to control circuit 47 in order to make the information concerning the size of the load current through actuator 42 available to the other circuit components and to control circuit 47 . If a ground separation or a voltage source separation occurs at inductive load 50 , the potential of source terminal 10 becomes negative due to the magnetic induction. As a result, protective diode 48 becomes conductive which guarantees that the source terminal of sense element 41 has a potential which is only a forward voltage higher than the potential of source terminal 10 . This effectively prevents the parasitic PMOS transistor from being activated. In normal operation, however, the diode does not influence the function of sense element 41 since in normal operation, protective element 48 is switched in reverse direction.
FIG. 3 shows an additional exemplary embodiment in which the same components are identified with the same reference symbols as in FIG. 2 and are not described again.
Instead of protective diode 48 in FIG. 2, a PMOS transistor 480 is connected to the source terminals of sense element 41 and actuator 42 , the transistor being connected as a diode in such a way that with negative potential of source terminal 10 of actuator 42 , the PMOS transistor is switched through.
FIG. 4 shows an additional exemplary embodiment in which a suppressor circuit 490 is arranged instead of protective element 48 . This suppressor circuit 490 has an NMOS transistor 62 , a first resistor 63 and a second resistor 64 . First resistor 63 is connected to the source terminal of actuator 42 . First resistor 63 is also connected with second resistor 64 . Second resistor 64 is connected to ground 45 . The first and second resistors are connected to the gate electrode of NMOS transistor 62 . The source terminal of transistor 62 is connected to source terminal 20 of actuator 42 . The drain terminal of transistor 62 is connected to the source terminal of sense element 41 .
NMOS transistor 62 switches through if actuator 42 has a negative source potential. The amount of the negative potential at which NMOS transistor 62 switches through can be adjusted via the resistance values of first resistor 63 and second resistor 64 .
FIG. 5 a shows a cross-section of a component according to FIG. 1 with an integrated protective diode 48 . The same reference symbols as in FIG. 1 are not described here once more. Protective diode 48 has a weakly p-doped region 72 incorporated in semiconductor layer 2 , a strongly p-doped region 71 being incorporated in turn in p-doped region 72 which surrounds p-doped region 71 . A strongly n-doped region 70 is in turn incorporated in strongly 10 p-doped region 71 . Strongly n-doped region 70 is electrically connected to source terminal 10 ; strongly p-doped region 71 is connected to sense terminal 12 . Similar to FIG. 1, electrical insulating layers and metal coatings have been left out of the drawing for simplification of presentation. This also explains, for example, the stage of the right-hand one of the three gate electrodes 6 shown which is underlaid with an insulating layer. FIG. 5 b shows a power component according to FIG. 1 with a protective element 480 designed as a PMOS transistor. Protective element 480 , which is arranged in the vicinity of the sense element, has two weakly p-doped regions 76 and 79 incorporated in semiconductor layer 2 , strongly p-doped regions 77 and 79 being incorporated in turn in weakly p-doped regions 76 and 78 , the strongly p-doped regions completely penetrating p-doped regions 76 and 78 and being in direct contact with semiconductor layer 2 . Gate electrode 75 of protective element 480 is connected to source terminal 10 ; strongly p-doped region 77 is connected to sense terminal 12 and strongly p-doped region 79 is, like gate electrode 75 , connected to source terminal 10 .
FIGS. 5 a and b show simple implementations of the circuits according to FIGS. 2 and 3, respectively. No additional expense is necessary to implement protective elements 48 and 480 since regions 71 , 72 , 76 , 77 , 78 and 79 can be produced together with the semiconductor regions necessary for the actuator and the sense element. Of course, protective elements 48 and 480 can also be used in back-contacted components, i.e., vertical power components or even IGBT components. | A power component is proposed which reliably switches inductive loads and has a current detection element to detect the current through the inductive load. The component includes a protective element which is connected to the source terminals of the sense element and of the actuator. The protective element protects against parasitic effects between the sense element and the actuator. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional application of application Ser. No. 11/701,716, filed Feb. 2, 2007; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates, generally, to wheel washing assemblies and more specifically, it relates to an automated wheel washing assembly for an automated vehicle wash or carwash. The invention further relates to a method of operating a wheel washing assembly.
[0003] In the past, automatic wheel washers commonly scrubbed the hubcap and tire sidewall areas of the wheel with a rotating brush. However on newer vehicles, this is objectionable because the scrubbing action mars the surface finish on the hubcaps and rims. Accordingly, there is a need for a touchless car wheel washer.
[0004] The cleaning of the wheels of a vehicle in a drive-through wash system has always been a difficult task to achieve automatically. While there have been numerous attempts to automatically wash vehicle wheels at a wheel cleaning station, the reliability and the cost of such devices have inhibited their general acceptance and usage in the industry. Today, most car washes have at least supplemented the washing of the vehicle wheels by manually spraying the vehicle wheels with a low-pressure jet of water from a wand manipulated by one or more attendants. However, this is not an option for a fully automated carwash with no attendants.
[0005] A more common approach is to spray a low pressure, i.e. less than 100 psi, stream of soapy water at the vehicle wheel in order to dislodge dirt and debris. The difficulty arises in effectively spraying the entire wheel surface in a relatively short segment of the drive-through washing system. A common attempt is to utilize a spray of liquid to clean wheels which is provided by a plurality of longitudinally spaced apart, stationary and sequentially operated nozzles. However, the low-pressure cleaning was not effective as the wheels passed the stationary spaced nozzles to quickly.
[0006] U.S. Pat. No. 4,830,033 teaches a wheel washing apparatus using a series of sequentially activated nozzles. The nozzles provide a high-pressure, 600 to 900 psi, stream of liquid dispensed from a series of longitudinally spaced and sequentially activated nozzles. These nozzles are mounted atop a parallelogram type tire washing apparatus so that the nozzles can be spaced at a uniform distance from the vehicle wheel regardless of vehicle width. However, once again the nozzles do not follow the wheel along the transport path.
[0007] A major expense of wheel washers in automated carwashes relates to the relative expense of the drive assembly formed of hydraulically driven cylinders for positioning the wheel washing assembly and to allow it to follow a wheel as it traverses through the car wash rather than be formed of stationary, spaced nozzles. In addition, to being complicated to construct, the drive assembly is subject to expensive maintenance and repair costs as many mechanical and hydraulic related moving parts are involved to allow the wheel washing assembly to follow the wheel. In addition, the tracking of the wheel is complicated as the conveyance speeds may be varied.
[0008] The need persists to develop a wheel washing assembly having a contactless sprayer that is driven by a simple mechanical drive for tracking the wheel and which does not have the complicated and expensive tracking mechanism. In addition to reduced manufacturing costs, a wheel washing assembly with the least maintenance needs and repair requirements is desirable.
SUMMARY OF THE INVENTION
[0009] It is accordingly an object of the invention to provide a wheel washing assembly for an automated carwash and a method of operating the wheel washing assembly that overcome the herein-mentioned disadvantages of the heretofore-known devices and methods of this general type, which is less complex than existing systems and easier to maintain and operate.
[0010] With the foregoing and other objects in view there is provided, in accordance with the invention, a wheel washing assembly. The wheel washing assembly contains a machine frame, a pendulum assembly pivotably supported on the machine frame, and two washing manifolds, including a first washing manifold and a second washing manifold, attached to the pendulum assembly. Each of the washing manifolds has a nozzle assembly for ejecting water at a wheel to be washed. The washing manifolds are pivotable between a start washing position and an end washing position by an automatic motion of the pendulum assembly. The washing manifolds further automatically track the wheel by a motion of one of the wheels. This allows a continuous washing of the wheel as it is being tracked.
[0011] In accordance with an added feature of the invention, a pendulum base frame is provided and has a recess formed therein and is disposed beneath the machine frame, the first washing manifold follows along a track defined by the pendulum base frame.
[0012] In accordance with an additional feature of the invention, the first washing manifold has a roller assembly which falls fully into the recess for allowing the wheel to traverse fully over and past the roller assembly, and upon the wheel fully traversing past the roller assembly, the pendulum assembly automatically initiates a pivoting motion from the end washing position to the start washing position due to a force of gravity and a position of the pendulum assembly.
[0013] In accordance with another feature of the invention, the nozzle assembly includes a central nozzle and four spinning nozzles rotating around the central nozzle.
[0014] Ideally, the pendulum assembly is formed of a frame containing main arms and lower arms having an articulated connection to the main arms. Each of the lower arms supports one of the washing manifolds and is height adjustable due to the articulated connection and allows the roller assembly to sink into the recess. The pendulum assembly further has a counter weight configured for controlling a motion of the pendulum assembly. Preferably, the machine frame and pendulum assembly are formed of metal tubing having a square shaped cross section.
[0015] In accordance with a further feature of the invention, bearing blocks are provided with one of the bearing blocks disposed on opposite sides of the machine frame for supporting the pendulum assembly in a pivotal manner.
[0016] In accordance with yet another feature of the invention, only a single pump for pumping water to the nozzle assembly is necessary.
[0017] In accordance with another further feature of the invention, the first washing manifold has a roller assembly which is pushed by one of the wheels starting around the start washing position and thus allows the washing manifolds to track the wheels due to the speed of the one wheel. A distance between the start washing position and the end washing position is at least four feet which allows the nozzle assembly to continuously eject the water at the wheels to be cleaned as the nozzle assembly moves with the wheels.
[0018] With the foregoing and other objects in view there is provided, in accordance with the invention, a method of washing wheels of a vehicle. The method includes providing a wheel washing assembly containing a pendulum assembly pivotably supported on a machine frame, and two washing manifolds, including a first washing manifold and a second washing manifold, attached to the pendulum assembly. Each of the washing manifolds has a nozzle assembly for ejecting water at the wheel to be washed, and the first washing manifold has a roller assembly. The vehicle is moved through the wheel washing assembly with one of the wheels engaging and pushing the roller assembly, beginning at a start position, causing an automatic tracking of two of the wheels by the first and second washing manifolds, respectively. Water is ejected at the two wheels being tracked by the first and second washing manifolds. The wheel will drive over the roller assembly at an end position. Subsequently, the first and second washing manifolds are pivoted back to the start position via the pendulum assembly.
[0019] Other characteristic features of the invention are set forth in the appended claims.
[0020] Although the invention is illustrated and described herein as embodied in a wheel washing assembly for an automated carwash and a method of operating the wheel washing assembly it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0021] The construction of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0022] FIG. 1 is a diagrammatic, front perspective view of a wheel washing assembly according to the invention;
[0023] FIG. 2 is a diagrammatic, plan view of the wheel washing assembly;
[0024] FIG. 3 is a diagrammatic, side view of the wheel washing assembly;
[0025] FIG. 4 is a diagrammatic, rear perspective view of the wheel washing assembly; and
[0026] FIG. 5 is a diagrammatic, side view of the wheel washing assembly showing a washing manifold in a start position and an end position.
DESCRIPTION OF THE INVENTION
[0027] In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case. Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is shown a wheel washing assembly 1 for installation in a non-illustrated automatic car wash. The wheel washing assembly 1 has a frame 2 formed of four posts 3 , four cross braces 4 , two transverse cross braces 5 , and a plurality of standard braces 6 all connected to each other for forming the frame 2 . The frame components 3 - 6 are welded and/or fastened via fasteners 7 to each other. The frame components 3 - 6 are ideally formed of aluminum, metal, metal alloys or composite materials and are shown to be formed from tubing having a square cross sectional shape. The frame components 3 - 6 can be of any shape as long as it has the necessary structural strength and balance but ideally has the square cross sectional shape as these components are cost effective to manufacture.
[0028] At a base of each of the posts 3 is an attachment bracket 10 containing a plurality of holes 11 for fastening the wheel washing assembly 1 to a floor or a base of the automatic carwash. The frame 2 is shown here with four posts 3 but can easily be extended by the addition of two to four more central posts 3 to provide a longer wheel cleaning area.
[0029] Disposed on top of the frame 2 are two oppositely positioned bearing blocks 20 for supporting a pendulum assembly 21 . As best shown in FIG. 4 , the pendulum assembly 21 has a pendulum frame 22 formed of one cross member 23 , two main arms 24 extending from the cross member 23 , two lower arms 25 extending from the main arms 24 , and one counter weight 26 attached approximately centrally on the cross member 23 . Each of the main arms 24 is mounted in one of the bearing blocks 20 and can swing or pivot about a central axis 27 of the bearing block 20 . The lower arms 25 are pivotably connected to the main arms 24 , via a clevis type assembly 28 that allows the lower arms 25 to pivot or rotate about an axis of rotation 29 . In this manner, the lower arms 25 can be raised and lowered as needed.
[0030] Attached to each of the lower arms 25 is a spinning wash manifold 30 containing four spinning zero-degree plus nozzles 31 and one turbo nozzle 32 to deliver the necessary water impact to loosen even the most difficult brake dust and other road grime from wheels as best seen in FIG. 2 . In FIG. 2 , a manifold housing 33 containing the nozzles 31 and 32 has been cut away on the right side of FIG. 2 so that the nozzles 31 and 32 are visible. The spinning nozzles 31 rotate or spin about the central stationary nozzle 32 as all of the nozzles eject water W at a desired pressure being either low pressure, less than 100 psi, or high pressure being greater than 100 psi, ideally 600-900 psi.
[0031] Attached to one of the lower arms 25 is a pendulum roller assembly 35 that is guided above and/or along a pendulum base plate 36 ( FIG. 4 ). At an end of the pendulum base plate 36 is a recess 37 that receives the pendulum roller assembly 35 . Upon entering an entry or starting point A of the wheel washing assembly 1 defined at the front of the pendulum base plate 36 , a front wheel of a vehicle runs into rollers 38 of the pendulum roller assembly 35 . The front wheel pushes the pendulum roller assembly 35 forward along the pendulum base plate 36 in a direction of travel T. The initial movement of the pendulum roller assembly 35 causes a diagrammatically illustrated pump assembly 50 to supply water, via water lines 51 , to the four spinning nozzles 31 and the one turbo nozzle 32 for both the left and right spinning wash manifolds 30 (see FIG. 3 ). The four spinning nozzles 31 spin about the middle turbo nozzle 32 and all five nozzles eject a pressurized stream of water W at the wheel and tire for cleaning the wheel and tire. The spinning wash manifold 30 and the associated nozzles 31 , 32 follow the wheel perfectly along the pendulum base plate 36 because it is pushed by the front wheel of the vehicle acting on the pendulum roller assembly 35 . Therefore, there is no need to make adjustments for different vehicle conveyor speeds as the vehicle wheel provides an automatic speed adjustment. Therefore, complicated tracking or controller systems can be dispensed with. As the front wheel and therefore the pendulum roller assembly 35 reach the recess 37 at the end position E of the pendulum base plate 36 , the pendulum roller assembly 35 sinks into the recess 37 and the front wheel rolls over the pendulum roller assembly 35 . After the front wheel passes over the pendulum roller assembly 35 housed in the recess 37 , the pendulum roller assembly 35 automatically swings back to the entry point A under a pendulum action of the pendulum assembly 21 . For a further understanding of the pendulum motion, FIG. 5 shows both the entry point A and the end point E of the pendulum action. It is noted the FIG. 5 is highly diagrammatic and is provided only for showing the two positions A, E and is not fully illustrated in the upper region of the drawing. Upon falling into the recess 37 , the water pump 50 is optionally signaled to stop providing water W and therefore the spinning wash manifold 30 shuts down. In another embodiment, the water flow is continuous and not turned off in anticipation of the rear wheels.
[0032] It is noted that the water supply system including the pump 50 , non-illustrated actuators and valves and the water lines 51 are only figuratively illustrated as they are known component parts. However, it is noted that a single pump 50 is all that is necessary for supplying water to the two spinning wash manifolds 30 which is not common in known wheel washing assemblies.
[0033] The pendulum action itself raises and lowers the spinning wash manifold 30 to the proper heights and ensures full coverage of various wheel heights. This is allowed to occur because of the articulated connection of the lower arm 25 to main arm 24 of the pendulum assembly 21 . The spinning wash manifold 30 perfectly tracks each wheel, following it with a pressurized stream of water along the extent of the pendulum base plate 36 , thus providing an extended washing period with a pressurized circular cleaning motion of the spinning nozzles 31 and the turbo nozzle 32 . It is noted that different water pressures can be provided to the different nozzles 31 and 32 for providing different cleaning actions. Furthermore, a travel path of the spinning wash manifold 30 is approximately five feet along the pendulum base plate 36 but the travel path can easily be varied to 4, 5, 6, 7, 8, 9 or greater feet depending on the frame and pendulum assembly structure in addition to the type of vehicle to be washed.
[0034] Next a rear wheel of the vehicle pushes the pendulum roller assembly 35 and initiates a washing cycle for the rear wheels. After the rear wheel pass over the recessed pendulum roller assembly 35 , the pendulum roller assembly 35 once again automatically swings back to the entry point A under a pendulum action of the pendulum assembly 21 .
[0035] As can be immediately recognized, the simple mechanical pendulum based configuration requires little maintenance, automatically adjusts to any conveyor speed, and automatically sets up for the entry of the next wheel. In other words, no complicated electronic controller assembly is required for the wheel washing assembly as it is based on a simple, automatic pendulum action. As compared to the prior art, no complicated hydraulically driven cylinders and controllers are required for positioning the spinning wash manifolds 30 and to allow the spinning wash manifolds 30 to perfectly track incoming wheels. Not only are the maintenance costs greatly reduced but construction costs are considerably lower than the prior art wheel washing assemblies due to the simple, yet highly affective pendulum assembly 21 . | A wheel washing assembly contains a machine frame, a pendulum assembly pivotably supported on the machine frame, and two washing manifolds, including a first washing manifold and a second washing manifold, attached to the pendulum assembly. Each of the washing manifolds has a nozzle assembly for ejecting water at a wheel to be washed. The washing manifolds are pivotable between a start washing position and an end washing position by an automatic motion of the pendulum assembly. The washing manifolds further automatically track the wheels to be washes by a motion of one of the wheels. | 1 |
FIELD OF THE INVENTION
This invention relates generally to the field of in situ hydrocarbon extraction and more particularly to in situ extraction of hydrocarbons by means of a condensing solvent process which mobilizes the hydrocarbons for extraction by, for example, gravity drainage.
BACKGROUND OF THE INVENTION
Tar sands or oil sands such as are found in Canada, contain vast reserves of hydrocarbon resources of the type referred to as heavy oil or bitumen. Such heavy oil or bitumen is a hydrocarbon that has a high specific gravity and viscosity. These properties make it difficult to extract the hydrocarbon from the tightly packed sand formations in which it is found because unlike lighter oil deposits, heavy oil and bitumen do not readily flow at in situ conditions.
In prior Canadian Patent No. 2,299,790, a condensing solvent based in situ hydrocarbon recovery process is disclosed. This patent teaches, among other things, using a condensing solvent and controlling the in situ pressure to achieve a condensation temperature for the solvent within the formation which is suitable for reducing a viscosity of the in situ hydrocarbon by warming and solvent effects so that the hydrocarbon will flow under the influence of gravity. The result of this process is a volume in the formation which is stripped of the mobilized hydrocarbons, and which is called a gravity drainage chamber. As more solvent is circulated more hydrocarbon is removed resulting in a chamber which grows upwardly and outwardly from the injection well.
Canadian Patent No. 2,351,148 teaches, among other things, using a solvent which has been purified sufficiently to allow the solvent to achieve bubble point conditions at the extraction interface of the gravity drainage chamber whereby non-condensable gases naturally arising from the warming bitumen or hydrocarbon will be carried away with the draining liquids also in liquid form. In this way, a continuous extraction process is achieved at the extraction interface, because the potential impediment of an insulating layer of non-condensable gases existing between the incoming condensing solvent and the extraction interface is removed as part of the process.
The geological characteristics of the tar sands or oil sands can vary from deposit to deposit. While some deposits are relatively thick deposits in the order of 40 to 50 or more meters thick, many deposits are relatively thin being less than 20 meters thick and in many cases even 10 meters or less thick. In addition, the characteristics of the overburden can vary considerably. In some cases, the overburden is comprised of the cap rock which can act as a containment layer, but in other cases the overburden may be a sand layer or gravel or other porous material that provides poor confinement.
Where good confinement is available it is preferred to let the chamber grow to all the way to the overburden layer to extract all of the available hydrocarbon, but, leaving the overburden exposed to condensing solvent in the chamber is undesirable. More specifically, the overburden will continue to attract condensing solvent and the latent heat of condensation of such condensing solvent will be passed to the overburden but to no useful extraction effect. There is simply no hydrocarbon located in the overburden which can be warmed and removed. Therefore, any heat transfer to the overburden layer is wasted, thereby reducing the efficiency of the condensing solvent process.
In some cases, the overburden layer may not be a good confinement layer. In cases where the overburden layer is sand or other porous material it may also be saturated with water. In such a case, if the chamber growth extends vertically to the overburden layer the water will be provided with a pathway into the chamber which could result in the chamber being water flooded. Once the chamber is water flooded, further extraction from the chamber through a condensing solvent process is unlikely. Thus, when poor confinement exists it is preferred to stop vertical chamber growth at a point below the overburden layer to preserve a layer of hydrocarbon to that provides the necessary confinement.
SUMMARY OF THE INVENTION
What is desired is a method of controlling the location in the gravity drainage chamber where the solvent condensation occurs to control the flow of heat and chamber growth in a condensing solvent process to more efficiently extract in situ heavy oil and bitumen from an oil sand deposit under an overburden layer. In other words, it is desirable, in some circumstances, to preserve the integrity of a layer of bitumen saturated sand at the top of the reservoir in order to provide a confining barrier for the extraction chamber. In other circumstances it is desirable to control the location of condensation in the extraction chamber in order to maximise the thermal efficiency of the condensing solvent process.
According to the present invention the growth of the extraction chamber in situ can be controlled through the accumulation of non-condensable gases within the extraction chamber that act as a thermal barrier between the condensing solvent on a warm side of said layer, and the overburden or unextracted bitumen on a cold side of said layer. The vapour density of the non-condensable barrier gas, relative to the vapour density of the solvent vapour, at in situ or extraction conditions can be selected to optimize chamber growth and improve extraction effectiveness. By accumulating non-condensable gases having a vapour density which is less than the vapour density of the condensing solvent at extraction conditions, the barrier layer can be preferentially located or floated to a top or attic of a gravity drainage chamber. In this manner, vertical heat flow and vertical chamber growth can be restricted when desired, without stopping continued chamber growth in other directions, such as horizontally along a bitumen layer. By limiting vertical heat flow and vertical growth while encouraging horizontal growth, the horizontal wells may be spaced within the layer to optimise capital costs.
According to a preferred aspect of the current invention, a relatively pure solvent can be used to commence initial extraction of hydrocarbons in situ to form an extraction chamber. According to the invention of U.S. Pat. No. 2,351,148 the purer the solvent the more non-condensables can be removed from the extraction chamber. Most preferably, the removal of heat transfer poisoning non-condensable gases, which arise for example, from the mobilization and extraction of the reduced viscosity hydrocarbons will occur at a rate that prevents non-condensable gas from accumulating within the extraction chamber, thereby permitting continued chamber growth to occur.
According to the present invention, the vertical heat flow and vertical growth of the chamber can be measured over time and at a time at or before the vertical growth reaches the top of the bitumen layer, i.e., reaches to the overburden layer, the solvent purity can be temporarily varied to permit non-condensable barrier gas to accumulate in the chamber. The non-condensable barrier gas can arise either naturally from the bitumen which is being warmed and extracted, or, can be specifically added to the solvent to be carried to the extraction surface by the solvent within the chamber and may be one or more than one species of non-condensable gases.
Therefore, according to one aspect of the present invention there is provided a method of forming an in situ gravity drainage chamber while extracting hydrocarbons from a hydrocarbon bearing formation, the method comprising:
a. Injecting a condensing solvent which is sufficiently pure, having regard to the in situ conditions, to extract non-condensable gases from said chamber in liquid form; b. Monitoring a growth of said chamber in a vertical direction; and c. Establishing a non-condensable barrier gas layer at a top of said chamber to reduce the vertical heat flow and vertical growth rate of said chamber at or before said chamber reaches an overburden layer.
According to a further aspect of the invention there is provided a method of forming an in situ gravity drainage chamber in a hydrocarbon bearing formation comprising injecting a condensing solvent into said formation and varying a solvent purity over time to cause enough of a barrier gas to be introduced into said chamber to halt vertical growth of said chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to preferred embodiments of the present invention, by way of example only, and in which:
FIG. 1 shows a schematic of solvent purity of injected solvent over time according to one aspect of the present invention;
FIG. 2 shows an extraction chamber being extracted during an initial stage with substantially pure solvent according to the present invention;
FIG. 3 shows the chamber of FIG. 2 at a later stage of extraction where the vertical growth of the chamber has reached a desired upper limit and a barrier gas is being accumulated in the chamber at the extraction (condensation) interfaces;
FIG. 4 is a different cross section view of the chamber of FIG. 3
FIG. 5 is a subsequent cross-section view similar to FIG. 4 ; showing that after a period of time, the barrier gas floats up towards the top of the chamber and begins to accumulate there;
FIG. 6 is the chamber of FIGS. 3 and 4 after a further period of time under substantially pure condensing solvent injection showing the continued horizontal extraction or growth of the chamber but very limited vertical growth according to the present invention;
FIG. 7 shows a buoyancy curve of methane in propane at various pressures and saturation temperatures;
FIG. 8 shows a buoyancy curve of methane and hydrogen or a 1:1 ratio in propane at various pressures and saturation temperatures; and
FIG. 9 shows the mol fraction of propane solvent in the saturated vapour as a function of chamber pressure and local temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , a time line schematic is provided that generally illustrates the trends of purity of the injected condensing solvent over time according to a first aspect of the present invention. The horizontal or x-axis represents time, and the vertical or y-axis represents solvent purity. A horizontal denoted line 10 is also shown, which represents a desired purity of the solvent which is capable of extracting hydrocarbons and bitumen from the formation. This purity is referred to here in as extraction purity since at this purity hydrocarbon extraction occurs. Extraction purity means a solvent that is pure enough to continuously remove non-condensable gases from the chamber. The precise solvent purity required for extraction purity will vary from reservoir to reservoir depending upon in situ conditions such as pressure, temperature and amount of non-solvent gas naturally present and dissolved into the bitumen.
Also shown is an injected solvent purity line 12 , which represents the purity of the injected condensing solvent over time. For efficient non-condensable gas removal the extraction purity is able to achieve bubble point conditions for the condensing solvent at the extraction interface in the chamber. To achieve effective chamber growth rates, it is most desirable to remove any such expressed non-solvent gases, which are non-condensable at extraction conditions, from the chamber. At extraction purity for the solvent such other gases are able to dissolve into the solvent condensing onto the bitumen interface to permit these other gases to be carried away in a liquid form out of the chamber.
As fresh solvent is continually injected into the extraction chamber, it condenses onto and mobilizes the bitumen, scavenges other non-solvent gases present and results in a liquid mixture of solvent and hydrocarbons and other liquids draining down the chamber walls to collect in the bottom of the extraction chamber. From there the liquids are lifted or pumped to the surface for separation of solvent and hydrocarbons and then purification and preferably reuse of the solvent in the formation. Over time the extraction chamber will grow as more solvent is circulated and more hydrocarbon and bitumen is produced. Provided that the bubble point conditions are achieved at the interface, due to the solvent being at extraction purity, the chamber will grow outwardly both horizontally and vertically without undue accumulations of non-condensable gases occurring within the chamber. As the chamber grows, the vertical growth will eventually reach a point where it is at or near the overburden, or at a maximum desired vertical height.
According to the present invention, it is desirable to monitor the vertical growth of the chamber to be able to identify when the vertical growth is at or near the overburden layer or more specifically at an optimum height. This, according to the present invention, is the time to preferentially reduce and restrict further vertical growth. The preferred means used to measure vertical growth of the chamber of the present invention is discussed in more detail below.
FIG. 2 shows an injection well 20 with extraction purity condensing solvent being injected (arrows 22 ) during an initial time period 15 ( FIG. 1 ). The condensing solvent 22 exits the injection well 20 into an extraction chamber 24 where it is shown flowing by convection outwardly as arrows 23 . It condenses on the extraction interface and results in draining liquids 26 which drain down the sides of the chamber 24 under the influence of gravity. These liquids 26 enter the production well 28 , and are pumped to the surface by a pump 30 . The hydrocarbon bearing formation 32 includes an overburden layer 34 , a hydrocarbon pay zone 36 , and an underburden 38 . FIG. 2 depicts the chamber at a point in time towards the end of the time period 15 of FIG. 1 .
While FIG. 2 and the other figures depict horizontal well pairs it will be understood that the wells need not be truly horizontal and may be sloped or the like. Thus the term horizontal as used herein means somewhat or generally horizontal. Further other well configurations are contemplated by the present invention, such as a generally vertical single well arrangements or configurations of multiple generally horizontal wells.
As can now be understood, during this part of the process (time period 15 ) the solvent has extraction purity and gases other than the solvent gas, which are noncondensable at the condensing conditions for the solvent, are being removed from the chamber 24 at a rate which permits extraction to continue. In other words, these other gases are not allowed to accumulate in the chamber to any significant degree during this step in the process and thus are not present in FIG. 2 . Time period 15 ends when the extraction chamber has reached its desired maximum height.
Once the maximum chamber height is reached, the present invention provides that the solvent purity of the injected condensing solvent is changed. This is shown in FIG. 1 , at 14 . At this point, it is desirable to reduce the solvent purity and introduce more non-condensable barrier gas into the chamber, in other words the injection solvent purity is no longer at extraction purity. The change in injection solvent purity will have two in situ effects according to the present invention. The first effect is that more non-condensable barrier gas will be carried into the chamber by the solvent itself and then concentrated at the condensation surfaces as the solvent condenses. The second effect is that the condensed liquid solvent leaving the chamber is less able to extract the non-solvent gases arising naturally in the formation as liquids as the solvent is somewhat or fully saturated with barrier gases already. Depending upon how far below extraction purity the solvent is it can only scavenge barrier gases from the chamber at a reduced rate, if at all. As a result, non-solvent barrier gases now begin to accumulate within the chamber, at the condensation surfaces, over the time period 16 of FIG. 1 .
According to the present invention the preferred non-solvent barrier gas is a light gas having a vapour density which is most preferably significantly lower than the vapour density of the solvent at extraction or in situ conditions. The density difference should be sufficient, at the extraction chamber temperature and pressure to permit the barrier gas to accumulate at a preferred location in the chamber, such as at the roof of the chamber as described below.
FIG. 3 shows the in situ conditions in the extraction chamber corresponding to the end of the time period 16 on FIG. 1 . As shown in FIG. 3 , as the condensing solvent carries the non-condensable or barrier gas into the formation where it will be released at the extraction interface around the perimeter of the chamber when the solvent condenses. The barrier gas will, over time, build up as a relatively thick barrier layer 50 on all of the surfaces on which the condensing solvent is condensing.
FIG. 4 is a different cross-sectional view of FIG. 3 and like numbers are used for like elements. Again the barrier gas layer can be seen on all of the condensing surfaces. At a certain point enough noncondensable gas has been allowed to accumulate in the chamber to form the desired barrier layer.
Turning back to FIG. 1 , during the time period 16 , the purity of the condensing solvent has been decreased to introduce an appropriate amount of barrier gas into the extraction chamber. The appropriate amount will depend upon the size of the chamber and the rate of extraction and will vary from chamber to chamber. However, for the purposes of this specification, it will be understood that an appropriate amount means an amount that will permit the barrier gas to accumulate in the chamber and form a barrier layer.
FIG. 5 is later in time than FIGS. 3 and 4 and depicts a transition period represented by the time span 52 in FIG. 1 . The solvent purity of the injected solvent has been changed again and the solvent is now at extraction purity again. In FIG. 5 the accumulated non-solvent barrier gases are shown moving towards the top of the chamber since they are less dense than the condensing solvent vapour. Eventually the non-condensable gases will accumulate and be confined to a layer which is floating at the top of the chamber into a relatively thicker layer 60 .
FIG. 6 shows the effect of the continued steady state extraction, further along in time period 52 of FIG. 1 . As can be seen the barrier layer 60 is restricting further vertical growth and vertical heat loss, while the absence of a barrier layer on the vertical surfaces of the chamber is permitting further horizontal growth of the chamber at 62 .
It can now be appreciated that the present invention provides a solution to both undesirable effects of having a chamber grow uncontrolled into the overburden layer. Firstly, the non-condensable barrier gas layer will prevent heat loss through the top of the chamber. This will permit more heat to be contained within the chamber and directed usefully to heating the bitumen at the extraction interfaces for continued horizontal extraction. Secondly, the presence of the barrier gas or insulating layer will prevent the extraction interface from continuing to grow upwardly limiting vertical chamber growth. In this manner, the chamber can be prevented from being flooded, for example from an overlying water layer. At the same time, a continued extraction can occur in the horizontal directions by means of the solvent which is at extraction purity. According to an alternate embodiment of the present invention during the time period 16 (after point 14 ) the solvent injection could stop altogether, to be temporarily replaced with an injection of an amount, preferably a defined amount, of non-solvent barrier gas. Thus the schematic of FIG. 1 is also intended to comprehend that solvent injection may temporarily halt at point 14 in order to permit a volume of non-condensable gases to be injected over a short period of time. Injection of the non-condensable gases then ceases and thereafter continued solvent extraction through use of extraction purity solvent can recommence. Convection flow will carry the barrier gases outwardly and distribute the barrier gas around the perimeter of the chamber on the condensing surfaces.
Although many different gases are comprehended by the present invention as the barrier gas, when the solvent gas is propane, the preferred barrier gas is one or more of helium, hydrogen, methane or ethane. Methane is desirable because it is naturally occurring and typically in abundance at the extraction site and has a low vapour density relative to propane. It will therefore tend to rise to the top of the chamber and form a barrier layer. Helium and hydrogen are desirable in that each is also a light gas which can be easily obtained and introduced in the chamber as needed to provide buoyancy. Other barrier gases are also comprehended by the present invention provided they meet the vapour density criteria of being able to rise within and remain above the solvent gas. In this specification the term solvent gas is meant to comprehend many different solvents, such as propane, ethane, butane, and the like. The choice of the condensing solvent will depend upon the reservoir conditions. According to the present invention, the choice of barrier gas will be one that is less dense than the selected solvent gas at reservoir conditions.
FIG. 7 shows the vapour density of various concentrations of methane in propane at various temperatures. FIG. 8 shows the vapour density of various concentrations of methane/hydrogen at 1:1 ratio in propane over a range of temperatures FIG. 7 shows the density of pure propane vapour as a function of saturation temperature. FIG. 7 also has a series of curves showing the density of saturated propane vapour at fixed pressures, ranging from 0.75 MPaA to 2.5 MPaA. In these curves, at fixed pressures, the saturation conditions are achieved by dilution of the propane vapour with a non-condensable gas, methane.
FIG. 8 is similar to FIG. 7 , except than the non-condensable gas is a 50/50 mixture of methane and hydrogen instead of methane. The hydrogen vapour has a lower density that the methane so the 50/50 mix is more likely to rise than methane alone. Consequently the curves of FIG. 8 show lower density at a given temperature and pressure than the curves of FIG. 7 .
As can now be appreciated from FIGS. 7 and 8 the barrier gas which is at the same pressure as the chamber, but at a lower temperature due to the non-condensable gas, has a vapour density which is less than that of pure propane vapour at the same pressure. This is relevant because this density difference provides a buoyancy driving force tending to float the barrier gas upwards towards the top of the chamber. Furthermore, the higher the accumulation of non-condensable gas (i.e. the lower the saturation temperature) in the barrier gas, the greater the buoyancy driving force.
Another aspect of the present invention is the convection flow rate of solvent through the chamber. If the solvent flow rate is very slow, diffusion forces can cause the non-condensable barrier gases to diffuse throughout the chamber and away from the condensation or extraction surfaces. However, providing that there is a sufficient flow of fresh condensing solvent gas flowing towards the condensing surfaces the diffusion effects will be mitigated. Thus, an aspect of the present invention is to maintain a sufficient flow of injection solvent through the chamber towards the extraction surfaces to overcome any diffusion effects that might otherwise encourage the barrier gases to diffuse through the chamber, and thus limit their effectiveness as a barrier gas. The exact rate will vary depending upon the chamber characteristics, but a flow rate of solvent that is higher than the diffusion rate of the barrier gas is most preferred.
To facilitate the operation of the present invention, it is desirable to know where the extraction interface which defines the extraction chamber is located. The present invention comprehends monitoring the movement of the extraction interface over time to ensure that the vertical growth of the chamber can be controlled. Various means of monitoring the extraction rate and the chamber growth can be used however, a preferred method according to the present invention is to position an observation well or wells in the formation at a location which is at or near a middle of said chamber (i.e., where the peak of the chamber roof will be). An example of such an observation well is shown as 70 in FIG. 6 . The position of the observation well may be offset slightly from production and injection wells to reduce the risk of damage of one or the other during well drilling as shown in FIG. 6 or could be directly above, but not as deep as these wells. A logging tool 72 such as a reservoir saturation tool (RST) can be used to determine the nature of the material in the pores space (i.e., gas, water or hydrocarbon liquid). This tool can be used to periodically locate the roof of the vapour chamber. A temperature sensor 74 located within the observation well 70 can provide temperature measurements at specific locations or heights within the chamber.
FIG. 9 shows the mol fraction of propane solvent in the saturated vapour as a function of temperature for various chamber pressures. The data of FIG. 9 can be used to relate the reduced temperatures within the barrier gas to the local concentration of propane solvent in the vapour. In this way, a real time vertical temperature profile can be used to calculate non condensable gas concentrations within the barrier gas blanket to determine its thickness and composition. This information can be used to monitor the gas blanket and relate the characteristics of the gas blanket to the vertical growth rate of the gravity drainage chamber. While this is the preferred method, the invention is not limited thereto and other methods of monitoring the chamber growth are also comprehended.
Prior to the extraction process being started, the position of the overburden layer will be identified. Then, it is a matter of monitoring a rise in temperature up the vertical column of the observation well or wells to monitor chamber growth.
In situations where the overburden is not capable of acting to confine the chamber, it will be desirable to maintain a pressure within the chamber at or slightly above formation pressure. This is to prevent leakage of fluid from the overburden layer of water into the chamber.
This invention comprehends that multiple adjustments to the solvent purity, may be necessary from time to time, to manage the barrier gas layer thickness and prevent it from thinning too much as the chamber grows horizontally. The horizontal growth of the chamber and/or removal of the barrier gas from the chamber via dissolution in the draining liquids would tend to thin the gas layer. By further adjustments to the solvent purity, it is possible to maintain the barrier layer to continue to restrict the upwards growth rate of the chamber and also reduce heat losses to the overburden.
In some cases the barrier layer may tend to be persistent in the attic region of the vapour chamber. This is because solvent condensation in the cooler region of the gas blanket will produce gas saturated liquid solvent. As this liquid drains down towards the bottom of the chamber, it will encounter warmer temperatures and consequently the non-condensable gas will be preferentially stripped out of the liquid. This non-condensable gas will then be returned to the gas blanket by convection movement of the injected condensing solvent in the gas phase.
It will be understood that as the chamber grows in size the heat losses to the overburden will increase and this has the effect of increasing the solvent to oil ratio. If the ability to recover and recycle the solvent is restricted, say by processing plant capacity, then it may not be feasible to maintain the chamber pressure at the desired pressure. In this situation, the use of a barrier layer to reduce overburden heat loss and consequently reduce solvent demand is desirable to allow the chamber pressure to be maintained at the preferred value.
It will be appreciated by those skilled in the art that while reference has been made to a preferred embodiment of the present invention above, various modifications and alterations can be made without departing from the broad spirit of the appended claims. Some of these variations have been discussed above and others will be apparent to those skilled in the art. What is desired according to the present invention is the use of a condensing solvent process to form an in situ gravity drainage chamber, where the chamber has a source of condensing fluid injection, a production means to remove extracted hydrocarbons and a system to monitor chamber growth and a means to preferentially accumulate barrier gas with the chamber. The precise choice of solvent and barrier gas can vary, provided that the barrier gas layer can be established where desired. | A solvent based gravity drainage process whereby the vertical growth rate of the chamber is restricted by placing, monitoring and managing a buoyant gas blanket at the top of the vapor chamber. The process reduces the heat loss to the overburden as well as providing a means to preserve a barrier layer of bitumen saturated reservoir sand at the top of the pay zone in reservoirs where there is limited or no confining layer present. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 09/916,468, filed Jul. 27, 2001, now U.S. Pat. No. 6,643,853.
BACKGROUND OF THE INVENTION
The present invention relates to flush valves of the type commonly used to operate toilets and urinals and more specifically to an actuator which moves a valve handle in either a manual operation or an automatic operation. The flush valve may be a diaphragm-type valve, such as that sold by Sloan Valve Company of Franklin Park, Illinois, under the trademark ROYAL, and which is shown in U.S. Pat. No. 6,216,730, or it may be a piston-type of flush valve sold by Sloan Valve Company under the trademarks GEM and CROWN and shown for example in U.S. Pat. No. 5,881,993.
It is known to use an automatic actuator with a flush valve. Some devices of this type require that the standard manual valve handle be removed and replaced with some sort of electric or hydraulic motor. Such devices are inconvenient and expensive to install, especially if they are used to retrofit standard manual flush valves to automatic operation. Other automatic actuators allow the manual flush valve handle to be retained but the actuators are complicated to install as they require multiple parts or components that must be at least partially disassembled to permit them to be attached to the flush valve. Some automatic actuators provide for automatic operation only, which means if the automatic system becomes inoperative, the entire valve is useless until repairs can be made. Other actuators that do permit either automatic or manual operation are designed such that operation of one type interferes with the components involved in the other type. Battery life, sensor aiming and structural integrity are other areas of concern with prior art automatic actuators.
SUMMARY OF THE INVENTION
The present invention relates to toilet room flush valves and more specifically to an actuator that allows manual or automatic operation of the flush valve.
The present invention is more specifically directed to a combined automatic/manual actuator for a handle-operated flush valve which may be installed without replacing, removing or disassembling any of either the flush valve components or the actuator components. All of the above types of flush valves have a handle which is mounted on the flush valve body for pivotal movement about a handle axis. The actuator of the present invention provides a housing including a handle assembly which adjoins the valve handle. A sensor and a drive motor are mounted in the handle assembly. When sensor action has been initiated, the sensor will connect a battery pack to the drive motor, with the drive motor causing movement of a push rod in the handle assembly. This provides automatic operation of the flush valve by movement of the flush valve handle about its normal or conventional axis. The handle assembly is pivotally movable, independent of the push rod, and may be used to manually operate the handle in the event the automatic system is temporarily inoperative or if a user wishes to initiate a flush apart from a sensor-initiated one.
Of particular advantage in the invention is the fact that the actuator can convert a flush valve from manual only operation to automatic or manual operation. Furthermore, this conversion can be completed through the mounting of a single additional unit on the existing flush valve. Installation does not require removing or altering any components of the flush valve or disconnecting the water supply to the flush valve. And the unit itself need not be opened, disassembled or altered in any way in order to install it. It simply slips directly over the valve handle and is fastened to the flush valve body.
A primary object of the invention is a flush valve actuator as described which may be installed without the removal, disassembly or alteration of any flush valve components or any actuator components and without disconnecting the water supply to the flush valve.
Another object of the invention is an actuator of the type described which mounts on the flush valve body and has a manually-movable handle assembly in which is mounted a motor-driven push rod movable to cause operation of the flush valve handle when such operation is initiated by an automatic sensor.
Still another object of the invention is an actuator as described including a manual override which is pivotally movable independently of the motor-driven push rod.
A further object of the invention is an actuator as described in which the motor-driven push rod is mounted for movement with the manual override.
A still further object of the invention is an actuator as described in which the manual override is stationary during operation of the motor-driven push rod.
Yet another object of the invention is an actuator which is suitable for right or left handle operation.
Another object of the invention is an actuator as described in which the motor-driven push rod when at rest has some slack between the valve handle and the drive motor so the motor current upon start up is reduced, thereby significantly increasing battery life.
Another object is an actuator as described in which the handle assembly includes a handle interface that contacts the flush valve handle when the unit is at rest so the motor-driven push rod is not loaded during a manual actuation of the handle assembly.
A further object is an actuator having a housing that transfers any mechanical loads on the unit to the flush valve body without loading the motor-driven drive train, the handle assembly or the fasteners holding the actuator together.
Still another object is an actuator as described having the sensor mounted as close as possible to the vertical centerline of the flush valve so it can sense the presence or absence users.
A still further object is an actuator as described that can be applied to flush valves having any style handle, whether long, short or otherwise.
Other objects will appear in the ensuing specification, drawings and claims. These and other desired benefits and objects of the invention, including combinations of features thereof, will become apparent from the following description. It will be understood, however, that a device could still appropriate the claimed invention without accomplishing each and every one of these desired benefits, including those gleaned from the following description. The appended claims, not these desired benefits, define the subject matter of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a flush valve with the actuator of the present invention mounted thereon.
FIG. 2 is a right side elevation view of the actuator mounted on a flush valve.
FIG. 3 is a section taken along line 3 — 3 of FIG. 2 .
FIG. 4 is a rear elevation view of the actuator with the battery hatch cover removed to show the interior of the rear cover.
FIG. 5 is a section taken along line 5 — 5 of FIG. 4 .
FIG. 6 is a perspective view of the mounting strap.
FIG. 7 is a side elevation view of the mounting strap.
FIG. 8 is a section through the rear cover, taken along line 8 — 8 of FIG. 4 .
FIG. 9 is a section through the front cover taken on a horizontal plane, similar to line 5 — 5 of FIG. 4 .
FIG. 10 is a rear elevation view of the front cover, looking at the interior of the cover.
FIG. 11 is a perspective view of the handle collar.
FIG. 12 is a right side elevation view of the handle collar.
FIG. 13 is a rear elevation view of the handle collar.
FIG. 14 is a section taken along line 14 — 14 of FIG. 13 .
FIG. 15 is a section taken along line 15 — 15 of FIG. 12 .
FIG. 16 is a right end elevation view of the actuator assembly, with parts shown schematically in section to illustrate the mating of the housing components.
FIG. 17 is left end elevation view of the actuator assembly, with parts shown schematically in section to illustrate the mating of the housing components. In this figure one of the lower torpedo tube projections is shown rotated out of its actual position for the purpose of illustrating the telescopic connection of the rear cover pillars and the torpedo tubes.
FIG. 18 is a perspective view of the interior of the handle assembly with the electronics package and drive train removed to show only the case and its internal walls.
FIG. 19 is a perspective view of the interior of the handle assembly with the electronics package removed to show drive train.
FIG. 20 is a horizontal section of the handle assembly and valve handle, taken through the centerline of the motor shaft, with the electronics package shown schematically.
FIG. 21 is a left end view, on an enlarged scale, of the handle assembly, with the cam and push rod shown in schematic section to highlight these parts.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an actuator that may be attached to a toilet room flush valve so that it may be operated either automatically by means of a sensor or manually by means of a handle assembly. The flush valve may be of the diaphragm type or of the piston type. A diaphragm-type flush valve is shown in U.S. Pat. No. 5,967,182, the disclosure of which is herein incorporated by reference, and is sold by Sloan Valve Company, the assignee of the present application, under their trademark ROYAL. The piston-type flush valve may be of the type shown in U.S. Pat. No. 5,881,993, the disclosure of which is herein incorporated by reference, and may be sold by Sloan Valve Company under their trademarks GEM or CROWN.
The actuator utilizes a sensor, which may be of the infrared type, and is preferably battery powered. The sensor may be as shown in U.S. Pat. No. 6,161,814, also owned by Sloan Valve Company, and the disclosure of which is herein incorporated by reference. Sensor-operated, battery powered flush valves are known in the art from the '261 patent and others. The present invention utilizes the technology in the '261 patent or similar technologies for infrared operation of a flush valve which may be of the types described in the above-referenced patents. The particular disclosure shown herein illustrates a valve of the ROYAL type.
Looking at FIGS. 1-4 , the flush valve is shown generally at 10 and mounted thereon is the actuator 12 of the present invention. The flush valve has a body 14 which includes a water inlet 16 , a water outlet 20 and a vacuum breaker 18 beneath the outlet. A handle opening 22 ( FIG. 3 ) in the water outlet is surrounded by a laterally-extending, annular boss 24 which is externally threaded. Inside the valve body 14 there is either a movable diaphragm or a piston (not shown) which will control the flow of water between the inlet 16 and the outlet 18 in the conventional manner. The diaphragm or piston has associated with it the usual relief valve whose depending stem (not shown) extends to a point opposite the handle opening 22 .
A valve handle 26 is mounted to the boss 24 by a handle mounting member. In this case the handle mounting member includes a handle socket 28 . The handle socket has a generally cylindrical cup 30 and an end face formed by a flange 32 . A lip on the opposite end of the cup is trapped by a coupling nut 34 . The coupling nut is threaded to the boss 24 . The valve handle 26 is pivotally movable about a three dimensional pivot when the handle is used to cause operation of the flush valve. A shank 35 inside the handle socket 28 captures the inner end of the valve handle 26 . A plunger 36 joins the shank and extends into the valve body where it can act on the relief valve stem. Tilting of the valve handle 26 causes movement of the shank 35 and plunger 36 that in turn trips the relief valve and begins a flushing cycle. The parts and operation described thus far are all conventional.
The primary components of the actuator 12 of the present invention include a housing and a handle assembly. The housing, shown generally at 38 , is preferably a three-part structure that includes a front cover 40 , a rear cover 42 , and a handle collar 44 . Screws fasten the front and rear covers together, with the handle collar disposed between them. The housing defines a receptacle for the valve handle 26 , with the handle collar providing an abutment that mates with the end face of the handle socket 28 . The handle assembly is shown generally at 46 . It is pivotally mounted on bearings formed in the housing 38 . An interior portion of the handle assembly resides within the housing while an exterior portion extends through an opening in the front cover to the outside of the housing. One aspect of the present invention is that the motor and drive train used to effect automatic operation of the flush valve are mounted in the handle assembly 46 , as will be described in detail below. This arrangement affords a compact package for the actuator. Another aspect of the invention is the simple and efficient manner in which the actuator can be attached to a flush valve. Neither the flush valve nor the actuator has to be disassembled or altered in any way in order to mount the actuator on the flush valve. The actuator simply slips over the valve handle and into operative engagement therewith. This is made possible by the housing receptacle and a mounting strap 48 .
Details of the mounting strap 48 are shown in FIGS. 5-7 . The strap includes an arcuate body portion 50 bounded on one end by a hinge sleeve 52 and on the other end by a folded back tab 54 . The tab has an aperture 55 which receives an internally threaded clinch nut 56 (FIG. 5 ). An end portion of the clinch nut fits through the aperture 55 and is crimped to the tab. The hinge sleeve 52 has a pin hole through it. The hinge sleeve 52 fits between a pair of ears on the front cover 40 . The ears also have pin holes which align with that of the sleeve 52 . A hinge pin 58 ( FIG. 5 ) fits through the pin holes to pivotally attach the strap to the front cover. The body portion 50 wraps around the water outlet 20 of the valve body as seen in FIGS. 1 and 3 . At the rear cover the clinch nut 56 is threadedly engaged by a mounting screw 60 . The mounting screw is rotatably fixed in the rear cover. It has a head 62 protruding from the rear cover wnere it can be tightened or loosened by a screwdriver. Preferably the screw head will accept either Phillips or straight screwdrivers. A retaining ring 64 , which can be a simple rubber O-ring, captivates the mounting screw in the rear cover and prevents it from falling out of the rear cover.
The installation procedure for the actuator is as follows. With the body of the mounting strap 48 pivoted away from the centerline of the actuator, the housing 38 is moved laterally over the free end of the valve handle 26 in a direction parallel to the axis of the handle. This movement continues until the collar mounting grommet 134 surrounds the handle socket and the handle collar 44 abuts the end face 32 of the handle socket 28 . Then the body 50 of the strap 48 is pivoted around the water outlet 20 of the flush valve. The clinch nut 56 is aligned with the end of the mounting screw 60 so the screw may be threaded into the nut. Turning the screw tightens the strap about the water outlet 20 . The actuator is clamped onto the body of the valve. Only one tool is required. There are no loose, dangling or separate parts for the installer to deal with. Nothing has to be removed or disassembled on either the actuator or flush valve. Installation is quick and so straightforward it can be performed by personnel of any skill level. Turning now to a discussion of the housing 38 , the rear cover 42 is shown in FIGS. 2-5 and 8 . The rear cover has an outer shell 66 including generally horizontal top and bottom walls 66 A, 66 B, a curved distal end wall 66 C and a proximal end wall 66 D. The inside edges of these walls define a large battery access hatch 66 E (FIG. 4 ). A battery hatch cover 68 ( FIG. 5 ) has tabs on its ends that engage the end walls in a snap fit. The inside edge of the distal end wall 66 C has an extension 70 having a hollow recess 72 on its outer surface. The recess defines a wall 73 ( FIG. 16 ) with a bore therethrough which receives the mounting screw 60 . The retaining ring 64 on the inside of the extension may cooperate with the wall in the extension or with the web 86 in the tray 82 to captivate the mounting screw in the rear cover. The other end of the mounting screw extends to an upset portion 74 on the proximal end wall 66 D. At the corners where the distal end wall 66 C meets the top and bottom walls 66 A, 66 B there are upper and lower mounting posts 76 on the inside of the shell which cooperate with recesses 78 on the outside of the shell. Self tapping screws 80 whose heads are in the recesses 78 and whose shanks extend through bores in the mounting posts 76 fasten the rear cover to the front cover 40 , as will be explained more fully below.
The interior of the shell 66 houses a tray 82 . The tray is made of two U-shaped troughs 84 connected by a central web 86 . The web has a slot 88 that permits passage of the mounting screw 60 . The troughs each have a cutout 90 near the proximal wall 66 D for receiving a portion of the handle collar 44 . Opposite ends of the troughs 84 mount a battery contact spring 92 , while the other ends carry battery contact clips 94 . The troughs are sized to support two C-sized batteries end to end. On the convex side of the troughs there are upper and lower mounting pillars 96 . These engage the torpedo tubes of the handle collar 44 as will be explained below. As seen in FIG. 8 the pillars are hollow with end walls having bores therethrough. FIGS. 4 and 17 show the mounting screws 97 that fit in the bores of the pillars to join the front and rear covers with the handle collar between. Details of this connection are shown below.
Details of the front cover 40 are shown in FIGS. 1 , 2 , 5 , 9 - 10 and 16 . The front cover has a shell 98 , somewhat similar in shape to the shell 66 , which has top and bottom walls 98 A, 98 B, a distal end wall 98 C and a proximal end wall 98 D. The inside edges of these walls define a large handle assembly opening 98 E. The proximal end wall 98 D has a pair of ears 100 formed thereon. As described above, ears 100 cooperate with the mounting strap sleeve 52 to form a hinge that joins the mounting strap 48 to the front cover 40 . At the corners where the distal end wall 98 C meets the top and bottom walls 98 A, 98 B there are upper and lower mounting posts 102 on the inside of the shell 98 . These posts have bores which receive the screws 80 to fasten the distal ends of the front and rear covers together. The bores in posts 102 do not extend through to the front of the shell. Near the proximal end wall 98 D there are upper and lower mounting pillars 104 . These engage the torpedo tubes of the handle collar as will be explained below. The pillars 104 are hollow but the bores therein do not extend through to the front of the shell 98 . Upper and lower saddles 106 have semi-circular cutouts in their free edges. The saddles cooperate with similar structures on the handle collar to form bearings on which the handle assembly pivots.
Turning now to FIGS. 11-15 , details of the handle collar 44 are shown. The collar has a cylindrical sleeve 108 bounded at its distal end by a radially-extending flange 110 and at its proximal end by an annular ring 112 of enlarged diameter. The sleeve 108 has a pair of central apertures 114 which receive tabs on a grommet as will be explained later. Near the junction between the ring and sleeve are upper and lower torpedo tubes 116 . As seen in FIG. 14 the torpedo tubes each has a cavity extending through. Each cavity includes a front portion 118 A, a conical central portion 118 B and a rear cylindrical portion 118 C. The front and central portions are divided by a partition 120 which has an aperture in it. Three projections 122 extend radially into the cavity and axially from the partition partially onto the rear portion cutout in its front edge. Saddles 124 cooperate with the saddles 106 on the front cover to form bearings for the handle assembly. The saddles are reinforced by gussets 126 . The ring 112 further includes a channel-shaped guide member 128 that has a U-shaped cutout in one face for receiving the mounting screw 60 . An additional feature of the ring 112 is a pair of depressions 130 ( FIG. 12 ) that fit in the cutouts 90 in the rear cover tray 82 . The axial extent of the ring is such that the ring fits through the cutouts. The depressions maintain the concave profile of the troughs 84 so the batteries will lie flush against the troughs.
FIG. 5 illustrates another component of the handle collar. A collar mounting grommet 132 fits inside the sleeve 108 of the collar 44 . The grommet includes a flange 134 and a ribbed skirt 136 . The skirt has locating tabs 138 which extend into the apertures 114 in the sleeve 108 . The flange 134 adjoins the flange 110 of the collar. The grommet is made of a pliant material such as rubber or a rubber compound.
FIGS. 16 and 17 illustrate how the housing components fit together and are held fast to one another. In FIG. 16 it can be seen that the ends of the upper and lower mounting posts 76 abut the facing ends of the front cover mounting posts 102 . Screws 80 have heads that fit in the recesses 78 . The threads of the screws engage the inside surface of the bores in posts 102 . FIG. 17 illustrates the telescoping engagement of the rear cover pillars 96 , the front cover pillars 104 and the torpedo tubes 116 . Specifically, the rear cover pillars 96 fit inside the rear cavities 118 C of the torpedo tubes 116 to a depth permitted by the cavity projections 122 . One of the projections in the lower torpedo tube is shown in phantom at 122 A rotated from its true position to illustrate how the ends of the projections limit the penetration of the rear pillars 96 into the tubes 116 . On the front side of the tubes the pillars 104 fit inside the front cavity portions 118 A to the extent permitted by the partitions 120 . Mounting screws 97 fit in the bores of the rear pillars 104 with the screw heads in contact with the end walls of the pillars. The shanks of the screws pass through the central cavity portions 118 B and the partitions 120 without engaging them. The screw threads engage the inner walls of the front cover pillars 104 . The telescoping engagement of the covers 40 , 42 and the collar 44 automatically aligns these three components. It also transfers all mechanical loading on the housing covers to the collar, which in turn transfers such loads to the valve body. All abusive loads applied to the housing end up directly on the collar. Furthermore, it is important that the structural members, namely the pillars and torpedo tubes, bear these loads, not the mounting screws 80 , 97 and their associated threads. This provides a more secure mounting for the actuator.
Turning now to consideration of the handle assembly 46 , this component, much like the front and rear covers has a generally five-side shell or case 140 . External features of the case are visible in FIGS. 1 and 2 . These include a top wall 140 A, a bottom wall 140 B, a distal end wall 140 C and a proximal end wall 140 D. The case also has a front wall 140 E. The remaining features of the handle assembly will be described in conjunction with FIGS. 18-21 . The top and bottom walls 140 A, 140 B each have a longitudinally extending ledge 142 . The ledge is engageable with the interior edges of the front cover walls about the large opening 98 E. This engagement prevents the handle assembly from coming completely out of the housing. Toward the proximal end of the case 140 the ledges 142 mount top and bottom stubshafts 144 . The stubshafts are held between the saddles 106 of the front cover and the saddles 124 of the handle collar to mount the case 140 for pivoting motion about a vertical axis. The pivot axis is close to the pivot axis A ( FIG. 3 ) of the valve handle 26 .
The interior of the case is divided by a double wall partition 146 . This partition defines an electronics compartment 148 and a drive train compartment 150 in the case 140 . The electronics compartment contains suitable mounting locations for a printed circuit board which is shown schematically at 152 in FIG. 20 . This board will include a sensor 154 and associated electronics for detecting a user near the flush valve. The board is electrically connected to the battery terminals 92 , 94 . The front wall 140 E has a window portion 140 F ( FIG. 20 ) which is transparent to the signals for the sensor. It will be understood the window may be opaque to visible light but allow other types of electromagnetic energy, e.g., infrared light, to pass freely.
The drive train compartment 150 incorporates several structures for mounting drive train components. These include a pair of motor mounts 156 having semi-circular cutouts therein. First and second panels 158 , 160 define a cam chamber between them. The first panel 158 has an arcuate cutout 162 for receiving the cam drive gear. A guide channel 164 is formed in the partition 146 .
The drive train itself is shown in FIGS. 19-21 . It includes a mounting tube 166 . This is a generally cylindrical tube with an enlarged portion 166 A near its open end. The tube rests in the cutouts of the motor mounts 156 . Brackets 166 B on the exterior of the tube 166 allow the tube to be screwed to posts built in to the motor mounts. The exterior of the tube also has an interface or pad 166 C which is sized and located to be in engagement with the valve handle 26 when the drive train is inactive. The enlarged portion 166 A of the tube receives an electric motor 168 therein. The motor is, of course, electrically connected to the printed circuit board 152 for control by the electronics thereon. The output shaft of the motor is connected to a planetary gear train. In the illustrated embodiment this is a three-stage planetary drive but it will understood that different numbers of stages could be used. Indeed, other types of gear trains could be substituted for the planetary drive so long as they provide the necessary speed reduction and torque. The planetary drive shown includes a fixed ring gear 170 in the closed end of the mounting tube 166 . The ring gear has internal teeth on its inner surface. These teeth mesh with those of plural planetary gears 172 which are mounted on carriers 174 the usual sun gears 176 on the centerline of the motor shaft. The output of the planetary gear train is an externally splined shaft which engages the internal splines of a cam drive gear 178 . This gear is fixed to a cam 180 . The gear 178 is supported by the arcuate cutout 162 in the first panel 158 . A cam shaft (not shown) attached to the cam 180 on the side opposite gear 178 is mounted for rotation on the second panel 160 . The cam in this embodiment includes two lobes, each having a curved actuating surface 180 A and a neutral surface 180 B. Different numbers of lobes could be used. The cam is operatively engageable with a push rod shown generally at 182 . The push rod is preferably an integral member which includes a cam follower 184 , an arcuate shoe 186 and a guide plate 188 . The push rod is mounted for linear motion in a horizontal plane. The guide plate 188 is slidably mounted in the guide channel 164 and constrains the push rod to linear motion. The shoe 186 is engageable with the valve handle 26 to impart a pivoting motion thereto when the motor 168 is activated by the sensor 154 .
It is important that the drive train have some slack between the motor and the valve handle. This can be achieved by spacing the surface of the push rod's shoe 186 slightly from the valve handle when the motor is at rest. Or the cam actuating surface 180 A might be spaced slightly from the follower 184 when the motor is at rest. Or there might be a combination of these two. Leaving some slack in the drive train will significantly increase battery life by allowing the gear train to begin movement while not under resistance from the valve handle. This no-load startup movement lasts only an instant but it is enough to get the entire drive train moving before encountering resistance from the valve handle. Another benefit to having slack in the drive train while at rest is when a manual actuation of the handle assembly 46 occurs the drive train experiences no load at all. It simply goes along for the ride with the case 140 . Using separate structures to effect the automatic and manual actuation increases the life of the drive train components.
The use, operation and function of the actuator are as follows. The installation of the actuator was described above. Once installed the unit can activate the flush valve 10 either automatically or manually. Automatic operation occurs when the sensor 154 detects a condition calling for a flush cycle. The sensor turns on the motor 168 . The motor shaft turn the first sun gear 176 causing the planetary gears 172 and carriers 174 of the drive stages to rotate, ultimately resulting in rotation of the output shaft and the cam drive gear 178 . The cam drive gear rotates the cam 180 , causing its actuating surface 180 A to engage the end of the cam follower 184 , as seen in FIG. 21 . The cam rotates in a clockwise direction as seen in FIG. 21 . The cam surface 180 A drives the push rod 182 to the left, i.e., toward the valve handle 26 . After the slack between the in the drive train is taken up, the push rod causes a pivoting motion of the valve handle 26 about its axis A. This initiates the flush cycle of the valve 10 in the usual manner. When the cam surface 180 A slides past the follower 184 the neutral surface 180 B is parallel to the follower. A feedback switch (not shown) turns off the motor. The return spring in the valve that acts on the valve handle causes the valve handle to return to its rest position, which also moves the push rod 182 back to its rest position. Once the valve completes its flush cycle and the electronics resets, the valve is ready for the next operation.
If the automatic system is inoperative for some reason, e.g., dead batteries, or if a user wishes to flush the fixture separate from the normal time programmed into the electronics, the valve can be flushed manually as follows. The user presses on the front wall 140 E of the handle assembly 46 toward the rear of the unit. This causes the entire case 140 to pivot about the stubshafts 144 . Since the mounting tube pad 166 C is already engaged with the valve handle 26 , this immediately causes a pivoting motion of the valve handle. Sufficient movement opens the flush valve at which point the user removes pressure from the handle assembly. The valve handle return spring causes the valve handle and the case 140 to return to their normal, non-actuated positions. Even if the user doesn't release the case, the plunger 36 disconnects from the relief valve, allowing the flush valve to cycle normally, as is conventional.
One of the advantages of the present invention is the arrangement of the compartments in the case 140 . It will be noted that the electronics compartment 148 is closer to the proximal end than the drive train compartment. This locates the sensor 154 closer to the centerline of the valve body which in turn makes it much more likely that the sensor will have the user in its field of view. No special optics or aiming of the sensor need be provided with the electronics located as described.
Of particular importance in the invention is the fact that the actuator assembly may be mounted on the flush valve without removing, loosening or otherwise altering any flush valve components or actuator components. Neither is disconnecting the water supply necessary. Once the batteries are installed, the actuator simply slides over the end of the handle until the flanges 134 and 110 of the grommet 132 and handle collar 44 contact the end face of the handle socket 28 . Then the mounting strap is wrapped around the water outlet 20 of the valve body and the mounting screw is tightened in the clinch nut 56 . This clamps the actuator on to the end face of the handle mounting member. It will be understood that the term handle mounting member is intended to encompass any structure surrounding the valve handle, whether it be the socket 28 , the coupling nut 34 or some alternate component that provides a solid mounting point for the collar. Alternate valve body constructions might make the body itself the component most available for clamping engagement with the actuator. All of these possibilities are within the contemplated scope of the invention.
While reference has been made herein to the advantages of the invention in retrofitting or converting manually-operated flush valves to automatic/manual operation, it will be understood that the actuator is not just for retrofitting previously-installed valves. New valves of standard construction can also benefit from the actuator of the present invention.
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. For example, while battery power is shown and preferred to make the unit self-contained, it would be possible to connect an external power supply. | A toilet room flush valve has a valve handle and an actuator mounted on the valve body to cause either sensor-initiated automatic movement or user-initiated manual movement of the valve handle. The actuator includes a handle assembly pivotally mounted in a housing. The handle assembly has an interface which is normally engaged with the valve handle. A motor driven push rod mounted on the handle assembly is engageable with the handle. A drive motor is mounted on the handle assembly and connected to the push rod to cause movement thereof. A battery for operating the drive motor is connected to a sensor mounted on the handle assembly, with the sensor being capable of connect the battery power to the drive motor. The actuator housing is arranged to allow it to slip over the valve handle and clamp on the valve body without disassembling either the flush valve or the actuator. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the production of carbon fibres from coal tar pitch or other strongly aromatic distillation residues.
2. Description of the Prior Art
Carbon fibres having excellent mechanical properties have already been obtained by oxidation and thermal conversion of fibres of organic polymers, such as poly-acrylo-nitrile and rayon. Nevertheless, the cost of fibres obtained in this manner is high because of the cost of the raw materials and the low yield of carbon. Fibres have also been obtained from coal tar pitch by subjecting the pitch to heat treatment at moderate temperature and possibly to other treatments or conditioning, and thereafter melt spinning the pitch so treated at a temperature of the order of 300°C. The fibers so obtained were subjected to oxidation intended to make them infusible, and were then carbonised in air. However, these processes result in fibres of a quality much inferior to that of fibres obtained from textile threads.
It is a main object of the present invention to provide a process producing fibres of improved quality obtained from a coal tar pitch or from a strongly aromatic substance similar to coal tar pitch.
SUMMARY
Carbon fibres are produced from a strongly aromatic distillation residue, such as a coal tar pitch, by firstly subjecting this distillation residue to heat treatment at moderate temperature. Thereafter the product of the heat treatment is spun into fibres which are then oxidised and carbonised. The improvement lies in adding an oxygen-containing polymer, preferably a non-cross linked polymer to the starting distillation residue.
The oxygen-containing polymer may be added to the distillation residue at the latest during the heat treatment phase preceding spinning. Among polymers which have given good results are phenol formaldehyde polymers, particularly first condensation resins such as the novolaks and the polyesters.
The strongly aromatic pitch, after being simply filtered, may be heated under conditions of temperature, time and with agitation such that the material obtained contains very little or no anisotropic material. The presence of this anisotropic material can easily be detected by examination with an optical microscope in polarised light (M. IHNATOWICZ, P. CHICHE, J. DEDUIT, S. PREGERMAIN, and R. TOURNANT, "Carbon" 4, 41, (1966)). This heat treatment may be carried out in a reactor provided with an agitation system and means for scavenging gases. In other words, the heat treatment is stopped, at the latest, at the beginning of the onset of the anisotropic phase.
The process according to the present invention yields fibres having properties of the same order as those obtained by the process of U.S. Pat. application Ser. No. 137,976 filed Apr. 27, 1971, now U.S. Pat. 3,784,679, but because in the process according to the present invention spinning may be carried out at a substantially higher temperature, subsequent operations are greatly facilitated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE I
A high temperature coal-tar pitch having the following characteristics was used:
Kraemer-Sarnow point 80°CDensity 1.32 g/cm.sup.3Index of volatile materials(according to standard ATIC-02-60 64.3%Elementary analysis in percentagesby weight: Carbon 92.14% Hyrdogen 4.5 Oxygen 1.3 Nitrogen 0.7 Sulfur 0.4
The pitch had previously been filtered at 190°C through a bronze filter with a mean pore opening of 2 μ in order to separate the solid and pseudo-solid particles which it contains naturally.
10% by weight of novolak resin of the trade mark GEDELITE 3110 of Societe "Huiles, Goudrons et Derives", obtained by reacting phenol with formaldehyde in acid medium was added to this pitch, this resin having a mean molecular weight of from 500 to 700 and drop-point of 78° at 80°C. The mixture was then heated to 407°C with constant agitation and with a heating rate of 2.2°C per minute. The volatile materials generated were entrained by a current of nitrogen with a flow of 1 liter per minute.
The product obtained was spun at 262°C with a drawing speed of 330 meters per minute.
All the fibre obtained was placed in a furnace and subjected to the following heating sequence:
from ambient temperature to 250°Cin the presence of air at 0.5°C/minute: 7.5 hoursfrom 250°C to 700°C) in the presence of 15 hoursnitrogen and withoutfrom 700°C to 1000°C) oxygen 2.5 hoursTotal 25 hours
The furnace was then allowed to cool naturally. The mechanical properties of the carbon fibres obtained were measured with the aid of an INSTROM mechanical test machine under the following conditions:
Length of test pieces 50 mmSpeed of traction 0.05 cm/minute
A mean breaking stress of 64 kg/mm 2 and a mean Young's modulus of 4000 kg/mm 2 were measured for a mean diameter of 13.3μ.
These values are mean values obtained from 100 measurements made on different filaments. The total yield of the operations comprising filtration, devolatilisation, spinning, oxidation and carbonisation was 65%.
EXAMPLE II
The operating conditions were identical to those of Example I, but the phenol-formaldehyde resin was replaced by a NORSODYNE 48, a non-cross-linked polyester resin (propylene glycol polymaleate) dissolved in styrene.
The spinning temperature is 275°C.
A mean breaking stress of 40 kg/mm 2 and a mean Young's modulus of 3000 kg/mm 2 were measured on the carbon fibres having a mean diameter of 15.25μ.
EXAMPLE III
The conditions of operation were identical with those of Example I, but the phenol-formaldehyde resin was replaced by NORSODYNE 292, a non-cross-linked polyester resin (mixture of propylene glycol polymaleate and diethylene glycol polymaleate), dissolved in styrene.
The spinning temperature was 270°C.
A mean breaking stress of 48 kg/mm 2 and a mean Young's modulus of 4000 kg/mm 2 were measured on the carbon fibres having a mean diameter of 17.37μ.
EXAMPLE IV
The conditions of operation were identical to those of Example I, but the phenol-formaldehyde resin was replaced by NORSODYNE 87, a non-cross-linked polyester resin (mixture of diethylene glycol polymaleate and diethylene glycol polyadipate), dissolved in styrene.
The spinning temperature was 270°C.
A mean breaking stress of 36 kg/mm 2 and a mean Young's modulus of 3800 kg/mm 2 are measured on the carbon fibres for a mean diameter of 17.16μ.
EXAMPLE V
The conditions of operation are identical with those of Example I, but here the pitch contains no additive.
The spinning temperature is 230°C.
A mean breaking stress of 25 kg/mm 2 and a mean Young's modulus of 2800 kg/mm 2 were measured on the carbon fibres having a mean diameter of 20.48μ. | A process for the production of carbon fibers from coal-tar pitch or from other strongly aromatic distillation residues wherein an oxygen-containing polymer is added to the starting material before or during the heat treatment which is followed by the usual stages of spinning, oxidizing and carbonizing. | 3 |
FOREIGN PRIORITY
[0001] This application claims priority to European Patent Application No. 15 150 019.6 filed Jan. 2, 2015, the entire contents of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to light units with extended light emission surfaces. In particular, the present invention relates to interior aircraft light units with extended light emission surfaces, such as interior aircraft light units, such as exit light units or wash room signal light units, commonly used for conveying signals to the passengers.
BACKGROUND OF THE INVENTION
[0003] For exit light units, the Federal Aviation Regulations (FAR) require a fairly even light intensity distribution. In particular, the FAR set limit values for the ratio between the brightest portion of the exit light unit and the least bright portion of the exit light unit on the extended light emission surface. An exemplary limit value for this ratio is 3. In order to satisfy such limit values, prior art approaches have employed very complicated optical structures, commonly employing a large number of light sources. Such approaches have proven to be not satisfactory with respect to their efficiency and their reliability.
[0004] Accordingly, it would be beneficial to provide an interior aircraft light unit that is able to satisfy such light intensity ratio requirements, has an improved efficiency and has an acceptable reliability.
SUMMARY
[0005] Exemplary embodiments of the invention include a light unit with an extended light emission surface, comprising a light source, and a flat light distribution body having a first principal surface and a second principal surface disposed on opposite sides of the flat light distribution body, wherein the light source is positioned outside of the flat light distribution body, with light emitted by the light source being coupled into the flat light distribution body and being propagated within the flat light distribution body via total internal reflection at the first and second principal surfaces, wherein the first principal surface has a plurality of surface irregularities, wherein light arriving at a surface irregularity at an angle of incidence is reflected at an angle of reflection that is different from the angle of incidence with respect to the first principal surface, with the angle of reflection allowing for the light to be coupled out of the flat light distribution body, and wherein a total irregularity ratio of the first principal surface is defined as a combined area of the plurality of surface irregularities on the first principal surface divided by a total area of the first principal surface and wherein a regional irregularity ratio is defined as a combined area of a subset of the plurality of surface irregularities in a sub-region of the first principal surface divided by a total area of said sub-region of the first principal surface, wherein the first principal surface has at least one square sub-region whose area is 10% of the total area of the first principal surface and whose regional irregularity ratio is at least 50% higher than the total irregularity ratio.
[0006] Distributing the surface irregularities in a manner that deviates significantly from a uniform distribution of the surface irregularities allows for achieving a highly uniform output light intensity distribution of the light unit. This can be explained best by comparing the highly non-uniform distribution of the light unit according to above described exemplary embodiment with the hypothetical case of a uniform distribution of surface irregularities. Surface irregularities are an efficient way of coupling light out of a flat light distribution body, where the light is trapped between the first and second principal surfaces via total internal reflection in the absence of such surface irregularities. By changing the path of propagation through the flat light distribution body, the surface irregularities alter the angle of the light with respect to the principal surfaces below the critical angle, which enables coupling out of the light. In this way, localised zones around the surface irregularities are created in which light leaves the light unit. In the hypothetical case of a uniform distribution of the surface irregularities across the first principal surface, different amounts of light are coupled out at the different surface irregularities. The reason for this non-uniform coupling out of the light is the relative positioning of the light source and the flat light distribution body as well as the particular geometry of the flat light distribution body. These two factors lead to a situation where more light arrives at certain surface irregularities, while less light arrives at other surface irregularities. As the surface irregularities provide for local zones of light emission, an overall highly non-uniform output light intensity distribution is the result. By providing at least one sub-region that has a greatly increased density of surface irregularities and/or a greatly increased size of the surface irregularities, light emission in this sub-region is increased as compared to above described hypothetical case. By providing at least one such sub-region with the regional irregularity ratio being at least 50% higher than the total irregularity ratio, the output light intensity distribution can be brought closer to a uniform light intensity distribution than is present in above described hypothetical case of a uniform distribution of surface irregularities. In other words, providing different regional irregularity ratios over the first principal surface allows for bringing the output light intensity distribution of the light unit closer to a uniform output light intensity distribution. This in turn allows for achieving light intensity ratio requirements, as for example required by the FAR.
[0007] Such distribution of the light coupled into the flat light distribution body by the light source allows for the provision of light units that are more efficient and more reliable than prior approaches. As a desired distribution of the light may be achieved entirely by the provision of the surface irregularities in different densities across the first principal surface, no complicated optical systems having multiple lenses and/or reflectors, as used in prior approaches, are necessary. Further, as the light distribution across the extended light emission surface may be achieved via the flat light distribution body, it is not necessary to have multiple light sources in different positions across the light unit to achieve a light intensity distribution with a low light intensity ratio, as employed in prior approaches. With previous approaches having multiple light sources, the light sources were operated below their nominal ratings, in order not to have a light unit that is brighter than allowed by FAR requirements. In such cases, the light sources were not operated in an efficient range, thus making the whole light unit inefficient, and were prone to failing due to not being operated in their preferred regime. Accordingly, overall more efficient and more reliable light units can be achieved with above described flat light distribution body.
[0008] The term flat light distribution body is used for a structure that has extensions in two dimensions that are significantly greater than the extension in a third dimension. In the exemplary case of an exit light unit in an aircraft, which commonly hangs from the aircraft ceiling or is attached to the aircraft body wall, the two dimensions with greater extension are the width and the height dimension, while the dimension with the lowest extension is the depth dimension. The first and second principal surfaces are those surfaces that substantially extend in those planes comprising the two dimensions of greater extension. In the case of the flat light distribution body being a substantially cuboid structure, the first and second principal surfaces are those surfaces that have the greatest surface area. It is pointed out that the flat light distribution body does not have to be cuboid. Rather, the flat light distribution body can have any other suitable geometric shape, such as a circular, oval, polygonal or other regular or irregular shape. The term flat just specifies that the extension of the flat light distribution body is smaller in one dimension as compared to the two other dimensions in a Cartesian coordinate system.
[0009] The expression total internal reflection refers to the arriving of light rays at the first or second principal surfaces at an angle that is larger than the critical angle of the material discontinuity present at the first and second principal surfaces. As a result of the angle of incidence being larger than the critical angle, the light rays are completely reflected and stay within the flat light distribution body. In this way, the light rays propagate within the flat light distribution body from total internal reflection to total internal reflection. Surface irregularities break this light ray propagation from total internal reflection to total internal reflection. In particular, these surface irregularities effect an angle of reflection that is different from the angle of incidence in the frame of reference of the first principal surface. In this way, at least a portion of the light rays that is reflected at the surface irregularities then has an angle of incidence with respect to the first principal surface or with respect to the second principal surface that is below the critical angle, with such angle then leading to the light ray being coupled out of the flat light distribution body.
[0010] An important factor for the amount of light being coupled out of the flat light distribution body in a particular zone or region of the flat light distribution body is the regional irregularity ratio in this particular region or zone. The term irregularity ratio refers to a ratio of the combined surface area of the surface irregularities under consideration, divided by the surface area of the first principal surface under consideration. If all surface irregularities and the whole first principal surface are under consideration, said measure is referred to as the total irregularity ratio. If only a sub-region of the whole first principal surface is under consideration, i.e. if an area of a sub-region of the first principal surface is put in relation with the surface area of the surface irregularities in that sub-region, the measure is referred to as regional irregularity ratio. With the regional irregularity ratio being larger than the total irregularity ratio, a larger portion of the light arriving in the sub-region under consideration is coupled out of the flat light distribution body. In this way, the light emissions of different sub-regions, which are subject to different levels of light arriving in these sub-regions, can be approximated or even equaled out.
[0011] According to a further embodiment, the first principal surface has two or three or more square sub-regions, with the area of each of the two or three or more square sub-regions being 10% of the total area of the first principal surface and with the regional irregularity ratio of each of the two or three or more square sub-regions being at least 50% higher than the total irregularity ratio. Said two or three or more square sub-regions cover mutually exclusive areas, i.e. they do not overlap.
[0012] According to a further embodiment, the regional irregularity ratio of the at least one square sub-region is at least 60%, in particular at least 80%, further in particular at least 100% higher than the total irregularity ratio. It is also possible that there are two or three or more square sub-regions, with the area of each of the two or three or more square sub-regions being 10% of the total area of the first principal surface and with the regional irregularity ratio of each of the two or three or more square sub-regions being at least 50% higher than the total irregularity ratio, wherein a subset of the two or three or more square sub-regions has a regional irregularity ratio that is at least 60%, in particular at least 80%, further in particular at least 100% higher than the total irregularity ratio. These features can also be combined. For example, it is possible that at least one square sub-region has a regional irregularity ratio that is at least 100% higher than the total irregularity ratio, while at least one other square sub-region has a regional irregularity ratio that is at least 50%, but less than 100% higher than the total irregularity ratio. Further combinations are possible as well.
[0013] According to a further embodiment, the second principal surface is the extended light emission surface, with light being coupled out of the flat light distribution body at the second principal surface after being reflected at the plurality of surface irregularities on the first principal surface. In this way, light is coupled out of the flat light distribution body after one reflection at a surface irregularity. If the light is not coupled out right after the reflection at the surface irregularity, it stays trapped within the flat light distribution body until it hits another surface irregularity. It is pointed out that not all light hitting a surface irregularity is coupled out of the flat light distribution body when reaching the second principal surface thereafter. It is possible that the angle of reflection is different from the angle of incidence with respect to the first principal surface, but that the angle of reflection is still above the critical angle, such that the light stays trapped within the flat light distribution body.
[0014] According to a further embodiment, the first principal surface is the extended light emission surface and the light unit comprises an extended reflector arranged outside of the flat light distribution body alongside the second principal surface, with light being coupled out of the flat light distribution body at the first principal surface after being reflected at the plurality of surface irregularities on the first principal surface and being reflected at the extended reflector. In this case, the first principal surface is both the surface carrying the surface irregularities and the surface acting as the extended light emission surface. This double function of the first principal surface is achieved via the provision of the extended reflector alongside the second principal surface. Whenever light is reflected at a surface irregularity and has an angle of reflection smaller than the critical angle, this light leaves the flat light distribution body at the second principal surface, is reflected by the extended reflector, enters the flat light distribution body again via the second principal surface, and exits the flat light distribution body at the first principal surface.
[0015] According to a further embodiment, the extended reflector is a diffuse reflector. In this way, the light exiting the flat light distribution body at the second principal surface is diffusely reflected, contributing to the evening out of the output light intensity distribution of the light unit. In addition to the evening out of the output light intensity distribution via the surface irregularities, which takes place on a larger scale, the diffuse reflector allows for an evening out on a smaller scale and within a smaller angular range. The diffuse reflector is therefore an efficient complement to the surface irregularities for evening out the output light intensity distribution. According to a particular embodiment, the diffuse reflector is a white diffuse reflector. In this way, a very large portion of the light is reflected at the diffuse reflector and used for the output light intensity distribution.
[0016] According to a further embodiment, the second principal surface has a plurality of second surface irregularities, wherein light arriving at a second surface irregularity at an angle of incidence is reflected at an angle of reflection that is different from the angle of incidence with respect to the second principal surface, with the angle of reflection allowing for the light to be coupled out of the flat light distribution body. In this way, the coupling out of the light out of the flat light distribution body can be initiated at both the first principal surface and the second principal surface. In this way, a higher degree of freedom is provided for the design of a particular light unit in order to achieve a desired output light intensity distribution. Surface irregularities on the first and second principal surfaces may cooperate to compliment their effects. All the features and modification discussed herein with respect to the surface irregularities on the first principal surface and with respect to the distribution and size of the surface irregularities on the first principal surface, apply to the second surface irregularities in an analogous manner.
[0017] According to a further embodiment, both the first and the second principal surfaces are extended light emission surfaces, with light being coupled out of the flat light distribution body at the second principal surface after being reflected at the plurality of surface irregularities on the first principal surface and with light being coupled out of the flat light distribution body at the first principal surface after being reflected at the plurality of second surface irregularities on the second principal surface. In this way, the light unit is able to emit light on opposite sides of the light unit. This is particularly useful for light units that require light emission towards two sides, such as aircraft exit signs hanging from the interior aircraft ceiling.
[0018] According to an alternative embodiment, the first principal surface is the extended light emission surface and the light unit comprises an extended reflector arranged outside of the flat light distribution body alongside the second principal surface, with light being coupled out of the flat light distribution body at the first principal surface after being reflected at the plurality of surface irregularities on the first principal surface and being reflected at the extended reflector and with light being coupled out of the flat light distribution body at the first principal surface after being reflected at the plurality of second surface irregularities on the second principal surface. In this way, above discussed benefits of having surface irregularities on both the first and second principal surfaces can be made use of, while all light emission is from the first principal surface, leading to a high output light intensity therefrom.
[0019] According to a further embodiment, the light source is an LED light source. LEDs are a particularly power-efficient and reliable kind of light sources. They are particularly useful in the framework of coupling light into the flat light distribution body, because the light distribution is effected by the flat light distribution body, while the LED or LEDs can be operated in their nominal rating, without having to adapt the emitted brightness to particular constraints of the desired output light intensity distribution. In this way, given LEDs can be operated particularly efficiently or particular LEDs can be selected for a desired overall output illumination by the light unit according to their power ratings. According to a particular embodiment, the light source is an LED light source consisting of exactly one LED. It is, however, also possible that two or more LEDs are present for coupling light into the flat light distribution body. The LEDs may be arranged adjacent to each other, thus coupling light into the flat light distribution body from roughly the same position. It is, however, also possible that the two or more LEDs are arranged at completely different positions with respect to the flat light distribution body.
[0020] According to a further embodiment, the flat light distribution body has a substantially cuboid shape and the light source is arranged in corner region of the flat light distribution body, with light from the light source being coupled into the flat light distribution body via a light entry surface. It is pointed out that it is also possible that the light source is arranged somewhere else around the perimeter of the substantially cuboid shape of the flat light distribution body. According to a particular embodiment, the light source is arranged between the two planes defined by the first and second principal surfaces. According to a further particular embodiment, the light source may be arranged in a cut-out portion of an overall cuboid shaped body. In other words, the flat light distribution body may be an overall cuboid shaped structure, with a portion thereof being cut out of the cuboid shape for placing the light source therein. In this way, efficient coupling of the light into the flat light distribution body may be achieved.
[0021] According to a further embodiment, the light entry surface has a concave shape, when seen from the light source, in a cross-sectional plane parallel to the first principal surface. In this way, a large portion of the light emitted by the light source can be coupled into the flat light distribution body. It is possible that only a small portion of the light of the light source or no light emitted by the light source is reflected by the flat light distribution body, leading to an overall high efficiency of the light unit.
[0022] According to a further embodiment, the light entry surface has a convex shape, when seen from the light source, in a cross-sectional plane orthogonal to first principal surface. In this way, a large portion or all of the light emitted by the light source may be refracted at the convex shaped light entry surface in such a way that it then hits the first and second principal surfaces at angles above the critical angle, leading to total internal reflection of the light. In particular, the light may be refracted in a way that all light entering the flat light distribution body is subject to total internal reflection thereafter.
[0023] According to a further embodiment, the light entry surface is shaped such that the light emitted by the light source and entering the flat light distribution body via the light entry surface reaches the first and second principal surfaces at angles of incidence of at least 60°. The angles of incidence are defined herein as the angles with respect to the direction normal to the surface under consideration.
[0024] According to a further embodiment, the surface connecting the first and second principal surfaces of the flat light distribution body is fully reflective for light within the flat light distribution body. This may be done via any suitable technique of making this connection surface reflective. In this way, no light is emitted by the flat light distribution body, unless it reaches surface irregularities.
[0025] According to a further embodiment, a distribution of the plurality of surface irregularities is such that an output light intensity distribution across the extended light emission surface has a ratio between its maximum light intensity and its minimum light intensity of at most 3. In this way, an output light intensity distribution is achieved that is perceived as highly uniform by the observer. In this way, a light unit can be achieved that is highly useful for signaling lights, such as exit lights in an aircraft. With the ratio between the maximum light intensity and the minimum light intensity being at most 3, such light units also satisfy very strict requirements, as given with respect to some interior aircraft lighting.
[0026] According to a further embodiment, the plurality of surface irregularities comprises holes in the first principal surface. Such holes may be drilled or milled into the flat light distribution body during the manufacture thereof. It is also possible that the surface irregularities are created by counter sinking, counter boring, etching or any other suitable king of operation. It is also possible that a mechanical force is exerted onto the material of the flat light distribution body at selected locations, leading to the holes/dents in the first principal surface.
[0027] According to a further embodiment, the plurality of surface irregularities comprises dots attached to the outside of the first principal surface. Such dots may be glued onto the first principal surface or may be printed thereon. Such dots may be of any suitable material that effects a change between the angle of incidence and the angle of reflection at the surface irregularity.
[0028] According to a further embodiment, the diameter of the plurality of surface irregularities is between 0.1 mm and 2 mm, in particular between 0.2 mm and 1.5 mm. The plurality of surface irregularities may be round or oval or polygonal or may have any other suitable form.
[0029] According to a further embodiment, the average distance of a surface irregularity to the nearest surface irregularity is between 2 mm and 10 mm, in particular between 3 mm and 7 mm, further in particular around 5 mm.
[0030] According to a further embodiment, the light unit has a lens cover or a plurality of lens covers. The one or more lens covers may be arranged along the one or more extended light emission surfaces. According to a particular embodiment, the one or more lens covers may carry markings, which markings may contain and convey the signal information to the observer. Exemplary markings have the shape of letters.
[0031] According to a further embodiment, the light unit is an interior aircraft light unit. According to a particular embodiment, the light unit is an exit light unit, in particular an emergency exit light unit, or a wash room signal light unit. Above discussed benefits of high efficiency and high reliability are particularly useful in the aircraft environment, because power is a scarce resource in an aircraft and maintenance is very cumbersome, complex, and expensive.
[0032] Exemplary embodiments of the invention further include a method of designing a light unit with an extended light emission surface, comprising the steps of (a) defining a geometry of a flat light distribution body, having a first principal surface, a second principal surface, and a light entry surface, (b) defining a position and a light intensity distribution of a light source, facing the light entry surface, (c) defining a starting pattern of a plurality of surface irregularities on the first principal surface, (d) simulating an operation of the light unit and analysing an output light intensity distribution across the extended light emission surface, (e) determining a maximum light intensity and a minimum light intensity of the output light intensity distribution and determining a ratio between the maximum light intensity and the minimum light intensity, (f) if the ratio between the maximum light intensity and the minimum light intensity is above a predetermined threshold, increasing the number and/or the size of the surface irregularities in regions with low output light intensity values.
[0033] By simulating the operation of the light unit and adapting the number or the size of the surface irregularities in regions with low output light intensity values, it is possible to even out the output light intensity distribution of the light unit without the need of performing complex predictive calculations about the light rays travelling through the flat light distribution body. The starting pattern may be a regular distribution of surface irregularities. In particular, the surface irregularities of the starting pattern may be arranged in a grid pattern. In this way, the starting pattern has a uniform distribution of the surface irregularities. It is also possible to provide a random starting pattern of the plurality of surface irregularities, with the random locations being selected in accordance with a uniform distribution. It is also possible to provide the starting pattern on the basis of existing knowledge of the geometry of the flat light distribution body. For example, it is possible to provide a starting pattern that has more surface irregularities in regions that are farther removed from the light source. Such a starting pattern is based on the assumption that, on average, less light reaches the parts of the flat light distribution body that are comparably farther removed from the light source.
[0034] The step of increasing the number and/or the size of the surface irregularities in regions with low output light intensity values may be based on different definitions of low output light intensity values. For example, the number and/or the size of the surface irregularities may be increased in regions where the light intensity of the output light intensity distribution is below the average light intensity value. It is also possible that the threshold is not the average light intensity value, but a value between the minimum light intensity and the average light intensity.
[0035] According to a further embodiment, step (f) may also include the step of decreasing the number and/or the size of the surface irregularities in regions with high output light intensity values. Again, the threshold for light intensity values being considered high can be the average light intensity value or any other suitable value. In particular, it is possible to decrease the number and/or the size of the surface irregularities in regions where the light intensity values are above a threshold value that is between the average light intensity and the maximum light intensity.
[0036] According to a further embodiment, steps (d) to (f) are performed iteratively, until the ratio between the maximum light intensity and the minimum light intensity is below the predetermined threshold. In this way, the pattern of the plurality of surface irregularities may be adjusted in multiple steps, with the respective intermediate results of the analysis of the output light intensity distributions leading to respective decisions about where to increase and/or decrease the number and/or the size of the surface irregularities. In this way, a more and more even output light intensity distribution may be approached over the multiple iterations, such that unintended changes in the output light intensity distribution, effected through changes in the pattern of the plurality of surface irregularities, can be mitigated again. In this way, a fairly well evened-out output light intensity distribution can be achieved without having to build various prototypes for analysing the output light intensity distribution.
[0037] According to a further embodiment, the predetermined threshold is between 2 and 5, in particular between 2.5 and 4, further in particular at or around 3.
BRIEF DESCRIPTION OF DRAWINGS
[0038] Further exemplary embodiments of the invention are described with reference to the accompanying drawings, wherein:
[0039] FIG. 1 shows a perspective view of an exemplary flat light distribution body to be used with a light unit in accordance with an exemplary embodiment of the invention;
[0040] FIG. 2 a - FIG. 2 b shows two cross-sectional views through the flat light distribution body of FIG. 1 , illustrating the light distribution taking place therein;
[0041] FIG. 3 shows a first exemplary embodiment of a light unit in accordance with the invention;
[0042] FIG. 4 shows a second exemplary embodiment of a light unit in accordance with the invention;
[0043] FIG. 5 a - FIG. 5 d illustrates an exemplary embodiment of a method for designing an exemplary embodiment of a light unit in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0044] FIG. 1 shows an exemplary flat light distribution body 6 , to be used in light units in accordance with exemplary embodiments of the invention, in a perspective view. The flat light distribution body 6 is a substantially cuboid body of Poly(methylmetacrylate), also referred to as PMMA. The flat light distribution body 6 may also be of other materials, such as polycarbonate, glass or any other suitable material. The flat light distribution body 6 is entirely cuboid, with the exception of a light entry surface 12 , which will be described in greater detail below.
[0045] The flat light distribution body 6 has a first principal surface 8 and a second principal surface 10 , which is opposite of the first principal surface 8 and is not visible in the viewing direction of FIG. 1 . Between the first and second principal surface 8 , 10 , a connection surface 14 and the light entry surface 12 are provided. The connection surface 14 surrounds the cuboid structure between the first and second principal surfaces 8 , 10 , with the exception of the light entry surface 12 . In other words, the connection surface 14 comprises all surfaces of the flat light distribution body 6 that are not the first and second principal surface 8 , 10 and are not the light entry surface 12 . In the exemplary embodiment of FIG. 1 , the extension of the first and second principal surfaces 8 , 10 is much greater both in a width and a height dimension than the distance between the first and second principal surfaces 8 , 10 . In this way, the light distribution body can be considered an overall flat structure.
[0046] The first principal surface 8 has a plurality of surface irregularities 16 . The plurality of surface irregularities 16 are distributed across the first principal surface 8 in a non-uniform manner, which will be described in greater detail below. In the exemplary embodiment of FIG. 1 , the surface irregularities 16 all have a round shape and all have the same size. It is, however, also possible that the surface irregularities 16 have different shapes and/or differ in size.
[0047] In order to illustrate the light distribution functionality of the flat light distribution body 6 of FIG. 1 , two cross-sectional views through the flat light distribution body 6 of FIG. 1 are shown in FIG. 2 . FIG. 2 a shows a cross-sectional plane that is parallel to the first and second principal surface 8 , 10 and is between the first and second principal surfaces 8 , 10 . FIG. 2 a shows both the flat light distribution body 6 and a light source 4 that couples light into the flat light distribution body 4 , which light is distributed therein.
[0048] The light source 4 is arranged in a way that it faces the light entry surface 12 . In particular, it is arranged in the space that is cut out of the hypothetical outline of the flat light distribution body 6 , if it were entirely cuboid. In the viewing plane of FIG. 2 a , the light source 4 is arranged in the top left corner of the flat light distribution body 6 . In the depicted exemplary embodiment, the light source 4 is a single LED.
[0049] The connection surface 14 , which surrounds the flat light distribution body 6 with the exception of the light entry surface 12 , comprises a reflective coating, such that all light hitting the connection surface 14 from within the flat light distribution body 6 experiences reflection at the connection surface 14 . The light entry surface 12 has a concave shape in the cross-sectional plane of FIG. 2 a , when seen from the light source 4 . In this way, the light entry surface 12 surrounds the light source 4 and provides a large surface for coupling the light of the light source 4 into the flat light distribution body 6 .
[0050] In FIG. 2 a , there are depicted three exemplary light rays 20 . These light rays 20 illustrate that light emitted by the light source 4 in very different directions is coupled into the flat light distribution body 6 via the light entry surface 12 . All the light of the light rays 20 is trapped within the flat light distribution body 6 , experiencing reflection when hitting the reflective connection surface 14 .
[0051] FIG. 2 b shows a second cross-sectional view through the flat light distribution body 6 of FIG. 1 . In particular, the cross-sectional view of FIG. 2 b is orthogonal to the cross-sectional view of FIG. 2 a . Further in particular, the cross-sectional view of FIG. 2 b is in the viewing direction A-A, indicated in FIG. 2 a . In the cross-sectional view of FIG. 2 b , the flat light distribution body 6 is circumscribed by the first principal surface 8 , the connection surface 14 , the second principal surface 10 , and the light entry surface 12 .
[0052] In the cross-sectional plane of FIG. 2 b , the light entry surface 12 has a convex shape. This convex shape provides for a refraction of the light emitted by the light source 4 and coupled into the flat light distribution body. This refraction is of such nature that the angle of incidence of the incoming light with respect to the first and second principal surfaces 8 , 10 is larger than in the absence of the convex shape of the light entry surface 12 . By making the angle of incidence larger, the incoming light can be conditioned in such a way that it is trapped in the flat light distribution body 6 and is propagated therethrough via total internal reflection. In the depicted particular embodiment, all light entering the flat light distribution body 6 has an angle of incidence of more than 60° with respect to the first and second principal surfaces 8 , 10 . The angle of incidence is defined with respect to the direction normal to the first and second principal surfaces 8 , 10 . In FIG. 2 b, 4 exemplary light rays 22 are shown that illustrate the refraction at the light entry surface 12 and the propagation through the flat light distribution body 6 via total internal reflection.
[0053] The coupling out of the light out of the flat light distribution body 6 via surface irregularities 16 is now described. It is pointed out that surface irregularities may have a variety of shapes. Further, different kinds of surface irregularities may be provided. For illustrative purposes, one printed surface irregularity and one geometric surface irregularity, embodied as a hole, are shown in the exemplary embodiment of FIG. 2 b . It is understood that the first principal surface 8 has a much greater number than those two depicted surface irregularities. However, for a clearer description of the functionality of the surface irregularities, only two are shown in FIG. 2 b.
[0054] Each of the surface irregularities 16 has the effect that the light arriving at the surface irregularities 16 changes its path through the flat light distribution body 6 in a different manner as compared to light hitting the first and second principal surfaces 8 - 10 at positions where no surface irregularities are present. In particular, the angle of reflection at such surface irregularities 16 is different from the angle of incidence, when looked at both angles with respect to the first principal surface 8 . This is illustrated by two of the light rays 22 that are depicted as arriving at the surface irregularities 16 at angles of incidence of more than 60°. These light rays 22 leave the surface irregularities at angles of reflection that are much less than the angles of incidence with respect to the first principal surface 8 . For the two depicted light rays, the angle of reflection is below 30°. As the angles of reflection are below the critical angle of the material of the flat light distribution body 6 , these light rays 22 exit the flat light distribution body 6 at the next surface they hit, i.e. at the second principal surface 10 . In this way, a coupling out of the light is achieved via the reflection at the surface irregularities 16 .
[0055] FIG. 3 shows a light unit 2 in accordance with an exemplary embodiment of the invention in a top view. The light unit 2 has a flat light distribution body 6 , embodied substantially as described with respect to FIGS. 1 and 2 . In the top view of FIG. 3 , the upper connection surface 14 and the light entry surface 12 are shown as extended structures. Further, the surface imperfections 16 are shown as extending beyond the first principal surface 8 . Further, the light source 4 is depicted.
[0056] A diffuse white reflector 34 is arranged along the second principal surface 10 of the flat light distribution body 6 . Further, a translucent cover 30 is arranged around the flat white distribution body 6 at those three sides that are not associated with the diffuse white reflector 34 . On the side of the first principal surface 8 , the translucent cover 30 comprises markings 32 that provide for the signaling capability of the light unit 2 . In particular, the markings 32 of the exemplary embodiment of FIG. 3 are transparent red markings in the shape of the four letters of the word EXIT, indicating the exit locations to the passengers of an aircraft. Accordingly, the exemplary light unit 2 or FIG. 3 is an interior aircraft exit light unit.
[0057] The operation of the light unit 2 of FIG. 3 is described as follows. Light is emitted by the light source 4 and coupled into the flat light distribution body 6 via the light entry surface 12 . This light propagates within the flat flight distribution body 6 until it hits one of the surface irregularities 16 . At the surface irregularities 16 , at least some of the light hitting the surface irregularities 16 is reflected in such a way that it reaches the second principal surface 10 at an angle that is smaller than the critical angle. In this way this light leaves the flat light distribution body 6 towards the diffuse white reflector 34 . At the diffuse white reflector 34 , the light is diffusely reflected towards the flat light distribution body 6 . The light re-enters the flat light distribution body 6 , travels from the second principal surface 10 to the first principal surface 8 and re-exits the flat light distribution body 6 . By the action of the plurality of surface irregularities 16 and the diffuse white reflector 34 , a light emission from the first principal surface is achieved. In other words, the first principal surface 8 is an extended light emission surface of the light unit 2 . From there, the light travels through the translucent cover 2 , illuminating the exit markings 32 and the remainder of the translucent cover 30 in different manners, thus achieving the desired signaling functionality.
[0058] FIG. 4 shows a light unit 2 in accordance with a second exemplary embodiment of the invention. The light unit 2 of FIG. 4 differs from the light unit 2 of FIG. 3 in that no white diffuse reflector is provided and in that the translucent cover 30 surrounds the flat light distribution body 6 on all sides in the top view of FIG. 4 . In particular, the translucent cover 30 is arranged along both the first principal surface 8 and the second principal surface 10 . In the absence of the white diffuse reflector, the light reflected by the surface irregularities 16 at an angle smaller than the critical angle finally exits the flat light distribution body at the second principal surface 10 . In this way, the second principal surface 10 is an extended light emission surface of the light unit 2 . This light then leaves the light unit 2 via the portion of the translucent cover 30 arranged alongside the second principal surface 10 .
[0059] The light unit 2 of FIG. 4 also deviates from the light unit 2 of FIG. 3 in that a plurality of second surface irregularities 18 are provided on the second principal surface 10 . The light reflected by the second surface irregularities 18 at an angle below the critical angle exits the flat light distribution body 6 at the first principal surface 8 , making the first principal surface an extended light emission surface of the light unit 2 . In this way, the first and second principal surface 8 , 10 are both extended light emission surfaces, leading to the light unit 2 shining light through the translucent cover 30 to two sides.
[0060] FIG. 5 illustrates an exemplary process for designing a non-uniform distribution of surface irregularities 16 that allows for reaching a highly even output light intensity distribution of an exemplary light unit 2 . In FIG. 5 , a light unit 2 substantially as shown in FIG. 3 is to be designed. The light unit is shown from a front view without the translucent cover. Accordingly, in the viewing direction of FIG. 5 a , the first principal surface 8 of the flat light distribution body 6 and the light source 4 are visible. Further, a starting pattern of surface irregularities 16 is shown. In the exemplary embodiment of FIG. 5 a , the starting pattern is a regular grid of surface irregularities 16 .
[0061] On the basis of the geometric extension and the material of the flat light distribution body 6 , of the position of the light source 4 with respect to the flat light distribution body 6 , of the starting pattern of the surface irregularities 16 , and of a model of the diffuse white reflector 34 , which is arranged behind the flat light distribution body 6 in the viewing direction of FIG. 5 a , the operation of the light unit is simulated. Such simulation may be done via suitable computing means, such as a computer with suitable programs. As the result of such simulation, the output light intensity distribution across the first principal surface 8 may be computed.
[0062] An exemplary extract of that output light intensity distribution is shown in FIG. 5 b . In particular, the simulated output light intensity values along line B-B, depicted in FIG. 5 a are shown in FIG. 5 b . This extract of the output light intensity distribution has a ratio between its maximum light intensity and its minimum light intensity of about 10. Accordingly, the ratio of the maximum light intensity across the entire first principal surface and the minimum light intensity across the entire first principal surface is at least 10. It can be seen from the extract of the output light intensity distribution, depicted in FIG. 5 b , that the output light intensity has generally higher values towards the right of the first principal surface 8 and has generally lower intensity values slightly towards the left of the center of the first principal surface 8 .
[0063] On the basis of these observations, the starting pattern of the surface irregularities 16 is adjusted. In particular, additional surface irregularities are provided slightly towards the left of the center of first principal surface 8 , and surface irregularities are removed from the right end of the first principal surface 8 . The resulting adjusted distribution of the surface irregularities 16 is illustrated in FIG. 5 c.
[0064] After this adjustment, the operation of the light unit is simulated again, as described above. The resulting output light intensity distribution differs from the starting output light intensity distribution. In FIG. 5 d , an extract of this output light intensity distribution along line B-B is shown again. In the present case, the output light intensity distribution along line B-B has changed in such a way that the ratio between the maximum light intensity and the minimum light intensity is around 3. In this way, a much more even output light intensity distribution has been achieved by the adjustment of the distribution of the surface irregularities 16 . In particular, in above discussed sub-regions towards the left of the center of the first principal surface 8 , a substantially increased density of surface irregularities is provided. In particular, the surface irregularity density in sub-region 40 is at least 50% higher than average surface irregularity density across the whole first principal surface 8 . It can also be said that the regional irregularity ratio in the sub-region 40 is at least 50% higher than the total irregularity ratio across the whole first principal surface 8 .
[0065] It is pointed out that the method of designing the light unit, as illustrated in FIG. 5 a to 5 d , is schematic and simplified. In reality, multiple iterations may be carried out in order to reach a desired output light intensity distribution across the entire first principal surface 8 .
[0066] Further, it is pointed out that, instead of or in addition to changing the number of surface irregularities, the size of the surface irregularities can be adjusted. In particular, the size of the surface irregularities in regions with low output light intensity values can be increased and/or the size of the surface irregularities in regions with high output light intensity values can be decreased. Accordingly, the changing of the size/extension of the surface irregularities is an alternative means for adjusting the regional irregularity ratio.
[0067] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. | A light unit with an extended light emission surface includes a light source, and a flat light distribution body having a first principal surface and a second principal surface disposed on opposite sides of the flat light distribution body, wherein the light source is positioned outside of the flat light distribution body, with light emitted by the light source being coupled into the flat light distribution body and being propagated within the flat light distribution body via total internal reflection at the first and second principal surfaces. | 6 |
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