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This application is a continuation of application Ser. No. 09/281,983, filed Mar. 31, 1999, pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for developing and executing a multimedia presentation. More particularly, the present invention concerns an extensible markup language (XML)-based system which allows development and execution of a synchronized multimedia presentation, wherein a sequence of the presentation and/or the behavior of a multimedia object therein is alterable in response to a user event, a system event, a timed event, and/or a detected state of another multimedia object.
2. Description of the Related Art
The hypertext markup language (“HTML”) is an XML-based language commonly used to create pages to be displayed by a World Wide Web browser application. More particularly, a developer creates a web page by developing an HTML source file which includes data specifying particular items to be included in the page and spatial relationships among the items. Upon receiving an HTML source file, a web browser parses the file to obtain instructions for formatting and displaying the items of the web page to a user.
Like other high-level programming languages, HTML utilizes fairly intuitive syntax and text-based commands. In addition, a previously-created HTML source file can easily be used as a model for a new source file and resulting web page, or can be edited so as to reformat its resulting web page using simple text-based editing. HTML has proved popular due to its reusability, editability, the simplicity of its required syntax and the functionality provided by its defined commands.
However, traditional HTML can be used only to define spatial, rather than temporal, relationships of objects within a web page. One proposal for providing control over temporal relationships between objects is video streaming, in which frames of a video presentation are sequentially delivered by an Internet server directly to a web browser. However, such a video presentation can be edited only by using sophisticated video-editing equipment, and is not easily-editable using a text-based markup language. Moreover, the video approach requires a very high bandwidth to produce a presentation of reasonable quality.
Another proposed approach requires animated GIF-formatted images to be merged into a single file, which is then downloaded to a web browser for rapid sequential display. Although such animation can be edited by adding, deleting, or substituting images of the animation, editing is significantly more difficult and less flexible than web page editing using a traditional markup language, particularly in the typical case in which a user has access only to the merged file. This approach also requires constant refresh of the web browser display, and therefore unacceptably consumes transmission bandwidth.
In addition to the above shortcomings, the content of a video presentation or an animated GIF presentation cannot be modified during execution of the presentation based on an occurrence of an event. It is possible to display, through a web browser, multimedia presentations which are responsive to events and/or user input by executing a suitable Java-language program using the browser's Java Virtual Machine. Development of these programs, however, requires a significant computer programming background. Therefore, this Java-based approach fails to provide the simplicity and editability of languages such as HTML.
In response to the foregoing, the World Wide Web Consortium (W3C) has circulated a proposed standard, entitled “Synchronized Multimedia Integration Language (SMIL) 1.0 Specification”, the contents of which are incorporated herein by reference. SMIL is text-based, XML-based, editable and reusable. In this regard, the W3C standard “Extensible Markup Language (XML) 1.0” is also incorporated herein by reference.
SMIL is intended to provide control over temporal relationships between web page objects. Specifically, SMIL allows a user to define whether multimedia objects of a page are executed in parallel or sequentially, and further provides nested control of parallel/sequential object execution.
For example, the SMIL specification defines the <par> element, which is used to specify elements to be executed in parallel. FIG. 1 shows an illustrative example of a SMIL source file portion utilizing the <par> element. The source file portion shown in FIG. 1 begins with <par> element 100 and ends with corresponding </par> notation 101 . It should be noted that the <element> </element> beginning/end syntax is an XML grammar requirement.
According to the SMIL specification, all child elements nested one level below elements 100 and 101 are to be executed in parallel. Therefore, since two child elements <seq> 110 and <seq> 120 exist at a first level below <par> element 100 , objects corresponding to elements 110 and 120 are each executed in parallel.
In the case of <seq> 110 , two media object elements exist between <seq> 110 and end notation 111 . In this regard, and also according to the SMIL specification, elements existing as children to a <seq> element are executed sequentially. Therefore, video element 130 is processed, followed by video element 140 . It should be noted that statements 130 and 140 each utilize the XML shorthand syntax which allows end notation “/” to be located within an element declaration.
As described above, child elements to <seq> element 120 are executed in parallel with the child elements of <seq> element 110 by virtue of <par> element 100 . Therefore, all elements between <seq> element 120 and notation 121 are processed in parallel with elements 130 and 140 . In this regard, nested within element 120 and notation 121 are <par> element 150 , corresponding notation 151 , <seq> element 160 and notation 161 . According to <seq> element 120 , the video sources indicated by video elements 170 and 180 are first played in parallel, followed by the video sources of video elements 190 and 200 , which are played sequentially.
FIG. 2 a and FIG. 2 b illustrate a portion of a multimedia presentation governed by the SMIL source file shown in FIG. 1 . As shown in FIG. 2 a , video V 1 begins executing at a same time that video V 31 and video V 32 begin executing in parallel. In this example, while either one of video V 31 or video V 32 continues to play, video V 1 finishes and, by virtue of <seq> element 110 , video V 2 begins to play. At time t 1 , the one of video V 31 and video V 32 having a longer duration than the other terminates.
Next, as shown in FIG. 2 b , video V 2 continues to play and video V 4 begins to play in parallel by virtue of <par> element 100 . It should be noted that video V 4 begins to play upon termination of the longer of video V 31 and V 32 due to <seq> element 120 . After termination of video V 4 , video V 5 is played.
FIG. 2 c shows a timeline describing the presentation illustrated in FIG. 2 a and FIG. 2 b . It also should be noted that FIG. 2 c represents only one possible timeline resulting from the FIG. 1 SMIL source file, and that the timeline of FIG. 2 c depends heavily upon relative durations of the video objects used therein. As described with respect to FIG. 1 , FIG. 2 a and FIG. 2 b , the timeline of FIG. 2 c shows that video V 1 and video V 2 are played sequentially while video V 31 and video V 32 are played in parallel. After termination of V 32 , and while video V 2 is playing in parallel, video V 4 and video V 5 are sequentially played.
The SMIL specification provides for presentation control mechanisms in addition to those shown in FIG. 1 . For example, attributes can be added to the <par> and <seq> statements to alter their above-described functionality. The SMIL specification also describes several media object elements which can be used in addition to the <video> element of FIG. 1 . These elements, which are described in detail in the SMIL specification, include <ref>, <animation>, <audio>, <img>, <video>, <text> and <textstream>. Each of the listed media object elements can also be used with specified attributes which influence their respective functioning.
Notably, the <par>, <seq>, and media object elements are each controllable based on system attributes, such as bit rate and screen size. As described in the SMIL specification, when an attribute specified for an element evaluates to “false”, the element carrying this attribute is ignored. For example, if statement 170 of FIG. 1 were replaced by
<video src “v 31 .mpg” system-bitrate=“56000”/>
then, upon encountering line 170 , a SMIL-enabled browser would evaluate the approximate bandwidth, in bits-per-second, available to the currently-executing system. In a case that the bandwidth is smaller than 56000, the replaced line 170 would be ignored. As a result, video V 31 would be absent from the display shown in FIG. 2 a.
Other system attributes defined in detail in the SMIL specification include “system-captions”, “system-language”, “system-overdub-or-caption”, “system-required” and “system-screen-depth”. Each of these attributes can be included in a <par>, <seq>, or media object statement as described above to change the functioning thereof.
SMIL 1.0 also provides a <switch> element which can be helpful in controlling a multimedia presentation based on the above-described system attributes. The <switch> element allows an author to specify a set of alternative elements from which only one acceptable element should be chosen.
In this regard, upon encountering a <switch> element in a SMIL document, a browser evaluates the children of the <switch> element in the order in which they are listed. The first accepted child is selected to the exclusion of all other children of the <switch> element.
For example, in a case that lines 160 , 190 , 200 and 161 of FIG. 1 were replaced with
<switch> <video src=“v 4 .mpg” system-bitrate=“56000”/> <video src=“v 5 .mpg” system-bitrate=“28800”/> </switch>,
the presentation sequence governed by FIG. 1 would depend upon the approximated bandwidth. Specifically, in a case that the bandwidth is greater than or equal to 56000, only video V 4 would be played in FIG. 2 b upon termination of parallely-executing video V 31 and video V 32 . On the contrary, if the system bitrate is less than 56000 but greater than 28800, video v 5 would be played exclusively in FIG. 2 b.
One shortcoming of the above-described elements is that the testable attributes defined by SMIL 1.0 are all system-based attributes, in that they concern characteristics of the computing system upon which the browser is executing, or the system to which the browser is connected. Thus, although the <par> and <seq> synchronization elements and the testable attributes described above are useful in creating a multimedia presentation, these features do not provide control of multimedia presentations based on anything non-system based, such as a user interaction, a timed event, or a state change of an object.
In addition, SMIL 1.0 offers no ability to change an attribute of an object during execution of a multimedia presentation. As such, the functionality and flexibility of SMIL 1.0 is somewhat limited.
Accordingly, what is needed is a system for producing and displaying pages to be transmitted over the World Wide Web which provides control of multimedia objects on a web page based on user events, system events, timed events, or object state, and control over object attributes. Such a system also preferably allows simple and efficient creation and editing of such a web page and the control mechanisms therein.
SUMMARY OF THE INVENTION
The present invention addresses the foregoing by providing XML-based markers representing functions to detect events and to control attributes of media objects in accordance with the detected events.
In one aspect, the present invention is an XML-based event marker which includes an event parameter indicating an event, the marker representing a function to detect the indicated event. According to the further aspects, the event can be a user event such as a mouse click or a system event such as a memory low alert.
The present invention also includes an XML-based action marker which contains an object parameter indicating a media object, an attribute parameter indicating an attribute of the media object, and a value parameter indicating a value of the attribute. Advantageously, the action marker represents a function to assign the value to the attribute of the media object.
In another aspect, an XML-based interpolate marker includes an object parameter indicating a media object, an attribute parameter indicating an attribute of the media object, a begin parameter indicating a first time, an end parameter indicating a second time, and an end value parameter indicating a value of the attribute. The interpolate marker according to the invention represents a function to gradually change a value of the attribute to the end value over a period beginning at the first time and ending at the second time.
In addition, the present invention contemplates an XML-based condition marker containing an Id parameter indicating an element, an attribute parameter indicating an attribute of the element, and a value parameter indicating a value of the attribute, wherein the condition marker represents a function to detect whether or not the attribute of the element possesses the value.
According to the invention, the above-described markers can be utilized together in order to provide sophisticated functionality. For example, in one embodiment, the invention is a set of XML-based markers including an event marker indicating an event, and an action marker indicating a media object, an attribute of the media object, and a value of the attribute, wherein the set of markers represents a function to assign the value to the attribute if the event is detected.
In another embodiment, the present invention is a set of XML-based markers including an event marker indicating an event, a condition marker indicating a state of a first media object, and an action marker indicating a second media object, an attribute of the second media object, and a value of the attribute. This set of markers represents a function to assign the value to the attribute of the second media object if the event is detected and if the first media object possesses the indicated state.
In an additional embodiment, the invention is a set of XML-based markers including an event marker indicating an event, and an interpolate marker indicating a media object, an attribute of the media object, a first time, a second time, and a value of the attribute, wherein the markers represent a function to gradually change a value of the attribute to the end value over a period beginning at the first time and ending at the second time if the event is detected.
In yet another embodiment, the invention is a set of XML-based markers which include an event marker indicating an event, a condition marker indicating a state of a first media object, and an interpolate marker indicating a second media object, an attribute of the second media object, a first time, a second time, and a value of the attribute. According to this embodiment, the markers represent a function to gradually change a value of the attribute to the end value over a period beginning at the first time and ending at the second time if the event is detected and if the first media object possesses the indicated state.
In another aspect, the present invention relates to a set of XML-based markers representing media object elements, each marker including a test-element attribute for indicating a particular media object element, a test-attribute attribute for indicating an attribute of the particular element, and a test-value attribute for indicating a test value to be compared with a value of the specified attribute.
Because of the extension of test attributes from mere system-based attributes according to the prior art, the invention is able to provide selection between alternative different multimedia presentations based on non-system-based characteristics, such as user interaction or the characteristics and content of other multimedia objects.
This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following detailed description of the preferred embodiment thereof in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a portion of document source code according to the SMIL 1.0 specification.
FIG. 2 a shows a display of a web browser executing a first part of the FIG. 1 source code.
FIG. 2 b shows a display of a web browser executing a second part of the FIG. 1 source code.
FIG. 2 c is a timeline showing temporal relationships of multimedia objects executing according to the FIG. 1 source code.
FIG. 3 is an outward view of a computing environment utilizing the present invention.
FIG. 4 is a block diagram illustrating the internal architecture of a computer utilizing the present invention.
FIG. 5 is a block diagram illustrating the internal architecture of a web server utilizing the present invention.
FIGS. 6 a and 6 b illustrate sequences of a multimedia presentation according to the present invention.
FIG. 7 a is a graph illustrating a volume change of an audio object according to the present invention.
FIG. 7 b is a graph of illustrating a volume change of an audio object according to the present invention.
FIG. 8 a and FIG. 8 b are views illustrating event detection and object state change during a multimedia presentation according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 is an outward view of a representative computing system utilizing the present invention.
Computing equipment 1 is preferably an Intel® Pentium®-based computer executing a windowing operating system such as Microsoft Windows98®. Computing equipment 1 includes display 2 for displaying images to a user and fixed disk 3 which stores computer-executable process steps of the windowing operating system and of other applications executed by computing equipment 1 , such as a World Wide Web browser application. Fixed disk 3 also stores data files and device drivers for use by computing equipment 1 . Also provided with computing equipment 1 are keyboard 4 for entering text and commands into appropriate fields displayed on display 2 , and pointing device 5 , such as a mouse, for pointing to, selecting and manipulating objects displayed on display 2 .
Floppy disk drive 6 provides an interface to computing equipment 1 for reading data from and writing data to a floppy disk inserted therein. Using floppy disk drive 6 , the above-described computer-executable process steps and/or data files may be input to computing equipment 1 and stored on fixed disk 3 . Computer-executable process steps and data files may also be retrieved over a network via network connection 8 or via telephone line 9 from World Wide Web 10 . In addition, image data files can be retrieved from scanner 12 and stored on fixed disk 3 .
Multimedia speakers 14 provide sound output based on audio data files executed by computing equipment 1 . Such an audio file may be in a monaural or stereo format, or in any other type of audio format, so long as computing equipment 1 is provided with a corresponding audio decoder and player application.
Computer-executable process steps and data files obtained by computing equipment 1 over World Wide Web 10 are transferred thereto by servers such as server 15 . In response to a request for data, server 15 collects the required data, properly formats the data, and sends the data to computing equipment 1 over World Wide Web 10 .
FIG. 4 is a block diagram of the internal architecture of computing equipment 1 . Shown in FIG. 4 is CPU 20 , which, as described above, is preferably a Pentium® processor. CPU 20 interfaces to computer bus 21 , as does scanner interface 22 for interfacing to scanner 12 , speaker interface 24 for interfacing to speakers 14 , network interface 25 for interfacing to network connection 8 , modem interface 26 for interfacing to telephone line 9 and display interface for interfacing to display 2 . Mouse interface 29 , which interfaces to mouse 5 , and keyboard interface 30 , which interfaces to keyboard 4 , are also connected to bus 21 . In this regard, interfaces 22 to 30 allow computing equipment 1 to access the functionality of their corresponding components. Also shown in FIG. 4 is disk 3 , having stored thereon the aforementioned windowing operating system, a web browser, XML-based source files according to the present invention, which, for convenience sake, are hereinafter referred to as Synchronized Multimedia Integration Language Extended (SMILE) source files, a SMILE file editor application, other applications, other data files and device drivers.
The web browser stored on fixed disk 3 is preferably capable of interpreting elements and attributes of a SMILE source file and executing a corresponding multimedia presentation in accordance with functionality dictated by the elements and attributes. For example, Netscape Navigator and Internet Explorer are common HTML-enabled browsers, and a SMIL enabled browser is currently available from Realnetworks.
Read only memory (ROM) 31 stores invariant computer-executable process steps for basic system functions such as basic I/O, start-up, or reception of key strokes from keyboard 4 .
Main random access memory (RAM) 32 provides CPU 20 with memory storage which can be accessed quickly. In this regard, computer-executable process steps of a web browser or other application are transferred from disk 3 over computer bus 21 to RAM 32 and executed therefrom by CPU 20 .
FIG. 5 is a block diagram of several relevant components internal to server 15 . As shown, server 15 is connected to World Wide Web 10 via World Wide Web connection 40 , which may be a telephone line, a T 1 line, a local area network connection, or the like. In a case that World Wide Web connection 40 connects directly to a local area network, the local area network is preferably connected to a router which, in turn, is connected to World Wide Web 10 . In such a configuration, the router includes firewall software for prevention of unauthorized access to the local area network.
Data packets received over World Wide Web 10 (IP packets) travel over connection 40 to TCP/IP layer 41 . TCP/IP layer 41 re-orders the IP packets and parses data therefrom. The parsed data is delivered to HTTP (hypertext transfer protocol) server 43 . Based on the parsed data, HTTP server 43 retrieves appropriate files from file storage 44 and transfers the files to TCP/IP layer 41 . The files are then formatted into IP packets and sent over World Wide Web connection 40 to computing equipment 1 .
According to the present invention, file storage 44 stores at least source files in a SMILE format according to the present invention, as well as text, video and audio objects which are referenced by stored SMILE source files. File storage 44 may also store Java applets which can be executed by a Java virtual machine of a web browser executing in computing equipment 1 .
It should be noted that other servers and protocol layers may be used by server 15 . In this regard, although HTTP server 43 and TCP/IP layer 41 are useful for transmitting text and fixed images over a firewall, a specialized streaming server utilizing the TCP or UDP protocol may be preferred for sending streaming audio or video data over World Wide Web 10 .
I. Test Attributes
As mentioned in the Background of the Invention, the SMIL specification allows conditional execution of elements based only on system attributes, such as bit rate or screen size. According to one aspect of the present invention, test attributes, which can be any attributes of an object or element, can be defined for use in any of the <par>, <seq>, or media object elements. As a result, presentation flow can be controlled based on non-system-based attributes.
More specifically, the present invention defines three new attributes for the <par>, <seq> and media object elements, “test-element”, test-attribute”, and “test-value”. The “test-element” attribute can be assigned an Id of a particular element to indicate that an attribute of the particular element is to be tested. In this regard, the “test-attribute” attribute specifies the attribute of the particular element to be tested. Finally, the “test-value” attribute indicates the value with which the value of the specified attribute is to be compared.
For example, the source code:
<audio id=“Audio” src=“Audio.wav” test- element=“Video” test-attribute=“sound” test- value=“on”/> <textstream id=“Text” src=“text.txt” test- element=“Video” test-attribute=“sound” test- value=“off”/>
causes a sound file “Audio.wav” to be played in a case that a “sound” attribute of a video object having the Id “Video” has the value “on”, and causes a text file “text.txt” to be displayed in a case that the “sound” attribute of the video object has the value “off”.
For media object elements, the present invention also defines a “status” attribute, a “sync” attribute, and a “start-asap”, attribute. The “status” attribute indicates whether an element is activated or deactivated and can be assigned the values “activate” (the default value) or “deactivate”.
The “sync” attribute is used to indicate a group of elements with which execution of an object should be strictly synchronized. In addition, the “start-asap” attribute indicates that object execution should begin as soon as possible.
II. The <Action> Element
A SMILE source file according to the present invention may include an <action> element for changing a value of an attribute of another element. The <action> element can therefore be used for inter-object communication or for changing the behavior of objects in a presentation in real-time. According to the present invention, the <action> element can include the “id” and “skip-content” attributes defined in the SMIL specification. Moreover, the <action> element can include the attributes “dest”, “order-number”, “attribute”, “value”, and “begin”.
The “dest” attribute refers to a particular element upon which the <action> element is intended to operate. In this case, an Id for the particular element can be defined using the SMIL “id” attribute and the Id can then be referred to using the “dest” attribute of the <action> element. For example, based on the source code
<video Id=“myVideo” src=“video.mpg”/>,
an <action> element statement for operating on the video element would contain the attribute definition dest=“myVideo”.
The “order number” attribute assigns an order number to an <action> element so as to indicate a time at which the particular <action> element is to be executed relative to other <action> elements. Such an attribute is useful if, as described above with respect to FIG. 1 , an object-execution sequence of a source file is dependent upon relative durations of the objects referenced therein.
The “attribute” element identifies an attribute of the particular element indicated by the “dest” attribute. In this regard, the “value” attribute indicates a value to which the identified attribute is to be altered. Accordingly, any defined attribute of any defined element can be altered simply by referencing the element and the attribute using the “dest” and “attribute” attributes, respectively. Finally, the “begin” attribute indicates a time delay from a time at which the <action> element is encountered by the web browser to actual execution of a specified value change.
The following is a representative example of code utilizing the above-described <action> element.
<par>
<audio src=“Audio 1 .wav” volume=“10” Id=“audio 1 ”/>
<seq>
<video src=“Video 1 .mpg”/>
<action dest=“Audio 1 ” attribute=“volume”
value=“20”/>
<seq>
</par>
As explained above, all child elements at a first level below the <par> element are to be executed in parallel. Therefore, in the present case, the above <audio> element and the elements encompassed by the <seq> element are performed in parallel.
As shown, the <audio> element according to the present invention can include a “volume” attribute, the value of which corresponds to a volume at which the referenced audio object is played through speakers 14 . By virtue of the above source code, the audio file Audio 1 .wav is played at a volume 10 .
FIG. 6 a shows a display of a browser executing the above source code. At time 0 , both audio file Audio 1 .wav and video file Video 1 .mpg are executed. It should be noted that Video 1 .mpg is executed since it is a first element in a sequence which is to be performed in parallel with the Audio 1 .wav file.
For the purpose of the present example, it is assumed that Video 1 .mpg has a duration of 5 seconds. Accordingly, after 5 seconds has elapsed, the above-listed <action> statement is executed. In this regard, the <action> statement includes a “dest” attribute and an “attribute” attribute, which identify, respectively, the listed <audio> element and the “volume” attribute of the <audio> element. The <action> element also includes a “value” attribute, which, as described above, refers to a value to which the attribute referenced by the <action> element is to be changed.
In the present example, the “volume” attribute of the <audio> element should be changed to 20. Accordingly, FIG. 6 b shows a representation of a multimedia presentation dictated by the above source code after 5 seconds have elapsed. As shown, Video 1 .mpg has ceased to play and file Audio 1 .wav is played at a volume corresponding to a “volume” attribute value of 20.
The functionality provided by the above-described <action> element is not provided by the SMIL specification. The <action> element advantageously provides control over object attributes before, during and after object execution, thereby greatly increasing the presentation options available to a presentation developer. A further advantage of the <action> element is that the <action> element is easy to understand, use and edit, thereby preserving the user friendliness of XML-based languages.
III. The <Interpolate> Element
According to the present invention, an <interpolate> element is provided for changing a value of an element attribute. In this respect, it will be noted that the <interpolate> element is similar to the <action> element. However, as described in detail below, the <interpolate> element provides greater control than the <action> element over the manner in which an attribute value is changed over time.
The <interpolate> element includes a “id” attribute and a “skip-content” attribute as defined by the SMIL specification. The <interpolate> element also includes a “dest” attribute which identifies an element, an attribute of which will be changed according to the <interpolate> element. In this regard, the <interpolate> element also includes an “attribute” attribute, which specifies the attribute of the referenced element which is to be changed.
The <interpolate> element further includes a “begin” attribute which specifies an elapsed time, from a time when the <interpolate> element is encountered by a web browser, after which the specified attribute should begin changing. Relatedly, an “end” attribute is also provided which specifies an elapsed time, from a time when the <interpolate> element is encountered, at which the attribute should cease changing. In addition, the <interpolate> element includes an “end-value” attribute, which indicates a value to which the referenced attribute should be changed.
FIG. 7 a is a graph of volume versus time for the presentation shown in FIG. 6 a and FIG. 6 b . As shown, and as described above, the volume of audio file Audio 1 .wav is set to 10 for the first 5 seconds of the presentation, after which time the volume attribute is set to 20 by virtue of the described <action> element.
FIG. 7 b shows a corresponding graph in a case that the <action> element statement is substituted with the statement:
<interpolate dest=“Audio 1 ” attribute=“volume” end-value=“20” begin=“2s” end=“5s”/>.
As described above, the attributes of the foregoing <interpolate> element indicate that the volume attribute of the element having the Id “Audio 1 ” should begin changing 2 seconds after encountering the <interpolate> element. Moreover, the attributes indicate that the changing should continue for 3 seconds (5 seconds-2 seconds) and the volume should be 20 at the end of the changing.
Continuing with the assumption that the Video 1 .mpg has a duration of 5 seconds, FIG. 7 b shows that Audio 1 .wav is played at a volume of 10 for the first 5 seconds of the presentation, after which point the <interpolate> element is encountered. Based on the “begin” attribute, the “volume” attribute begins changing 2 seconds after the <interpolate> element is encountered, or 7 seconds into the presentation. The changing continues until 5 seconds after the <interpolate> element was encountered, or 10 seconds into the presentation. As shown by FIG. 7 b , the result of the <interpolate> element is a gradual transition from the initial attribute value to the final attribute value.
Accordingly, the <interpolate> element offers new functionality similar to that offered by the <action> element, and also allows for gradual change of element attribute values.
Conventionally, controls of an object utilized in a HTML or a SMIL presentation are not exposed in corresponding HTML or SMIL source code. Rather, according to those languages, an object is merely downloaded from a web location indicated in the source code. As such, object controls cannot be manipulated through editing of the source file. Therefore, the <action> and <interpolate> elements of the present invention advantageously offer simple control over presentation objects not offered by the above conventional systems.
IV. The <Event> Element
According to another aspect, the present invention includes a <event> element which captures user events or system events. Upon capture of a specified event, child elements to the <event> element are processed.
The <event> element includes the “id” and “skip-content” attributes defined in the SMIL specification. Also included are a “source-event” attribute, which defines the type of event to be captured, and a “coord” attribute for specifying a coordinate position on a browser display. The “source-event” attribute can have the following values: “leftmouseclick”, “rightmouseclick”, “mouseover”, “mousein”, “mouseout”, “mousedown”, and “timerevent”. If no value for the “source-event” attribute is specified in an <event> element, the element defaults to a TRUE value.
The “source-event” attribute value “leftmouseclick” refers to a press-and-release of the left button of mouse 5 . Several distinct types of situations can be detected by setting the “source-event” attribute to “leftmouseclick”. First, in a case that the <event> element is not a child element to a media object and the “source-event” attribute is assigned a value of “leftmouseclick”, any press and release of the left mouse button is detected upon encountering the <event> element. On the other hand, if particular coordinates are specified using the “coord” attribute, only those press-and-releases of the left mouse button which occur while a displayed mouse pointer is within the specified coordinates are captured.
Moreover, in a case that an <event> element is a child element to an element such as, for example, a video element specifying a video object, only those press-and-releases of the left mouse button which occur while the pointer is on the executing video object are captured. However, if coordinates are also specified using the “coord” attribute, then only those press-and-releases occurring while the pointer is within the specified coordinates are captured.
The “rightmouseclick” attribute value functions as described above with respect to the “leftmouseclick” value, but instead with respect to the right button of mouse 5 . In addition, the “mousedown” value of the “source-event” attribute operates similarly to the “leftmouseclick” and “rightmouseclick” values, however, the “mousedown” value describes and is used to detect a situation in which a mouse button is merely pressed but not necessarily released in an appropriate area.
The “mouseover” value operates similarly to the “leftmouseclick” and “rightmouseclick” values described above, however, a “mouseover” source event does not require any movement of a mouse button. Rather, if a “mouseover” attribute value is specified with an <event> element, then an event is captured in a case that the pointer is in a region of the browser display specified by a parent element of the <event> element or by values of a “coordinate” attribute of the <event> element. Using the previous example, in a case that such an <event> element is a child element to a <video> element, the event is captured in a case that a pointer is moved to any area of the executing video. In a case that the <event> element is not a child of a media object and does not include a “coordinate” attribute, the region of detection is the entire browser display.
A “mousein” or “mouseout” source event is captured in a case that a mouse pointer is moved into a region of a parent media object element or out of the region of the parent media object element, respectively. If used in conjunction with a “coordinate” attribute, a “mousein” or “mouseout” source event is captured in a case that a mouse pointer is moved into a region defined by a specified value of the “coordinate” attribute. Similarly to the “mouseover” value, the region of interest is the entire browser display for an <event> element specifying a “mousein” or “mouseout” source event value which is not a child of a media object and does not include a “coordinate” attribute.
The “timerevent” value of the “source-event” attribute is preferably not used with a specified “coord” attribute value. This attribute value is used in <event> elements which are child elements to a media object element. The “timerevent” value is used to detect an interrupt included with the parent media object.
The foregoing is an example of a portion of a source code file according to the present invention which utilizes the above-described <event> and <action> elements:
<par>
<video src=“Video 2 .avi” Id=“Video 2 ”
status=“deactivate”/>
<Img src=“Image 1 .gif”>
<event source-event=“leftmouseclick”/>
<action dest=“Video 2 ”
attribute=“status”
value=“activate”/>
</event>
</img>
</par>
The <video> element of the above source code is assigned an Id “Video 2 ” and a source “Video 2 .avi”. Moreover, the <video> element is assigned a “deactivate” value to its “status” attribute. Accordingly, upon encountering the <video> element, a web browser executing the source file does not play the referenced video file “Video 2 .avi ”. The next statement in the source code is an <img> element having a source file “Image 1 .gif”. Accordingly, as shown in FIG. 8 a , the referenced image “Image 1 .gif” is displayed by the web browser.
An <event> element is defined as a child element to the above-described <img> element. Accordingly, the <event> element is evaluated during display of the referenced image. As shown above, the assigned value of the “source-event” attribute is “leftmouseclick”. Based on the above discussion, a “leftmouseclick” event is deemed to be captured upon detection of a press and release of the left mouse button of mouse 5 while a mouse pointer is within the display area of Image 1 , as shown in FIG. 8 a . As also described above, in a case that a “coord” attribute is also defined in the <image> element, the pointer must be located within the specified coordinates for the event to be deemed captured.
Upon capture of the specified event, the listed <action> element is processed. As shown, the <action> element contains attributes which indicate that the “status” attribute of the <video> element indicated by the Id “Video 2 ” is to be changed to “activate”. Accordingly, and as shown in FIG. 8 b , “Video 2 .avi” begins to play.
V. The <Condition> Element
The <condition> element can be used to test for the existence of a particular situation so as to allow selective performance of an action based on whether or not the situation exists.
The <condition> element includes an “id” and a “skip-content” attribute as defined by the SMIL specification. The <condition> element also includes a “dest” attribute, which refers to an Id of a particular element to be tested, an “attribute” attribute, which refers to a particular attribute of the particular element to be test, and a “value” attribute, which refers to a value to be compared with the value of the particular attribute to be tested. In operation, if the value indicated by the “value” attribute of the <condition> element is equal to the value of the referenced attribute, the condition is deemed true and a next line of source code is executed.
The following portion of source code is identical to that described above with respect to FIG. 8 a and FIG. 8 b , with the addition of a <condition> statement:
<par>
<video src=“Video 2 .avi” Id=“Video 2 ”
status=deactivate/>
<img src=“image 1 .gif”>
<event source-event=“leftmouseclick”/>
<condition dest=“Video 2 .avi”
attribute=“status” value=“activate”/>
<action dest=“Video 2 ”
attribute=“status”
value=“activate”/>
</event>
</img>
</par>
In the above example, the <condition> statement is evaluated after a “leftmouseclick” is detected within the display area of image 1 . In this regard, the <condition> statement evaluates whether the “status” attribute of the element indicated by the “Video 2 ” Id has the value “activate”. If not, the subsequent <action> statement is not processed, even though the <action> statement is not nested within the <condition> statement. Conversely, if the <condition> statement is evaluated as true, the <action> statement is processed.
According to the invention, the <event>, <condition> and <action> elements can also be used together so as to change an attribute of an object based on a state change of an object. For example, in a case that the <event . . . > element of the previous example was replaced with “<event>”, a browser encountering the replaced line would immediately evaluate the following <condition> element and execute or not execute the following <action> element based thereon.
VI. The <and-Condition> and <or-Condition> Elements
The <and-condition> element allows several conditions to be logically AND'd together. Specifically, the <and-condition> element can be used as follows to logically AND two conditions A and B:
<and-condition> <condition id=“A” . . . /> <condition id=“B” . . . /> </and-condition>
The <and-condition> element returns a TRUE value in a case that all <condition> elements nested therein evaluate to TRUE. The <or-condition> element follows a similar syntax as that described above with respect to the <and-condition> element, however, the <or-condition> element logically ORs any <condition> elements nested therein.
The <and-condition> and <or-condition> elements can be nested. In this regard, the following portion of source code performs the function ((C or D) and (E and (F or G))):
<and-condition>
<or-condition>
<condition id=“C” . . . />
<condition id=“D” . . . />
</or-condition>
<and-condition>
<condition id=“E” . . . />
<or-condition>
<condition id=“F” . . . />
<condition id=“G” . . . />
</or-condition>
</and-condition>
</and-condition>
Both the <and-condition> and the <or-condition> elements contain the attributes “id” and “skip-content” as defined by the SMIL specification. Also, as described above, both elements can contain <and-condition>, <or-condition> and <condition> child elements.
In a case that either an <and-condition> or an <or-condition> element are evaluated as true, a subsequent <action> statement is processed, as described above with respect to <condition> element.
VII. The <Switch> Element
As described above, the <switch> element as presently defined by the SMIL 1.0 specification does not provide for switching between child elements based on attributes other than system-based attributes. According to the present invention, however, the <switch> element includes test attributes which allow testing of attributes of other elements defined in a source code file.
The <switch> element according to the present invention includes a “id” and a “title” attribute, as defined by the SMIL 1.0 specification. The <switch> element also includes a “selection” attribute, which can be changed during source file execution using the elements described herein. The following source code is an example of such a use.
<image src=“selection.gif”>
<event source-event=“leftmouseclick” coord=“0%,
0%, 50%, 100%”>
<action dest=“mySwitch”
attribute=“selection” value= “1”/>
</event>
<event source-event=“leftmouseclick” coord=“0%,
50%, 100%, 100%”>
<action dest=“mySwitch”
attribute=“selection” value=“2”/>
</event>
</image>
<switch id=“mySwitch”>
<video src=“myVideo1.mpg” test-
element=“mySwitch” test-attribute=“selection”
test-value=“1”/>
<video src=“myVideo2.mpg” test-
element=“mySwitch” test-attribute=“selection”
test-value=“2”/>
</switch>
According to the above code, a detection of a left mouse click at one portion of a browser display causes a value of the “selection” attribute of a <switch> element having the Id “mySwitch” to change to (or remain at) “1”. If the event is detected at another part of the display, the value changes to (or remains at) “2”.
Next, a first TRUE conditional statement nested in the <switch> element is processed, and the other is ignored. As shown, both statements nested in the <switch> statement are conditional media object statements by virtue of the attributes “test-element”, “test-attribute” and “test-value” explained above. Accordingly, myVideo1.mpg is played in a case that the “selection” attribute of the <switch> element has a value of “1”, while myVideo2.mpg is played if the attribute has a value of “2”.
The foregoing example illustrates several advantages of the present invention. Among others, one advantage lies in the ability provided by the invention to use <par>, <seq> and media object element statements which are conditionally executed based on an evaluation of non-system attribute values.
While the present invention is described above with respect to what is currently considered its preferred embodiments, it is to be understood that the invention is not limited to that described above. To the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A set of XML-based markers includes an event marker indicating an event, a condition marker indicating a state of a first media object, and an action marker indicating a second media object, an attribute of the second media object, and a value of the attribute. The markers represent a function to assign the value to the attribute of the second media object if the event is detected and if the first media object possesses the indicated state. A set of XML-based markers representing media object elements. Each marker includes a test-element attribute for indicating a particular media object element, a test-attribute attribute for indicating an attribute of the particular element, and a test-value attribute for indicating a test value to compare with a value of the specified attribute. | 8 |
BACKGROUND AND SUMMARY
[0001] The present invention relates to actuators operated by fluid pressure, and more particularly to a manufacturing module system for having variants thereof with two and three stable positions.
[0002] Fluid-operated actuators, that is, actuators that are operated with fluid pressure are widely used. Some examples are hydraulic cylinders in excavators and pneumatic cylinders in production automation equipment. In transmissions for heavy trucks and buses, pneumatic actuators are often used for automation, fully or in part, of the gear shifting.
[0003] Simplified, a simple fluid-operated actuator is composed of a cylinder housing, at least one cover and a piston that is fixedly connected to a piston rod. The piston is located inside the cylinder housing and cover. Thereby two pressure chambers are created, one on each side of the piston. A sealing arrangement allows a difference in pressure between these chambers. By applying fluid pressure in either chamber, force is applied on the piston that will urge to move. The cylinder housing and cover allow axial motion of the piston and piston rod between two end positions. These end positions will be referred to as stable positions. They correspond to equilibrium positions when fluid pressure is applied in either chamber.
[0004] For special purposes, more complex fluid-operated actuators have been developed. More than two stable positions have been achieved by means of more chambers and additional coaxial pistons. These additional pistons have a limited axial motion possible relative to both the cylinder housing and the piston rod.
[0005] A typical transmission for a heavy truck is shown in EP1035357. In order to achieve a large number of useful gear ratios with a limited number of gearwheels, the transmission is composed of three main functional units; a splitter section 34, a main section 35 and a range section 38. The splitter section provides two possible paths of transmitting the power from an input shaft 2 to a countershaft 4. Which of these paths that is active is determined by a double-acting tooth clutch (“synchronised coupling”) 12. The main section 35 provides several possible paths of transmitting the power from the countershaft 4 to a main shaft (“intermediate shaft”) 3. A number of tooth clutches 18, 20 and 32 can be engaged, one at a time, to make these paths active. Finally, the range section 38 can be regarded as a two-speed gearbox that is connected in series with the main section 35. The range section has a speed reduction gear, normally referred to as low range, and a direct gear, high range, that has no speed change. The position of a tooth clutch sleeve 44 determines which range gear that is active.
[0006] In most heavy truck transmissions, the splitter section and the range section are operated by pneumatic actuators. Conventionally, the tooth clutch in the splitter section has two stable positions, one for each of said paths. Likewise, the range section tooth clutch conventionally has two stable positions, one for high range and one for low range. Thus, in the conventional case the splitter section and the range section can each be operated by a simple pneumatic actuator that has two stable positions.
[0007] In recent years, solutions have been presented that would make it advantageous in some cases to use a middle, neutral, position in the splitter section or the range section. EP1035357 presents a splitter section with a neutral position that is used to reduce the risk of damaging the transmission at some inappropriate shifts. However, such a device would not be necessary for some designs of gear lever and shift pattern for the main section. Neither would it be required for automated variants of the transmission in question.
[0008] Furthermore, EP1055845 presents a range section that has a neutral position. This is used to reduce the effort at manual main section shifts, and it enables the use of smaller and less costly tooth clutches. It would also facilitate the use of simple centrifugal clutches, like the one presented in US-2004/0262115, since the clutch does not need to be disengaged during a main section shift. However, the shift time might increase, and the use in automated variants can be questioned.
[0009] In conclusion, splitter sections and range sections with a neutral position may not be used in all variants of a heavy truck transmission family. In some cases, it would make sense to use the simpler conventional design with two stable positions and no neutral position.
[0010] So, there is a need for a way to enable variants with two or three stable positions of fluid-operated actuators in a cost-efficient way. According to an aspect of the present invention, substantially the same blank is used for the cylinder housings of the actuator variants with two and three stable positions. In a first embodiment the invention is characterized in that said blank comprises at least one opening for said cover and that it is identical for said variants of said two and three stable position actuator, and that the blank is at least prepared for the arrangement of:
a first pressure duct, a second pressure duct and a first cylinder diameter of said cylinder housing.
[0014] It can be noted that the cylinder housing in general is a large and fairly expensive part whose blank requires a complex and costly tool. The cylinder housing blank can be, for instance, cast, forged, extruded, pressed or injection moulded. The blank will be finished to a cylinder housing by means of operations like milling and honing of cylinder and sealing surfaces, drilling of access ducts to the pressure chambers, and making fastening arrangements for the cover. If the same blank can be used for different actuator variants, the costs for tooling can be reduced, and higher production volumes of the blank can be achieved. According to another embodiment of the invention it is also possible that at least one of said first and second pressure ducts and said first cylinder diameter are finally produced with same set of tools creating same dimensions for said at least one of said first and second pressure ducts and said first cylinder diameter respectively in both said two and three stable position variants. According to a further developed embodiment of the invention the same set of tools can be used in both said two and three stable position variants, thus creating same dimensions for said first and second pressure duct and said first cylinder diameter respectively for all variants.
[0015] In a preferred embodiment, the actuator is an integrated part of an actuator unit that comprise, for instance, sensors, other actuators and valves that control the flow of pressurised fluid to the pressure chambers. The cylinder housing is part of a large housing whose blank requires very high tooling costs. Thereby, it is of particular advantage to avoid variants of the blank.
[0016] In another preferred embodiment, the variant with three stable positions is designed with a main piston, which is fixedly attached to the piston rod, and a ring piston with limited axial motion relative to the main piston. There are three cylinder-piston system diameters, one small between said main and ring pistons, one larger for the main piston alone, and one even larger for the ring piston alone. This largest diameter is identical to the cylinder-piston diameter of the variant with two stable positions. This gives a compact design with substantially equal actuator strokes between the end positions for the variants with two and three stable positions.
[0017] In still another preferred embodiment, there is a ring-shaped protrusion in the cover for the variant with three stable positions. The inner periphery of this protrusion serves as the outer part of a cylinder-piston system for the main piston and one of the pressure chambers. A duct between the inner and outer peripheries form a part of the supply duct to said pressure chamber. The outer periphery of the protrusion also forms part of sealing devices between an intermediate chamber, said supply duct and the ambient air. With this design, the required different cylinder-piston diameters are achieved in a convenient way.
[0018] In yet another preferred embodiment, on said outer periphery between said supply duct and said intermediate chamber, the sealing device has a larger diameter than the cylinder-piston system diameter of the variant with two stable positions. Thereby, said intermediate chamber can have a breathing duct in the cylinder housing that will not risk damaging the sealing device of said large-diameter cylinder-piston system of said ring piston.
[0019] In a further preferred embodiment, the devices that guide and centre the axial motion of said ring piston are axially spaced apart. This will improve the stability of that motion.
[0020] In an additional preferred embodiment, the breathing duct for the intermediate chamber is located in the cover. Thereby, the cylinder housing can be the same for both two and three stable position variants.
[0021] In an alternative preferred embodiment, the breathing duct is located in the main piston and piston rod. The cylinder housing can be the same for both two and three stable position variants here, too. Moreover, if the main piston is attached to the piston rod with a hollow pin, that pin could be a part of the breathing duct.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will be exemplified by means of the enclosed drawings.
[0023] FIG. 1 shows a schematic longitudinal section of a typical fluid-operated actuator with two stable positions, which as such is an example of prior art, but which also is part of the inventive module system.
[0024] FIGS. 2 a , 2 b and 2 c show a schematic longitudinal section of a typical fluid-operated prior art actuator with three stable positions in each of these three stable positions.
[0025] FIG. 3 shows an embodiment of the invention with a ring-shaped protrusion on the cover.
[0026] FIG. 4 shows an embodiment of the invention where the ring piston has its guiding devices located at different axial positions and where there is an increased diameter for the sealing device between the intermediate chamber and the pressure duct to the left pressure chamber.
[0027] FIG. 5 shows an embodiment of the invention with modified ring piston and with breathing ducts for the intermediate chamber located in the cover and in the main piston and piston rod.
[0028] FIG. 6 shows an embodiment of the invention where the main piston is attached to the piston rod with a hollow pin that forms a part of the breathing duct for the intermediate chamber.
DETAILED DESCRIPTION
[0029] FIG. 1 shows a simplified longitudinal section of a fluid-operated actuator 101 with two stable positions, which actuator forms a part of the inventive module system and which as such can be regarded as conventional technique, comprising a cylinder housing 102 , piston 103 , piston rod 104 and cover 105 . The cylinder housing 102 and the cover 105 are axially connected in a not showed way. Thereby, the cylinder housing 102 , piston rod 104 and cover 105 will enclose a left pressure chamber 106 and a right pressure chamber 107 on either side of the piston 103 . The cylinder housing 102 has a left supply duct 108 and a right supply duct 109 that are in fluid connection with the left pressure chamber 106 and right pressure chamber 107 , respectively. Valves (not shown) connect the left supply duct 108 and right supply duct 109 to either a pressure supply or to an exhaust of ambient pressure.
[0030] In FIG. 1 the right supply duct 109 is connected to the pressure supply. Thereby, the right pressure chamber 107 is filled with pressurized fluid and a fluid pressure acts on the piston 103 . The left supply duct 108 is connected to the exhaust, and hence there is ambient pressure in the left pressure chamber 106 . So, the piston 103 and piston rod 104 are urged to move to the left. The leftwards motion is stopped when the left end stop abutment 103 a of the piston 103 comes into contact with the mating part of the cover 105 . This represents the left stable position of the actuator 101 . Similarly, if the left supply duct 108 were connected to the pressure supply and the right supply duct 109 were connected to the exhaust, then the piston 103 and piston rod 104 would be urged to the right. The right stable position would then be reached when the right end stop abutment 103 b of the piston 103 is in contact with the mating part of the cylinder housing 102 .
[0031] In order to prevent leakage between the pressure chambers and the surroundings, sealing devices are required. Sealing devices can be of any of different available types, as readily known by a person skilled in the art, for instance elastomeric lip seal type. Furthermore, for proper function the axially moving parts, as the piston 103 and piston rod 104 , need to be centred and kept substantially coaxial with the mating parts of the cylinder housing 102 and cover 105 . This is achieved by means of guiding devices that can be of various types, for instance polymeric guide bands or ball bushings, as would be known by a person skilled in the art. A sealing device may be integrated with a guiding device, but may also be separate. In case of separate, non-integrated, sealing and guiding devices, they may be located close to each other or wide apart. They may even act on different surfaces, as would be recognized by a person skilled in the art. In the figures of the present document, the guiding devices are left out, for simplicity, or can be regarded as integrated in the sealing devices, where appropriate. So, in FIG. 1 there is a static sealing device 111 (e.g. o-ring or gasket) to prevent leakage between the cylinder housing 102 and cover 105 from the left pressure chamber 106 . Moreover, a left rod sealing device 112 prevents leakage between the cover 105 and piston rod 104 . Similarly, a right rod sealing device 113 prevents leakage between the cylinder housing 102 and piston rod 104 from the right pressure chamber 107 .
[0032] Finally, a piston sealing device 114 on the outer periphery of the piston 103 prevents leakage between the pressure chambers 106 and 107 .
[0033] In the right pressure chamber 107 , the fluid pressure acts on the piston 103 on an effective ring-shaped area defined by a cylinder-piston system diameter 103 d and a piston rod diameter 104 d . The actuator 101 has its piston rod 104 extending out of the cylinder housing 102 and cover 105 on both sides. This is a general case, designs where the piston rod extends out on one side, only, are also common. In such a case, the pressure in one of the pressure chambers will act on an effective circular area defined by the cylinder-piston system diameter 103 d.
[0034] FIGS. 2 a , 2 b and 2 c show a prior art fluid-operated actuator 210 with three stable positions. A cylinder housing 202 and a cover 205 enclose a main piston 203 , which is fixedly attached to a piston rod 204 , and a ring piston 221 . The cylinder housing 202 , main piston 203 and piston rod 204 enclose a left pressure chamber 206 where the pressure can act on the main piston 203 on an effective ring-shaped area defined by a main cylinder-piston system diameter 203 d and a piston rod diameter 204 d . The ring piston 221 is located on the outside of an axial extension 203 e of the main piston 203 . The axial motion of the ring piston 221 is limited by diameter steps in the cylinder housing 202 , main piston 203 and cover 205 . A right pressure chamber 207 is enclosed by the cylinder housing 202 , main piston 203 , piston rod 204 , cover 205 , and ring piston 221 . A pressure in the right pressure chamber 207 will act on the ring piston 221 on an effective ring-shaped area defined by an outer cylinder-piston system diameter 221 d (between the cylinder housing 202 and ring piston 221 ) and an inner cylinder-piston system diameter 221 i (between the ring piston 221 and axial extension 203 e of the main piston 203 ). Furthermore, a pressure in the right pressure chamber 207 will act on the main piston 203 on an effective ring-shaped area defined by the inner cylinder-piston system diameter 221 i and the main cylinder-piston system diameter 203 d and a piston rod diameter 204 d . Between the left pressure chamber 206 and the right pressure chamber 207 there is an intermediate pressure chamber 222 enclosed by the cylinder housing 202 , main piston 203 and ring piston 221 .
[0035] The left pressure chamber 206 is in fluid connection with a left supply duct 208 . Similarly, the right pressure chamber 207 is in fluid connection with a right supply duct 209 . Valves (not shown)’ connect the supply ducts 208 and 209 to either a pressure supply or to an exhaust of ambient pressure. The intermediate chamber 222 is not to be pressurized; hence a breathing duct 223 in the cylinder housing 202 connects it to ambient pressure.
[0036] A static sealing device 211 prevents leakage between the cylinder housing 202 and cover 205 from the left pressure chamber 206 . A left rod sealing device 212 prevents leakage between the cylinder housing 202 and piston rod 204 . Similarly, a right rod sealing device 213 prevents leakage between the cover 205 and piston rod 204 from the right pressure chamber 207 . A main piston sealing device 214 on the outer periphery of the main piston 203 prevents leakage between the left pressure chamber 206 and the intermediate chamber 222 at the main cylinder-piston system diameter 203 d . On the ring piston 221 there are two sealing devices that prevent leakage between the right pressure chamber 207 and the intermediate chamber 222 ; an inner ring piston sealing device 215 at the inner cylinder-piston system diameter 221 i and an outer ring piston sealing device 216 at the outer cylinder-piston system diameter 221 d.
[0037] In FIG. 2 a the left pressure chamber 206 is pressurized. The fluid pressure will urge the main piston 203 and piston rod 204 to the right. A right stable position is reached when the right end stop abutment 203 b of the main piston 203 is in contact with the mating part of the cover 205 .
[0038] In FIG. 2 b the right pressure chamber 207 is pressurized. The fluid pressure has urged the main piston 203 and piston rod 204 to a left stable where the left end stop abutment 203 a of the main piston 203 is in contact with the mating part of the cylinder housing 202 .
[0039] Finally, in FIG. 2 c both the left pressure camber 206 and right pressure chamber 207 are pressurized. A middle stable position is thereby reached when the ring piston 221 mates with a housing diameter step abutment 202 a in the cylinder housing 202 and with a piston diameter step abutment 203 a on the main piston 203 . The pressure in the left pressure chamber 206 , acting between diameters 203 d and 204 d , cannot alone push the main piston 203 to the right of this position, since that would lift the ring piston 221 off the housing diameter step abutment 202 a . That motion would be counteracted by the pressure in the right pressure chamber 207 that acts on the larger area between diameters 221 d and 204 d . Analogously, a motion of the main piston 203 to the left of the middle stable position would axially separate the ring piston 221 from the piston diameter step abutment 203 a . Thus, the pressure in the right pressure chamber 207 , acting between diameters 221 i and 204 d , cannot alone push the main piston 203 left of the middle stable position, since that would be counteracted by the left pressure chamber 206 whose pressure acts on the larger area between diameters 203 d and 204 d.
[0040] FIG. 3 shows a fluid-operated actuator 301 with three stable positions that is a variant of the plain actuator 101 in FIG. 1 , and thus part of the inventive module system. The cylinder housing 102 a has been modified with an additional breathing duct 323 for the intermediate chamber 322 . A cover 305 is fixedly attached to, mated against or, preferably, integral with a ring-shaped protrusion 305 p , whose inner periphery forms the cylinder-piston sealing diameter 303 d for the left pressure chamber 306 and main piston 303 with sealing device 314 . There is a cover supply duct 305 c in the cover 305 that provides a fluid connection between the left supply duct 108 and the left pressure chamber 306 . A cover abutment 305 a defines the middle stable position for a ring piston 321 . Leakage from the supply ducts 108 and 305 c are prevented by static sealing devices 111 and 111 a . The original cylinder-piston system diameter 103 d of the cylinder housing 102 serves in the variant 102 a as the sealing diameter for the static sealing device 111 a and as the cylinder-piston system diameter for the right pressure chamber 307 and outer sealing device 316 of the ring piston 321 . An inner sealing device 315 acts at cylinder-piston system diameter 321 i on an extension 303 e of the main piston 303 .
[0041] The difference between the original cylinder housing 102 of the plain actuator 101 and the cylinder housing 102 a is minimal. The breathing duct 323 for the intermediate chamber 322 has been added in the cylinder housing 102 a . Thereby, according to the invention, the same blank can be used for both cylinder housings 102 and 102 a . That will save tooling costs and facilitate the use of variants with two and three stable positions. That is especially the case when the cylinder housings 102 and 102 a are integrated with other parts, for instance a gear-shift control unit in a vehicle transmission, and, hence, would require complex and expensive tooling.
[0042] In the fluid-operated actuator 301 in FIG. 3 the cylinder-piston system diameter 103 d of the cylinder housing 102 a is used for the outer sealing device 316 of ring piston 321 as well as for the static sealing device 111 a . That may facilitate the manufacturing of the cylinder housing blank and the machining thereof. However, edges and burrs may occur where the breathing duct 323 ends at the cylinder-piston system diameter 103 d . This will pose a risk of damaging the outer sealing device 316 at the assembly, when the seal surface will pass over the end of the breathing duct 323 .
[0043] This is solved in the modified actuator 401 in FIG. 4 , which actuator also forms part of the inventive module system. There, the cylinder housing 102 b has a larger diameter 102 d where the breathing duct 423 for the intermediate chamber 422 ends. Hence, the risk of damaging the outer sealing device 316 at the assembly has been reduced greatly. Furthermore, the diameter 102 d could be used for both static sealing devices 111 and 111 b between the cover 405 and the cylinder housing 102 b . Then, the static sealing devices 111 and 111 b could be identical, which would save costs.
[0044] The ring piston 421 in the actuator 401 has been made wider than the corresponding ring piston 321 in FIG. 3 . Thereby, several advantages have been gained. Firstly, the large cylindrical surface with diameter 103 d in the cylinder housings 102 , 102 a and 102 b has been used, so the volume of the right pressure chamber 407 has been minimized, which may improve the dynamic performance of the actuator 401 . Secondly, it is no longer possible for the ring piston 421 to move that far to the right from the position in FIG. 4 that the inner sealing device 315 would no longer be in contact with the extension 303 e of the main piston 303 . Thirdly, the larger width of the ring piston 421 has made it possible to locate the sealing devices 315 and 316 , with integrated guiding devices, significantly axially apart from each other. That will improve the stability against misalignment for the ring piston 421 .
[0045] FIG. 5 shows a further modified actuator 501 of the variant with three stable positions. Actuator 501 also forms part of the inventive module system. There, the ring piston 521 has been extended axially inside the ring-shaped protrusion 505 p of the cover 505 . Thereby, the guiding devices are axially located even further apart than the actuator 401 in FIG. 4 . Moreover, the inner sealing and guiding device has been separated into a pure sealing device 515 s , acting on the inner cylinder-piston system diameter 321 i , and a guiding device 515 g that acts on the inside of the ring-shaped protrusion 505 p . The guiding device 515 g thereby acts on the main cylinder-piston system diameter 303 d , which is larger and possibly stiffer than for the corresponding sealing and guiding device 315 in FIG. 3 . Furthermore, with the ring piston 521 extending axially inside the ring-shaped protrusion 505 p , the sealing device 515 s will be in contact with the extension 503 e of the main piston 503 even for the most extreme relative positions of the main piston 503 and ring piston 521 .
[0046] FIG. 5 also shows two alternative breathing ducts for connecting the intermediate chamber 522 to ambient pressure. There is a cover breathing duct 523 c in the cover 505 and a piston rod breathing duct composed of a mainly radial duct 523 p in main piston 503 and a mainly axial duct 523 r in piston rod 504 . With any of these breathing ducts, the cylinder housing 102 , as a finished part, can be identical for actuator variants with two and three stable positions.
[0047] FIG. 6 shows another embodiment of a piston rod breathing duct in an actuator 601 of the variant with three stable positions, which actuator also forms part of the inventive module system. A substantially radial duct 623 p through the main piston 603 and piston rod 604 is formed, at least in part, by a hollow pin 630 that fixedly connects the main piston 603 to the piston rod 604 . The duct 623 p is in fluid connection with a substantially axial duct 623 r in the piston rod 604 . This fluid connection could be achieved with, e.g., a slot or a radial hole 630 h in the hollow pin 630 . A corresponding ring piston is here numbered 621 . Also in this case the cylinder housing 102 , as a finished part, can be identical for actuator variants with two and three stable positions.
[0048] According to further embodiments of the invention it is also possible that at least one of said first and second pressure ducts and said first cylinder diameter are finally produced with same set of tools creating same dimensions for said at least one of said first and second pressure ducts and said first cylinder diameter respectively in both said two and three stable position variants. In yet another embodiment of the invention all of said first and second pressure ducts and said first cylinder diameter are finally produced with different sets of tools creating different dimensions for said first and second pressure ducts and said first cylinder diameter respectively, when comparing said two stable position variants with said three stable position variants. However, said blank is still identical for said two and three stable position variants.
[0049] Finally, in a preferred embodiment the actuator is arranged for controlling a splitter or range section in a vehicle transmission.
[0050] Although the present invention has been set forth with a certain degree of particularity, it is understood that various modifications, substitutions and rearrangements of the components are possible without’ departing from the spirit and scope of the invention as hereinafter claimed. | In a module system for manufacturing variants of two and three stable positions fluid-operated actuators a cylinder housing of both variants of two and three stable positions actuators are manufactured from a blank, including at least one opening for the cover and being identical for the variants of said two and three stable position actuator, and being at least prepared for the arrangement of:
a first pressure duct, a second pressure duct, and a first cylinder diameter of the cylinder housing, thus decreasing manufacturing costs. | 8 |
[0001] This application is a priority based on prior application No. JP 04-52329, filed Nov. 10, 2004, in Japan.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a cell-phone terminal device, a mail processing method and a program for preparing and transmitting a mail of the multi-part format comprising an HTML part permitting image pasting into a main mail text, a text part and an attached file, and particularly, to a cell-phone terminal device, a mail processing method and a program for preparing a mail by selecting an image from an image contents application.
[0004] 2. Description of the Related Art
[0005] In the conventional cell-phone services, an image photographed by a camera can be transmitted by attaching to a text-format mail. Preparation of such a mail attached with an image is accomplished through selection of an image by opening an image content application such as a camera in menu selection on the mail preparing screen. There is provided a function of deploying a mail preparing screen of a mail automatically attached with a selected image and transmitting the thus prepared mail by pressing the software key for mail preparation for the image selected from the image content application.
[0006] More recently, a new cell-phone service has been started by adopting a W-CMDA method permitting high-speed transfer in a broadband. In this cell-phone service, an HTML mail is provided, which can be transmitted, in addition to attachment of a still image photographed by a camera or the like to the main mail text, by an inline attachment of pasting to the main mail text.
[0007] The HTML mail is described in the MIME format including an HTML part. In addition to simple attachment to the image mail, inline attachment of pasting the image into the HTML main mail text can be used.
[Patent Document 1] Japanese Unexamined Patent Application Publication No. 2001-325196 [Patent Document 2] Japanese Unexamined Patent Application Publication No. 2002-116975
SUMMARY OF THE INVENTION
[0010] In such a conventional HTML mail, however, the main mail text is prepared by opening an HTML mail preparing screen, and during or after preparation of the main mail text, an image content application such as a camera is opened from the menu to select an image. This results in a problem of much time and labor consumed for selection of the image to be pasted to the mail.
[0011] Particularly, when pasting an image during preparation of a mail, it is the usual practice to first determine for example a picture of a tour relevant to the subject, but to select an image to be actually pasted while watching pictures by opening the image content application. Since the image to be pasted is not selected in advance, preparation of the mail having the pasted image takes much time and labor.
[0012] A user may, when selecting a picture by opening an image content application, want to transmit a selected image simple-attached to the mail, not an image pasting to the main mail text. In such a case, on an HTML mail preparing screen, the image is automatically pasted onto a designated position upon completion of the image selection, and the inline attachment of the image cannot be changed to the simple attachment on the way of image selection.
[0013] The present invention has an object to provide a cell-phone terminal device, a mail processing method and a program which make it possible to easily carry out mail preparation through image pasting based on inline attachment to the HTML main mail text, not limited to the main preparation of simple attachment from a image contents application.
[0014] FIG. 1 is a descriptive view of the principle of the present invention. The present invention provides a cell-phone terminal device such as a cell phone. The cell-phone terminal device of the present invention comprises:
[0015] A mail processing unit (mail application) which prepares and transmits a mail of the multi-part format comprising a main mail text, any or both of an HTML part permitting pasting of an image and a text part comprising a main mail text alone, and selective attached files permitting attachment of an image;
[0016] an image processing unit (image contents processing unit) which selects an image for screen display and instructs preparation of the mail; and
[0017] a mail deploying unit which can deploy a mail preparing screen by performing an inline attachment of pasting the image to the main mail text upon receipt of the instruction to prepare a mail from the image processing unit.
[0018] Furthermore, the present invention has a storage unit which can register an inline attachment in preference which affords a preference to inline attachment or a simple attachment in preference which affords a preference to simple attachment of simply attaching the image to the main mail text; wherein:
[0019] When any of the inline attachment in preference and the simple attachment in preference is registered in advance, the mail deploying unit deploys a mail preparing screen corresponding to the details of preference of the prior registration.
[0020] In a deployed state of the mail preparing screen by the mail deploying unit, the mail processing unit makes it possible for a mail preparing screen of inline attachment to be switched over to a mail preparing screen of simple attachment upon selecting mail switching from the menu.
[0021] The present invention provides a mail preparing method of a cell-phone terminal device. More specifically, the present invention provides a mail processing method of a cell-phone terminal device which prepares and transmits an HTML mail of a multi-part format comprising a main mail text, any or both of an HTML part permitting pasting of an image and a text part comprising a main mail text alone, and selective attached piles permitting attachment of an image. This mail processing method comprises:
[0022] an image processing step which selects an image for screen display and instructs preparation of the mail; and
[0023] a mail deploying step which, upon receipt of an instruction to prepare a mail from the image processing step performs an inline attachment of pasting the image onto the main text for deployment of a mail preparing screen.
[0024] The present invention provides a program for mail processing which is to be executed by a computer of a cell-phone terminal device. The program of the present invention causes a computer of a cell-phone terminal device which prepares and transmits an HTML mail of a multi-part format comprising a main mail text, any or both of an HTML part permitting pasting of an image and a text part comprising a main mail text alone, and selective attached files permitting attachment of an image to execute:
[0025] an image processing step which selects an image for display on a screen and instructs preparation of the mail; and
[0026] a mail deploying step which, upon receipt of an instruction to prepare a mail from the image processing step, performs an inline attachment of pasting the image onto the main mail text for deployment of a mail preparing screen.
[0027] Details of the main processing method and the program of the cell-phone terminal device of the present invention are the same as those of the cell-phone terminal device of the present invention.
[0028] According to the present invention, it is possible to select, after selecting an image from an image contents application such as a camera, an image viewer or a browser, whether the selected image is to be pasted to the main mail text by inline attachment, or to be attached to the main mail text as a simple attachment, thus making it possible to achieve a higher degree of freedom for the selection by the user.
[0029] By registering automatic selection in advance by the user, it is possible to rapidly deploy a mail preparing screen of inline attachment or simple attachment set in preference without the need for a selecting operation, leading to an easier operation.
[0030] In the deployed state of the mail preparing screen of inline attachment, the screen is switched over to a mail preparing screen of simple attachment by selecting mail switching from the menu. In the deployed state of the mail preparing screen of simple attachment, in contrast, the screen is switched over to a mail preparing screen of inline attachment having an image pasted to the main mail text. Even after deploying the main screen, the user can freely select image pasting or image attachment.
[0031] The above and other objects, features, and advantages of the present invention will become more apparent from the following detailed description with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a descriptive view of a cell phone to which the HTML mail preparing processing of the present invention is applicable;
[0033] FIG. 2 is a block diagram of the functional configuration of the present invention in the cell phone shown in FIG. 1 ;
[0034] FIGS. 3A to 3 C are descriptive views of the MIME mail format of the multi-part format in the cell phone of the present invention;
[0035] FIG. 4 is a descriptive view of the mail deploying processing according to the present invention;
[0036] FIG. 5 is a flowchart of the mail deploying processing according to the present invention corresponding to FIG. 4 ;
[0037] FIG. 6 is a descriptive view of the mail deploying processing according to the present invention which dialog-selects the template;
[0038] FIGS. 7A and 7B are flowchart of the mail deploying processing according to the present invention corresponding to FIG. 6 ;
[0039] FIG. 8 is a descriptive view of the mail deploying processing according to the present invention which automatically selects an HTML mail and a text mail;
[0040] FIGS. 9A and 9B are flowcharts of the mail deploying processing according to the present invention corresponding to FIG. 8 ;
[0041] FIG. 10 is a descriptive view of the mail deploying processing according to the present invention capable of switching over the mail deploying screen between the HTML mail and the text mail;
[0042] FIGS. 11A and 11B are flowcharts of the mail deploying processing according to the present invention corresponding to FIG. 10 ; and
[0043] FIGS. 12A and 12B are flowcharts of the mail deploying processing according to the present invention, which automatically changes the image size on the mail preparing screen.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] FIG. 2 is a descriptive view illustrating a cell phone as an example of the cell-phone terminal device applied for the HTML mail preparing processing of the present invention. In FIG. 2 , a cell phone 10 comprises a display 12 and an operating key 14 . For example, a liquid crystal color display is used as a display 12 .
[0045] The operating keys 14 include “0” to “9” numbered keys, and in addition, above the numbered keys, physical keys 14 - 1 to 14 - 4 carrying out switch operations corresponding to software keys (hereinafter referred to as “soft keys”) displayed on the display 12 are arranged, with a decision key 15 provided in between. The decision key 15 is used for deciding operation by on and off, and has a seesaw structure
[0000] which permits scrolling selection of selection items of diialog on the display 12 by pressing the upper or lower portion thereof.
[0046] FIG. 2 is a block diagram of the functional configuration of the present invention in the cell phone shown in FIG. 1 . In FIG. 2 , the cell phone 10 has a platform 16 including an OS, a file system and the like, and a communication control unit 18 performing mobile communication of the W-CSMA method. The platform 16 comprises a display 12 , an operating key 14 , a microphone 20 , a speaker 22 , an RAM 24 , an ROM 26 and a radio unit 28 .
[0047] For the platform 16 , a telephone application 30 , a mail application 32 serving as a mail processing unit, and a browser 40 are provided via the communication control unit 18 . Also for the platform 16 , an image viewer 36 and a camera photographing processing unit 38 are provided. The image viewer 36 , the camera photographing unit 38 and the browser 40 form an image content processing unit 34 which functions as an image processing unit.
[0048] For the image content processing unit 334 and the mail application 32 , a mail deploying unit 42 is provided anew in the present invention.
[0049] The mail application 32 serving as a mail processing unit has a function of preparing and transmitting an HTML mail. The HTML mail is of the multi-part format composed of an HTML part and an image part, or an HTML part, an image part and a text part, in which an image can be pasted onto the main mail text of the HTML part. Not the HTML mail, but a mail having an attached image by simple attachment to the mail comprising a text part alone may be prepared and transmitted.
[0050] FIG. 3 is a descriptive view of the MIME mail format of the multi-part type in the cell phone 10 of the present invention. FIG. 3 (A) shows an MIME format without an attached file 44 - 1 , comprising a text part 46 and an HTML part 48 . The text part 46 stores only the main text, and the HTML part stores only the HTML main text in this case.
[0051] FIG. 3 (B) is a descriptive view of an HTML format 44 - 2 with an attached file. In this case, an attached file 50 is simple-attached to an MIME format 44 - 1 without an attached file, having a text part 46 and an HTML part 48 as in FIG. 2 (A). The attached file 50 is an image, having a simple-attached GIF file coded with base64.
[0052] FIG. 3 (C) is a descriptive view of an MIME format 44 - 3 with an inline image in which the image is pasted to the HTML main text. In this case, an inline file 52 is added to the MIME format 44 - 1 without an attached file including the same text part 46 and HTML part 48 as those shown in FIG. 3 (A).
[0053] The inline file 52 is an image file, and has a JPEG file coded with base64 attached thereto in this case. A script text 48 - 1 for pasting an image <img src =“cid: xxxx”> is described in the HTML part. A content ID “content-ID: <xxxx>” is described in the inline file 52 . Therefore, the image designated by the content ID is pasted at a position specified by the script text of the HTML part 48 .
[0054] Referring again to FIG. 2 , the image viewer 36 , the camera photographing processing unit 38 and the browser composing the image content processing unit 34 activates respective applications, and upon selecting an image therefrom and screen-displaying the image on the display 12 , display the soft key instructing preparation of a new HTML mail on the screen.
[0055] When the soft key is operated in a selected state of an image by any of the applications of the image content processing unit 34 , the mail deploying unit 42 first displays a dialog for selecting the inline attachment of pasting the image onto the main mail text or the simple attachment of attaching the image to the main mail text. For the displayed dialog, the mail preparing screen in which the selected image is pasted is deployed by the mail application when inline attachment is selected. When simple attachment is selected, the mail preparing screen in which the selected image is simple-attached is deployed in the mail application 32 .
[0056] FIG. 4 is a descriptive view of the mail deployment processing by the mail deploying unit 42 shown in FIG. 2 . In FIG. 3 , a selected image 56 to be used for the mail is determined, as shown in the image selecting screen 58 , by activating, for example, the image viewer 36 shown in FIG. 2 . At right bottom of the image selecting screen 58 deployed by the image viewer 36 , the soft key 60 for preparing a mail are displayed. As the soft keys, apart from the soft key 60 for mail preparation, the soft key for menu and the soft key for compiling are displayed.
[0057] The soft key 60 corresponds to the physical key 14 - 4 of the cell phone 10 . When it is desired to prepare a mail by using a selected image 56 of such an image selecting screen 58 , the soft key 10 is operated. More specifically, the physical key 14 - 4 shown in FIG. 1 corresponding to the soft key 60 is operated. By the application of this soft key 60 , the dialog 62 indicated by an arrow is displayed.
[0058] A message “Is it to be pasted in the main text?” is displayed for selection on the dialog 62 , with an inline attachment selection window 64 having a heading “Yes” and a simple attachment selection window 66 having a heading “No” are displayed thereunder. The dialog 62 is currently in the state of selection of the inline attachment selection window 64 . By pressing the definite key 15 of the cell phone 10 shown in FIG. 1 in this state, the HTML mail preparing screen 68 shown at left bottom is opened, and at the same time, the selected image 56 is pasted in the main mail text of the HTML mail preparing screen 68 .
[0059] On the other hand, when the simple attachment selection window 66 is selected by the seesaw operation by pressing the underside of the decision key 15 shown in FIG. 2 for the dialog 62 , and the decision key 15 is pressed down, the text mail preparing screen 70 shown at right bottom is displayed.
[0060] The HTML mail preparing screen 68 corresponds to the MIME format 44 - 3 with an inline image shown in FIG. 3 (C), and the text mail preparing screen 70 corresponds to the MIME format 44 - 2 with an attached file shown in FIG. 3 (B).
[0061] In the cell phone of the present invention, as described above, in the attached state of any of the applications provided in the image content processing unit 34 such as an image viewer 36 , a camera photographing processing unit 38 and a browser 40 , the display 62 is displayed by pressing the soft key 60 after selecting an image to be used in the mail. Whether to paste the image to the main mail text or to attach the same to the main mail text is selected from the dialog 62 . When this selection becomes definitive, the HTML mail preparing screen 68 is displayed in the state having the selected image 56 pasted thereto. After the decision of the pasted image, the user can prepare the main mail text and transmit the same.
[0062] On the other hand, when the simple attachment of the image is selected, the text mail preparing screen is opened. At this stage of operation, the selected image is already in the simple-attached state, and after determination of image attachment, a main mail text can be prepared and transmitted.
[0063] In the mail preparing processing shown in FIG. 4 , it is possible to select and deploy the HTML mail preparing screen 68 or the text mail preparing screen 70 and deploy the same by use of the soft key. For this purpose, it is necessary to provide two soft keys for NTML mail and for text mail on the image selecting screen 58 . Since the soft keys which can be used in a cell phone are limited in number, for the image selecting screen 58 in the present invention, only one soft key 60 is provided for mail preparation. The number of soft keys used is reduced by causing the dialog 62 opened by pressing the soft key 60 to accomplish selection between HTML mail and text mail.
[0064] When the HTML mail preparing screen 68 is opened in FIG. 4 , the selected image 56 is pasted at a position specified in the main mail text. If the main mail text does not contain a specification of a pasting position, the image is pasted last.
[0065] FIG. 5 is a flowchart of the mail deploying processing according to the present invention corresponding to FIG. 4 . In FIG. 5 , in a state in which the image processing application is activated in step S 1 , an image to be used for the mail is selected nd displayed in step S 2 . Then in step S 3 , is checked whether or not the mail preparing soft key 60 has been pressed down.
[0066] Upon determining pressing of the spot key 60 for mail preparation, the process advances to step S 4 to display the selection dialog between HTML mail and text mail. Upon display of this dialog, if the selection of HTML mail is determined in step S 5 , the process goes to step S 6 : an image to be pasted in the HTML mail is designated and the mail application 32 is activated. The activated mail application 32 displays a preparing screen of the HTML mail in which an image has been pasted in step S 7 . In step S 8 , a transmitting processing is carried out after preparation of the main text of the HTML mail.
[0067] On the other hand, when text mail is selected in step S 4 , the process advances from step S 5 to step S 9 in which selection of the text mail is determined. In step S 10 , a simple-attached image to the text mail is specified, and the mail application is activated. In step S 11 , a mail preparing screen of a text mail having the image attached thereto is displayed. In step S 12 , a text mail main text is prepared, and transmitted.
[0068] When a canceling operation is carried out in the dialog for image selection, display of the dialog is cancelled in step S 13 , and the process returns to selection display of the image in step S 2 .
[0069] FIG. 6 is a descriptive view of the mail deploying processing according to the present invention for dialog-selecting a template. In the mail deploying processing shown in FIG. 6 , upon deciding a selected image 56 through image selection on the image selecting screen 58 , the dialog 62 is displayed by operating the soft key 60 . In this embodiment, a template selecting window 72 is newly provided in addition to the inline attachment selecting window 64 and the simple attachment selecting window 66 .
[0070] When the template selecting window 72 is selected through a selecting operation and a deciding operation by the use of a decision key 15 for the dialog 62 , and operated, an HTML template list 74 - 1 shown therebelow is displayed. The template list includes an HTML template list 74 - 1 and a text template 74 - 2 to permit selection of any of them by switching on the list screen.
[0071] Since the HTML template list 74 - 1 is currently displayed, when an appropriate one is selected from among these templates, an HTML mail preparing screen 68 in conformity to the contents of the template is deployed by the mail application 32 , and the selected image 56 is pasted at a position specified in the selected template.
[0072] When any of the templates is selected by displaying the text template list 74 - 2 , the text mail preparing screen 70 is displayed by the activation of the mail application 32 . In this case, the selected image 56 is simple-attached. When a position for pasting the image is not specified in the template selected from the HTML template list 74 - 1 , the image is pasted at the end.
[0073] FIG. 7 is a flowchart of the mail deploying processing in the present invention corresponding to FIG. 6 . In FIG. 7 , the application for image processing is activated in step S 1 , and an image to be used for a mail is selection-displayed in step S 2 . In step S 3 , the soft key 60 for mail preparation is pressed down. Then in step S 4 , selecting dialogs of the HTML mail, the text mail and the template are displayed.
[0074] When selection of the HTML mail is determined from the dialog in step S 5 thereafter, the process advances to step S 6 , in which the mail application is activated by specifying an image to be pasted in the HTML mail. In step S 7 , the preparing screen of the mail having the pasted image is displayed, and in step S 8 , the main text of the HTML mail is prepared and transmitted.
[0075] When template selection is determined in step S 9 , the template list is displayed in step S 10 . In this display of the template list, the HTML template list is first displayed, and as required, this can be switched over to display of the text template list. To simplify the description of the flowchart, a case where only the HTML template list is displayed is taken up.
[0076] When an arbitrary template is selected in this state of display of the HTML template list, the mail application 32 is activated by specifying an image to be pasted to the HTML mail and a template to be used in step S 11 . In step S 7 , the mail preparing screen of the selection template having the pasted image is displayed. In step S 8 , an HTML mail main text is prepared and transmitted.
[0077] When the text mail is selected in step S 12 , the mail application 32 is activated by specifying an attached image of the text mail in step S 13 , and thereafter in step S 14 , a preparing screen of a text mail having a simple-attached image is displayed, and in step S 15 , a text mail main text is prepared and transmitted.
[0078] FIG. 8 is a descriptive view of the mail deploying processing according to the present invention in which an HTML mail or a text mail is automatically selected. In FIG. 8 , prior to the processing of selecting an image to be used in the mail in the image selecting screen 58 of the image content application such as an image viewer, the user registers a preferential selection mode of the mail preparing screen using the image in advance. The preferential modes thus registered in advance include:
(1) HTML mail in preference (2) Template in preference (3) Text mail in preference (4) No priority
[0083] When setting of such a preferential mode for mail preparation is registered in advance, pressing of the soft key 60 of the image selecting screen 58 in which a selected image has been decided leads to determination of the HTML mail in preference 76 . The HTML mail preparing screen is automatically deployed without the necessity for selection by dialog display, and at the same time, the selected image 56 is pasted to the mail main text.
[0084] When the template in preference 78 based on a prior registration is determined, the HTML template list 74 is displayed, and by selecting any of the displayed templates, the HTML mail preparing screen 68 corresponding to the template is displayed.
[0085] When the text mail in preference 80 based on a prior registration is determined, the text mail preparing screen 70 is displayed. In the case of “no priority”, the dialog 62 is displayed as shown in FIG. 6 .
[0086] When “template in preference” 78 is registered in advance in this case, the HTML template list 74 - 1 is displayed. A text template list which can be switched over by the selecting operation of the template list may be provided so that the text mail preparing screen 70 is opened from the template also for the ext mail.
[0087] FIG. 9 is a flowchart of the mail deploying processing according to the present invention corresponding to FIG. 8 . In FIG. 9 , in step S 1 , the prior mode of the mail preparing screen is set in advance. This prior mode is any of the HTML mail in preference mode, the template in preference ode, the text mail in preference mode and the “no priority”, as shown in FIG. 8 .
[0088] When the preference mode of the mail preparing screen is registered in advance, in the step S 2 and subsequent steps, the image selection and display are carried out in step S 3 . When pressing of the mail preparing soft key 60 is determined in step S 4 , the dialog is displayed in the above-mentioned embodiments. In this embodiment, however, the dialog is not displayed, but the mail preparing screen is automatically deployed in accordance with the prior mode set in step S 1 .
[0089] More specifically, when the preference of the HTML mail is determined in step S 5 , the HTML mail preparing screen is deployed and the image is pasted in steps S 6 to S 8 . When the preference of template is determined in step S 9 , the template list is displayed in step S 10 . In step S 11 , after activating the mail application is activated for deploying the HTML mail preparing screen corresponding to the selected template list, processes of steps S 6 to S 8 are carried out.
[0090] Furthermore, when the preference of text mail is determined in step S 12 , the text mail preparing screen is displayed through processes of steps S 13 to S 14 , and the mail is prepared and transmitted with the selected image simple-attached.
[0091] In the flowchart of FIG. 9 , processing is omitted for cases without priority. In this case, the dialog is displayed. The HTML mail template or the text mail is selected from the dialog, and the image processed on the mail preparing screen and the mail main text is prepared and transmitted.
[0092] FIG. 10 is a descriptive view of the mail deploying processing according to the present invention in which switching is possible between the HTML mail and the text mail on the mail preparing screen. In the mail deploying processing shown in FIG. 10 , when the soft key 60 of the image selecting screen 58 is pressed down after deciding a selected image 56 used in the mail, the dialog is displayed. When the inline-attachment selection window 64 is selection-operated, the HTML mail preparing screen 68 is displayed, and the selected image 56 is pasted. When the simple-attachment selecting window 66 is selection-operated, the text mail preparing screen 70 is displayed, and the selected image 56 is switched over to simple attachment.
[0093] In this HTML mail preparing screen 68 , when the menu 82 - 1 is opened, a switching window 85 - 1 showing switching from inline attachment of pasting the image to the current main mail text to simple attachment is displayed in the menu screen. By selecting and operating the switching window 85 - 1 , the screen is switched over to the text mail preparing screen. In this case, the image is switched over from an image pasted to the main mail text to a simple-attached image.
[0094] Also for the text mail preparing screen 70 , when opening the menu screen 84 - 2 by operating the menu 82 - 2 , the switching window 85 - 2 for the HTML mail preparing screen 68 is displayed in it. Therefore, when the switching window 85 - 2 is selected and operated for the menu screen 84 - 2 , the screen is switched over to the HTML mail preparing screen 68 , and the selected image is pasted to the mail main text.
[0095] According to the embodiment shown in FIG. 10 , as described above, an image used for the mail is selected from the image content application. After selecting a mail preparing screen of any of an HTML mail with an pasted image or a text mail with a simple-attached image, the user can switch over the mail preparing screen between HTML mail and text mail as required, and thus can freely decide which of pasting of the image to the mail main text and simple attachment of the image is to be adopted during the mail preparing process.
[0096] FIG. 11 is a flowchart of the mail deploying processing according to the present invention corresponding to FIG. 10 . In the flowchart of FIG. 11 , determination of text mail switching in step S 8 and determination of switching of HTML mail in step S 13 are added, the other processes being the same as in the flowchart of FIG. 5 .
[0097] That is, when switching to text mail by the menu selection is determined in step S 8 in a state in which the HTML mail preparing screen with a pasted image is displayed in step S 7 , the process advances to step S 12 , and a preparing screen of a text mail having a simple-attached image is displayed. On the other hand, in the display state of the preparing screen of the text mail having a simple-attached image, when switching to HTML mail in step S 113 by menu selection is determined, the process goes to step S 7 , and the HTML mail preparing screen with an image pasted to the main mail text is displayed.
[0098] FIG. 12 is a flowchart of the mail deploying processing according to the present invention in which the size of an image selected in the mail preparing screen is automatically changed. In the mail deploying processing shown in FIG. 12 , the changing mode of the image size is set through a prior registration in step S 1 . More specifically, in a cell phone, the image displayed on the display is of the upright type QVGA (Quarter Video Graphics Arrays) having an image size of 320×240 dots.
[0099] Therefore, image portion wider than 240 dots are not necessary. For an image having a width over 240 dots, the size can be automatically change upon pasting to the main mail text of the HTML mail.
[0100] For automatic size changing processing in this case, the following modes can be registered in advance:
(1) Automatic image size reducing mode: Reducing the image to a width of 240 dots without changing the aspect ratio. (2) Automatic image cutting: As measured from the center of the image, each 120 dots to the right and left, 240 dots in total are cut without changing the aspect ratio. (3) No change.
[0104] In the case of no change, inquiry is required upon viewing the mail preparing screen by opening the dialog.
[0105] When the size changing function of image to be pasted to such an HTML mail has been registered in advance in step S 1 , and when selection of the HTML mail is determined in step S 6 , the changing processing to the image size previously registered in step S 8 is executed after activating the mail application in step S 7 , and in step S 9 , the size-changed image is pasted to the HTML mail and the preparing screen of the HTML mail is displayed in.
[0106] Except for these processes of steps S 1 and S 8 resulting from the image size changing mode, the processes are the same as in the flowchart of FIG. 4 .
[0107] The present invention provides a program used for mail preparing processing of a cell phone. This program has details of processing corresponding to the flowcharts of FIGS. 5, 7 , 9 , 11 and 12 .
[0108] The above-mentioned embodiments have covered a cell phone as the cell-phone terminal device. The present invention is applicable with no modification to relevant devices having mail applications corresponding to image pasting to the main mail text by an HTML mail such as a PDA, cell-phone terminal devices and the like.
[0109] In the above-mentioned embodiments, the mail preparing screen is displayed by main mail text having a pasted image or a mail having a simple-attached image, by displaying the dialog by pressing the soft key on the image selecting screen. The processing may be conducted so that the mail preparing screen is deployed from the sub-menu by means of pasting of image to the main mail text or simple attachment of an image to the main mail text, without displaying the dialog.
[0110] Furthermore, the present invention includes appropriate variations without impairing the object and advantages thereof, and is not restricted by numerical values shown in the above-mentioned embodiments.
[0111] The features of the present invention are as described in the following claims. | The mail application prepares and transmits a mail of the multi-part format comprising a main mail text, any or both of an HTML part permitting image pasting into the main mail text and a text part comprising only a main mail text, and a selective attached file permitting image attachment. The image contents processing unit selects an image for screen display and instructs preparation of a mail. The mail deploying unit 42 performs inline attachment of pasting an image to the main mail text upon receipt of an instruction to prepare a mail from the image contents processing unit 34, to make it possible to deploy a mail preparing screen. | 7 |
RELATED APPLICATION
This application claims priority to United Kingdom Patent Application No. 0910426.6 filed Jun. 17, 2009.
FIELD OF THE INVENTION
The present invention relates to monitoring of undesirable fluid ingress into subsea control modules.
BACKGROUND OF THE INVENTION
The hydraulic and electronic components of a subsea well, such as a hydrocarbon extraction well, are typically housed in a sealed vessel termed a subsea control module (SCM), located on a Christmas tree which is mounted on the sea bed above the well bore. An SCM is, typically filled with electrically insulating oil, to alleviate the need to design it to withstand high pressures and provide a first line of defense for the control system against the sea water environment. Typically, an SCM houses hydraulic manifolds, directional control valves and a subsea electronics module (SEM) which is itself a sealed unit. Thus, ingress of sea water resulting from a leak in the SCM housing, or ingress of hydraulic fluid from a small leak in the hydraulic system, will not in itself cause a malfunction of the control system. However, well operators, historically, have needed to know if there is a sea water leak since this will result in corrosion of the components in the SCM and possible failure of the system earlier than expected.
Existing arrangements consist of sets of metal electrode pairs mounted on an insulating panel or a metal frame with insulating inserts within the SCM, typically four, at equal intervals between the bottom and the top, each connected to an operational amplifier via a low voltage source and a series resistor, thus enabling the detection of the presence of the ingress of electrically conductive sea water, and, in a crude manner, the degree of displacement of the original oil filling. A typical application of the technique is illustrated diagrammatically in FIG. 1 in which a casing 1 of an SCM is shown as a transparent outline to show an electrically insulating panel 2 , mounted on the base 3 of the SCM, with pairs 4 of electrodes mounted on it. FIG. 2 shows circuitry 5 around an operational amplifier 6 , typically housed in the SEM within the SCM, to which the electrode pairs, are connected. Since the resistance across a pair of electrodes when in contact with sea water is very low, i.e. effectively a short circuit, they are shown in a block 7 as simple switch contacts 8 , 9 , 10 and 11 . One of the electrodes of each pair is connected to a voltage source V, typically 2 volts. The gain of the circuit 5 is the ratio of the resistance of a feedback resistor 12 across amplifier 6 and the effective resistance provided by input resistors 13 , 14 , 15 and 16 , each of which is in series with a respective one of the electrode pairs 4 and an input of amplifier 6 . Each of the input resistors is chosen to be of a resistance which is one quarter of that of the feedback resistor 12 . Thus, if there is water ingress into the casing 1 to the level of the lowest electrode pair, then the contacts 8 of the block 7 are effectively closed and the output 17 of the operational amplifier 6 will rise to ¼ of V. Likewise, further ingress of sea water reaching the remaining electrode pairs will result in the output 17 rising to ½ V, ¾ V and V respectively as the contacts 9 , 10 and 11 become effectively closed. Thus, a crude indication of the sea water ingress level is obtained by the electronic circuitry of the SEM reading the output 17 of the circuit 5 and transmitting the information topside, as a digitised version of the analogue signal, to the well operator, typically via the well umbilical, as part of the well housekeeping/diagnostic telemetry.
A problem with the existing technique is that it is unable to detect the ingress of hydraulic fluid into the SCM resulting from a leak in the hydraulic system in the SCM. Currently, a well operator has relied on hydraulic fluid leak detectors at the fluid source but these cannot confirm whether the leak is actually within the SCM. A further problem is that current flow through the electrode pairs results in their corrosion.
This invention enables the detection of both the ingress of sea water and hydraulic fluid in the SCM and provides a better indication of the degree of ingress, and reduces corrosion of the sensing electrodes.
Recent measurements have been made in the laboratory of the change in conductivity of the insulating oil in an SCM with contamination by the hydraulic fluid used for the well control system, which is a glycol based trans-aqua fluid. Results show that the conductivity of the contaminate in the oil is much less than that due to sea water and thus the existing contamination detection technique described before was not sensitive enough to be able to detect the ingress of trans-aqua fluids. Measurements have also shown that sea-water and trans-aqua hydraulic fluid (glycol) in insulating oil result in an immiscible fluid with both contaminants having a greater density than the oil. Thus, ingress of these contaminants displaces the transformer oil from the base of the SCM upwards. This invention provides an improved method for the monitoring of undesirable fluid ingress into an SCM to enable detection of the ingress of trans-aqua hydraulic fluid as well as sea water, whilst still providing a zoned measure of the degree of ingress and using a variety of methods of measurement which also reduces, substantially, corrosion of sensing electrode pairs.
SUMMARY OF THE INVENTION
According to the present invention from one aspect, there is provided a subsea control module having a casing inside which there is at least one pair of electrodes, there being electronic means connected with the electrodes of the or each pair for monitoring at least one electrical characteristic between the electrodes as a result of a fluid to which the electrodes are exposed, wherein the or each pair of electrodes comprises an array in which each electrode of the pair has finger portions interleaved with finger portions of the other electrode.
There could be at least one such array on a base of the casing. Preferably, there is a plurality of such arrays on the base of the casing, each of which; for example, is at or near a respective corner of the casing.
Preferably, there is such an array disposed on a side wall of the casing and covering a zone of the side wall. In this case, said array disposed on a side wall could cover a lower zone of the side wall, which array, for example, also covers a portion of the base of the casing. Said portion of the base of the casing could be at or near a corner of the casing.
Preferably, there is at least one further such array after said array disposed on a side wall of the casing, the or each further such array covering a respective zone up the side wall of the casing.
Said at least one electrical characteristic could comprise at least one of resistance and capacitance.
Preferably, the or each array is disposed on a mat of electrically insulating material. Preferably, said electronic means is provided by a subsea electronics module of the control module.
According to the present invention from another aspect, there is provided a subsea control module having a casing inside which there are a plurality of electrode pairs, there being electronic means connected with the electrodes of each pair for monitoring at least one electrical characteristic between the electrodes of the pair as a result of a fluid to which the electrodes are exposed, wherein said electrode pairs are disposed on a base of the casing.
Preferably, there are also a plurality of further electrode pairs, each of which covers a respective zone up a side wall of the casing, said electronic control means being connected with the electrodes of each of the further electrode pairs.
Preferably, for both aspects of the invention, the electronic means applies a signal between the electrodes of the or each pair of electrodes for selected periods of time at selected intervals.
A module according to the invention could include pressure sensing means for sensing the pressure of fluid in the casing for use in providing an indication of an increase in pressure due to fluid leakage within the casing.
A module according to the invention could include release means for releasing fluid from the casing in response to an increase in fluid pressure within the casing above a threshold.
There could be a flowmeter coupled with said release means for providing an indication of the release of fluid.
According to the present invention from a further aspect, there is provided a subsea control module having a casing inside which there is at least one electrode pair, there being electronic means connected with the electrodes of the or each pair for monitoring at least one electrical characteristic between the electrodes of the pair as a result of a fluid to which the electrodes are exposed, wherein said electronic means applies a signal between the electrodes of the or each pair of electrodes for selected periods of time at selected intervals.
According to the present invention from yet a further aspect, there is provided a subsea control module including pressure sensing means for sensing the pressure of fluid in a casing of the module for use in providing an indication of an increase in pressure due to fluid leakage within the casing.
According to the present invention from yet a further aspect, there is provided a subsea control module including release means for releasing fluid from a casing of the module in response to an increase in fluid pressure within the casing above a threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art system;
FIG. 2 illustrates circuitry for use with the system of FIG. 1 ;
FIG. 3 illustrates a system according to an embodiment of the invention;
FIGS. 4 , 5 and 6 illustrate forms of circuitry for use with the system of FIG. 3 ; and
FIG. 7 shows how pressure release means can be provided.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 3 , the individual electrode pairs of the system of FIG. 1 are replaced with electrode pairs, in each of which each electrode of the pair has finger portions interleaved or interlaced with finger portions of the other electrode to form an electrode array. The arrays are on an electrically insulating mat 18 , typically mounted on the internal base 3 of the casing 1 of the SCM and extending up a side wall of the SCM. Typically, each array is printed in copper on to a flexible printed wiring board and then gold plated for protection against corrosion, the board being mounted on a frame. The mat is divided into four sections, a lower section with a first electrode array 19 , including a horizontal portion 19 a on an electrically insulating mat on the base 3 at or near a corner of the casing 1 , and a vertical portion, with the latter rising to a quarter of the height of the SCM. The other three sections have respective electrode arrays 20 , 21 and 22 and cover half, three quarters and the top quarter of the height of the SCM, resulting in four vertical detection zones. Three other small horizontal gold plated electrode arrays with interleaved electrode pairs in the form of arrays 23 , 24 and 25 are also mounted on the SCM base 3 on electrically insulating mats, at or near each of the other three corners respectively. The electrode pairs of each of the detection zones and the three corner mats are connected to conditioning and detection circuitry housed in the SEM within the SCM. The vertical arrays 19 to 22 provide a measure of the quantity of ingress of undesirable fluid into the SCM, i.e. up to a quarter, half, three quarters and full displacement of the original insulating oil by sea-water or hydraulic fluid or both. The electrode array 19 by virtue of portion 19 a , and the electrode arrays 19 , 23 , 24 and 25 provide early detection of small quantities of sea-water and/or hydraulic fluid ingress even when the installation of the SCM is not truly vertical and are typically connected in parallel to the conditioning and detection circuitry and treated as one array.
FIG. 4 shows a block diagram of the conditioning and detection circuitry for the detection of fluid ingress using changes of resistance between the electrodes of the arrays. With the SCM filled with clean, uncontaminated oil, the resistance between the terminals of any of the electrode array 19 to 25 is very high, typically tens of megohms. With a small ingress of trans-aqua fluid, e.g. enough to cover arrays on the mats mounted on the SCM housing base, the resistance will fall typically to a few hundred kilohms. Ingress of sea water will also be detected by the system as only a small amount of ingress will cover at least one of the arrays of the mats on the SCM base and reduce the resistance between the electrodes of the array to only a few tens of ohms. The electrode pair on each mat, for example that of array 19 , is fed from a low voltage DC source 26 , typically 2 volts, via a current measuring resistor 27 and isolator switches 28 and 29 . The current flow through the electrode pair produces a voltage fed to a differential amplifier 30 , which produces an analogue output, converted to a digital message that is added to the well monitoring telemetry, fed topside, via the well umbilical. Although only one electrode array ( 19 ) is shown in FIG. 4 , the other arrays 20 - 25 are selected in turn by isolator switches similar to 29 of FIG. 4 . The connection of the low voltage source 26 to the arrays is controlled by the isolator switch 28 , which is operated by a digital control system also located typically in the SEM. The isolator switch 26 is closed only for a brief period, just long enough for the conditioning and detection circuitry to make a measurement, and repeated infrequently. Since the ingress of fluid is typically a slow process, measurement cycle time to measurement execution time ratios in excess of 10,000 to 1 are adequate. This reduces the corrosion of the electrode pairs on a mat due to electrolytic action to a negligible level. The process described above is repeated for the detection of sea-water ingress, by the same low voltage source 26 , connected to the arrays via a current measuring resistor 31 and an isolator switch 32 , producing an output to the well telemetry system from a differential amplifier 33 . Since the resistance between the electrode pairs on mats resulting from hydraulic fluid ingress is much greater (kilohms) than that resulting from sea water ingress (tens of ohms), the value of the measuring resistor 27 is much greater than the resistor 31 to produce a greater detection circuitry gain. Although the ingress of sea-water will swamp the hydraulic fluid ingress detection circuitry, this is of little concern since the detection of sea water ingress is itself sufficiently serious to warrant corrective action by the well operator.
FIG. 5 shows a block diagram of alternative conditioning and detection circuitry for the detection of fluid ingress utilising the change of capacitance between the electrode pair on any of the mats. This method can also be employed as an addition to the resistance measuring method, to provide greater confidence to the well operator that the detection of hydraulic fluid ingress, in particular, is accurate. A low voltage AC source is connected across two of the arms of a bridge circuit comprising three capacitors 35 , 36 and 37 and the electrode pair of array 19 , with two isolator switches 38 and 39 . The other two arms of the bridge are connected to AC amplification and detection circuitry 40 , to produce a DC output which is fed to the telemetry system of the well. The values of the capacitors 35 , 36 and 37 are chosen to match the capacitance between the electrode pair of array 19 when immersed in the oil within the SCM, so that the bridge circuit is balanced and there is no output to the circuitry 40 . Ingress of hydraulic fluid into the SCM results in a change of capacitance between the electrode pair of array 19 and thus an AC output from the bridge and into the amplification and detection circuitry 40 , which in turn produces an output to the well telemetry system. A variation of this method is to electronically adjust the value of the capacitor 36 , to maintain the balance of the bridge, i.e. zero output from the amplification and detection circuitry 40 , and use a measure of the bridge balancing capacitance as the source to the well telemetry system. Again, the arrays 19 , 23 , 24 and 25 are typically connected in parallel to the conditioning and detection circuitry and treated as one array and monitoring of other zones achieved by selecting the arrays 20 , 21 and 22 by additional isolator switches.
FIG. 6 shows a block diagram of an alternative method of detecting a change of capacitance due to undesirable fluid ingress. This method utilises the change of capacitance between the electrodes of array 19 , resulting from the change of dielectric constant of the fluid it is immersed in, when there is ingress of sea-water and/or hydraulic fluid. The change of capacitance results in a change of frequency of an oscillator 41 which can be measured and translated into a DC output using a frequency measuring circuit 42 , such as a discriminator and detector, as an output to the well telemetry system. The array 19 is selected by isolator switches 38 and 39 and different zones can be monitored by further isolator switches selecting the arrays. Again, the arrays 19 , 23 , 24 and 25 are typically connected in parallel to the conditioning and detection circuitry and treated as one array, and monitoring of other zones achieved by selecting the arrays 20 , 21 and 22 by additional isolator switches.
Leakage of hydraulic fluid in the SCM results in an increase in pressure within the outer casing 1 . This can be monitored, typically, by a diaphragm type pressure sensor 43 , mounted on the wall of the SCM outer casing 1 , and connected to the SEM within the SCM and its output also fed into the well monitoring telemetry system. The detection of hydraulic fluid ingress by the methods described above can thus be supported by a change of pressure, giving greater confidence of the detection process to the well operator.
An additional method of monitoring leakage of hydraulic fluid into the SCM, to provide even greater corroboration of the electrical detection method, is to it a differential pressure release valve and a flowmeter to the SCM casing as illustrated in FIG. 7 . The pressure release valve 44 , is set, typically, to open when the pressure in the SCM exceeds the external environmental pressure by 5 psi, resulting from a hydraulic fluid leak. When the valve 44 opens the flow of liquid from the SCM to the environment is detected by the flowmeter 45 , whose electrical output is connected to the well monitoring telemetry system, thus advising the well operator to a fluid leak.
ADVANTAGES OF USING THE INVENTION
The key advantage is that the invention permits detection of hydraulic fluid leakage within the SCM in the absence of sea water ingress, and provides an indication of the degree of leakage, neither of which are possible with existing SCM ingress fluid ingress detection systems. Furthermore the system detects the ingress of sea water as well. Corrosion of the detection electrodes is also virtually eliminated. | A subsea control module has a casing ( 1 ) inside which there is at least one pair of electrodes, there being electronic means ( 26 - 33 ) connected with the electrodes of the or each pair for monitoring at least one electrical characteristic between the electrodes as a result of a fluid to which the electrodes are exposed, the or each pair of electrodes comprising an array ( 19 ) in which each electrode of the pair has finger portions interleaved with finger portions of the other electrode. | 4 |
PRIORITY CLAIM
[0001] This application is a continuation-in-part of U.S. Ser. No. 12/428,811, entitled “Robust Downlink Speech and Noise Detector,” filed Apr. 23, 2009; and is a continuation-in-part of U.S. Ser. No. 11/644,414, entitled “Robust Noise Estimation,” filed Dec. 22, 2006; and claims the benefit of priority from U.S. Ser. No. 61/055,913 entitled “Ambient Noise Compensation System Robust to High Excitation Noise,” filed May 23, 2008, all of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This disclosure relates to ambient noise compensation, and more particularly to an ambient noise compensation system that prevents uncontrolled gain adjustments.
[0004] 2. Related Art
[0005] Some ambient noise estimation involves a form of noise smoothing that may track slowly varying signals. If an echo canceller is not successful in removing an echo entirely, this may not affect ambient noise estimation. Echo artifacts may be of short duration.
[0006] In some cases the excitation signal may be slowly varying. For example, when a call is made and received between two vehicles. One vehicle may be traveling on a concrete highway, perhaps it is a convertible. High levels of constant noise may mask or exist on portions of the excitation signal received and then played in the second car. This downlink noise may be known as an excitation noise. An echo canceller may reduce a portion of this noise, but if the true ambient noise in the enclosure is very low, then the residual noise may remain after an echo canceller processes. The signal may also dominate a microphone signal. Under these circumstances, the ambient noise may be overestimated. When this occurs, a feedback loop may be created where an increase in the gain of the excitation signal (or excitation noise) may cause an increase in the estimated ambient noise. This condition may cause a gain increase in the excitation signal (or excitation noise).
SUMMARY
[0007] A speech enhancement system controls the gain of an excitation signal to prevent uncontrolled gain adjustments. The system includes a first device that converts sound waves into operational signals. An ambient noise estimator is linked to the first device and an echo canceller. The ambient noise estimator estimates how loud a background noise would be near the first device prior to an echo cancellation. The system then compares the ambient noise estimate to a current ambient noise estimate near the first device to control a gain of an excitation signal.
[0008] Other systems, methods, features, and advantages will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The system may be better understood with reference to the following drawing and descriptions. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figure, like referenced numerals designate corresponding parts throughout the different views.
[0010] FIG. 1 is an ambient noise compensation system.
[0011] FIG. 2 is an excitation signal process.
[0012] FIG. 3 is a noise compensation process.
[0013] FIG. 4 illustrates contributions to noise received at an input.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Ambient noise compensation may ensure that audio played in an environment may be heard above the ambient noise within that environment. The signal that is played may be speech, music, or some other sound such as alerts, beeps, or tones. The signal may also be known as an excitation signal. Ambient noise level may be estimated by monitoring signal levels received at a microphone that is within an enclosure into which the excitation signal may be played. A microphone may pick up an ambient noise and an excitation signal. Some systems may include an echo canceller that reduces the contribution of the excitation signal to the microphone signal. The systems may estimate the ambient noise from the residual output of the microphone.
[0015] Some systems attempt to estimate a noise level near a device that converts sound waves into analog or digital signals (e.g., a microphone) prior to processing the signal through an echo canceller. The system may compare (e.g., through a comparator) this estimate to the current ambient noise estimate at the microphone, which may be measured after an echo cancellation. If the excitation noise played out or transmitted into the environment is expected to be of lower magnitude than the ambient noise (e.g., FIG. 4C ), then a feedback may not occur. If the excitation noise is expected to be of a higher magnitude than the ambient noise (e.g., FIG. 4A and Figure & 4 B: 405 vs. 415 ), then a feedback may occur. The feedback may depend on how much louder the excitation noise is and how much the excitation noise may be expected to be reduced by an echo canceller. For example, if the echo canceller may reduce a signal by 25 dB and the expected excitation noise is only 10 dB higher than the ambient noise estimate (e.g., 405 in FIG. 4C ), and then the system may be programmed to conclude that the noise estimated is the ambient cabin noise. The system programming may further conclude that the ambient cabin noise includes no (or little) contribution from the excitation signal. If an expected excitation noise is more than 20 dB or so than the ambient noise estimate (e.g., 405 in FIG. 4A ) then it is possible, even likely, for the system's programming to conclude that part or all of the noise estimated is the excitation noise and its signal level does not represent the a true ambient noise in the vehicle.
[0016] When a situation like the one described above occurs, a flag is raised or a status marker may be set to indicate that the excitation noise is too high. The system may determine that further increases in gain made to the excitation signal should not occur. In addition, if any gain currently being made to the excitation signal prior to the signals transmission to an enclosure (e.g., in a vehicle) through an amplifier/attenuator then the current gain may also be reduced until the flag or status indicator is cleared.
[0017] The programming may be integrated within or may be a unitary part of an ambient noise compensation system of FIG. 1 . A signal from some source may be transmitted or played out through a speaker into an acoustic environment and a receiver such as a microphone or transducer may be used to measure noise within that environment. Processing may be done on the input signal (e.g., microphone signal 200 ) and the result may be conveyed to a sink which may comprise a local or remote device or may comprise part of a local or remote device that receives data or a signal from another device. A source and a sink in a hands free phone system may be a far-end caller transceiver, for example.
[0018] In some systems, the ambient noise compensation is envisioned to lie within excitation signal processing 300 shown in FIG. 2 . In FIG. 2 , the excitation signal may undergo several operations before being transmitted or played out into an environment. It may be DC filtered and/or High-pass filtered and it may be analyzed for clipping and/or subject to other energy or power measurements or estimates, as at 310 .
[0019] In some processes, there may be voice and noise decisions made on the signal, as in 320 . These decisions may include those made in the systems and methods described in U.S. Ser. No. 12/428,811, entitled “Robust Downlink Speech and Noise Detector” filed Apr. 23, 2009, which is incorporated by reference. Some processes know when constant noise is transmitted or being played out. This may be derived from Noise Decision 380 described in the systems and methods described in the “Robust Downlink Speech and Noise Detector” patent application.
[0020] There may be other processes operating on the excitation signal, as at 330 . For example, the signal's bandwidth may be extended (BWE). Some systems extend bandwidth through the systems and methods described in Ser. No. 11/317,761, entitled “Bandwidth Extension of Narrowband Speech” filed Dec. 23, 2005, and/or Ser. No. 11/168,654, entitled “Frequency Extension of Harmonic Signals” filed Jun. 28, 2005, both of which is incorporated by reference. Some systems may compensate for frequency distortion through an equalizer (EQ). The signal's gain may then be modified in Noise Compensation 340 in relation to the ambient noise estimate from the microphone signal processing 200 of FIG. 2 . Some systems may modify gain through the systems and methods described in U.S. Ser. No. 11/130,080, entitled “Adaptive Gain Control System” filed May 16, 2005, which is incorporated by reference.
[0021] In some processes, the excitation signal's gain may be automatically or otherwise adjusted (in some applications, through the systems and methods described or to be described) and the resulting signal limited at 350 . In addition, the signal may be given as a reference to echo cancellation unit 360 which may then serve to inform the process of an expected level of the excitation noise.
[0022] In the noise compensation act 340 , a gain is applied at 345 (of FIG. 3 ) to the excitation signal that is transmitted or played out into the enclosure. To prevent a potential feedback loop, logic may determine whether the level of pseudo-constant noise on the excitation signal is significantly higher than the ambient noise in the enclosure. To accomplish this, the process may use an indicator of when noise is being played out, as in 341 . This indicator may be supplied by a voice activity detector or a noise activity detector 320 . The voice activity detector may include the systems and methods described in U.S. Ser. No. 11/953,629, entitled “Robust Voice Detector for Receive-Side Automatic Gain Control” filed Dec. 10, 2007, and/or Ser. No. 12/428,811, entitled “Robust Downlink Speech and Noise Detector” filed Apr. 23, 2009, both of which are incorporated by reference.
[0023] If a current excitation signal is not noise then the excitation signal may be adjusted using the current noise compensation gain value. If a current signal is noise, then its magnitude when converted by the microphone/transducer/receiver may be estimated at 342 . The estimate may use a room coupling factor that may exist in an acoustic echo canceller 360 . This room coupling factor may comprise a measured, estimated, and/or pre-determined value that represents the ratio of excitation signal magnitude to microphone signal magnitude when only excitation signal is playing out into the enclosure. The room coupling factor may be frequency dependent, or may be simplified into a reduced set of frequency bands, or may comprise an averaged value, for example. The room coupling factor may be multiplied by the current excitation signal (through a multiplier), which has been determined or designated to be noise, and the expected magnitude of the excitation noise at the microphone may be estimated.
[0024] Alternatively, the estimate may use a different coupling factor that may be resident to the acoustic echo canceller 360 . This alternative coupling factor may be an estimated, measured, or pre-determined value that represents the ratio of excitation signal magnitude to the error signal magnitude after a linear filtering device stage of the echo canceller 360 . The error coupling factor may be frequency dependent, or may be simplified into a reduced set of frequency bands, or may comprise an averaged value. The error coupling factor may be multiplied by the current excitation signal (through a multiplier), which has been determined to be noise, or by the excitation noise estimate, and the expected magnitude of the excitation noise at the microphone may be estimated.
[0025] The process may then determine whether an expected level of excitation noise as measured at the microphone is too high. At 344 the expected excitation noise level at the microphone at 342 may be compared to a microphone noise estimate (such as described in the systems and methods of U.S. Ser. No. 11/644,414 entitled “Robust Noise Estimation,” which is incorporated by reference) that may be completed after the acoustic echo cancellation. If an expected excitation noise level is at or below the microphone noise level, then the process may determine that the ambient noise being measured has no contribution from the excitation signal and may be used to drive the noise compensation gain parameter applied at 345 . If however the expected excitation noise level exceeds the ambient noise level, then the process may determine that a significant portion of raw microphone signal comes is originating from the excitation signal. The outcomes of these occurrences may not occur frequently because the linear filter that may interface or may be a unitary part of the echo canceller may reduce or effectively remove the contribution of the excitation noise, leaving a truer estimate of the ambient noise. If the expected excitation noise level is higher than the ambient noise estimate by a predetermined level (e.g., an amount that exceeds the limits of the linear filter), then the ambient noise estimate may be contaminated by the excitation noise. To be conservative some systems apply a predetermined threshold, such as about 20 dB, for example. So, if the expected excitation noise level is more than the predetermined threshold (e.g., 20 dB) above the ambient noise estimate, a flag or status marker may be set at 344 to indicate that the excitation noise is too high. The contribution of the excitation to the estimated ambient noise may also be made more directly using the error coupling factor, described above.
[0026] If an excitation noise level is too high then the noise compensation gain that is being applied to the excitation signal may be reduced at 343 to prevent a feedback loop. Alternatively, further increases in noise compensation gain may simply be stopped while this flag is set (e.g., or not cleared). This prevention of gain increase or actual gain reduction may be accomplished several ways, each of which may be expected to similarly prevent the feedback loop.
[0027] The methods and descriptions of FIGS. 1-3 may be encoded in a signal bearing medium, a computer readable storage medium such as a memory that may comprise unitary or separate logic, programmed within a device such as one or more integrated circuits, or processed by a controller or a computer. If the methods are performed by software, the software or logic may reside in a memory resident to or interfaced to one or more processors or controllers, a wireless communication interface, a wireless system, an entertainment and/or comfort controller of a vehicle or types of non-volatile or volatile memory remote from or resident to a speech enhancement system. The memory may retain an ordered listing of executable instructions for implementing logical functions. A logical function may be implemented through digital circuitry, through source code, through analog circuitry, or through an analog source such through an analog electrical, or audio signals. The software may be embodied in any computer-readable medium or signal-bearing medium, for use by, or in connection with an instruction executable system, apparatus, device, resident to a hands-free system or communication system or audio system and/or may be part of a vehicle. In alternative systems the computer-readable media component may include a firmware component that is implemented as a permanent memory module such as ROM. The firmware may programmed and tested like software, and may be distributed with a processor or controller. Firmware may be implemented to coordinate operations of the processor or controller and contains programming constructs used to perform such operations. Such systems may further include an input and output interface that may communicate with an automotive or wireless communication bus through any hardwired or wireless automotive communication protocol or other hardwired or wireless communication protocols.
[0028] A computer-readable medium, machine-readable medium, propagated-signal medium, and/or signal-bearing medium may comprise any medium that includes, stores, communicates, propagates, or transports software for use by or in connection with an instruction executable system, apparatus, or device. The machine-readable medium may selectively be, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. A non-exhaustive list of examples of a machine-readable medium would include: an electrical or tangible connection having one or more wires, a portable magnetic or optical disk, a volatile memory such as a Random Access Memory “RAM” (electronic), a Read-Only Memory “ROM,” an Erasable Programmable Read-Only Memory (EPROM or Flash memory), or an optical fiber. A machine-readable medium may also include a tangible medium upon which software is printed, as the software may be electronically stored as an image or in another format (e.g., through an optical scan), then compiled by a controller, and/or interpreted or otherwise processed. The processed medium may then be stored in a local or remote computer and/or machine memory.
[0029] Other alternate systems and methods may include combinations of some or all of the structure and functions described above or shown in one or more or each of the figures. These systems or methods are formed from any combination of structure and function described or illustrated within the figures or incorporated by reference. Some alternative systems interface or include the systems and methods described in Ser. No. 11/012,079, entitled “System for Limiting Receive Audio” filed Dec. 14, 2004 as the context dictates, which is incorporated by reference. Some alternative systems are compliant with one or more of the transceiver protocols may communicate with one or more in-vehicle displays, including touch sensitive displays. In-vehicle and out-of-vehicle wireless connectivity between the systems, the vehicle, and one or more wireless networks provide high speed connections that allow users to initiate or complete a communication or a transaction at any time within a stationary or moving vehicle. The wireless connections may provide access to, or transmit, static or dynamic content (live audio or video streams, for example). As used in the description and throughout the claims a singular reference of an element includes and encompasses plural references unless the context clearly dictates otherwise.
[0030] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. | A speech enhancement system controls the gain of an excitation signal to prevent uncontrolled gain adjustments. The system includes a first device that converts sound waves into operational signals. An ambient noise estimator is linked to the first device and an echo canceller. The ambient noise estimator estimates how loud a background noise would be near the first device before or after an echo cancellation. The system then compares the ambient noise estimate to a current ambient noise estimate near the first device to control a gain of an excitation signal. | 6 |
PRIORITY CLAIM
The present application is the National Stage (§371) of International Application No. PCT/EP2014/052404, filed Feb. 7, 2014, which claims priority from European Application No. 13154936.2, filed Feb. 12, 2013 incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to a process and system for dispensing hydrogen of more than one quality.
BACKGROUND OF THE INVENTION
In recent years, there has been a great deal of interest in the development of alternative energy sources, or energy carriers, such as hydrogen. Automobiles and other vehicles that use hydrogen as a fuel source have been developed, and methods for refueling these vehicles that can compete with gasoline fuelling stations on scale and/or cost have been designed and are being further developed.
Nowadays, there is a range of possible supply chains for hydrogen to refueling stations, including delivery routes (e.g. truck or pipeline) and forecourt production routes (e.g. hydrocarbon reforming or water electrolysis). Hydrogen of a purity high enough for fuel cell cars and up to the relevant standards is delivered (in gaseous form, commonly) to one or more storage tanks at the station, then compressed and stored in high pressure buffer tanks. It is then cooled and dispensed. A single dispenser may have more than one hose, providing hydrogen of different purities or at a different pressure. Depending on the source of the hydrogen, an initial purification step at the refueling station may be necessary in order to produce a hydrogen stream of sufficient purity for use in fuel cell cars.
Cars powered by proton exchange membrane (PEM) fuel cells depend on a supply of pure hydrogen. While some impurities (e.g. inert gases) are an issue in that their presence simply reduces the proportion of hydrogen present in the fuel and thus the efficiency of the car, other impurities have more serious consequences for the lifetime of the fuel cell. Cumulative and irreversible efficiency reduction through ‘poisoning’ of the catalyst (adsorption on to its surface, reducing the number of active sites), for example, is caused by even very small (ppm) amounts of sulphur.
Standards are under development which will specify hydrogen purity requirements at the refueling station. SAE J 2719, an international Standard which provides background information and a hydrogen fuel quality standard for commercial proton exchange membrane (PEM) fuel cell vehicles (‘Hydrogen fuel quality for fuel cell vehicles), serves as a starting point for ISO14687 (‘Hydrogen Fuel Product Specification for PEMFC Applications for Road Vehicles’), currently under development, as shown in the Table below. The specification from a commercial hydrogen provider (Linde) is also given for information. While the purity levels in the proposed standard are commensurate with an acceptable lifetime for fuel cells, clearly lower levels of impurities would be even more advantageous.
Contaminant
upper limits in
ppm unless spec-
SAE
ISO DIS
Linde
Limit of
ified otherwise
J 2719
14687-2
5.0
detection
Hydrogen fuel
99.99%
99.97%
100.00%
—
index
Total
100
300
—
—
allowable non-
H 2 , non-He
Water
—
—
—
Liquid water
5
5
5
1
Water vapour
Total
2
2
0.5
0.05
hydrocarbons
(C1 basis)
Oxygen
5
5
2
0.1
Inerts
Helium
TBD
300
—
10
Nitrogen
TBD
100
3
0.1
Argon
—
Carbon Dioxide
1
1
0.1
Carbon
0.2
0.2
0.1
Monoxide
Total sulphur
0.004
0.004
—
0.1
compounds
H2S
—
—
—
0.005
Formaldehyde
0.01
0.01
—
0.06
Formic Acid
0.2
0.2
—
0.2
Ammonia
0.1
0.1
—
0.1
Total
0.05
0.05
—
0.005-0.05
halogenated
compounds
Particulate
10 μm
—
—
0.1
(max. size)
Particulate
1 μg/l
1 mg/kg
—
0.005 mg/kg;
concentration
1 μg/l
Furthermore, it may be financially advantageous to reduce impurity levels. Calculations indicate that improving the CO levels in fuel from the ISO14687 proposed minimum of 0.2 ppm to 0.1 ppm, for example, may reduce the lifetime fuel cost by over 1%. This does not include potential reduced capital and maintenance costs which could also be exploited when purer hydrogen is used, resulting from use of lower catalyst loadings and higher current densities, combined with less frequent maintenance.
SUMMARY OF THE INVENTION
A new process has now been found that provides the possibility to clean a part of the hydrogen supplied at the refueling station by a purification process integrated into the system between delivery of hydrogen to the station and dispensation to customer vehicles.
Accordingly, the present invention provides a process for dispensing gaseous hydrogen at a refueling station comprising before dispensing dividing an initial hydrogen stream (delivered at a purity level meeting the relevant standard, e.g. for use in PEM fuel cells) into at least two streams, wherein at least one, but not all, of the streams is purified in a hydrogen purification step or steps.
The process of the invention allows sale of hydrogen of two qualities, a main grade and a premium grade with higher purity. In an embodiment of this process, all of the supplied hydrogen can be purified to obtain the hightest quality hydrogen.
A further embodiment of the invention relates to a system for performing the process of the invention. This is a system for dispensing gaseous hydrogen comprising in a subsequent line-up a combination of the following: a low pressure buffer tank (LPB), a compressor (Comp.), a high pressure buffer tank (HPB), a chiller (Ch.) and at least one final dispenser (disp.), wherein at least one of LPB, Comp. and HPB has two exits, one for separating a part of the hydrogen stream, the other for the remaining part of the hydrogen stream, and wherein the system further comprises a purifier, the inlet of the purifier being located in line after one exit of one of LPB, Comp. and HPB.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a shows a simplified schematic diagram of the hydrogen flow at a refueling station according to the prior art. Hydrogen of industrial purity flows from the input, possibly via a purifier (see FIG. 1 b ), (potentially via a compressor, Comp.1) to a low pressure buffer tank (200-350 bar), via a compressor (Comp.2) to a high pressure tank (up to 700 bar) and then through a chiller to the final dispenser. Details of mass flows and options such as multiple dispensers and storage tanks are omitted for the sake of simplicity.
FIG. 2 provides a schematic representation of a system according to the invention illustrating purification after the low pressure buffer tank.
FIG. 3 provides a schematic representation of a system according to the invention illustrating purification after the compression step.
FIG. 4 provides a schematic representation of a system according to the invention illustrating purification between high pressure buffer and dispenser.
FIG. 5 provides a schematic representation of a system according to the invention illustrating dispensing of high-purity hydrogen from a dedicated unit (the location of the purifier is not specific, may also be at different positions).
DETAILED DESCRIPTION OF THE INVENTION
The invention described herein provides a process for dispensing gaseous hydrogen in different qualities.
In a further embodiment of the invention, the process further comprising passing the initial stream of hydrogen from a supply (potentially via a compressor), into a low pressure buffer tank (200-350 bar), subsequently passing the stream via a compressor into a low pressure buffer tank (up to 700 bar), followed by passing the strea, via a chiller to a final dispenser, wherein the process further comprises a step in which a part of the hydrogen stream is separated and passed through a purifier which is located in line after the low pressure tank.
In a further embodiment of the invention, the process further comprising passing the initial stream of hydrogen from a supply (potentially via a compressor), into a low pressure buffer tank (200-350 bar), subsequently passing the stream via a compressor into a high pressure buffer tank (up to 700 bar), followed by passing the stream via a chiller to a final dispenser, wherein the process further comprises a step in which a part of the hydrogen stream is separated and passed through a purifier which is located in line after the low pressure tank.
In another embodiment of the invention, the part of the hydrogen that is separated in the process, is passed through a purifier before it is compressed, preferably using the same compressor as is used for compressing the remaining part of the hydrogen.
Preferably, a fraction of the initial hydrogen stream (delivered at a purity level meeting the relevant standard) of below 50%, in an embodiment of below 25% and in another embodiment of below 10% is taken from the bulk (low pressure) storage and purified further. The pure stream is then compressed, preferably using the same compressor as the rest of the hydrogen (but at a different time) and stored in a separate high pressure buffer storage ( FIG. 2 ). Preferably, the (second) compressor is designed appropriately and run in such a way that it runs on a schedule which maintains both buffer tanks full for as much of the time as possible, to make the best use of the equipment. From the high pressure storage the purified hydrogen stream passes through the same cooler and can be dispensed by the same dispenser as the main grade (remaining hydrogen stream); the customer can select the quality at the dispenser.
Preferably, the purification is carried out as close as possible to the dispensing point, i.e. after the (second) compression step. Thus, a further embodiment relates to a process, wherein the stream of hydrogen is first passed through the compressor and thereafter a part is separated for passing through a purifier. Preferably, the separated part of hydrogen is subsequently led into a second high pressure buffer tank followed by passing it into the same chiller as is used for chilling the remaining part of the hydrogen ( FIG. 3 ). In this process, it is highly preferred that chilling of the separated part of the hydrogen takes place at a different time than that of the remaining part of the hydrogen. Otherwise, the streams get mixed and only one grade of hydrogen can be dispensed. Preferably, the system runs on a schedule which maintains all buffer tanks full for as much of the time as possible.
Still closer to the dispensing point, the hydrogen stream may be separated and purified at an even later stage. Thus, in another embodiment, the stream of hydrogen is first passed through both the compressor and the high pressure buffer tank and thereafter a part is separated for passing it through a purifier ( FIG. 4 ).
In this process, it is highly preferred that chilling of the separated part of the hydrogen takes place at a different time than that of the remaining part of the hydrogen. Otherwise, the streams are mixed and only one grade of hydrogen can be dispensed. Preferably, the system runs on a schedule which maintains all buffer tanks full for as much of the time as possible.
In another embodiment of the invention, a separate dispenser is used for the purified hydrogen (see FIG. 5 ).
Purification of hydrogen according to the invention takes place using techniques known in the art, and preferably, wherein the purification comprises use of a membrane or a palladium catalyst. | The present invention provides a process for dispensing gaseous hydrogen at a refueling station comprising before dispensing dividing an initial hydrogen stream into at least two streams, wherein at least one of the streams is purified in a hydrogen purification step. In a further aspect the invention provides a system for dispensing gaseous hydrogen. | 5 |
BACKGROUND OF THE INVENTION
The present invention generally relates to pyridone substituted benzothiazole compounds that are adenosine receptor ligands. Specifically, the compounds of the present invention have a good affinity to the A 2A -receptor and a high selectivity to the A 1 - and A 3 receptors and, in addition, they have a good water solubility.
Adenosine modulates a wide range of physiological functions by interacting with specific cell surface receptors. The potential of adenosine receptors as drug targets was first reviewed in 1982. Adenosine is related both structurally and metabolically to the bioactive nucleotides adenosine triphosphate (ATP), adenosine diphosphate (ADP), adenosine monophosphate (AMP) and cyclic adenosine monophosphate (cAMP); to the biochemical methylating agent S-adenosyl-L-methione (SAM); and structurally to the coenzymes NAD, FAD and coenzym A; and to RNA. Together adenosine and these related compounds are important in the regulation of many aspects of cellular metabolism and in the modulation of different central nervous system activities.
The receptores for adenosine have been classified as A 1 , A 2A , A 2B and A 3 receptors, belonging to the family of G protein-coupled receptors. Activation of adenosine receptors by adenosine initiates signal transduction mechanism. These mechanisms are dependent on the receptor associated G protein. Each of the adenosine receptor subtyps has been classically characterised by the adenylate cyclase effector system, which utilises cAMP as a second messenger. The A 1 and A 3 receptors, coupled with G i proteins inhibit adenylate cyclase, leading to a decrease in cellular cAMP levels, while A 2A and A 2B receptors couple to G s proteins and activate adenylate cyclase, leading to an increase in cellular cAMP levels. It is known that the A 1 receptor system include the activation of phospholipase C and modulation of both potassium and calcium ion channels. The A 3 subtype, in addition to its association with adenylate cyclase, also stimulates phospholipase C and so activates calcium ion channels.
The A 1 receptor (326-328 amino acids) was cloned from various species (canine, human, rat, dog, chick, bovine, guinea-pig) with 90-95% sequence identify among the mammalian species. The A 2A receptor (409-412 amino acids) was cloned from canine, rat, human, guinea pig and mouse. The A 2B receptor (332 amino acids) was cloned from human and mouse with 45% homology of human A 2B with human A 1 and A 2A receptors. The A 3 receptor (317-320 amino acids) was cloned from human, rat, dog, rabbit and sheep.
The A 1 and A 2A receptor subtypes are proposed to play complementary roles in adenosine's regulation of the energy supply. Adenosine, which is a metabolic product of ATP, diffuses from the cell and acts locally to activate adenosine receptors to decrease the oxygen demand (A 1 ) or increase the oxygen supply (A 2A ) and so reinstate the balance of energy supply: demand within the tissue. The actions of both subtyps is to increase the amount of available oxygen to tissue and to protect cells against damage caused by a short term imbalance of oxygen. One of the important functions of endogenous adenosine is preventing damage during traumas such as hypoxia, ischaemia, hypotension and seizure activity.
Furthermore, it is known that the binding of the adenosine receptor agonist to mast cells expressing the rat A 3 receptor resulted in increased inositol triphosphate and intracellular calcium concentrations, which potentiated antigen induced secretion of inflammatory mediators. Therefore, the A 3 receptor plays a role in mediating asthmatic attacks and other allergic responses.
Adenosine is a neuromodulator, able to modulate many aspects of physiological brain function. Endogenous adenosine, a central link between energy metabolism and neuronal activity, varies according to behavioulal state and (patho)physiological conditions. Under conditions of increased demand and decreased availability of energy (such as hypoxia, hypoglycemia, and/or excessive neuronal activity), adenosine provides a powerful protective fedback mechanism. Interacting with adenosine receptors represents a promising target for therapeutic intervention in a number of neurological and psychiatric diseases such as epilepsy, sleep, movement disorders (Parkinson or Huntington's disease), Alzheimer's disease, depression, schizophrenia, or addiction. An increase in neurotransmitter release follows traumas such as hypoxia, ischaemia and seizures. These neurotransmitters are ultimately responsible for neural degeneration and neural death, which causes brain damage or death of the individual. The adenosine A 1 agonists which mimic the central inhibitory effects of adenosine may therefore be useful as neuroprotective agents. Adenosine has been proposed as an endogenous anticonvulsant agent, inhibiting glutamate release from excitory neurons and inhibiting neuronal firing. Adenosine agonists therefore may be used as antiepileptic agents. Adenosine antagonists stimulate the activity of the CNS and have proven to be effective as cognition enhancers. Selective A 2a antagonists have therapeutic potential in the treatment of various forms of dementia, for example in Alzheimer's disease, and of neurodegenerative disorders, e.g. stroke. Adenosine A 2a receptor antagonists modulate the activity of striatal GABAergic neurons and regulate smooth and well-coordinated movements, thus offering a potential therapy for Parkinsonian symptoms. Adenosine is also implicated in a number of physiological processes involved in sedation, hypnosis, schizophrenia, anxiety, pain, respiration, depression, and drug addiction (amphetamine, cocaine, opioids, ethanol, nicotine, cannabinoids). Drugs acting at adenosine receptors therefore have therapeutic potential as sedatives, muscle relaxants, antipsychotics, anxiolytics, analgesics, respiratory stimulants, antidepressants, and to treat drug abuse. They may also be used in the treatment of ADHD (attention deficit hyper-activity disorder).
An important role for adenosine in the cardiovascular system is as a cardioprotective agent. Levels of endogenous adenosine increase in response to ischaemia and hypoxia, and protect cardiac tissue during and after trauma (preconditioning). By acting at the A 1 receptor, adenosine A 1 agonists may protect against the injury caused by myocardial ischemia and reperfusion. The modulating influence of A 2 a receptors on adrenergic function may have implications for a variety of disorders such as coronary artery disease and heart failure. A 2a antagonists may be of therapeutic benefit in situations in which an enhanced antiadrenergic response is desirable, such as during acute myocardial ischemia. Selective antagonists at A 2a receptors may also enhance the effectiveness of adenosine in terminating supraventricula arrhytmias.
Adenosine modulates many aspects of renal function, including renin release, glomerular filtration rate and renal blood flow. Compounds which antagonise the renal affects of adenosine have potential as renal protective agents. Furthermore, adenosine A 3 and/or A 2B antagonists may be useful in the treatment of asthma and other allergic responses or and in the treatment of diabetes mellitus and obesity.
Numerous documents describe the current knowledge on adenosine receptors, for example the following publications:
Bioorganic & Medicinal Chemistry, 6, (1998), 619-641,
Bioorganic & Medicinal Chemistry, 6, (1998), 707-719,
J. Med. Chem., (1998), 41, 2835-2845,
J. Med. Chem., (1998), 41, 3186-3201,
J. Med. Chem., (1998), 41, 2126-2133,
J. Med. Chem., (1999), 42, 706-721,
J. Med. Chem., (1996), 39, 1164-1171,
Arch. Pharm. Med. Chem., 332,339-41, (1999),
Am. J. Physiol., 276, H1113-1116, (1999) or
Naunyn Schmied, Arch. Pharmacol. 362, 375-381, (2000).
SUMMARY OF THE INVENTION
The present invention relates to compounds of the formula
wherein R is as defined herewithin.
The present invention relates to compounds of formula I per se, the use of compounds of formula I and their pharmaceutically acceptable salts for the manufacture of medicaments for the treatment of diseases related to the adenosine A 2 receptor. The present invention further relates to the manufacture of compounds of formula I, medicaments based on compounds of formula I and their production, as well as the use of compounds of formula I in the control or prevention of illnesses based on the modulation of the adenosine system. These illnesses include Alzheimer's disease, Parkinson's disease, Huntington's disease, neuroprotection, schizophrenia, anxiety, pain, respiration deficits, depression, drug addiction, such as amphetamine, cocaine, opioids, ethanol, nicotine, cannabinoids, or against asthma, allergic responses, hypoxia, ischaemia, seizure and substance abuse. Furthermore, compounds of the present invention may be useful as sedatives, muscle relaxants, antipsychotics, antiepileptics, anticonvulsants and cardiaprotective agents for disorders such as coronary artery disease and heart failure. The most preferred indications in accordance with the present invention are those, which base on the A 2A receptor antagonistic activity and which include disorders of the central nervous system, for example the treatment or prevention of Alzheimer's disease, certain depressive disorders, drug addiction, neuroprotection and Parkinson's disease as well as ADHD.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to compounds of the formula
wherein
R is phenyl, pyridin-2-yl, —C(O)—O-lower alkyl, C(O)-lower alkyl, —C(O)-morpholinyl, —C(O)—NR′ 2 , —(CH 2 ) n —NR′ 2 or —(CH 2 ) n —O-lower alkyl and each R′ is independently hydrogen or lower alkyl;
and pharmaceutically acceptable salts thereof.
As used herein, the term “lower alkyl” denotes a saturated straight- or branched-chain alkyl group containing from 1 to 6 carbon atoms, for example, methyl, ethyl, propyl, isopropyl, n-butyl, i-butyl, 2-butyl, t-butyl and the like. Preferred lower alkyl groups are groups with 1-4 carbon atoms.
The term “pharmaceutically acceptable acid addition salts” embraces salts with inorganic and organic acids, such as hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, citric acid, formic acid, fumaric acid, maleic acid, acetic acid, succinic acid, tartaric acid, methane-sulfonic acid, p-toluenesulfonic acid and the like.
Preferred compounds of the present application are those, wherein R is phenyl, pyridin-2-yl, —C(O)—O—CH 2 CH 3 , —C(O)—CH 2 CH 3 , —C(O)-morpholinyl or —C(O)—N(CH 3 ) 2 , which are the following:
1-benzyl-2-oxo-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide,
[4-(4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl-carbamoyl)-2-oxo-2H-pyridin-1-yl]-acetic acid ethyl ester,
2-oxo-1-(2-oxo-butyl)-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide,
2-oxo-1-pyridin-2-yl-methyl-1,2-dihydio-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide,
1-(2-morpholin-4-yl-2-oxo-ethyl)-2-oxo-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide or
1-dimethylcarbamoylmethyl-2-oxo-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide.
The present compounds of formula I and their pharmaceutically acceptable salts can be prepared by methods known in the art, for example, by processes described below, which processes comprise
a) reacting a compound of formula
with a compound of formula
to yield a compound of formula
wherein R is phenyl, pyridyl, —C(O)O-lower alkyl or —C(O)-lower alkyl, or
b) reacting, a compound of formula
with a compound of formula
to yield a compound of formula
wherein R is —C(O)-morpholinyl, —(CH 2 ) n —O-lower alkyl, —(CH 2 ) n NR′ 2 or —C(O)NR′ 2 , and if desired, converting the compounds obtained into pharmaceutically acceptable acid addition salts.
Preparation of Compounds of Formula I Wherein R is Phenyl, Pyridyl, —C(O)O-Lower Alkyl or C(O)-Lower Alkyl
One method of preparation of compounds of formula I, wherein R is phenyl, pyridyl, —C(O)O-lower alkyl or C(O)-lower alkyl, is from a 2-methoxy-isonicotinamide intermediate of formula (6), as shown in reaction Schemes 1 and 2 below.
In this scheme the following abbreviation has been used:
HATU O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate
wherein R is phenyl, pyridyl, —C(O)O-lower alkyl or C(O)-lower alkyl.
Preparation of Compounds of Formula (2)
The starting 2-chloroisonicotinic acid or 2-bromoisonicotinic acid of formula (1) may be obtained commercially, for example from Maybridge Chemicals, or may be prepared according to methods well known in the art.
The 2-haloisonicotinic acid of formula (1) may be converted to the corresponding acyl halide derivative of formula (2) by reacting a compound of formula (1) with an excess of a halogenating agent, such as oxalyl chloride or oxalyl bromide, or thionyl chloride or thionyl bromide, using a catalyst such as N,N-dimethylformamide or pyridine, in an organic solvent, prefereably dichloromethane or dichloroethane, at room temperature for about 2-16 hours, preferably 16 hours. The product of formula (2) is isolated by conventional means, and preferably reacted in the next step without further purification.
Preparation of Compounds of Formula (4)
The starting 2-amino-benzothiazole compound of formula (3) may be prepared according to methods disclosed in EP 00113219.0.
The compounds of formula (4) are prepared by treating the 2-amino-benzothiazole compounds of formula (3) with a slight excess of the acyl halide compounds of formula (2) in a non-protic organic solvent, preferably a mixture of dichloromethane and tetrahydrofuran, containing a base, preferably N-ethyldiisopropylamine or triethylamine, at room temperature for 2-24 hours, preferably 24 hours. The product of formula (4) is isolated by conventional means, and preferably purified by means of chromatography or recrystallization.
Alternative Preparation of Compounds of Formula (4)
The compounds of formula (4) may also be prepared directly from compounds of formula (1). In this method, the compound of formula (1) is treated with a stoichiometric equivalent of a peptide-coupling reagent, preferably O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexatluorophosphate (HATU), in an ethereal solvent, preferably tetrahydrofuran, containing a base, preferably N-ethyldiisopropylamine, at room temperature for 30-90 minutes. This mixture is then treated with a 2-amino-benzothiazole compound of formula (3) in a solvent mixture, preferably a mixture of tetrahydrofuran, dioxane and N,N-dimethylformamide, at room temperature for 16-24 hours, preferably 24 hours. The product of formula (4) is isolated by conventional means, and preferably purified by means of chromatography or recrystallization.
Preparation of Compounds of Formula (6)
One method of preparation of a compound of formula (6) is by treatment of a compound of formula (4) with an excess of methanol, together with a metal-hydride base, preferably sodium hydride or potassium hydride. These reactions may be carried out in an ethereal solvent such as such as dioxane, tetrahydrofuran or 1,2-dimethoxyethane, preferably dioxane, optionally containing a co-solvent such as N,N-dimethylformamide, at a temperature between room temperature and the reflux temperature of the solvent, preferably about 100° C., for 2-72 hours, preferably 16 hours. The product of formula (6) is isolated by conventional means, and preferably purified by means of chromatography or recrystallization.
The compound of formula (6) is treated with an excess of an alkyl bromide of formula (7), which may be commercially available or may be prepared by methods well known in the art, according to the procedure of Synthetic Commun. 1999, 29, 4051-4059. These reactions may be carried out in a polar organic solvent such as acetonitrile or N,N-dimethylformamide, preferably N,N-dimethylformamide, at an elevated temperature, preferably the reflux temperature of the solvent used, for 2-18 hours, preferably 16 hours. The product of formula I, where R is phenyl, pyridyl, —C(O)O-lower alkyl or C(O)-lower alkyl, is isolated by conventional means, and preferably purified by means of chromatography or recrystallization.
Preparation of Compounds of Formula I, Wherein R is —C(O)-Morpholinyl, —(CH 2 ) n —NR′ 2 , —(CH 2 ) n —O-Lower Alkyl or C(O)NR′ 2
One method of preparation of compounds of formula I, wherein R is —C(O)-morpholinyl, —(CH 2 ) n —NR′ 2 , —(CH 2 ) n —O-lower alkyl or C(O)NR′ 2 , is from a 2-oxo-1,2-dihydro-pyridine-4-carboxylic acid amide intermediate of formula (8), the preparation of which is shown in reaction scheme 3 below.
wherein R is —C(O)-morpholinyl, —(CH 2 ) n —NR′ 2 , —(CH 2 ) n —O-lower alkyl, or —C(O)NR′ 2 and TMSI is iodotrimethylsilane.
Preparation of Compounds of Formula (8)
The compound of formula (6) is treated with an excess of iodotrimethylsilane in a halogenated organic solvent, preferably chloroform, at room temperature or above, preferably at the reflux temperature of the solvent, for 2-16 hours, preferably about 8 hours. The reaction mixture is then treated with an alcohol, preferably methanol, at room temperature or above, preferably at the reflux temperature of the solvent mixture, for 2-18 hours, preferably about 16 hours. The product of formula (8) is isolated by conventional means, and preferably purified by means of chromatography or recrystallization.
Preparation of Compounds of Formula I, Wherein R is —C(O)-Morpholinyl, —(CH 2 ) n —NR′ 2 , —(CH 2 ) n —O-Lower Alkyl or —C(O)NR′ 2
The compound of formula (8) is treated with an excess of an alkyl bromide of formula (7) or an alkyl chloride of formula (9), which may be commercially available or maybe prepared by methods well known in the art. In the case where an alkyl chloride of formula (9) is used, the reaction is performed in the presence of a stoichiometric equivalent of lithium bromide. These reactions may be carried out in a polar organic solvent such as dioxane or N,N-dimethylformamide, preferably a mixture of N,N-dimethylformamide and dioxane, at a temperature between room temperature and the reflux temperature of the solvent mixture used, for 2-18 hours, preferably 16 hours. The product of formula I is isolated by conventional means, and preferably purified by means of chromatography or recrystallization.
Isolation and Purification of the Compounds
Isolation and purification of the compounds and intermediates described herein can be effected, if desired, by any suitable separation or purification procedure such as, for example, filtration, extraction, crystallization, column chromatography, thin-layer chromatography, thick-layer chromatography, preparative low or high-pressure liquid chromatography or a combination of these procedures. Specific illustrations of suitable separation and isolation procedures can be had by reference to the Preparations and examples herein below. However, other equivalent separation or isolation procedures could, of course, also be used.
Salts of Compounds of Formula I
The compounds of formula I may be basic, for example in cases where the residue R contains a basic group such as an aliphatic or aromatic amine moiety. In such cases the compounds of formula I may be converted to a corresponding acid addition salt.
The conversion is accomplished by treatment with at least a stoichiometric amount of an appropriate acid, such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid and the like, and organic acids such as acetic acid, propionic acid, glycolic acid, pyruvic acid, oxalic acid, malic acid, malonic acid, succinic acid, maleic acid, fumaric acid, tartaric acid, citric acid, benzoic acid, cinnamic acid, mandelic acid, methanesulfonic acid, ethanesulfonic acid, p-toluenesulfonic acid, salicylic acid and the like. Typically, the free base is dissolved in an inert organic solvent such as diethyl ether, ethyl acetate, chloroform, ethanol or methanol and the like, and the acid added in a similar solvent. The temperature is maintained between 0° C. and 50° C. The resulting salt precipitates spontaneously or may be brought out of solution with a less polar solvent.
The acid addition salts of the basic compounds of formula I may be converted to the corresponding free bases by treatment with at least a stoichiometric equivalent of a suitable base such as sodium or potassium hydroxide, potassium carbonate, sodium bicarbonate, ammonia, and the like.
The compounds of formula I and their pharmaceutically usable addition salts possess valuable pharmacological properties. Specifically, it could be demonstrated that the compounds of the present invention are adenosine receptor ligands and possess a high affinity towards the adenosine A 2A receptor and a good selectivity towards A 1 receptor.
The compounds were investigated in accordance with the tests given hereinafter.
Human Adenosine A 1 Receptor
The human adenosine A 1 receptor was recombinantly expressed in chinese hamster ovary (CHO) cells using the semliki forest virus expression system. Cells were harvested, washed twice by centrifugation, homogenised and again washed by centrifugation. The final washed membrane pellet was suspended in a Tris (50 mM) buffer containing 120 mM NaCl, 5 mM KCl, 2 mM CaCl 2 and 10 mM MgCl 2 (pH 7.4) (buffer A). The [ 3 H]-DPCPX (([propyl- 3 H]8-cyclopentyl-1,3-dipropyxanthine); 0.6 nM) binding assay was carried out in 96-well plates in the presence of 2.5 μg of membrane protein, 0.5 mg of Ysi-poly-1-lysine SPA beads and 0.1 U adenosine deaminase in a final volume of 200 μl of buffer A. Non-specific binding was defined using xanthine amine congener (XAC; 2 μM). Compounds were tested at 10 concentrations from 10 μM-0.3 nM. All assays were conducted in duplicate and repeated at least two times. Assay plates were incubated for 1 hour at room temperature before centrifugation and then bound ligand determined using a Packard Topcount scintillation counter. IC 50 values were calculated using a non-linear curve fitting program and Ki values calculated using the Cheng-Prussoff equation.
Human Adenosine A 2A Receptor
The human adenosine A 2A receptor was recombinantly expressed in chinese hamster ovary (CHO) cells using the semliki forest virus expression system. Cells were harvested, washed twice by centrifugation, homogenised and again washed by centrifugation. The final washed membrane pellet was suspended in a Tris (50 mM) buffer containing 120 mM NaCl, 5 mM KCl, 2 mM CaCl 2 and 10 mM MgCl 2 (pH 7.4) (buffer A). The [ 3 H]-SCH-58261 (Dionisotti et al., 1997, Br J Pharmacol 121, 353; 1 nM) binding assay was carried out in 96-well plates in the presence of 2.5 μM of membrane protein, 0.5 mg of Ysi-poly-1-lysine SPA beads and 0.1 U adenosine deaminase in a final volume of 200 μl of buffer A. Non-specific binding was defined using xanthine amine congener (XAC; 2 μM). Compounds were tested at 10 concentrations from 10 μM-0.3 nM. All assays were conducted in duplicate and repeated at least two times. Assay plates were incubated for 1 hour at room temperature before centrifugation and then bound ligand determined using a Packard Topcount scintillation counter. IC 50 values were calculated using a non-linear curve fitting program and Ki values calculated using the Cheng-Prussoff equation.
It has been shown that compounds of formula I have a good affinity to the A 2A receptor and a high selectivity toward the A 1 receptor. The preferred compounds show a pKi>7.2, as described in the table below:
Example No.
hA 1 (pKi)
hA 2 (pKi)
1
5.90
8.67
2
5.18
8.19
3
5.18
8.24
4
5.18
8.10
5
5.18
7.23
6
5.18
7.30
The compounds of formula I and the pharmaceutically acceptable salts of the compounds of formula I can be used as medicaments, e.g. in the form of pharmaceutical preparations. The pharmaceutical preparations can be administered orally, e.g. in the form of tablets, coated tablets, dragees, hard and soft gelatine capsules, solutions, emulsions or suspensions. The administration can, however, also be effected rectally, e.g. in the form of suppositories, parenterally, e.g. in the form of injection solutions.
The compounds of formula I can he processed with pharmaceutically inert, inorganic or organic carriers for the production of pharmaceutical preparations. Lactose, corn starch or derivatives thereof, talc, stearic acids or its salts and the like can be used, for example, as such carriers for tablets, coated tablets, dragées and hard gelatine capsules. Suitable carriers for soft gelatine capsules are, for example, vegetable oils, waxes, fats, semi-solid and liquid polyols and the like. Depending on the nature of the active. Substance no carriers are, however, usually required in the case of soft gelatine capsules. Suitable carriers for the production of solutions and syrups are, for example, water, polyols, glycerol, vegetable oil and the like. Suitable carriers for suppositories are, for example, natural or hardened oils, waxes, fats, semi-liquid or liquid polyols and the like.
The pharmaceutical preparations can, moreover, contain preservatives, solubilizers, stabilizers, wetting agents, emulsifiers, sweeteners, colorants, flavorants, salts for varying the osmotic pressure, buffers, masking agents or antioxidants. They can also contain still other therapeutically valuable substances.
Medicaments containing a compound of formula I or a pharmaceutically acceptable salt thereof and a therapeutically inert carrier are also an object of the present invention, as is a process for their production, which comprises bringing one or more compounds of formula I and/or pharmaceutically acceptable acid addition salts and, if desired, one or more other therapeutically valuable substances into a galenical administration form together with one or more therapeutically inert carriers.
In accordance with the invention compounds of formula I as well as their pharmaceutically acceptable salts are useful in the control or prevention of illnesses based on the adenosine receptor antagonistic activity, such as Alzheimer's disease, Parkinson's disease, neuroprotection, schizophrenia, anxiety, pain, respiration deficits, depression, asthma, allergic responses, hypoxia, ischaemia, seizure and substance abuse. Furthermore, compounds of the present invention may be useful as sedatives, muscle relaxants, antipsychotics, antiepileptics, anticonvulsants and cardiaprotective agents and for the production of corresponding medicaments.
The most preferred indications in accordance with the present invention are those, which include disorders of the central nervous system, for example the treatment or prevention of certain depressive disorders, neuroprotection and Parkinson's disease.
The dosage can vary within wide limits and will, of course, have to be adjusted to the individual requirements in each particular case. In the case of oral administration the dosage for adults can vary from about 0.01 mg to about 1000 mg per day of a compound of formula I or of the corresponding amount of a pharmaceutically acceptable salt thereof. The daily dosage may be administered as single dose or in divided doses and, in addition, the upper limit can also be exceeded when this is found to be indicated.
Tablet Formulation (Wet Granulation)
mg/tablet
Item
Ingredients
5 mg
25 mg
100 mg
500 mg
1.
Compound of formula I
5
25
100
500
2
Lactose Anhydrous DTG
125
105
30
150
3.
Sta-Rx 1500
6
6
6
30
4.
Microcrystalline Cellulose
30
30
30
150
5.
Magnesium Stearate
1
1
1
1
Total
167
167
167
831
Manufacturing Procedure
1. Mix items 1, 2, 3 and 4 and granulate with purified water.
2. Dry the granules at 50° C.
3. Pass the granules through suitable milling equipment.
4. Add item 5 and mix for three minutes; compress on a suitable press.
Capsule Formulation
mg/capsule
Item
Ingredient
5 mg
25 mg
100 mg
500 mg
1.
Compound of formula I
5
25
100
500
2.
Hydrous Lactose
159
123
148
—
3.
Corn Starch
25
35
40
70
4.
Talc
10
15
10
25
5.
Magnesium Stearate
1
2
2
5
Total
200
200
300
600
Manufacturing Procedure
1. Mix items 1, 2 and 3 in a suitable mixer for 30 minutes.
2. Add items 4 and 5 and mix for 3 minutes.
3. Fill into a suitable capsule.
The following preparation and examples illustrate the invention but are not intended to limit its scope.
EXAMPLE 1
1-Benzyl-2-oxo-1,2-dihydro-pyridine-4-carboxylic Acid (4-Methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide
To a stirred solution of 85 mg (0.21 mmol) 2-methoxy-N-(4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-isonicotinamide in 2 ml acetonitrile were added 73 mg (0.43 mmol) sodium iodide and 0.05 ml (0.43 mmol) benzyl bromide. The mixture was heated at reflux for 16 h. The reaction mixture was then cooled to room temperature, diluted with ethyl acetate, and washed sequentially with water and saturated brine. The organic phase was then dried over sodium sulfate and concentrated in vacuo. Flash chromatography (2/1 EtOAc/toluene) afforded 32 mg (32%) 1-benzyl-2-oxo-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide as a yellow crystalline solid. ES-MS m/e (%)): 499 (M+Na + , 14), 477 (M+H + , 100).
In an analogous manner there were obtained:
EXAMPLE 2
[4-(4-Methoxy-7-morpholin-4-yl-benzothiazol-2-ylcarbamoyl)-2-oxo-2H-pyridin-1-yl]-acetic Acid Ethyl Ester
From 2-methoxy-N-(4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-isonicotinamide with sodium iodide and ethyl bromoacetate in DMF. ES-MS m/e (%): 495 (M+Na + , 25), 473 (M+H + , 100).
EXAMPLE 3
2-oxo-1-(2-oxo-Butyl)-1,2-dihydro-pyridine-4-carboxylic Acid (4-Methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide
From 2-methoxy-N-(4-methoxy-7-morpholin-4-yl-beinzothiazol-2-yl)-isonicotinamide with sodium iodide and 1-bromo-2-butanone in DMF. ES-MS m/e (%): 479 (M+Na + , 32), 457 (M+H + , 100).
EXAMPLE 4
2-oxo-1-Pyridin-2-ylmethyl-1,2-dihydro-pyridine-4-carboxylic Acid (4-Methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide
From 2-methoxy-N-(4-methoxy-7-morpholin-4-yl -benzothiazol-2-yl)-isonicotinamide with sodium iodide and 2-(bromoethyl)pyridine hydrobromide in DMF. ES-MS m/e (%): 500 (M+Na + , 30), 478 (M+H + , 100).
EXAMPLE 5
1-(2-Morpholin-4-yl-2-oxo-ethyl)-2-oxo-1,2-dihydro-pyridine-4-carboxylic Acid (4-Methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide
To a stirred solution of 200 mg (0.52 mmol) 2-oxo-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide in 1 ml DMF and 4 ml 1,2-dimethoxyethane was added 44 mg (1.04 mmol) sodium hydride (60% dispersion in mineral oil). After stirring for 15 min at room temperature, 90 mg (1.04 mmol) lithium bromide was added and stirring continued for a further 15 min. 95 mg (0.58 mmol) 4-(2-chloroacetyl)morpholine was then added and the mixture was stirred at room temperature for 16 h. The reaction mixture was then diluted with ethyl acetate, and washed sequentially with 0.5 M hydrochloric acid, saturated sodium bicarbonate solution and saturated brine. The combined aqueous phases were filtered, and the filter cake washed with ether, then resuspended in toluene and concentrated in vacuo. Flash chromatography (MeOH/CH2Cl2) followed by trituration in ethyl acetate afforded 83 mg (31%) 1-(2-morpholin-4-yl-2-oxo-ethyl)-2-oxo-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide as a yellow crystalline solid. ES-MS m/e (%): 536 (M+Na + , 25), 514 (M+H + , 100).
In an analogous manner there were obtained:
EXAMPLE 6
1-Dimethylcarbamoylmethyl-2-oxo-1,2-dihydro-pyridine-4-carboxylic Acid (4-Methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide
From 2-oxo-1,2-dihydro-pyridine-4-carboxylic acid (4-methoxy-7-morpholin-4-yl-benzothiazol-2-yl)-amide with sodium hydride, lithium bromide and 2-chloro-N,N-thylacetamide in 1,2-dimethoxyethane and DMF. ES-MS m/e (%): 494 (M+Na + , 22), (M+H + , 100). | The present invention relates to compounds of the formula
wherein R is as defined herewithin. The compounds of formula I have a good affinity to the A 2A receptor and therefore they may be used in the control or prevention of illnesses based on the modulation of the adenosine system, such as Alzheimer's disease, Parkinson's disease, Huntington's disease, neuroprotection, schizophrenia, anxiety, pain, respiration deficits, depression, drug addiction, such as amphetamine, cocaine, opioids, ethanol, nicotine, cannabinoids, or against asthma, allergic responses, hypoxia, ischaemia, seizure and substance abuse. Furthermore, compounds of the present invention may be useful as sedatives, muscle relaxants, antipsychotics, antiepileptics, aniticonvulsants and cardiaprotective agents for disorders such as coronary artery disease and heart failure. | 2 |
FIELD OF THE INVENTION
[0001] This invention relates to a method of reducing carbon levels from the combustion products of incompletely combusted fossil fuels and, more particularly to a microwave process for reducing carbon levels in fly ash.
BACKGROUND OF THE INVENTION
[0002] Coal combustion is one of the oldest industrial processes which is still widely practiced today. Aside from environmental issues related to combustion of fossil fuels, the efficient use of such fuels, for example coal, depends on nearly complete oxidation of the carbon. The high combustion system operating temperatures that are employed (in the range of 3000° C.) often lead to the formation of nitrous oxides. Current environmental emission restrictions on nitrous oxide generation have lead to a reduction in the operating temperatures of fossil fuel combustion systems, resulting in incomplete burning of the carbon (loss on ignition, “LOI”) and transmission of this carbon through the stack gas to the gas filters and finally into fly ash (as used herein the term “fly ash” refers to a carbon-containing by-product of the incomplete combustion of a fossil fuel).
[0003] Fly ash is commonly used as a cement additive; however, high carbon content in fly ash substantially reduces its commercial value as an additive. For example, reduction of the LOI (carbon content) from approximately 10% to 3% in fly ash results in a value increase of to 2 to 3 fold. Therefore, a means of substantially reducing or eliminating the LOI is of significant economic value.
[0004] One method used to reduce the residual carbon content of fly ash is to roast the fly ash either with or without the addition of an auxiliary fuel, depending upon the LOI of the ash. For autogenous combustion, an LOI of at least 6%-9% is generally required. For lower LOI ashes, an auxiliary fuel such as petroleum or natural gas is used to provide combustion energy; this method has the disadvantages of added cost and of producing additional combustion by-products which are themselves the subject of environmental concern.
[0005] Other proposed methods of treating carbonized fly-ash are known, including: mechanical and pneumatic classification, flotation or frothing, electrostatic classification and burnout through the addition of auxiliary fuel. Such processes may result in a segregated carbon-rich stream which must then be combusted under conditions which are identical or similar to those of primary combustion which will generally lead to NO x generation. This may aggravate the environmental situation which caused the selection of a primary combustion method producing unburned carbon in the first place.
[0006] Typical methods of treating NO x necessitate scrubbing the gas stream to remove NO x products using various converters which inject ammonia into the hot gas stream, chemically reducing the nitrous oxides and forming simple nitrogen gas and water. The combination of ammonia with the flue gas products is not entirely efficient, resulting in some ammonia adsorbing to the ash in the form of ammonia salts, a condition known in the industry as ammonia slip.
[0007] Once in the ash, the ammonia salts (usually in the form of ammonium sulfate) will generally decompose with time and in the presence of moisture to release ammonia gas. Since one of the major uses of fly ash is as a cement additive, the release of ammonia gas at cement construction sites is a significant personnel health hazard as well as an environmental contaminant.
[0008] Currently available ammonia removal technologies rely principally on the thermal removal of ammonia from the ash. This is commonly carried out simultaneously with the ash incineration used to combust (burnout) the unburned carbon in the ash. None of the current processes for ammonia removal are completely acceptable in terms of performance or cost. There remains, therefore, a need for an effective means of removing adsorbed ammonia from fly ash.
[0009] If the production of a carbon-enriched ash stream is not followed by recombustion, then the material must be otherwise disposed, usually in landfill which is becoming increasingly costly and environmentally difficult. It is therefore desirable to have a method of reducing carbon levels in fly ash of broadly ranging LOI while minimizing formation of additional undesirable combustion by-products.
[0010] The application of microwave energy to the treatment of various minerals is well known in the art. Crawford and Curran (U.K. Patent 1,092,861) disclose a method for heating coal whereby the volatile products are liberated. Connell and Moe (U.S. Pat. No. 3,261,959) teach a method for applying microwave energy to iron ores in order to oxidize the product and further teach that this process may require the addition of water to increase the microwave receptivity of the materials being processed. Jukkola (U.S. Pat. No. 3,632,312) discloses a method for roasting sulphide ores in order to produce an enriched SO 2 gas product. Kruesi (U.S. Pat. No. 4,311,520, U.S. Pat. No. 4,321,089, and U.S. Pat. No. 4,324,582) further teaches processes whereby microwave energy may be used to treat several ores for the recovery of copper, nickel, cobalt, manganese, molybdenum, rhenium and other metals. In each of these cases, the microwave energy is used to generate heat in the mineral resulting in a chemical reaction which produces an intermediate product ready for subsequent metal recovery. Beeby (WO 92/18249) discloses a process utilizing pulsed microwave energy which results in increased metal leachability from ores due to either oxidation or thermally induced microfracturing.
[0011] U.S. Pat. No. 5,160,539 and U.S. Pat. No. 5,399,194 both to Cochran disclose the use of a dry, bubbling bed comprising a mixture of fly ash and partially combusted ash wherein the apparatus is maintained at oxidizing temperature sufficient to ignite the carbon. In particular, Cochran discloses in U.S. Pat. No. 5,160,539, a method of reducing carbon content in fly ash using a fluidized bed reactor wherein the fluidized bed is essentially free of any material other than carbon-containing fly ash. The use of a fluidized bed consisting essentially of carbon-containing fly ash may cause “clinkering” and fusing of the fly ash resulting from localized overheating. This can reduce the efficiency of the carbon-reduction process and lead to the production of a less desirable carbon-depleted product.
[0012] U.S. Pat. No. 5,161,471 to Piekos discloses the use of a bubbling bed of burning ash material wherein both underfire and overfire combustion air is introduced. U.S. Pat. No. 5,390,611 to John describes a process in which fly ash is electrically preheated and combusted while being tumbled to effect good oxygen-solids contacts. U.S. Pat. No. 5,484,476 to Boyd describes a method for preheating fly ash prior to its being injected into a combustion vessel.
[0013] U.S. Pat. No. 4,663,507 to Trerice discloses a method for using microwave energy at approximately 2450 MHz in an elongated waveguide apparatus for both oxidizing the carbon from fly ash and for measuring the residual carbon content therein. His disclosure of the selective absorption characteristics of the carbon constituent in fly ash is well known, being the basis of selective heating of a wide range of admixtures, including mineral substances, and is well understood by those knowledgeable in the art of microwave processing.
[0014] Although the Trerice patent discloses the use of 2450 MHz microwave energy for the oxidation of carbon in fly ash, there remains a need for a more optimal and effective means for mixing, agitating, controlling and transporting the fly ash being processed in order to avoid uncontrolled, localized heating and clinkering of the fly ash. The phenomenon of highly localized overheating of microwave receptive materials is well known, often referred to as thermal runaway, leading to a generally uncontrolled process which, in the case of minerals and similar materials, usually leads to a clinkering and fusing of the material. This is particularly the case for very highly absorptive materials such as carbon in the presence of silicates (which easily fuse into glass) and iron compounds (which fuse into various iron oxides such as magnetite and hematite). The difficulty is greatly exacerbated when the material being processed contains sufficient fuel value that it is capable of autothermal reaction, i.e. the oxidation reaction, once initiated, is sustained by the heat released from the burning fuel.
[0015] The Trerice patent is susceptible to the problems of clinkering and thermal runaway. In particular, desirable reaction control requires a continuous, intimate mixing of oxygen and fly ash, which is not taught by Trerice.
[0016] It is therefore an object of the present invention to provide an improved method of reducing carbon levels in a material to be processed, utilizing microwave radiation.
[0017] It is also an object of the present invention to provide an improved method of reducing ammonia levels in a material to be processed, utilizing microwave radiation.
SUMMARY OF THE INVENTION
[0018] The present invention provides in one aspect a method of reducing carbon level in fly ash comprising: placing a carbon-free material in a microwave reactor; placing fly ash in the microwave reactor; providing a stream of oxygen, which causes agitation of the carbon-free material and fly ash so as to form a mixture; exposing the mixture to microwave radiation so as to raise the temperature of the mixture to at least 600° C.; and terminating exposure of microwave radiation when the temperature falls below 600° C., which is indicative of the reduction of carbon level in treated fly ash to a predetermined level.
[0019] According to a second aspect, the invention provides a method of reducing carbon and ammonia levels in fly ash comprising: placing a carbon-free material in a microwave reactor; placing fly ash in the microwave reactor; providing a stream of oxygen, which causes agitation of the carbon-free material and fly ash so as to form a mixture; exposing the mixture to microwave radiation so as to raise the temperature of the mixture to at least 600° C.; and terminating exposure of microwave radiation when the temperature falls below 600° C., which is indicative of the reduction of carbon level and ammonia level in treated fly ash to predetermined levels.
[0020] According to a third aspect, the invention provides a method of reducing ammonia level in fly ash comprising: placing a carbon-free material in a microwave reactor; placing flay ash in the microwave reactor; providing a stream of oxygen which causes agitation of the carbon-free material and fly ash so as to form a mixture; exposing the mixture to microwave radiation so as to raise the temperature of the mixture to at least 350° C.; and terminating exposure of microwave radiation when the temperature falls below 350° C., which is indicative of the reduction of ammonia level in treated fly ash to a predetermined level.
[0021] In a preferred embodiment, the method according to each of the above aspects further comprises the steps of removing the treated fly ash from the microwave reactor; introducing fresh carbon-free material in the reactor; and introducing fresh fly ash in the reactor. More preferrably, these steps can be continuous and the temperature of the mixture can be maintained in the range of 800° C. to 850° C. Optionally, the temperature of the mixture can be maintained in the range of 350° C. to 850° C. The temperature of the mixture can also be monitored during the process according to the invention.
[0022] In other preferred embodiments, the microwave reactor is a fluidized bed vessel. The carbon level in the fly ash to be treated may be at least 3% by weight and the ammonia level may be at least 50 parts per million. These levels in the treated fly ash can be about 3% by weight for carbon and about 50 parts per million for ammonia. The fly ash may have a size in excess of 106 microns.
[0023] In yet other preferred embodiments, the microwave radiation has a frequency between 300 MHz and 3000 MHz. More preferrably, the frequence can be between 915 MHz and 2450 MHz. The microwave radiation power level and the process duration employed should be sufficient to produce a specific energy in the fly ash of between 2 Kw-h/t and 25 Kw-h/t. More preferrably, the specific energy in fly ash can be between 5 Kw-f/t and 10 Kw-h/t.
[0024] In other preferred embodiments, the carbon-free material can be selected from manganese dioxide, silica, metallic oxides, silicaceous oxides and mixtures thereof. More preferrably, the carbon-free material is either manganese dioxide or silica. The ratio of fly ash to carbon-free material can be between 25/75 and 75/25. More preferrably, this ratio is 50/50.
[0025] In accordance with a fourth aspect, the invention provides an apparatus specifically adapted to carry out the method of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0026] FIG. 1 is a perspective view of an apparatus for carrying out an embodiment of the method of the present invention, shown in partial cut-away.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] In an embodiment of the present invention, fly ash is processed in a microwave reactor 5 . The microwave reactor 5 preferably comprises a chamber 15 , a microwave input 18 , a vent 26 and an oxygen input 34 . The chamber 15 preferably includes a top 12 and a bottom 14 fixedly sealed to a wall 16 , said top 12 , bottom 14 and wall 16 preferably comprising microwave impenetrable material. The oxygen input 34 is preferably a source of atmospheric air and may be a conduit having a first end in communication with the chamber and a second end open to the exterior environment such that atmospheric air passes through the conduit and into the chamber as required for combustion. In one embodiment of the invention, the microwave reactor 5 further includes a fluidized bed, which facilitates continuous intimate mixing of air and fly ash.
[0028] The vent 26 preferably has an uptake end 36 and a discharge end 38 and a vent tube 40 connecting said uptake end 36 and side discharge end 38 . The uptake end 36 of the vent 26 is preferably in communication with the upper portion of the interior of the microwave reactor 5 , such that gaseous products of the microwave treatment of the fly ash 10 will enter the uptake end. The vent 26 preferably further comprises a filter 28 located along the vent tube 40 and adapted to remove dust, solids and residues from the gaseous material passing through the vent tube 40 . The vent 26 preferably further includes a heat exchanger 30 adapted to facilitate the transfer of heat from the gaseous material to fly ash 10 entering the microwave reactor 5 .
[0029] Implicit and essential in the composition of the fluidized bed material is a secondary material, or host material 44 , which is a substantially carbon-free material and which is selected to be somewhat coarser and denser than the fly ash. The host bed material may be selected in particular to be an efficient microwave receptor as is later disclosed. Although the host bed material is generally coarser than fly ash in particle size composition, both materials are completely fluidized and comprise a single fluidized bed medium. For reasons related to the density and particle size composition of the host bed material as later disclosed, the host bed material will generally remain in the reactor much longer than the fly ash and its distribution may be more concentrated in the lower region of the reactor vessel. Fly ash introduced into the reactor vessel 5 is caused to pass through and to become intermixed with the host bed material during processing.
[0030] The carbon-free material 44 will be suitably selected from any heat-stable material which is substantially free of carbon, does not chemically react significantly with fly ash 10 or its process products during microwave exposure and can be conveniently mixed with the fly ash during processing. The type of carbon-free material employed may be selected based on the carbon content of the fly ash to be treated. The type of carbon-free material may be varied during processing as the characteristics of the fly ash treated and the overall reaction temperature vary. For example, where the fly ash to be treated has a low LOI (for example, below 5-8%) carbon depletion can be initiated more rapidly by employing a carbon-free material which is a good microwave receptor at its temperature in the fluidized bed. Where the fluidized bed, including the carbon-free material, is at about 20° C., manganese dioxide is a suitable carbon-free material where rapid initiation of the carbon-depletion process is desired.
[0031] Other types of carbon-free materials will be suitable at various reaction temperatures. For example, silica is a good microwave receptor at 800° C. and is a preferred carbon-free material used in the fluidized bed when carbon depletion is occurring. It will be appreciated that the method of the present invention can be carried out using a variety of suitable carbon-free materials such as manganese dioxide and many other metallic oxides and combinations of oxides and silicaceous compounds. Specifically, low microwave receptivity of a carbon-free material can be compensated for by longer heating and mixing of the fly ash, whereas use of carbon-free material having high microwave receptivity can allow for shorter processing times.
[0032] The use of a suitable carbon-free material provides improved heating uniformity and reduces clinkering, fusing of materials, and auto thermal runaway. The carbon-free material can also act to grind fused material by mixing. It has been found that the use of a suitable host bed material, in conjunction with microwave energy, enables the carbon burnout process to operate at a higher temperature that otherwise possible while simultaneously avoiding clinker formation. This set of operating conditions results in a higher carbon burn rate and an increased reactor efficiency and throughout.
[0033] The substantial lack of carbon in the carbon-free material is important to avoid having the material react during microwave exposure, which could lead to clinkering, fusing, and auto thermal runaway.
[0034] Preferably, carbon-free material is mixed with fly ash at a ratio of between about 75 parts carbon-free material to 25 parts fly ash, and about 25 parts carbon-free material to 75 parts fly ash. In more preferred embodiments, a ratio of between about 50 parts carbon-free material to 50 parts fly ash can be used. The precise ratio of carbon-free material to fly ash can be varied, depending on the carbon content of the fly ash and the carbon-free material employed, in order to provide satisfactory heating uniformity.
[0035] The quantity of fly ash present in the microwave reactor may be determined by methods known in the art, in light of the disclosure herein, with reference to the size of the microwave reactor, the microwave power to be applied and the mineral composition of the fly ash. The quantity of fly ash present in the microwave reactor is preferably that quantity which can be heated in a substantially uniform manner, taking into consideration the agitation and mixing action of the fluidizing gas stream. Preferably, the fly ash contains at least 3% carbon by weight prior to microwave exposure. There is no allowable upper limit to carbon composition. The method of the present invention permits carbon depletion of fly ash to levels below 3% by weight and preferably within the range of 2±0.5% by weight. The method of the present invention permits fly ash to be carbon depleted without the need for the addition of an auxiliary fuel and without the production of significant nitrogen oxide gaseous byproducts.
[0036] The microwave radiation employed in the treatment of the fly ash may be selected from any frequencies within the microwave range of 300 MHz to 3000 MHz. Preferably, the microwave radiation employed has an average frequency of either approximately 915 MHz or approximately 2450 MHz. The use of microwave radiation having a frequency of 915 MHz or 2450 MHz is desirable because commercial microwave generating equipment is readily available in these frequency ranges. Any convenient microwave incident power may be employed in treating the fly ash, provided that the specific energy is appropriate to the volume and condition of the fly ash to be treated. In a preferred embodiment, a microwave power level and process duration time are employed which are sufficient to cause the temperature in the fly ash to rise above 600° C. and to impart a specific energy in the fly ash of between 2 kW-h/t and 25 kW-h/t. In another preferred embodiment, a specific energy of between 5 kW-h/t and 10 kW-h/t is imparted to the fly ash. It will be apparent to one skilled in the art that the microwave power level and process duration time necessary to produce a desired specific energy in the fly ash may be readily determined, in light of the disclosure herein and standard procedures in the field.
[0037] It is desirable to monitor the temperature of the fly ash during its exposure to microwave radiation, in order to assess the stage of the process. In particular, in batch processes it will sometimes be desirable to know when the fly ash temperature has increased to over 600° C. and subsequently decreased below 600° C. as this can indicate that the carbon content of the fly ash in the batch process has fallen below a predetermined level. Methods and systems for monitoring the temperature of a material during microwave radiation exposure are known in the art. Preferably, the temperature is continuously monitored using an infra-red pyrometer, or by way of thermocouplers embedded in the walls of the reactor vessel.
[0038] In a preferred embodiment, the fly ash is exposed to microwave radiation in a batch mode of operation until the fly ash temperature has exceeded 600° C. and has commenced a decrease in temperature. In one embodiment, the fly ash is exposed to microwave radiation until it has exceeded 600° C. in temperature, and has subsequently declined in temperature below 600° C. In another embodiment, the fly ash is exposed to microwave radiation until it has exceeded 600° C. in temperature, and subsequently declined in temperature to a temperature of no more than 550° C. Once the fly ash has decreased in temperature to the desired temperature, exposure to microwave radiation is preferably terminated.
[0039] In another preferred embodiment the treatment of fly ash is conducted in an on-going flow-type system. The microwave reactor 5 may further include a material feed system 24 to introduce fresh (non-microwave exposed) fly ash, and a removal system 32 to remove calcine (fly ash which has been exposed to microwave radiation having a carbon content of below 3% by weight). The removal system 32 removes calcine from the microwave reactor 5 . The material feed system 24 adds fresh fly ash to the microwave reactor to replace calcine removed by the removal system 32 , thereby allowing an ongoing flow-type process. In this preferred embodiment, fly ash is fed into the microwave reactor 5 by the material feed system 24 at a rate determined in light of the time required for the fly ash to achieve a temperature of between 600° C.-850° C. and remain at this temperature for a prescribed average duration, at which point it is removed from the microwave reactor by the removal system 32 . It will be apparent to one skilled in the art that the time required for fly ash to achieve 600° C.-850° C. and the magnitude of the prescribed average duration can be readily determined with reference to the prior art and the material herein disclosed, and in light of the microwave frequency, microwave incident power, microwave reactor configuration, the quantity of fly ash introduced at a given time, and the correlation between the treatment temperature and the fly ash depletion rate. In one embodiment, fly ash is monitored for carbon content during the treatment process and fly ash is removed by the removal system when carbon content of the fly ash has fallen below a predetermined level, which may be 3% or more or less than 3%.
[0040] The removal system 32 preferably comprises a discharge tube 46 located at the bottom 14 of the microwave reactor 5 , and adapted to carry calcine from the microwave reactor 5 to a calcine collection vessel. In a particularly preferred embodiment, the removal system further includes a heat exchanger adapted to facilitate the transfer the heat from the calcine to fly ash prior to the entry of that fly ash into the microwave reactor.
[0041] In one commercial scale application of an embodiment of the method of the present invention, 35 lbs of fly ash was processed in a microwave reactor under steady state operating conditions for 45 minutes at a reaction bed temperature of 800° C. A specific energy of between 15 and 20 kW-h/t (based on metered AC power consumption and actual fly ash produced) was employed. In this instance, initial fly ash carbon content was 13% and the carbon content of the resultant fly ash was below 3%.
[0042] The method of the present invention is also useful in depleting ammonia from fly ash. While the method will typically be carried out on fly ash containing both carbon and ammonia, the method is also useful in treating samples containing only one of these two materials.
[0043] Fly ash can be efficiently heated using microwave energy due to the residual carbon content in the ash and/or the microwave heating of a secondary bed material. Using the carbon or secondary bed material as a microwave receptor, the fly ash can be heated to a temperature sufficient to combust the carbon in the presence of air (a process known as carbon burnout). At these temperatures, in the range of 600° C.-900° C., the ammonia compounds are chemically decomposed with the resultant ammonia gas passing off in the gas stream. A temperature of 350° C. is adequate for ammonia depletion and samples containing ammonia can be heated to this temperature for treatment even where the sample contains little or no carbon.
[0044] In an embodiment of the present invention, fly ash and host bed material are heated in a fluidized bed chamber into which microwave energy is introduced. Atmospheric air is used as the fluidizing gas. The temperature of the ash is maintained in the range 600° C.-900° C. which is sufficient to cause the residual carbon to combust and to cause the reduction of ammonia products. For reasons which are not yet completely understood, possibly due to the close affinity between the ammonia compounds and the carbon particles acting as adsorbing surfaces, the use of the disclosed microwave burnout process is more effective in eliminating ammonia compounds than are conventional thermal burnout techniques.
[0045] The invention will be further described for illustrative purposes, with reference to the following specific examples.
EXAMPLE 1
[0046] A sample of 991.2 grams of fly ash, sieved to greater than 106 microns, was heated in a microwave reactor into which atmospheric air was introduced to supply oxygen for carbon combustion. For this experiment, a microwave incident power of between 10 and 15 kW was used. Carbon content of the fly ash sample was measured by LECO™ combustion analysis to be 25.2% organic carbon. Microwave power was applied for approximately 30 minutes. The temperature of the fly ash was continuously monitored using an infra-red pyrometer.
[0047] The fly ash material was observed to heat very rapidly in response to the application of microwave power. Peak temperatures exceeding 600° C. were reached. The material was observed to glow brightly for a short period and then to spontaneously cool down due to carbon depletion. Since carbon is the principle microwave receptive component of the fly ash, the depletion of carbon results in a substantially microwave “transparent” material which is a poor microwave receptor.
[0048] The microwave reactor employed in this experiment is a type of fluidized bed in which air is pumped through the material to be reacted (fly ash). Very fine material (less than 106 microns) tends to be blown out of the reactor vessel and is captured in a filter installed in the vent.
[0049] Samples collected through this experiment included:
1. Unprocessed fly ash, designated “head” material in Table 1; 2. Processed fly ash, designated “experiment calcine” material, remaining in the reactor in the completion of the experiment; 3. Partially processed fly ash, designated “grab” material, which was extracted from the reactor before completion of the combustion process; 4. Processed fly ash, designated “light calcine” which was extracted from the reactor after completion of the combustion process, but before disassembly of the reactor such that the sample did not contain material (possibly not fully combusted) dislodged from the inner lining of the reactor; 5. Essentially unprocessed fly ash, designated “filter” material, which was collected from the filter and which represented material blown out of the reactor prior to combustion.
[0055] All samples except the “head” sample were tested for carbon content by roasting in air in a electric furnace and measuring weight loss. As previously discussed, “head” material was assessed for carbon content using LECO™ combustion analysis according to standard methods. The results of these analysis is depicted in Table 1.
TABLE 1 Mass of Sample % Carbon Mass (g) Carbon (g) Input Head 25.2 991.2 249.782 Output Calcine 1.3 74.6 0.955 Light Calcine 0.2 9.9 0.018 Grab 1.9 2.4 0.045 Filter 25.4 826.6 209.874 Loss — — 77.7 38.891
[0056] A detailed chemical and mineralogical composition of “head” material is depicted in Table 2.
TABLE 2 Fly Ash Chemical Composition Al 9.02% As 203 ppm C 14% Ca 0.59% Co 55 ppm Cr 127 ppm Cu 136 ppm Fe 7.52% K 1.26% Li 121 ppm Mg 0.33% Mn 152 ppm Na 0.71% Ni 121 ppm P 0.12% Pb 31 ppm S 0.14% Sb 29 ppm Zn 227 ppm
[0057] X-ray diffraction analysis of the “head” material also indicated mullite (Al 6 Si 2 O 13 ), quartz, hematite (Fe 2 O 3 ) and magnetite (fe 3 O 4 ) as well as other unidentified, amorphous compounds including the elements listed in Table 2.
[0058] Each of the processed materials depicted in Table 1 (calcine, light calcine, grab) shows a very high degree of carbon depletion, in each case well below 3% carbon content by weight (LOI), and in the case of Experiment calcine, below 2% carbon content by weight.
EXAMPLE 2
[0059] A sample of fly ash from a coal generating station was selected for continuous microwave processing using a fluidized bed reactor vessel with atmospheric air as the fluidizing oxygen input. The fly ash was analyzed for size distribution with 50% passing 20μ.
[0060] Fly ash was fed to (and discharged from) the reactor vessel at the rate of 1.5 lb/min and microwave power was adjusted to maintain a measured bed temperature of 800° C.-850° C. The test was continued at steady state conditions for at least 130 minutes during which substantially all discharge material was collected. The initial ash LOI was measured to be 9%. A total of 13 processed ash samples were analyzed yielding an average LOI of 2.7%.
EXAMPLE 3
[0061] A sample of fly ash was processed as described in Example 2 using a feed (and discharge) rate of 1.4 lb/min and a bed temperature of 825° C. The initial ash LOI was 9%; a total of 10 processed ash samples was analyzed yielding average LOI of 0.6%.
EXAMPLE 4
[0062] A sample of fly ash from a coal generating station was selected for continuous microwave processing using a fluidized bed reactor with atmospheric air as the fluidizing oxygen input. The ash was analyzed for size distribution with 50% passing 20 microns.
[0063] A host bed material consisting of coarsely ground manganese dioxide was heated by microwave radiation while being fluidized. Once the bed temperature had reached 600° C., fly ash was fed to (and discharged from) the reactor vessel at the rate of 1.5 lb/min and microwave power was adjusted to maintain a measured bed temperature of 800° C.-850° C. The test was continued at steady state conditions for at least 130 minutes during which substantially all discharge material was collected. The initial ash LOI was measured to be 9% with an ammonia concentration of 770 ppm. A total of 13 processed ash samples was analyzed yielding an average LOI of 2.7% and an average ammonia concentration of 2.98 ppm.
EXAMPLE 5
[0064] A sample fly ash was processed as described in Example 4 using a feed (and discharge) rate of 1.4 lb/min and a bed temperature of 825° C. The initial ash LOI was 9% with an ammonia concentration of 770 ppm; a total of 10 processed ash samples was analyzed yielding average LOI of 0.6% and an average ammonia concentration of 3.14 ppm.
[0065] While the invention has been described in conjunction with illustrated embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention. | There is disclosed a method of reducing carbon levels in fly ash. The method comprises the steps of: (a) placing the fly ash in a microwave reactor; (b) exposing said fly ash to microwave radiation in the presence of carbon-free material so as to raise its temperature to at least 600° C. while agitating the fly ash in the presence of oxygen; and; (c) terminating exposure of said fly ash to said microwave radiation when the carbon content of the fly ash falls below a predetermined value. The method is also used to reduce ammonia levels in fly ash. | 5 |
TECHNICAL FIELD
The present invention relates to devices and methods for measuring the mass of a fluid flowing in a duct.
BACKGROUND OF THE INVENTION
Internal combustion engines today include electronic controls to provide optimal engine operation. Typically, the electronic control systems include a primary control unit for processing control algorithms and a variety of sensors for providing control signals to the primary control unit. One critically important sensor for achieving optimal engine control is a mass fluid flow sensor for measuring air intake into the internal combustion engine.
It is critical that the mass fluid flow measurement is accurate in order to provide optimal engine operation. One significant problem affecting the mass fluid flow measurement, is reverse flow or back flow in the direction opposite of fluid intake. Typically, mass fluid flow sensors detect the flow of air in both the forward and reverse directions relative to air intake, therefore reverse flow causes an inaccurate mass fluid flow reading.
Prior art mass fluid/air flow devices have attempted to address this problem by providing mass air flow sensor configured as disclosed in U.S. Pat. No. 5,556,340 issued to Clowater et al. In Clowater, a mass air flow sensor having a U-shaped air passage and a longitudinally converging elliptical inlet configuration is disclosed, and hereby incorporated by reference. This configuration increased measurement efficiency and reduced the effect of back flow on the measurement of air flow into the internal combustion engine. Further, such a configuration produces advantageously low signal to noise ratio, as well as high velocity across the mass fluid flow sensor element.
While prior art mass fluid flow sensors, such as the one disclosed in Clowater, significantly improved the accuracy of the mass fluid flow measurement. Improvements are still needed to address other problems.
For example, it would be advantageous to provide a mass fluid/air flow sensor having an improved housing configuration. The improved housing should provide enhanced structural stability, be able to withstand harsh vibration environments, and reduce manufacturing complexity, for example.
BRIEF SUMMARY OF THE INVENTION
In an embodiment of the present invention, a mass fluid flow sensor is provided for determining the amount of air inducted into an internal combustion engine, in accordance with the present invention. The mass fluid flow sensor of the present invention includes an external intake air temperature element which improves the accuracy of the mass air reading. An external cold wire element is further provided which improves response time. The mass fluid flow sensor of the present invention has an improved aerodynamic design which provides a lower system pressure drop.
Moreover, a molded one-piece isolated jet nozzle having a hot element disposed therein is provided in a tubular flow passage of the sampling portion of the housing. Consequently, an improved lower internal flow passage pressure drop is achieved. Additionally, an improved signal to noise ratio, as well as a larger dynamic range is an advantageous consequence of the present invention. The present invention further provides improved electromagnetic interference performance.
In an embodiment of the present invention, a mass fluid flow sensor having a circular opening or inlet of the nozzle is provided.
In another embodiment of the present invention, control electronics are located in a longitudinally extending section of the mass fluid flow sensor housing above the sampling portion. Thus, the present invention provides an integrated circuit cavity and sampling portion in one package.
In another aspect of the present invention, a U-shaped flow passage is provided having one constant radius bend r for capturing a sample of the intake air.
In yet another embodiment of the present invention, an outlet of the U-shaped flow passage is provided to allow the fluid to exit and flow out of the bottom of the flow passage, as well as, the sides of the housing.
In yet another embodiment of the present invention, a measuring element is located within the flow passage at the exit or outlet of the jet nozzle, in accordance with the present invention.
In yet another aspect of the present invention, the measuring element is centered at the exit of the converging nozzle.
In still another embodiment of the present invention, the control electronics are located adjacent the flow passage within the circuit cavity.
Further objects, features and advantages of the invention will become apparent from consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a mass fluid flow sensor in accordance with the present invention;
FIG. 2 is a perspective view of a mass fluid flow housing in accordance with the present invention;
FIG. 3 is a perspective view of a mass fluid flow housing cover, in accordance with the present invention;
FIG. 4 a is an inside perspective view of a mass fluid flow housing cover, in accordance with the present invention;
FIG. 4 b is an outside perspective view of the housing with the housing cover installed thereon, in accordance with the present invention;
FIG. 4 c is a perspective view of the housing with the housing cover installed thereon, in accordance with the present invention;
FIG. 5 is a perspective inside view of an electronics cover for a mass fluid flow sensor, in accordance with the present invention;
FIG. 6 is an outside view of an electronics cover of a mass fluid flow sensor, in accordance with the present invention;
FIG. 7 a is a fully assembled perspective view of a mass fluid flow sensor in accordance with the present invention;
FIG. 7 b is a cross-sectional view through the mass fluid flow sensor as indicated in FIG. 7 a in accordance with the present invention;
FIG. 8 is cross-sectional view through an automotive fluid intake manifold and further illustrated in exemplary location of the mass fluid flow sensor, in accordance with the present invention;
FIGS. 9 a - 9 d are perspective and cross-sectional views through an alternate embodiment of a mass fluid flow sensor, in accordance with the present invention;
FIG. 9 e is a computational fluid dynamics diagram illustrating the fluid flow direction and velocity through the mass fluid flow sensor;
FIG. 10 is a perspective view of the mass fluid flow sensor having an improved sensor housing, in accordance with the present invention;
FIG. 11 a is a perspective view of the mass fluid flow sensor and further illustrating the mounting configuration of the present invention;
FIG. 11 b is a cross-sectional view through the mass fluid flow sensor and the duct interface of the fluid carrying duct illustrating a three surface contact seal, in accordance with the present invention;
FIG. 12 is a cross-sectional view of the sensor housing and the heat sink cover, in accordance with the present invention; and
FIG. 13 is a perspective magnified view of the nozzle exit and heating element disposed in the housing, in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, exploded and perspective views of a mass fluid flow sensor 10 for calculating the amount of fluid flowing in a duct is illustrated, in accordance with the present invention. One application or use for sensor 10 is for measuring the amount of air inducted into an internal combustion engine (not shown). However, the present invention contemplates other uses and application for sensor 10 . For example, sensor 10 may be used to calculate the amount of fluid (other than air) flowing through a duct (other than an air intake duct of an internal combustion engine). Mass fluid flow sensor 10 includes a housing 12 , housing cover 14 , a secondary housing cover 16 , an electronics cover 18 , and a gasket 20 .
Housing 12 includes an integral connector 30 having connector terminals (not shown) that are in electrical communication with engine operation control electronics external to mass fluid flow sensor 10 and in electrical communication with a circuit module 32 disposed within a central housing portion 34 . Adjacent to central housing portion 34 , housing 12 further provides an integrally attached fluid sampling portion 36 . Fluid sampling portion 36 includes an inlet 38 that opens into a nozzle 39 . Nozzle 39 communicates with a substantially U-shaped flow passage 40 . U-shaped flow passage 40 terminates at an outlet 42 .
Nozzle 39 has, generally, a jet nozzle configuration or shape. As will be further illustrated and described, nozzle 39 is defined by a generally circular opening or inlet 38 that meets longitudinally converging elliptical side surfaces (as shown in FIG. 7 b ). The longitudinally converging elliptical side surfaces of the nozzle create a relatively high pressure at an exit 41 of nozzle 39 . Further, the jet nozzle configuration of nozzle 39 creates a critical area 43 located at exit 41 having a uniform fluid flow velocity across the critical area. This critical area created by the nozzle provides enhanced fluid flow detection and measurement as will be described hereinafter. To further enhance the flow of fluid through passage 40 a wedge deflector 45 is positioned on an end of housing 12 upstream of outlet 42 . Wedge deflector 45 has a surface that is tilted to create an advantageously low pressure area adjacent outlet 42 . If the angle of the surface of deflector 45 (indicated by the letter α in FIG. 7 b ) is too small with respect to the direction of fluid flow an insufficient pressure drop is created at outlet 42 . Conversely, if the angle of the surface of deflector 45 is too large with respect to the direction of fluid flow an insufficient pressure drop is created at outlet 42 . Preferably, the angle α of the surface of deflector 45 is between 47° and 60° with respect to a horizontal line.
As illustrated in FIG. 2, a plurality of resistive elements are operatively disposed and supported by housing 12 and are in electrical communication with circuit module 32 via electrical conductors, such as integrally molded leads or terminals. The resistive elements include a hot wire element 44 , a cold wire element 46 and an internal fluid temperature (IAT) element 48 . Generally, these elements change resistance as a function of temperature.
Circuit module 32 senses a fluid, such as, air flowing through passage 40 by monitoring the power dissipated by the elements. Circuit module 32 may be a single integrated circuit chip or a substrate having discrete, as well as, integrated circuits mounted thereon. The sensed resistance change in the elements is converted to an output signal that is received by the electronic engine control system (not shown). Typically, the electronic engine control system regulates the quantity of fuel injected into the engine by controlling the air to fuel ratio.
The IAT or element 48 is generally a thermistor or similar device. Element 48 is located on housing 12 to insure an accurate reading of the temperature of the air charge during the induction cycle of the internal combustion engine. As shown in FIG. 2, element 48 is located, preferably, external of passage 40 to minimize the fluid heating effects caused by the heat dissipation from hot element 44 .
In a preferred embodiment of the present invention, a fluid flow sensor 10 is provided having elements 44 and 46 made of platinum wire wound resistors. Generally, these elements have a positive temperature coefficient. Thus, any resistive changes in the elements will correspond with a temperature change in the same direction. That is, if the temperature increases, the resistance will increase, and if the temperature decreases, the resistance will decrease. Preferably, hot element 44 is located at exit 41 of nozzle 39 and within the critical area 43 . The location of the hot element within the critical area insures that fluid, having a uniform velocity profile, flows over the hot element causing heat to dissipate from the entire surface of the element. Thus, the present invention provides enhanced fluid flow detection.
In an embodiment of the present invention, hot element 44 may for example have a resistance of 20 Ohms at 21.1° C. Thus, if the temperature increases by +17.2° C. the resistance of the hot wire will increase by approximately 0.025 Ohms. The hot element 44 is used primarily for detecting the velocity of the fluid flowing through passage 40 from which the mass of fluid flowing through passage 40 may be derived.
The cold wire element 46 , may for example have a nominal resistance of 500 Ohms at 21.1° C. If the temperature of the cold wire is increase by +17.2° C. the resistance of cold wire will increase by approximately 0.5 Ohms. The primary purpose of the cold wire element 46 is to provide temperature correction.
In operation hot wire element 44 is held at approximately 200° C. above the ambient temperature. This is accomplished by placing the hot wire element in a voltage divider circuit. With reference to FIG. 3, an exemplary voltage divider circuit 500 for fixing hot wire element 44 at a desired constant resistance and temperature is illustrated, in accordance with the present invention. In an embodiment of the present invention circuit 500 is disposed in integrated circuit 32 , along with other control circuitry. Exemplary circuit 500 includes two voltage divider networks 502 and 504 in communication with an operational amplifier 506 . Voltage divider network 502 generally has two 500 Ohm resistors 508 and 510 which form a 50% voltage divider network and force plus pin 512 of op-amp 506 to half the output voltage on line 518 . The other voltage divider network 504 includes generally a 25 Ohm resistor 514 in series with the hot wire element 44 . The minus pin 516 of op-amp 506 is connected between resistor 514 and hot wire element 44 . Thus the ratio of this network starts with a ratio of 20 Ohms to 45 Ohms, so minus pin 516 is forced to 20/45 th of the output voltage. For example, the op-amps output voltage on output line 518 will increase if the voltage on plus pin 512 is greater than the voltage on the minus pin 516 . Likewise, the output voltage on line 518 will decrease if the voltage on plus pin 512 is less than the voltage on minus pin 516 . Accordingly, the op-amp's output voltage on line 518 will increase or decrease by a voltage amount necessary to force the voltage on plus pin 512 to equal the voltage on minus pin 516 .
Since resistor network 502 provides a greater voltage on plus pin 512 that is 50% of the output voltage as compared to 44% on minus pin 516 , the op-amps output voltage will increase on line 518 . As the voltage increases, the power dissipated by the hot wire element 44 causes an increase in resistance of the hot element. It takes approximately one quarter watt of power in still air to increase the temperature of hot element 44 by 93.3° C. A 93.3° C. increase in temperature raises hot wire element 44 's resistance by 5 Ohms. The ratio of the hot wire resistance at the increased temperature to the total resistance in resistor network 504 forms a 50% voltage divider network. Thus, the plus and minus pins 512 and 516 of op-amp 506 are at the same voltage since both networks 502 and 504 form 50% voltage divider networks. Thus the temperature of hot wire element 44 is forced to approximately 132.2° C.
The circuit 500 provides an output on line 518 to an electronic engine control module (not shown) which determines the proper air fuel ratio for optimal engine operation, as well known in the art. Since it takes a quarter watt as disclosed above for voltages on plus and minus pins 512 and 516 to be equal, the voltage across the hot wire element 44 and resistor 514 can be calculated using the equation: Power=(voltage) 2 /resistance and then solving for voltage (V): V=(power×resistance) 1/2 or (0.25×25) 1/2 . Since the voltage across resistors in series add the nominal output of the circuit is 5 volts for no air flow. Obviously, more circuitry would be used to level shift and amplify the output of the circuit 500 .
As air flows over hot wire element 44 , power in the form of heat is transferred from the hot wire element to the air. Heat removed from the hot wire element 44 causes the resistance of element 44 to decrease. Decreasing resistance causes the voltage applied to the minus pin 516 to decrease. Accordingly, the output voltage on line 518 would increase causing more power to be dissipated by the hot wire element 44 . Thus, the increase in power dissipated by the hot wire element causes the temperature of element 44 to increase and return to 132.2° C. When this temperature is reached, the voltage on pins 512 and 516 of op-amp 506 will be at equilibrium.
Accordingly, since the circuit regulates the resistance of hot wire element 44 the output of the circuit on line 518 is proportional to the square root of the power removed from the hot wire times two minus 5 volts, for example. Nominal power dissipated by the hot wire element 44 is one-quarter of a watt which is the amount of power needed to keep the hot wire element 44 at 132.2° C. Any heat removed from the hot wire is replaced by applying more power to element 44 . Resistance of the hot wire is regulated to 25 Ohm thus resistance is considered to be constant. Power removed equals the power applied minus the amount needed to maintain the hot wire at 132.2° C. Solving the power formula for voltage: v=(power×resistance)½, any increase in power applied to the hot wire element 44 is also applied to the 25 Ohm resistor. Therefore, the voltage necessary to compensate for power removed from element 44 is doubled.
For proper operation of sensor 10 , the temperature of hot wire element 44 needs to be maintained at 200° C. above ambient temperature. If the ambient temperature is constant there is no need for temperature correction. That is, a constant difference in temperature guarantees the same amount of power will be removed from the hot wire element 44 for a given air flow. However, when a fluid flow sensor is placed in an automobile (as shown in FIG. 8 ), ambient air temperature is not constant. Typically, sensor 10 will be exposed to temperatures below freezing and above boiling. Thus, air flow temperatures lower than expected will cause a larger than desired output voltage and temperatures higher than expected will cause a lower than desired output voltage.
The present invention provides temperature correction to compensate for the variable ambient temperature environment present in an automobile. Temperature correction is achieved through the use of the cold wire element 46 . The cold wire element 46 is placed in resistor network 502 in place of resistor 510 , as illustrated in FIG. 3 . Circuit 500 uses cold wire element 46 for temperature compensation. Element 46 is supported by housing 12 and is placed in the air stream outside of flow passage 40 . Placing cold wire element 46 in the air stream allows the circuit to quickly respond to changes in the ambient air temperature. The temperature of cold wire element 46 will follow the temperature changes of the incoming air. Since the resistance of the cold wire element (500 Ohms) is relatively large compared to the voltage drop across the element, the power dissipated is very small. For example, at 21.1° C. the resistance of element 46 is 500 Ohms with a voltage drop of 2.5 volts. Moreover, the power dissipated by element 46 is 0.0125 watts which results in a temperature increase of about +12.2° C.
Accordingly, the resistance of the cold wire element 46 would increase by 5 Ohms and resistor network 502 resistance ratio would change. For example, the voltage applied to plus pins 512 would equal 505/1005 or 50.25% of the output voltage on line 518 . In turn resistor network 504 will also have to form a ratio equal to 50.25% of the output voltage. Thus, to form the same ratio, the hot wire resistance would need to be maintained at 25.25 Ohm to develop the same resistance ratio of 50.25% thus the hot wire element 44 will be maintained at 200° C. above the cold wire element 46 or 137.7° C. if the ambient temperature is 21.1° C. Cold wire element 46 is +12.2° C. above the ambient temperature of 21.1° C. Thus, the temperature difference that is necessary for handling environmental extremes is maintained. The nominal output of this circuit is still five volts. It takes ¼ watt of power to raise the temperature of the hot wire element by 93.3° C. Solving the power equation for current (i), i=(power/resistance) 1/2 . Thus, current in the hot wire network equals 0.099503 amps ((0.25/25) 1/2 ). The output voltage is then (0.099503×50.25), which is approximately five volts. The circuit in FIG. 3 can dynamically adjust to ambient air temperature changes because the change in the cold wire network is directly proportional to the properties of the hot wire network.
The values for resistance and changes in resistance are solely for explanatory purposes and other values certainly may be used.
Referring now to FIGS. 4 a and 4 b , a perspective view of housing cover 14 is further illustrated, in accordance with the present invention. FIG. 4 a is an inside view of housing cover 14 and FIG. 4 b is an outside view of housing cover 14 . Housing cover 14 is fixedly joined to housing 12 (as shown in FIG. 4 c ) along a protruding ridge 60 and 62 . Ridge 60 protrudes from an inside surface 64 of housing cover 14 and matingly seals with channel 50 disposed on an inside surface 52 of housing 12 . Ridge 62 , protruding from an inside surface 64 of housing cover 14 , matingly seals with channel 54 disposed within surface 52 and around the perimeter of flow passage 40 , thus creating an enclosed and sealed flow passage 40 . Housing cover 14 further includes a window aperture 66 for providing access, during manufacture, to integrated circuit 32 (as shown in FIG. 4 c ). For example, window aperture 66 provides access to integrated circuit 32 during the calibration step in the manufacturing process. Further, as shown in FIG. 4 c , integrated circuit 32 is wire bonded using wire bonds to various terminal and/or bonding pads disposed on housing 12 .
As shown in FIG. 4 b a channel 68 is provided around a perimeter of window 66 to matingly seal the secondary housing cover 16 to housing cover 14 . Further, a side opening 70 allows air exiting flow passage 40 to flow out of both side surfaces 72 and of cover 14 . A ramped portion 75 is included in surface 72 to funnel and direct air passing over the surface toward cold wire element 46
A perspective inside view of secondary housing cover 16 is illustrated in FIG. 5 . Cover 16 includes a perimeter ridge protrusion 80 which matingly seals with housing cover 14 along the perimeter of window 66 and within channel 68 . Secondary housing cover 16 is substantially flat and maybe constructed of a heat conductive material, such as a metal for dissipating heat generated by integrated circuit 32 . As shown in FIG. 1, secondary housing cover 16 has a generally planar outside surface 84 . After cover 16 is positioned on housing cover 14 , both the cover 14 and the secondary housing cover 16 create a longitudinally extending and generally planar surface to insure minimal disturbance of the air flowing around sensor 10 .
A perspective inside view of electronics cover 18 is illustrated in FIG. 6 . In an embodiment of the present invention integrated circuit 32 is bonded to cover 18 and the resulting circuit and cover assembly is loaded into and matingly seals against housing 12 . Cover 18 has a protruding ridge 83 rising from a surface 85 of cover 18 . Protruding ridge 83 sealingly mates with a corresponding channel (not shown), disposed on housing 12 , to create a weather resistant sensor housing. Preferably, cover 18 functions as a heat sink to draw heat emanating from circuit module 32 . In an embodiment of the present invention, heat sink 18 is made from a metallic material or other material having similar thermal conductive properties.
A perspective view of a fully assembled mass fluid flow sensor 10 is illustrated in FIG. 7 a , in accordance with the present invention. A flange 90 is integrally formed in housing 12 and includes a plurality of mounting apertures 92 and 94 . Mounting apertures 92 and 94 receive fasteners (not shown) such as screws for securing sensor 10 to a mounting surface. Further, flange 90 has a mating surface 96 for matingly engaging an engine air intake duct 304 (shown in FIG. 8) as will be described below. Gasket 20 is configured to engage a flange ledge or shelf 98 . Gasket 20 is positioned between engine intake duct 304 and flange 90 to provide an air tight seal between mass fluid flow sensor 10 and air intake duct 304 .
As illustrated in FIG. 7 a , air flows into inlet 38 of mass fluid flow sensor 10 in a direction, as indicated by arrow i, and out of outlet 42 in a direction, as indicated by arrows O. Inlet 38 is generally circular and as illustrated in FIG. 7 b has a generally elliptical cross-section.
With specific reference to FIG. 7 b , elliptical surfaces 200 which define the perimeter of inlet 38 and nozzle 39 . Moreover, as shown, elliptical surfaces 200 converge along a longitudinal axis 202 , creating an inlet and nozzle having a longitudinally converging elliptical surface. This inlet and nozzle configuration is known as a jet nozzle. Further, it is known that this jet nozzle configuration creates a critical area, at the exit of the nozzle, having a uniform fluid flow velocity. As stated above the present invention has improved accuracy as compared to the prior art because, for example, the hot element 44 is located in the critical are and therefore is evenly cooled by incoming fluid.
Referring now to FIG. 8, an exemplary automotive environment in which a mass fluid flow sensor may be operatively disposed is illustrated, in accordance with the present invention. Typically, an automotive vehicle has an air intake manifold 300 for supplying fresh air to the vehicle's engine (not shown). Generally, air intake manifold 300 includes a filter 302 for filtering the intake air and extract contaminants from the air drawn into manifold 300 .
Air intake manifold 300 is typically attached to an air duct 304 for communicating the clean air to the vehicle's engine. As illustrated, mass fluid flow sensor 10 is positioned and fixedly secured to air duct 304 through an aperture 306 in air duct 304 . Outside air is drawn into intake manifold 300 in a direction indicated by arrow A and flows through manifold 300 as indicated by arrows A′ and A″. When the intake air reaches air duct 304 , a portion of the intake air flows into the mass air flow sensor, as indicated by arrow i, and then out of the mass fluid flow sensor as indicated by arrow o. All of the intake air eventually exits air duct 304 and enters the vehicle's engine, as indicated by arrow e. Electrical control signals containing information regarding the amount of air flowing through the air duct 304 , derived from measurements and processing carried out on integrated circuit 32 , is communicated to the vehicle's electronic control systems through a connector 308 and wire harness 310 .
The present invention contemplates an assembly and/or manufacturing method or process for constructing mass fluid flow sensor 10 . In an initial step the resistive elements are electrically connected to the housing using solder or other like material or other bonding process (i.e. resistance welding). At a next step, the electronics cover 18 and integrated circuit assembly 32 is mounted to the housing 12 , using an adhesive or similar material. At a next step, the housing cover 14 is mated to housing 12 and bonded thereto using an adhesive or similar material. At a next step, the assembly is placed in an oven or other environment suitable for curing the adhesive. At a next step, the integrated circuit 32 is wire bonded to terminals and/or bonding pads on housing 12 . At a next step, the integrated circuit 32 is calibrated and/or adjusted and/or resistors disposed within circuit 32 are trimmed. At a next step, the secondary housing cover 16 is mated to housing 12 and bonded thereto using an adhesive or similar material. At a final step, sensor 10 is tested to insure proper function at different operating states and environmental conditions.
Referring now to FIGS. 9 a-e , an alternate embodiment of a mass air flow sensor housing 412 is illustrated, in accordance with the present invention. As in the previous embodiments, housing 412 has a connector end 414 having electrical terminals 415 for communicating electrical signals from the mass air flow sensor to external circuitry (not shown), as illustrated in perspective view of FIG. 9 a and in the cross-sectional view of FIG. 9 b . Connector end 414 further has a flange 416 that enables housing 412 to be mounted to an air duct 304 of an air intake of an engine (see FIG. 8 ), for example.
Additionally, housing 412 has a central portion 418 and an air sampling end 424 . Central portion 418 includes an aperture 420 for receiving a circuit module 422 . At air sampling end 424 , an air sampling passage 426 is disposed. Air sampling passage 426 includes an inlet 428 , a sampling channel 430 , and an outlet 432 . Sampling channel 430 is in-molded or integrated into air sampling end 424 . More specifically, sampling channel 430 has two portions a housing portion 430 a and a housing cover portion 430 b , as shown in FIGS. 9 a and 9 c . The housing portion 430 a is in-molded or integrated into housing 412 and housing cover portion 430 b is in-molded or integrated into housing cover 414 . When the housing cover 414 is bonded to housing 412 the two portions, housing portion 430 a and housing cover portion 430 b mate to form a uniform tubular sampling channel 430 .
To further enhance the flow of fluid through channel 430 a wedge deflector 445 is positioned on an end of housing 412 upstream of outlet 442 . Wedge deflector 445 has a surface that is tilted (with respect to a horizontal) to create an advantageously low pressure area adjacent outlet 432 . If the angle of the surface of deflector 445 (indicated by the letter a in FIG. 9 b ) is too small with respect to the direction of fluid flow an insufficient pressure drop is created at outlet 432 . Conversely, if the angle of the surface of deflector 445 is too large with respect to the direction of fluid flow (and horizontal line h) an insufficient pressure drop is created at outlet 432 . Preferably, the angle α of the surface of deflector 445 is between 47° and 60° with respect to the horizontal line h.
In a preferred embodiment channel 430 includes an expansion tube portion 431 , a re-directional portion 433 and channel exit portion 435 . Expansion tube portion has a length I e (see FIG. 9 e ) and extends from the nozzle exit to the entrance of re-directional portion 433 . The re-directional portion 433 is semi-circular in shape and extends from the expansion tube portion to the channel exit portion. Further, re-directional portion 433 has an inner wall having a constant inner radius r l and an outer wall having a constant outer radius r o (see FIG. 9 e ). Thus, the present invention provides a sampling channel 430 having reduced turbulent flow.
Disposed within the fluid sampling passage 426 is a thermal sensor 434 . Thermal sensor 434 is in communication with circuit module 422 for detection and signal processing of electrical signals indicative of a change in power dissipation of thermal sensor 434 . Processed and/or conditioned signals are then communicated through an electrical lead frame to terminals 415 for communication to external circuitry.
Inlet 428 of fluid sampling passage 426 is configured to have elliptically converging interior surfaces 436 that define a jet nozzle 437 , as shown in FIG. 9 b . Thermal sensor 434 is positioned at an exit 438 of jet nozzle 437 . Again, channel 430 of fluid sampling passage 426 is preferably tubular in shape. Further, the jet nozzle exit 438 has a diameter e that is less than a diameter t of tubular channel 430 , as shown in the partial-expanded view of fluid sampling end 424 of FIG. 9 d . The different diameters of jet nozzle exit 438 and tubular channel 430 create a transitional section 460 at the interface of nozzle exit 438 and channel 430 . A fully annular vortices is created in transitional section 460 . Such a controlled fully annular vortices spins within transitional section 460 creating a fluid bearing 502 which extends circumferentially around the nozzle exit 438 (see FIG. 9 e ). Fluid bearing 502 creates a substantially frictionless area at transitional section 460 that promotes (enhances) fluid flow through sampling channel 430 .
With specific reference to FIG. 9 e , a computational fluid dynamics diagram indicating the direction and velocity of fluid flowing through channel 430 is illustrated. As shown, fluid enters inlet 428 and the velocity and pressure of the fluid rises as the fluid moves toward nozzle exit 438 . At the transition from the nozzle exit to channel 430 opening the pressure and velocity of the fluid drops dramatically due to the channel diameter t being larger than the diameter e of the nozzle exit (shown in FIG. 9 d ). As previously stated, channel 430 includes expansion tube portion 431 having an expansion tube length I e . The expansion tube has generally straight walls and runs between nozzle exit 438 and an entrance 514 of re-directional portion 433 of channel 430 . The length of the expansion tube is predetermined such that at a maximum fluid flow velocity the fluid contacts or “attaches” to a wall 510 of the expansion tube before reaching an end 512 of expansion tube 431 . The Fluid bearing 502 creates a low pressure at nozzle exit 438 . Thus, fluid is pulled through the nozzle and into the sampling channel 430 to wall 510 of the channel and prevents fluid from re-circulating backward in the channel. Therefore, the present invention has many benefits over the prior art. For example, the present invention has increased dynamic range, such that the mass fluid flow may be determined at very low fluid intake speeds as well as at very high fluid intake speed.
Referring now to FIGS. 10 and 11 a-b , an alternative sensor housing 600 is illustrated, in accordance with the present invention. Housing 600 includes a connector portion 602 , a mounting portion 604 , a circuit portion 606 , and a fluid flow sampling portion 608 . Connector portion 602 cooperates with a mating connector portion (not shown), in a conventional manner, to produce a secure mechanical as well as electrical connection.
Mounting portion 604 includes a plurality of mounting apertures 610 for mounting sensor housing 600 to a fluid flow duct 622 (shown in FIG. 11 a ). Further, mounting portion 604 is configured to reduce movement of sensor housing 600 especially in an x-direction where the x-direction is perpendicular to a fluid flow direction fd. To that end, a sealing ledge 612 is provided in mounting portion 604 to receive a gasket 614 (shown in FIG. 11 a ). Gasket 614 seats against a side surface 611 of ledge 612 and an underside surface 616 of mounting portion 604 . Further, when housing 600 is mounted to a duct interface 620 of fluid carrying duct 622 , gasket 614 is compressed against an inclined surface 624 of mounting interface 620 . Thus, a three surface contact seal is achieved where gasket 614 contacts side surfaces 611 , underside surface 616 and inclined surface 624 (as shown in FIG. 11 b ). This three surface contact seal provides enhanced sealing between housing 600 and duct 622 as well as dampen lateral and transverse movement of the housing within the duct. Preferably, inclined surface 624 is inclined at an angle between 40 and 70 degrees with respect to a top surface 626 of mounting interface 620 .
Housing 600 is mounted to mounting interface 620 through mechanical attachment of mounting portion 604 to mounting interface 620 . For example, by fastening means such as screws or bolts through apertures 610 and mounting interface apertures 628 in mounting interface 620 .
With continuing reference to FIG. 11 a , improved housing 600 is further illustrated. Improved housing 600 provides ribs and/or gussets 650 at a transition area 652 that connects circuit portion 606 with fluid flow portion 608 . Gussets 650 are configured to reduce torque effects on fluid flow portion 608 . More specifically, gussets 650 are angled toward the mass moment of inertia of housing 600 about a longitudinal axis of the housing. This configuration reduces movement of fluid flow portion 608 with respect to circuit portion 606 . Further, advantageously housing 600 has enhanced virbrational characteristics to reduce twisting or torquing of the circuit portion 606 for example corner ribbing 654 as provided in circuit chamber 656 . Corner ribbing 654 is preferable over square (90° corners) or radius corners for enhancing the structural stability of the circuit chamber.
Referring now to FIG. 12, a cross-sectional view through housing 600 is illustrated, in accordance with the present invention. Heat sink cover 700 as illustrated in FIG. 10 is mounted to circuit portion 606 of housing 600 . An inside view of cover 700 is further illustrated in FIG. 11 a as viewed through circuit chamber 656 . Heat sink cover 700 includes a plurality of ribs/fins 702 . Ribs/fins 702 serve at least two purposes provide enhanced (1) structural stability to the cover and (2) heat dissipation through the cover. Cover 700 mates with housing 600 by the cooperation of a tongue 706 protruding from a peripheral surface 704 of cover 700 . Tongue 706 mates with a groove 708 and is sealed using an epoxy or similar material.
With respect to assembly, a circuit module or integrated circuit (not shown) is placed adjacent to cover 700 to allow heat buildup in the circuit to dissipate through cover 700 and ribs/fins 702 . Heat sink cover 700 further provides a grounding plane for the circuit module. For this purpose, a grounding post 710 is formed in cover 700 . The circuit module is wire bonded to grounding post 710 to achieve an electrical ground reference.
Referring now to FIG. 13, an exploded view of fluid flow sampling portion 608 is illustrated, in accordance with the present invention. As previously described, a hot element 800 is mounted at an outlet of the fluid flow nozzle. A pair of hot element posts 802 and 804 are provided on either side of the outlet for mounting wire leads 806 and 808 of hot element 800 . Hot wire posts 802 and 804 facilitate the mounting of hot wire element 800 thereto by providing a flat surface that extends into the fluid flow sampling chamber. Moreover, this mounting scheme does not interfere with fluid bearing 502 shown in FIG. 9 e . Thus, the present housing 600 configuration provides reduced manufacturing complexity, for example.
The foregoing discussion discloses and describes a preferred embodiment of the invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that changes and modifications can be made to the invention without departing from the true spirit and fair scope of the invention as defined in the following claims. | A mass fluid flow sensor for determining the amount of fluid inducted into an internal combustion engine, for example, is disclosed. The mass fluid flow sensor includes an external intake fluid temperature element which improves the accuracy of the mass fluid reading. An external cold wire element is further provided which improves response time. The mass fluid flow sensor has an improved aerodynamic design which provides a lower system pressure drop. A molded one-piece isolated jet nozzle having a hot element disposed therein is included in a fluid sampling portion. The fluid sampling portion has a tubular sampling channel, wherein the sampling channel has one bend having a constant bend radius. Consequently, an improved lower internal flow passage pressure drop is achieved. Additionally, an improved signal to noise ratio, as well as a larger dynamic range is an advantageous consequence of the present invention. A three surface contact seal is provided between the sensor housing and an intake duct to further enhance the vibrational characteristics of the sensor. | 6 |
FIELD OF THE INVENTION
The present invention pertains generally to a computer apparatus and method facilitating marketing promotions.
BACKGROUND OF THE INVENTION
Retailers, manufacturers, and others use a number of marketing methods to attract customers to their products. Typical marketing campaigns include advertising promotion, contest and prize give-aways, discount coupons, and an array of similar techniques. Managing such promotional campaigns is a costly and labor intensive undertaking.
SUMMARY OF THE INVENTION
A computer system and method are disclosed for automating advertising and promotional campaigns. The computer system of the present invention includes a magnetic stripe card reader, bar code reader, monitor, printer, keyboard, and touchscreen input device. Software executing on the computer manages the operations of these devices. The present invention provides means for displaying advertisements on the monitor. The software also comprises means for attracting customers to the computer system thus enhancing the effectiveness of the advertisements. The means for attracting customers is comprised of means for managing promotional sweepstakes, displaying product or store locator maps, dispensing coupons, accepting product orders, and managing customer surveys. The computer system of the present invention can communicate with a centralized site thereby providing centralized control of remote installations. Files, programs, and other data may be electronically transmitted from the central site to the computer system. In addition, player logs, consumer surveys, enrollment files, product ordering files, in error logs, and other data may be electronically transmitted from the computer system of the present invention to the central site.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, where like numerals referred to like elements throughout the several views:
FIG. 1 is a block diagram describing a computer system and associated peripheral devices according to the present invention;
FIG. 2 is a block diagram describing a first alternative configuration for said computer system;
FIG. 3 is a block diagram describing a second alternative configuration for said computer system and;
FIG. 4 is a third alternative configuration for said computer system;
FIG. 5 is a block diagram describing a fourth alternative configuration for said computer system;
FIG. 6 is a flow chart describing the, startup sequence routine;
FIG. 7 is a flow chart describing the promotion network program;
FIG. 8 is a flow chart describing the set-up routine;
FIG. 9 is a flow chart describing the flash ad set-up routine;
FIG. 10 is a flow chart describing the promotion set-up routine;
FIG. 11 is a flow chart describing the product locator set-up routine
FIG. 12 is a flow chart describing the store locator set-up;
FIG. 13A and 13B combined are a flow chart describing the coupon set-up functions;
FIG. 14 is a flow chart describing the survey set-up routine;
FIG. 15 is a flow chart describing the promotion network routine;
FIG. 16 is a flow chart describing the flash ad routine;
FIG. 17 is a flow chart describing the show routine;
FIG. 18 is a flow chart describing the read touch screen routine;
FIG. 19 is a flow chart describing the main menu routine;
FIG. 20A and 20B combined are a flow chart describing the promotion program routine;
FIG. 21 is a flow chart describing the card reader routine;
FIG. 22 is a flow chart describing the read serial port routine;
FIG. 23 is a flow chart describing the bar code routine;
FIG. 24 is a flow chart describing the touch screen entry routine;
FIG. 25 is a flow chart describing the keyboard entry routine;
FIG. 26 is a flow chart describing the promotion routine;
FIG. 27 is a flow chart describing the product locator routine;
FIGS. 28A and 28B combined are a flow chart describing the list products routine;
FIG. 29 is a flow chart describing the store to locator routine;
FIG. 30A and 30B combined are a flow chart describing the display stores routine;
FIG. 31A and 31B combined are a flow chart describing the coupon routine;
FIG. 32 is a flow chart describing the specials routine;
FIG. 33 is a flow chart describing the events routine;
FIG. 34 is a flow chart describing the order processing routine;
FIG. 35A and 35B combined are a flow chart describing the display item routine;
FIG. 36 is a flow chart describing the survey routine;
FIG. 37 is a flow chart describing the enrollment routine;
FIG. 38 is a flow chart describing the enrollment card reader routine;
FIG. 39 is a flow chart describing the enrollment touch screen routine;
FIG. 40 is a flow chart describing the enrollment keyboard routine;
FIG. 41 is a flow chart describing the system help routine;
FIG. 42 is a block diagram describing the enrollment file;
FIG. 43 is a block diagram describing the orders file;
FIG. 44 is a block diagram describing the events file;
FIG. 45 is a block diagram describing the specials file;
FIG. 46 is a block diagram describing the player log files;
FIG. 47 is a block diagram describing the order processing file;
FIG. 48 is a block diagram describing the survey question file;
FIG. 49 is a block diagram describing the coupon file;
FIG. 50 is a block diagram describing the coupon/text directory listing file;
FIG. 51 is a block diagram describing the store file;
FIG. 52 is a block diagram describing the product file;
FIG. 53 is a block diagram describing the promotion winners list file;
FIG. 54 is a block diagram describing the flash ad script file;
FIG. 55 is a block diagram describing the system pictures file;
FIG. 56 is a block diagram describing the ad pictures file;
FIG. 57 is a block diagram describing the error file;
FIG. 58 is a block diagram describing the counts file;
FIG. 59 is a block diagram describing the frequent shopper file;
FIG. 60 is a block diagram describing the frequent shopper prize file;
FIG. 61 is a flow chart describing the frequent shopper set-up routine;
FIG. 62 is a flow chart describing the counts set-up routine;
FIG. 63A and 63B combined are a flow chart describing the frequent shopper routine;
FIG. 64A and 64B is a flow chart describing the read frequent shopper file routine;
FIG. 65 is a flow chart describing the check prize level routine;
FIG. 66 is a flow chart describing the write frequent shopper file routine;
FIG. 67 is a block diagram describing the phone number file;
FIG. 68 is a block diagram describing the instruction buffer file;
FIG. 69 is a flow chart describing the receiver routine;
FIG. 70 is a flow chart describing the dial back routine;
FIG. 71A and 71B are a flow chart describing the receive routine;
FIG. 72 is a flow chart describing the instruction routine;
FIG. 73 is a flow chart describing the frequent purchase routine;
FIG. 74 is a flow chart describing the view balance routine; and
FIG. 75 is a flow chart describing the dial frequent shopper database routine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following detailed description of the preferred embodiment, reference is made to the accompanying drawings which form a part hereof and in which is shown by way of illustration a specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized without departing from the scope of the present invention.
The present invention is a Mall Promotion Network Computer System and Method. The Mall Promotion Network automates marketing campaigns and advertising. When located in a mall, or similar retail area, the Mall Promotion Network will control sweepstakes, frequent buyer and other similar frequency programs, discount coupons, prizes, give-aways, rebates, and, of course, visual advertising.
In national sweepstakes promotions, national "Fortune 500" companies and other organizations would use the Mall Promotion Network to distribute prize notifications and advertise to attract customers to their products. A direct mail campaign distributes magnetic or bar code cards (similar to credit cards) to selected customers in the geographic vicinity of a retail mall or similar shopping area. These customers would bring the cards to the Mall Promotion Network kiosk located at a mall and scan their cards through a card reader. If the customer has a winning number, they would be awarded a prize. If the customer doesn't win a prize, they might still be awarded a coupon or discount for merchandise.
Stores or manufacturers could prepare promotions. Buyers of products would be given a "chit" (which is a receipt or "playing card") with a bar code printed thereon. This chit would be scanned by the present invention and a customer could win a prize as a result. Again, if the customer doesn't win a prize, they could still be awarded a coupon or some type of discount (although not necessarily from the store running the promotion).
It is envisioned that the Mall Promotion Network could award coupons or prizes based on the number of visits the amount of the purchases the customer makes to the mall or retail outlet where the present invention is located. The Mall Promotion Network would track the frequency of the card scans and award coupons, discounts, rebates, or prizes based on a schedule and the number of visits. If the card is scanned at the same time that a chit is scanned, the Mall Promotion Network could track the number of visits or by the customer purchases and award prizes on this basis as well.
The Mall Promotion Network can dispense discount coupons at the customer's request. Retail outlets, manufacturers, and the mall management would pay to place their coupons on the system.
The Mall Promotion Network can dispense coupons which entitle a customer to free gifts given away by manufacturers, retail outlets, or the mall itself. The number of free gifts to be dispensed can be set at a predetermined number to limit the liability of the sponsor. Access to such prizes can also be controlled through the use of the magnetic cards and chits.
The Mall Promotion Network can issue rebate tickets to customers upon request. Thus, it is possible to electronically transmit the rebate to the manufacturers thereby eliminating the need for the user to mail the rebate form.
The Mall Promotion Network can issue discount tickets at a customer's request. These discount tickets typically permit a customer to purchase any item in a particular store at a price reduced by flat percentage.
Finally, the Mall Promotion Network permits the display of electronic advertisements. Sophisticated images can be displayed on the computer system's monitor. These displays would, of course, be paid for by the manufacturer or the retail outlet featuring the product.
FIG. 1 is a block diagram describing the preferred configuration of the computer hardware components of the present invention. Shown in FIG. 1 is a computer 10 with some amount of memory 12. The computer 10 includes a monitor 14 interfaced to the computer 10 by means of a video card 16. The computer 10 has a number of associated peripheral devices, including a hard drive 18, floppy drive 20, modem or satellite interface 22, magnetic stripe reader 24, bar code reader 26, touch screen input 28, keyboard 30, and a printer 32. The modem or satellite interface 22 permits communications between the computer 10 and a centralized control site. This communications link permits centralized control of remote installations. Database files, programs, and other data may be downloaded to the computer 10. In addition, the communications link provides for centralized data gathering. Data from player logs, consumer surveys, enrollment files, product ordering, and error logs may be uploaded to the centralized control site. Although FIG. 1 describes the preferred embodiment, four alternative embodiments have also been developed.
FIG. 2 is a block diagram describing a first alternative configuration of the computer system and associated peripherals. This first alternative is comprised of a centralized PC directly controlling the operations of a plurality of Amiga PCs 38. The Amiga PCs 38 generate the graphics for display on the monitors 14. Thus, this particular configuration permits the Mall Promotion Network software to reside on the centralized PC 34 and offload graphics generation to the Amiga PCs 38.
FIG. 3 is a block diagram of a second alternative configuration for the computer system and associated peripherals. In this configuration, computers such as those described in FIG. 2 or FIG. 1 communicate with a centralized PC 42 by means of a communications network 40.
FIG. 4 is a block diagram describing a third alternative configuration to the computer system and associated peripherals. In this configuration, the Amiga PCs 38 are used for both graphics generation and for executing the control program software. The Amiga PCs 38 are linked by means of a communications network 40, thus providing for the centralized control and data gathering.
FIG. 5 is a block diagram describing a fourth alternative configuration for the computer system and associated peripherals. In this configuration, the computer 10 employs a laser disk 44 as a means of providing TV quality images. The laser disk 44 also permits the use of "rolling video", such as that seen on normal TV. The computer 10 can still generate graphics images and display them on the monitor 14 by means of the video card 16. The laser disk 44 is attached to the monitor 14 by means of a gen-lock device 46. The gen-lock device 46 accepts input from both the laser disk 44 and the computer 10 and combines the two into the appropriate image for display on the monitor 14.
FIG. 6 is a flow chart describing the functions of the startup sequence routine. When the control program means on the computer 10 begins executing, the startup sequence routine is the first routine executed. The startup sequence sets the program stack size (48), the system time (50), and initializes the data base. The ad picture files are copied from either the floppy disk 20 or the hard disk 18 into a RAM disk within the memory 12 (52). The structure of the ad picture files is described in FIG. 56. In a similar fashion, the system picture files are copied to the RAM disk in the memory 12 (54). The structure of the system picture files is described in FIG. 55. All the necessary program files, described herein below, are also copied to the RAM disk (56). The current directory is changed to point at the RAM disk (58). The operating system is told to execute the promotion network program (60) or the receiver routine (61), and the startup sequence terminates (62).
FIG. 7 is a flow chart describing the functions of the promotion network program. This is the main routine in the Mall Promotion Network software. The promotion network program never terminates, it runs forever, or at least until the computer 10 is turned off. The promotion network program starts (64) when executed by the startup sequence as described in FIG. 6. First, it executes the set-up routine (66). Upon completion of the set-up routine, an "infinite" loop is entered. Within the loop, the first step is to execute the flash ad routine (68). After this routine completes, the main menu routine is executed (70). Control returns from the main menu routine when a customer enters a selection or if a timer expires (72). If a timer expires, control transfers back to the beginning of the loop to re-execute the flash ad routine (68). Statistics concerning the customer selection are gathered for later marketing or performance analysis (73). Statistics are gathered in the counts file described in FIG. 58. Each record 1166 in the counts file is comprised of a customer ID 1168 and an array of counters 1170. The frequency of customer selections is stored in the array of counters 1170. If a customer entered a selection, then the selected program is executed (74). The promotion network program determines which one of a plurality of programs has been requested (76 and 80). Upon completion, control transfers back to the main menu routine (70). If the customer does not exit from the selected program, the program will time-out (78). In the case of a time-out, control is not returned to the main menu program (70), but instead, the flash ad routine is reexecuted (68).
FIG. 8 is a flow chart describing the functions of the set-up routine. The set-up routine starts (82) when executed by the promotion network program as described in FIG. 7 (66). If a product locator file exists (84), then the product locator set-up routine is executed (86). If a store locator file exists (88), then the store locator set-up routine is executed (90). If a coupons/text directory file exists (92), then the coupon set-up routine is executed (94). If a survey question file exists (96), then the survey set-up routine is executed (98). If an order processing file exists (100), then the order processing set-up routine is executed (102). If a frequent shopper file exists (101) then the frequent shopper set-up routine is executed (103). Finally, the counts set-up routine is executed (104). Upon completion, control is returned to the promotion network program (105).
FIG. 9 is a flow chart describing the functions of the flash ad set-up routine. The flash ad set-up routine starts (106) when executed by the flash ad routine as described in FIG. 16 (316). The flash ad set-up routine initializes the flash ad error flag (108) and the flash ad script file is opened (110). The structure of the flash ad script file is described in FIG. 54. If the script file does not exist (112), then the flash ad error flag is set (116), a message is written to the error file (122, 126, and 130) and the flash ad set-up routine terminates (132). If the script file does exist (112), then the error code is cleared (114), and a read is issued against the flash ad script file (120). If the read returns a record 1106, and not an end-of-file indicator (124), then the flash ad picture name 1108 and display time 1108 are added to the list in memory 12 (118), and the routine prepares to read the script file again (114). When an end-of-file indication occurs (124), the script file is closed (128), and the flash ad set-up routine (132).
FIG. 10 is a flow chart describing the functions of the promotion set-up routine. The promotion set-up routine starts (134) when executed by the promotion program as described in FIG. 20 (404). The promotion error flag is initialized (136), and the requested promotion winners list file is opened (138). The structure of the promotion winners list file is described in FIG. 53. If the open operation fails (140), then a promotion error flag is set (144), a message is written to the error file (148, 152, and 156), the error file is closed and the promotion set-up routine terminates (158). If the requested promotion winners list file opened correctly (140), then a loop is entered whereby the winning numbers are read into an array in memory 12. A read is issued for each promotion winners list record 1100 (142). Each record 1100 contains a sweepstakes number 1102 and a prize description 1104 (146). All the sweepstakes numbers 1102 and prize descriptions 1104 are read until an end-of-file indication occurs (150). Upon the occurrence of this indication, the requested promotion winners list file is closed (154), and the promotion set-up routine terminates (158).
FIG. 11 is a flow chart describing the functions of the product locator set-up routine. The product locator set-up routine starts (160) when executed by the set-up routine as described in FIG. 8 (86). The product locator error flag is initialized (162), and an open is attempted against the product file (164). The structure of the product file is described in FIG. 52. If the open operation fails (166), then the product locator error flag is set (170), a message is written to the error file (174, 180, and 184), and the product locator set-up routine terminates (186). If the open of the product file is successful (166), then a loop is entered to read records 1092 from the product file. Each record 1092 contains a product name 1094 (168) and the product image coordinates 1096 (176) and 1098 (172). The coordinates 1096 and 1098 indicate the placement of a pointer on a product locator map. All records 1092 in the product file are read until an end-of-file indication occurs (178). Upon this indication, the product pointer set-up routine is executed (182), and the product locator set-up routine terminates (186).
FIG. 12 is a flow chart describing the functions of the store locator set-up routine. The store locator set-up routine starts (188) when executed by the set-up routine as described in FIG. 8 (86). The store locator error flag is initialized (190), and an open is attempted against the store file (192). The structure of the store file is described in FIG. 51. If the open operation fails (194), then the store locator error flag is set (200), a message is written to the error file (204, 210, and 214), and the store locator set-up routine terminates (216). If the open of the store file is successful (194), then a loop is entered to read records 1082 from the store file. Each record 1082 contains a store name 1084 (198), store category 1086 (206), and the store image coordinates 1088 (202) and 1090 (196). The coordinates 1088 and 1090 indicate the placement of a pointer on a store locator map. All records 1082 from the store file are read until an end-of-file indication occurs (208). Upon this indication, the store pointer set-up routine is executed (212), and the store locator set-up routine terminates (216).
FIGS. 13A and 13B combined are a flow chart describing the functions of the coupon set-up routine. The coupon set-up routine starts (218) when executed by the set-up routine as described in FIG. 8 (94). The coupon/text directory listing is accessed (220) and examined to determine if there are any coupons (222). The structure of the coupon/text directory file is described in FIG. 50. If there are no coupon file names 1080, a coupon error flag is set (224), and the coupon set-up routine terminates (252). If there are coupon file names 1080 (222), they are copied to memory 12 (226). The first coupon file name is accessed from the memory 12 (228), and a loop is entered to read each file in turn. As each file name is accessed from the memory 12, the corresponding coupon file is opened (230). The structure of the coupon file is described in FIG. 49. If the coupon file fails to open correctly (232), then a message is written to the error file (238, 242, and 246), and the coupon file name is removed from the memory 12 (248). If the coupon file opens correctly (232), then the coupon file is read for the coupon text 1072, 1074, and 1076 (236) and the number of coupons to print 1076 (240). After reading the coupon file record 1068, the coupon file is closed (244). This sequence is repeated for the next coupon file name in the memory 12 (234), until there are no more coupon file names to access (250). Following the last coupon file name (250), the coupon set-up routine terminates (252).
FIG. 14 is a flow chart describing the functions of the survey set-up routine. The survey set-up routine starts (254) when executed by the set-up routine as described in FIG. 8 (98). The survey error flag is initialized (256), and the survey question file is opened (258). The structure of the survey question file is described in FIG. 48. If the survey question file does not open correctly (260), then the survey error flag is set (262), a message is written to the error file (266, 270, and 274), and the survey set-up routine terminates (282). If the survey question file opened correctly (260), then a loop is entered to read the survey question records 1036 into the memory 12. The survey question file is read first for questions, for example, questions 1038, 1052, or 1060 (264). Immediately following each question 1038 and 1052 are multiple answers 1040-1050 and 1054-1064 (268). When all questions are read (278), the survey question file is closed (280), and the survey set-up routine terminates (282).
FIG. 15 is a flow chart describing the functions of the order processing set-up routine. The order processing set-up routine starts (284) when executed by the set-up routine as described in FIG. 8 (102). The order processing error flag is initialized (286), and the order processing file is opened (288). The structure of the order processing file is described in FIG. 47. If the order processing file does not open correctly (290), then the order processing error flag is set (294), a message is written to the error file (298, 302, and 306), and the order processing set-up routine terminates (312). If the order processing file opens correctly (290), then a loop is entered to read the records 1028 from the order processing file (292). Each record 1028 includes the item number 1030 (300), the item picture name 1032 (304), and the item price 1034 (308). All this information is stored in memory 12. When an end-of-file indication occurs (296) the order processing file is closed (310), and the order processing set-up routine terminates (312).
FIG. 16 is a flow chart describing the functions of the flash ad routine. The flash ad routine starts (314) when executed by the promotion network program as described in FIG. 7 (68). First, the current count file record 1166 (i.e. for the prior customer) is written to the counts file and a new counts file record 1166 is initialized (315). The flash ad set-up routine is executed (316). Upon completion, the flash ad error flag is examined to determine if an error occurred (318). If the error flag is set (318), then the show routine is executed to display the advertising promotion screen (322). Next, the read touch screen routine is executed (326). If the screen was not touched (330), then the show routine (322) and the read touch screen routine (326) are executed again. If the screen was touched (330), then the flash ad routine is terminated (344). If the flash ad set-up routine did not return an error (318), then the current flash ad is displayed on the monitor 14 (320). If the flash ad did not display correctly (324), then the flash ad pointer is incremented (334) to a new flash ad entry which displays on the monitor 14 (320). During this incrementing process, the pointer is reset to the first entry in the table (342) if it increments beyond the end of the table (338). If the picture is displayed correctly on the monitor 14 (324), then the read touch screen routine is executed (328). The return code from the read touch screen routine is evaluated to determine if an error occurred or if valid data was entered by the customer (332). If an error occurred, then the flash ad pointer is incremented (334) and the next flash ad is displayed in the monitor occurs (320). If valid data was entered by the customer (332), then the picture screen is closed (336), the picture memory is deallocated (340), and the flash ad routine terminates (344).
FIG. 17 is a flow chart describing the functions of the show routine. The show routine (346) is executed to display pictures on the monitor 14 such as described in FIG. 16 (320). The picture file name is passed as a parameter to the show routine and the requested picture file is opened (348). The structure of the system and ad picture files are described in FIGS. 55 and 56 respectively. Each record 1112 in a picture file includes a raster width 1114, a raster height 1116, an x image position 1118, a y image position 1120, the number of bit planes 1122, a pad byte 1124, a transparent color 1126, an x aspect 1128, a y aspect 1130, the page width 1132, the page height 1134, and the body of the picture 1136. If an error occurs during the open operation (350), then a message is written to the error file (360, 364, and 366), and the show routine terminates (368). If the file opens correctly (350), then the picture size is determined (352) and a portion of the memory 12 is allocated for the picture (354). If the memory allocation step fails (356), then a message is written to the error file (360, 364, and 366), and the show routine terminates (368). If the memory allocation succeeds (356), then the picture image is loaded into the allocated memory space (358). Once in memory, the picture can then be displayed on the monitor 14 (362) and the show routine terminates (368).
FIG. 18 is a flow chart describing the functions of the read touch screen routine. The read touch screen routine starts (370) when user input is desired, for example, as described in FIG. 16 (326) and (328). First, the touch screen counters are initialized (372) and the system time is read into a timer variable (374). A loop is entered whereby user input is accepted during a timed read operation. The timed read operation begins by waiting for a read signal (376). Once the user input is accepted, or a timer indicates that the program has waited long enough for user input, the read touch screen routine terminates (390). When the read signal occurs, a units value is read from the touch screen (378) and then a tens value is read from the touch screen (380). The tens and units values are converted into a number (382) and that number is examined to determine if it has the value zero (384). If the value is non-zero, then valid user input was read, and the read touch screen routine terminates (390). If the number has the value of zero (384), then it must be determined whether the timer has expired. The system time is read (386) and the system time is compared to the prior system time read during initialization (388). If the comparison indicates that the timer has not expired, then the read touch screen routine transfers control to await another read signal (376). If the timer has expired (388), then the read touch screen routine terminates (390).
FIG. 19 is a flow chart describing the functions of the main menu routine. The main menu routine starts (392) when executed by the promotion network program as described in FIG. 7 (70). The main menu routine executes the show routine to display the menu screen on the monitor 14 (394). The read touch screen routine is executed to accept user input (386). The touch pad number value is converted into a selection (398), and the selection is returned to the calling program as the main menu routine terminates (400).
FIGS. 20A and 20B combined are a flow chart describing the functions of the promotion program routine. The promotion program routine starts (402) when executed by the promotion network program as described in FIG. 7 (76). The promotion set-up routine is executed and the promotion1 winners list file name is passed as a parameter (404). Upon return from the promotion set-up routine, the promotion error flag is examined (406). If an error occurred (406), then the show routine is executed to display an error screen (416). The read touch screen routine is executed (420) to provide a timer for the error screen display, following which the promotion program routine terminates (446). If the promotion error flag is not set (406), then the show routine is executed to display the instruction screen (408). The user must input a player number (410) by means of a card reader 24, bar code reader 26, touch screen 28, or keyboard 30 (412). If a device error occurs during user input (414), then an error screen is displayed (416) for a predetermined amount of time (420) before the promotion program routine terminates (446). If no error occurs on the user input (414), then the player number is compared with the sweepstakes numbers 1102 in the promotion winners list (418). If a match is found, then the show routine is executed to display a winner instruction screen (426). A list of instructions are also sent to the printer 32 (430). If the player's number did not match any of the sweepstakes numbers 1102 in the promotion winners list (424), then the show routine is executed to display a non-winning instruction screen (422). It is possible for the system to send to the printer 32 a consolation prize or a different set of instructions (428). Immediately following the check of the promotion winners list, the player log file is opened (432). The structure of the player log file is described in FIG. 46. If the open fails for some reason (434), a message is written to the error file (438, 442, and 444), and the promotion program routine terminates (446). If the player log file is opened correctly (434), then the current player information, including the player id number 1022, the player name 1024, and the access time 1026, is written to the player log file (436). The player log file is then closed (440) and the promotion program routine is terminated (446).
FIG. 21 is a flow chart describing the functions of the card reader routine. The card reader routine starts (448) when executed by a higher level routine requesting input from a customer. The card reader routine sets the baud rate, the number of stop bits, the parity type, and the duplex mode for the card reader device 24 (450). The read serial port routine is then executed (452), and the card reader routine terminates thereafter, returning either the user input or device error (456).
FIG. 22 is a flow chart describing the functions of the read serial port routine. The read serial port routine starts (458) when executed by a higher level routine, such as the card reader routine described in FIG. 21 (452). The requested parameters for the serial I/0 are set (460), and the error code is initialized (462). An initial check is made of the status of serial device (464). If the serial device is not on (466), then the error code is set (486), and the read serial port routine terminates (490). If the serial device is on (466), then the specific serial request is set-up (468). The system clock is read (470) to provide a timer for the I/0 operation (472). An I/0 loop is entered, whereby the serial port is checked periodically for user input (476). If there was no user input (482), then the system clock is read (480) and compared with the timer value set earlier (478). If 20 seconds, or some other pre-determined period, have passed (474), then the error code is set (486), and the read serial port routine terminates (490). If the 20 second period has not expired (474), then the serial port is checked once again for user input (476). When user input is finally signalled (482), then the input is read from the serial device (484), and the serial port is closed (488). The read serial port routine terminates and returns the user input (490).
FIG. 23 is a flow chart describing the functions of the bar code routine. The bar code routine starts (492) when executed by a higher level routine, such as the promotion program described in FIGS. 20A and 20B (412). The bar code routine sets the baud rate, the number of stop bits, the parity, and the duplex mode for the bar code reader 26 (494). The read serial port routine is then executed (496). Upon acceptance of the user input, the bar code routine terminates and returns the user input or a device error (498).
FIG. 24 is a flow chart describing the functions of the touch screen entry routine. The touch screen entry routine starts (500) when executed by a higher level program, such as the promotion program described in FIG. 20A and 20B (412). The show routine is executed to display the touch screen keyboard (502). A loop is then entered to await the user input. The read touch screen routine is executed (504) and the results returned from the read touch screen routine are examined to determine if a character was entered (506). If a character was not entered (506), the information screen is set as a null string (512), and the touch screen entry routine terminates (518). If a character was entered (506), then the touch screen pad number is converted to a character (508). The character is displayed on the monitor 14 (510) and is added to the information string (514). If the character is not the last character of user input (516), then the read touch screen routine is executed once again (504). If the last character of user input has been processed (516), then the information string is returned to the calling program (518).
FIG. 25 is a flow chart describing the functions of the keyboard entry routine. The keyboard entry routine starts (520) when executed by a higher level routine, for example, the promotion program routine described in FIGS. 20A and 20B (412). The keyboard entry routine is comprised of a control loop that waits for user input from the keyboard 30. The keyboard 30 is checked to determine if a character has been entered (522). If a character was not entered (524), then the information string is set as a null string (530), and the keyboard entry routine terminates (536). If a character was entered (524), then the touch screen pad number is converted to a character (526), the character is displayed on the monitor 14 (528), and the character is added to the information string (532). If the character was not the last character of the user input (534), then the keyboard 30 is checked for input once again (522). If the character was the last character of user input (534), then the keyboard entry routine terminates and returns the information string to the calling in program (536).
FIG. 26 is a flow chart describing the functions of the promotion2 routine. The promotion2 routine starts (538) when executed by the promotion network program as described in FIG. 7 (76). The promotion set-up routine is executed and the promotion2 winners list file name is passed as a parameter (540). Upon return from the promotion set-up routine, the promotion error flag is examined (542). If an error occurred (542), then the promotion2 routine terminates (564). If the promotion error flag is not set (542), then the show routine is executed to display the instruction screen on the monitor 14 (544). The user must input a player number (546) by means of a card reader 24, bar code reader 26, touch screen 28, or keyboard 30 (548). If a device error occurs during user input (550), then the promotion2 routine terminates (564). If no error occurred on the user input (550), then the player number is compared with the sweepstakes numbers 1102 from the promotion winners list (418). If a match is found, then the show routine is executed to display a winner instruction screen on the monitor 14 (558). A list of instructions are also sent to the printer 32 (562). If the player's number did not match any of the sweepstakes numbers 1102 in the promotion winners list (554), then the show routine is executed to display a non-winning instruction screen on the monitor 14 (558). It is possible for the system to send to the printer 32 a consolation prize or a different set of instructions (560). In this promotion2 routine, the player log file is not updated, and the promotion2 routine terminates (564).
FIG. 27 is a flow chart describing the functions of the product locator routine. The product located routine starts (566) when executed by the promotion network program as described in FIG. 7 (76). The product locator error flag is examined to determine if it has been set by the product locator set-up routine described in FIG. 11 (568). If the product locator error flag is set (568), then the show routine is executed to display the "out-of-service" picture on the monitor 14 (572). The touch screen entry routine is executed for its timer function (576) and the product locator routine terminates (590). If the product error flag was not set (568), then a loop is entered to guide the customer through the product locator menu structure. The show routine is executed to display the main product locator menu on the monitor 14 whereby products are located in categories ordered alphabetically (570). The touch screen entry routine is executed to accept user input (574). If the user input is a request for help (580), then the system help routine is executed (578) following which control transfers to the main product locator menu (570). If the user input is a request to restart (582), then the product locator routine terminates (590). In all other cases, it is assumed that the customer has selected a particular category of products. The user input from the touch screen pad is converted into a letter (584). The list products routine is executed according to the user input (586). Upon completion of the list products routine, if the user input is the command "previous" (588), then the main product locator menu is displayed on the monitor 14 again (570). Otherwise, the product locator routine terminates (590).
FIGS. 28A and 28B combined are a flow chart describing functions of the list products routine. The list products routine starts (592) when executed by the product locator routine as described in FIG. 27 (586). The list products routine is a loop that allows a customer to browse through product listings according to a selected letter. The initial letter for this browse function is the value passed as a parameter when the list products routine is executed. The product listing beginning with the letter selected is displayed on the monitor 14 (594). If there are more than 40 items in the product listings (596), which is the maximum number of listings that can be displayed on the monitor 14, then a "more" indicator is displayed on the monitor 14 (598). The touch screen entry routine is executed to accept user input (600). If there is no response (602) and the touch screen entry routine terminates because of the timer, then the list products routine terminates (624). If the user input is a "previous" command (604), then the list products routine terminates (624). If the user input is the "more" command (608), then the list products routine moves to the next entry in the product listing (606) and displays the product listing beginning with the letter selected on the monitor 14 (594). If the user input is the "help" command (612), then the system help routine is executed (610) following which the product listing is re-displayed on the monitor 14 (594). In all other cases, the user input is considered to be a product listing selection (614). The show routine is executed to display a map of the retail area on the monitor 14 (616). The product pointer is displayed on the map based on the customer's selection (618). The pointer is located according to the coordinates 1096 and 1098 described in FIG. 52. The read touch screen routine is executed to wait for further user input or a possible time-out condition (620). If there is a time-out from the map display (622) then the list products routine terminates (624). If there is a response from the customer (622), then the product listing is redisplayed according to its last position (594).
FIG. 29 is a flow chart describing the functions of the store locator routine. The store routine locator starts (626) when executed by the promotion network program as described in FIG. 7 (76). The store locator error flag is examined (628) to determine if an error occurred during the store locator set-up routine. If the store locator error flag is set (628), then the show routine is executed to display the "out-of-service" picture on the monitor 14 (632), the read touch screen routine is executed for its timer function (636), and the store locator routine terminates (650). If the store error flag is not set (628), then a loop is entered to guide the customer through the store locator menu structure. The show routine is executed to display the main store locator menu on the monitor 14 whereby stores are located in categories ordered alphabetically (630). The touch screen entry routine is executed to accept user's input (634). If the user input is a request for help (640), then the system help routine is executed (638) following which control transfers to the main store locator menu (630). If the user input is a request to restart (642), then the store locator routine terminates (650). In all other cases, it is assumed the customer has selected a particular category of stores. The user input from the touch screen pad is converted into a letter (644). The display stores routine is executed according to the user input (646). Upon completion of the display stores routine, if the user input is the command "previous" (648), then the main store locator menu is displayed on the monitor 14 again (630). Otherwise, the store locator routine terminates (590).
FIGS. 30A and 30B combined are a flow chart describing the functions of the display stores routine. The display stores routine starts (652) when executed by the store locator routine as described in FIG. 29 (646). The display stores routine is a loop that allows a customer to browse through store listings according to a selected letter. The initial letter for this browse function is the value passed as a parameter when the display stores routine is executed. The store listing beginning with the letter selected is displayed on the monitor 14 (654). If there are more than 40 items in the store listings (656), which is the maximum number of listings that can be displayed on the monitor 14, then a "more" indicator is displayed on the monitor 14 (658). The touch screen entry routine is executed to accept user input (660). If there is no response (602) and the touch screen entry routine terminates because of the timer, then the display stores routine terminates (684). If the user input is a "previous" command (664), then the display stores routine terminates (684). If the user input is the "more" command (668), then the display stores routine moves to the next entry in the store listing on the monitor 14 (666) and displays the store listing on the monitor 14 beginning with the letter selected (654). If the user input is the "help" command (672), then the system help routine is executed (670) following which the store listing is re-displayed on the monitor (654). In all other cases, the user input is considered to be a store listing selection (674). The show routine is executed to display a map of the retail area on the monitor 14 (616). The store pointer is displayed on the map based on the customers selection (678). The pointer is located according to the coordinates 1088 and 1090 described in FIG. 51. The read touch screen routine is executed to wait for further user input or a possible time out condition (680). If there is a time-out from the map display (682), then the display stores routine terminates (684). If there is a response from the customer (682), then the store listing is re-displayed according to its last position (654).
FIG. 31A and 31B combined are a flow chart describing the functions of the coupon routine. The coupon routine starts (686) when executed by the promotion network program as described in FIG. 7 (76). The coupon error flag is examined (688) to determine if an error occurred during the coupon set-up routine. If the coupon error flag is set (688), then the show routine is executed to display the "out-of-service" picture on the monitor 14 (690). The read touch screen routine is executed to provide a timer function (694) and the coupon routine terminates (722). If no error occurred during the coupon set-up routine (688), then a flag is examined (692) to determine if the display should begin with the first coupon (696). In all other cases, the display begins with the next sequential coupon (698). The show routine is executed to display the next 4 coupons in the list on the monitor 14 (700). If more than 4 coupons remain in the list (702), then a "more" indicator is displayed on the monitor 14 to signal that additional coupons may be displayed. The read touch screen routine is executed to await user input (708). Upon return from the read touch screen routine, it first must be determined whether the user entered a selection or if the timer expired (710). If the timer expired (710), then the coupon routine terminates (722). Otherwise, the user input is examined to see if the "previous" command is selected (714). If the "previous" command is selected (714), then the "previous" flag is set (712) and the coupons routine terminates (722). If the user input was the "more" command (716), then the coupon pointer is incremented to the next entry in the coupon list (698) and the next 4 coupons are displayed on the monitor 14 (700). In all other cases, it is assumed that the customer selected a particular coupon and the coupon is sent to the printer 32 (718). The selected coupon is removed from the display on the monitor 14 (720) and control transfers to await additional user input (706).
FIG. 32 is a flow chart describing the functions of the specials routine. The specials routine starts (724) when it is executed by the promotion network program as described in FIG. 7 (76). The specials routine attempts an open operation against the specials file (726). The structure of the specials file is described in FIG. 45. If the open operation fails (728), then the show routine displays the "out-of-service" picture on the monitor 14 (732). A message is written to the error file (736, 740, and 744) and the specials routine terminates (756). If the specials file opens correctly (728), then the specials text 1018 is read into memory 12 (730) and the file is closed (734). The show routine displays the "specials" picture on the monitor 14 (738). This picture is filled in by the specials text 1018 stored in memory 12 (742). The read touch screen routine is executed to await user input (746). If the timer expires (748), then the specials routine terminates (756). If user input is accepted (748), then the input is examined for a "print" command (752). If the "print" command is not entered (752), then the "previous" flag is set (750) and the specials routine terminates (756). If the "print" command is entered by the customer (752), the specials text 1018 is sent to the printer 32 (754), and the specials routine terminates (756).
FIG. 33 is a flow chart describing the functions of the events routine. The events routine starts (758), when it is executed by the promotion network program as described in FIG. 7 (76). An open operation occurs against the events file (760). The structure of the events file is described in FIG. 44. If the open operation fails (762), the show routine displays the "out-of-service" picture on the monitor 14 (766). A message is written to the error file (770, 774, and 778) and the events routine terminates (790). If the open operations succeeds (762), the events text 1016 is read into memory 12 (764) and the events file is closed (768). The show routine displays the "events" picture on the monitor 14 (772). The events text 1016 stored in memory 12 fills out the "events" picture (776). The read touch screen routine is executed to await user input (780). Upon completion, the information returned from the read touch screen routine is examined to determine if user input was accepted or if the timer expired (782). If the timer expired (782), then the events routine terminates (790). If user input is accepted (782), then the user input is examined to see if a "print" command was entered (786). If a "print" command was entered (786), the events text 1016 is sent to the printer 32 (788), and the events routine terminates (790). If the "print" command was not entered (786), the "previous" flag is set (784), and the events routine terminates (790).
FIG. 34 is a flow chart describing the functions of the order processing routine. The order processing routine starts (792) when executed by the promotion network program routine as described in FIG. 7 (76). First, the order processing error flag is examined (790) to determine if an error occurred during the order processing set-up routine described in FIG. 15. If an error occurred (794), the show routine displays the "out-of-service" screen (796) on the monitor 14. The read touch screen routine is executed as a timer (802) and the order processing routine terminates (828). If no errors occurred during the order processing set-up (794), then the item list described in FIG. 47 is displayed on the monitor 14. A check is made to determine if there are more than 20 items in the item list (800) which is the maximum number of items that can be displayed at one time. If more than 20 items are in the list (800), then a "more" indicator is displayed on the monitor 14 (798). The item list in memory 12 is displayed on the monitor 14 (804). The read touch screen routine is executed to await user input (808). The value returned from read touch screen routine is examined to determine if user input was accepted or if the timer expired (810). If the timer expired (810), then the order processing routine terminates (828). If user input was accepted (810), then the input is examined for commands. If the "previous" command is entered (814), then the "previous" flag is set (812) and the order processing routine terminates (828). If the "help" command is entered (816), the help routine is executed (818), following which the item list is re-displayed on the monitor 14 (806). If the "more" command is entered (820), then the next 20 items are selected (822), and the item list is re-displayed on a monitor 14 (806). In all other cases, it is assumed that the customer selected a particular item (820), and the display item routine is executed (824). Upon return from the display item routine the last user input is examined to determine if the "previous" command is entered (826). If the "previous" command was entered (826), then the item list is re-displayed on the monitor 14 (806). In all other cases, upon return from the display item routine, the order processing routine terminates (828).
FIGS. 35A and 35B combined are a flow chart describing the functions of the display item routine. The display item routine starts (830) when executed by the order processing routine as described in FIG. 34 (824). Passed as a parameter to this routine is the item picture name 1032, as described in FIG. 47, for the item selected by the customer. The item picture is displayed on the monitor 14 (832). The read touch screen touch routine is executed to await user input (834). Upon completion of the read touch screen routine, it must be determined whether the customer entered a selection or whether the timer expired (836). If the timer expired (836), then the display item routine terminates (870). If the customer entered a command, then the type of command must be determined. If the "previous" command is entered (840), the "previous" flag is set and the display item routine terminates (870). In all other cases, it is assumed that the customer selected an item to order (844). A message is displayed on the monitor 14 asking for insertion into the card reader 24 of the customer's credit card (846). The card reader routine is then executed (848). The card expiration date must first be examined (852). If the card has expired (852), the appropriate message is displayed on the monitor 14 (850). If the card is valid (852), the order transaction is written to the order file (854, 860 and 864), and the display item routine terminates (870). The structure of the order file is described in FIG. 43. Each order file record 1006 includes the credit card number 1008, the customer name 1010, the item number 1012, and the item price 1014. If an error occurs during the order file processing (856), an appropriate message is displayed on the monitor 14 (858) and a message is written to the error file (862, 866, and 868).
FIG. 36 is a flow chart describing the functions of the survey routine. The survey routine starts (872) when executed by the promotion network program as described in FIG. 7 (76). The survey error flag is examined (874), to determine if an error occurred during the survey set-up routine. If the survey error flag is set (874), then the show routine displays the "out-of-service" picture (876) on the monitor 14. The read touch screen routine is executed to provide a timer (880) and the survey routine terminates (908). If there were no errors during the survey set-up routine (874), then a loop is entered to display the survey questions. The show routine displays the question and its multiple-choice answers on the monitor 14 (878). The read touch screen routine is executed to await user input (882). Upon completion, it must be determined whether the customer entered a response or whether the timer expired (886). If the timer expired (886), then the survey routine terminates (908). If a response was entered (886), then that response is stored in memory 12 (888). The question is examined to determine if it is the last question in the list (890). If it is not the last question, then the next question is selected (884), and the show routine displays the question and its multiple-choice answers on the monitor 14 (878). When the last question is answered (890), a coupon or other discount offer is sent to the printer 32 (892). The responses are written to the survey log file (894, 900, and 904), and the survey routine terminates (908). If an error occurs while processing the survey file (896), a message is written to the error file (898, 902, and 906).
FIG. 36 is a flow chart describing the functions of the enrollment routine. The enrollment routine starts (910) when executed by the promotion network program as described in FIG. 7 (80). Initially, the enrollment routine examines the enrollment error flag to determine if an error occurred during a prior attempted enrollment file operation (912). If the enrollment error flag is set (912), the show routine displays the "out-of-service" picture on the monitor 14 (914). The read touch screen routine is executed to provide a timer function (918) and the enrollment routine terminates (938). If there have been no prior enrollment file errors (912), an enrollment instruction screen is displayed on the monitor 14 (916). The participant information is accepted from the customer (920) by means of any of the input devices such as the card reader 24, the touch screen 28, or the keyboard 30 (922). The structure of the enrollment file is described in FIG. 42. Each record 990 in the enrollment file includes the enrollee's name 992, address 994, city 996, state 998, zip code 1000, phone 1002, and country 1004. The participant information is written to the enrollment file (824, 928, and 932) and the enrollment routine terminates (938). If an error occurs during the enrollment file processing (926), then a message is written to the error file (930, 934, and 936).
FIG. 38 is a flow chart describing the functions of the enrollment card reader routine. The enrollment card reader routine starts (940) when executed by the enrollment routine as described in FIG. 37 (922). The card reader routine is executed (942) and the participant information read therefrom is returned to the enrollment routine (944).
FIG. 39 is a flow chart describing the functions of the enrollment touch screen routine. The enrollment touch screen routine starts (946) when executed by the enrollment routine as described in FIG. 37 (922). An instructional screen for the customer is first displayed on the monitor 14 (948). The read touch screen routine is executed to accept the customers name (950), address (952), city (954), state (956), zip code (958), and phone number (960). This participant information is then returned to the enrollment routine (962).
FIG. 40 is a flow chart describing the functions of the enrollment keyboard routine. The enrollment keyboard routine starts (964) when executed by the enrollment routine as described in FIG. 37 (922). An instructional screen is displayed on the monitor 14 (966). The keyboard entry routine described in FIG. 25 is executed to accept the customer name (968), address (970), city (972), state (974), zip code (976), and phone number (978). This participant information is then returned to the enrollment routine (980).
FIG. 41 is a flow chart describing the functions of the system help routine. The system help routine starts (982) when executed by the promotion network program as described in FIG. 7 (80), the product locator routine as described in FIG. 27 (578), the list products routine as described in FIGS. 28A and 28B (610), the store located routine as described in FIG. 29 (638), and the display stores routine as described in FIGS. 30A and 30B (670). A help screen is displayed on the monitor 14 (984) and the read touch screen routine is executed to await user input or the expiration of the timer (986). Upon completion of the read touch screen routine the system help routine terminates (988).
FIG. 59 has a flow chart describing the functions of the frequent shopper set-up routine. The frequent shopper set-up routine starts (1196) when executed by the set-up routine as described in FIG. 8 (103). The frequent shopper error flag is initialized (1198) and the frequent shopper prize file is opened (1200). The frequent shopper prize file is described in FIG. 58. If the open operation fails (1202), then the frequent shopper prize error flag is set (1204), a message is written to the error file (1208, 1212, and 1218), and the frequent shopper set-up routine terminates (1224). If the frequent shopper prize file opens correctly (1202), then a loop is entered whereby the records 1184 from the frequent shopper prize file are read into the memory 12. The first record 1184 read from the frequent shopper prize file contains the official time 1186 required between visits (1206). An official time 1186 would require, for example, at least one day between visits for a user to qualify as a "frequent shopper". The remaining records 1184 in the frequent shopper prize file describe the prize 1188 (1210) and the number of visits 1190 required before the prize 1188 can be won (1222). The records 1184 are read (1216) until an end-of-file indication occurs (1214). When the end-of-file is indicated, the frequent shopper prize file is closed (1220), and the frequent shopper set-up routine terminates (1224).
FIG. 60 is a flow chart describing the functions of the counts set-up routine. The counts set-up routine starts (1226) when executed by the set-up routine described in FIG. 8 (104). First, the counts file is opened (1228). The structure of the counts file is described in FIG. 56. If the open operation fails (1230), then a message is written to the error file (1232, 1236, and 1240) and the counts set-up routine terminates (1248). If the counts file opens correctly (1230), then a loop is entered whereby the count records 1166 are read into the memory 12. Each record read may be a count title 1168 (1234) or the number of counts 1170 (1246). When an end-of-file indication occurs (1238), the count file is closed (1242) and the counts set-up routine terminates (1248).
FIG. 61 is a flow chart describing the functions of the frequent shopper routine. The frequent shopper routine starts (1250) when executed by the promotion network program described in FIG. 7 (80). If the frequent shopper flag is set (1252), then the show routine is executed to display the "out-of-service" picture (1270), a message is written to the error file (1274, 1280, and 1286), and the frequent shopper routine terminates (1294). If the frequent shopper flag is not set (1252), then the show routine is executed to display the frequent shopper instruction screen on the monitor 14 (1254). The shopper ID is requested (1258), which the user may enter by means of the magnetic stripe card reader 24, bar code reader 26, touchscreen 28, or keyboard 30 (1256). If a device error occurs during the user input (1260), then the show routine is executed to display the "out-of-service" screen on the monitor 14 (1270), a message is written to the error file (1274, 1280, and 1286), and the frequent shopper routine terminates (1294). If no error occurs on the user input (1260), then the read frequent shopper file routine is executed to determine the customer status (1262). If an error occurs (1266), then the show routine is executed to display the "out-of-service" screen on the monitor (1270), a message is written to the error file (1274, 1280, and 1286), and the frequent shopper routine terminates (1294). If there is no error (1266), and the user has returned before the official time 1186 has elapsed, then the frequent shopper status of the user is displayed on the monitor 14 (1282) and sent to the printer 32 (1288). The write frequent shopper file routine is executed (1292) and the frequent shopper routine terminates (1294). If the official time 1186 required between visits has elapsed (1264), then the number of visits is incremented (1268), and the check prize level routine is executed (1272). If a new prize level has not been reached (1276), then the user's frequent shoppers status is displayed on the monitor 14 (1282) and sent to the printer 32 (1288). The write frequent shopper file routine is executed (1292), and the frequent shopper routine terminates (1294). If a new prize level has been reached (1276), then the prize level is incremented (1278). The show routine is executed to display the prize screen on the monitor 14 (1284) and the prize coupon is sent to the printer 32 (1290). The read frequent shopper file routine is executed (1292) and the frequent shopper routine terminates (1294).
FIG. 62 is a flow chart describing the functions of the read frequent shopper routine. The read frequent shopper file routine starts (1296) when executed by the frequent shopper routine described in FIG. 61 (1262). First, the frequent shopper file is opened. The structure of the shopper file is described in FIG. 57. Each record 1172 in the frequent shopper file contains the shopper ID 1174, the date of the last visit 1176, the time of the last visit 1178, the total number of visits 1180, and the last prize level 1182. If the frequent shopper file does not open correctly, (1300), the frequent shopper status is set to the file error (1310), and the read frequent shopper file routine terminates (1334). If the frequent shopper file opens correctly (1300), then a loop is entered whereby all records 1172 from the frequent shopper file are read until an end-of-file indication occurs (1306) or until the shopper ID 1174 matches the current user's ID (1308). If an end-of-file indication occurs (1306), the frequent shopper status is set to "first visit" (1314), and the frequent shopper is closed (1322). Because it is the user's "first visit" (1324), the read frequent shopper file routine terminates (1334). If a match is found between the user's entered ID and a shopper ID 1174 (1308), then the contents of the matching record 1172 are stored into the memory 12 (1312, 1316, 1318, and 1320), and the frequent shopper file is closed (1322). The number of visits 1180 is examined to determine if the value is greater than one (1324). If this is not the user's "first time" (1324), the system time is read (1326) and compared to the date 1176 and time 1178 of the last visit (1328). If this time interval is greater than the official time 1186 read from the frequent shopper prize file (1330), then the frequent shopper status is set to an "official visit" (1330), and the read frequent shopper file routine terminates (1334). If the time between visits does not exceed the official time 1186 read from the frequent shopper prize file (1330), then the frequent shopper status is set to "no visit" (1332), and the read frequent shopper file terminates (1334).
FIGS. 63A and 63B combined are a flow chart describing the functions of the check prize level. The check prize level routine starts (1336) when executed by the frequent shopper routine in FIG. 61 (1272). The check prize level routine compares the information contained in the record 1172 read from the frequent shopper file with the information contained in the record 1184 read from the frequent shopper prize file. A loop is entered whereby the last prize level 1182 of the frequent shopper record 1172 is used to determine the prize level 1188 or 1192 from the frequent shopper prize file. Beginning at the first prize level 1188 (1338), the prize level 1188 or 1192 is compared to the user's last prize level 1182 until the prize level 1188 or 1192 is less than the last prize level 1182 (1340). If the prize level 1188 or 1192 is greater than or equal to the last prize level 1182, then the next lower prize level in the frequent shopper prize file is examined (1342). When the last prize 1182 is greater than the prize level from 1188 or 1192 (1340), then the number of visits 1190 or 1194 associated with a prize level 1188 or 1192 is compared to the user's number of visits 1180. If the user's number of visits 1180 is greater than or equal to the number of visits 1190 or 1194 (1344), then the user's frequent shopper status is set to "prize level" (1348) and the check prize level routine terminates (1350). If the user's number of visits 1180 is less than the number of visits 1190 and 1194 (1344), then the user's frequent shopper status is set to "no prize" (1346), and the check prize level routine terminates (1350).
FIGS. 64A and 64B combined are a flow chart describing the functions of the write frequent shopper routine. The write frequent shopper file routine starts (1352) when executed by the frequent shopper routine in FIG. 61 (1292). First, the frequent shopper file is opened (1354). The structure of the frequent shopper file is described in FIG. 57. If the frequent shopper does not open correctly (1356), then the show routine is executed to display the "out-of-service" picture (1358), a message is written to the error file (1362, 1368, and 1374), and the write frequent shopper file routine terminates (1386). If the frequent shopper file opens correctly (1356), then a loop is entered whereby the records 1172 of the frequent shopper file are read (1360) until an end-of-file indication occurs (1364) or a shopper ID 1174 is found which matches the user's entered ID (1372). If an end-of-file indication occurs (1364), then the user's entered ID is written to the frequent shopper file (1370). Immediately following this new shopper ID 1174, or a matching shopper ID 1174 if found (1372), a new date 1176 (1376), time 1178 (1378), number of visits 1180 (1380), and last payoff level 1182 (1382), are written to the frequent shopper file. Then, the frequent shopper file is closed (1384), and the write frequent shopper file routine terminates (1386).
FIG. 69 is a flow chart describing the functions of the receiver routine. The receiver routine starts (1398) when executed by the start-up sequence routine as described in FIG. 6 (61). The serial port is initialized (1400) and the modem parameters are set (1402). A loop is entered to await signals from the modem (1404). If the proper signal is not received (1406), then the loop returns to await further signals from the modem (1404). If the proper signal is received (1406), then the login code is read from the modem (1408). If the login code is incorrect (1410), an error message is returned to the caller (1412) and the loop returns to await further signals from the modem (1404). If the login code is correct (1410), a return code is sent to the caller (1414) and the receiver routine waits for an "acknowledgment" signal (1416). If there is no "acknowledgment" signal (1418), then the phone is hung up (1420) and the loop returns to await further signals from the modem (1404). If an "acknowledgment" signal is received (1418), then the dial back code is read (1422), the phone is hung up (1424), and the dial back routine is executed (1426). If an error is returned from the dial back routine (1430), then the loop returns to await further signals from the modem (1404). If there is no error from the dial back routine (1430), then the receive routine (1428) and the instruction routine (1432) are executed, after which the loop returns to await further signals from the modem (1404). Thus the receiver routine never terminates, until the computer 10 is turned off.
FIG. 70 is a flow chart describing the functions of the dial back routine. The dial back routine starts (1434) when executed by the receiver routine as described in FIG. 69 (1426). First, the phone number file is opened (1436). The structure of the phone number file is described in FIG. 67. The phone number file contains a phone number 1388. If the phone number file does not open correctly (1440), then a default phone number is used by the dial back routine (1438). If the phone number file opens correctly (1440), then the dial back phone number 1388 is read from the phone number file (1442) and the phone number file is closed (1446). Regardless of which phone number is used, the dial back phone number is dialed (1448). When the communications link is established, the dial back routine sends the "start of header" byte (1450), login code (1452), and waits for the returning login code (1454). If the login codes do not match (1456), the error status is set (1458), and the dial back routine terminates (1462). If the login codes match (1456), an "acknowledgement" signal is sent (1460) and the dial back routine terminates (1462).
FIGS. 71A and 71B combined are a flow chart describing the functions of the receive routine. The receive routine starts (1464) when executed by the receiver routine as described in FIG. 69 (1428). First, the instruction buffer file is opened (1466). The structure of the instruction buffer file is described in FIG. 68. The instruction records 1390 in the instruction buffer file are comprised of commands 1392, and a maximum of 3 parameters, 1394, 1396, and 1397. After the instruction buffer file opens, the receive routine synchronizes communication with the sender (1468). A loop (1472) is entered to await information from the sender (1470). Once the incoming information is signaled, an information packet is read (1474). If a time-out occurs (1476), a "no acknowledgement" signal is sent (1478), and the loop returns to await further information packets (1474). If the information packet is a "end of transmission" message (1482), an "acknowledgement signal" is sent (1480), the transfer ends (1498), and the receive routine terminates (1500). If a "cancel" signal is received (1484), then the transfer ends (1498), and the receive routine terminates (1500). In all other cases, the information received is validated (1486) and examined for errors (1488). If no error occurs (1488), an "acknowledgement" signal is sent (1490), and the loop returns to await further information packets (1474). If there is an error (1488) then it must be examined (1492). If the error is not fatal (1492), a "no acknowledgement" signal is sent (1494), and the loop returns to await further information packets (1474). If the error is fatal (1492), then a "cancel" signal is sent (1496), the transfer ends (1498), and the receive routine terminates (1500).
FIG. 72 is a flow chart describing the functions of instruction routine. The instruction routine starts (1502) when executed by the receiver routine as described in FIG. 69 (1432). The first instruction is read from the instruction buffer (1504) and a loop is entered to read all remaining commands in the buffer. Each command is examined to determine if it is a "set variables" (1510), "system instruction" (1514), "dial" (1518), or "quit" command (1520). If the command is a "set variables" command (1510), then the variables are set (1508), and the next command of the buffer is examined (1506). If the command is a "system instruction" command (1514), then the system instruction is executed (1512), and the next command in the buffer is examined (1506). If the command is a "dial" command (1518), then the specified or default phone number is dialed (1516), and the next command in the buffer is examined (1506). If the command is unrecognized (1520), it is skipped, and the next command of the buffer is examined (1506). If the command is a "quit" command (1520), then the instruction routine terminates (1522).
FIG. 73 is a flow chart describing the functions of the frequent purchase routine. The frequent purchase routine starts (1524) when executed by the promotion network program as described in FIG. 7 (80). The menu is displayed (1526) and the read touch screen routine is executed to await the customer selection (1528). If a time-out occurs (1530), then the frequent purchase routine terminates (1550). If the customer selects "return" (1532) then the frequent purchase routine terminates (1550). If the customer selects "view balance" (1536), then the view balance routine is executed (1534) and the loop returns to re-display the menu (1526). If the customer selects "sign up" (1540), then the enrollment routine is executed (1538) and the loop returns to re-display the menu (1526). If the customer selects "purchase" (1544), then the order processing routine is executed (1542) and the loop returns to re-display the menu (1526). If the customer selects "help" (1548), then the system help routine is executed (1546) and the loop returns to redash display the menu (1526).
FIG. 74 is a flow chart describing the functions of the view balance routine. The view balance routine starts (1552) when executed by the frequent purchase routine as described in FIG. 73 (1534). First, the status is initialized (1554). The show routine is executed to display the instruction screen on the monitor 14 (1556). The buyer's ID is requested (1558) and accepted from the magnetic stripe card reader 24, bar code reader 26, touchscreen 28, or keyboard 30 (1560). If the device error occurs (1562), then the show routine is executed to display the "out-of-service" screen on the monitor 14 (1570), a message is written to the error file (1574, 1578, and 1582), the status is set to the error (1588), and the view balance routine terminates (1590). If no error occurs (1562), then the dial frequent buyer database routine is executed (1564). If an error occurs (1566) or the line is busy (1568), then the same error handling sequence is executed as before (1570, 1574, 1578, 1582, 1588, and 1590). If the dial frequent buyer database routine was successful, then the show routine is executed to display the frequent shopper picture on the monitor 14 (1572). The information from the remote computer system is also displayed on the monitor 14 (1576). The read touch screen routine is executed (1580), and the view balance routine (1590).
FIG. 75 is a flow chart describing the dial frequent buyer database routine. The dial frequent buyer database routine starts (1592) when executed by the view balance routine as described in FIG. 74 (1564). The status is initialized (1594), the port parameters are set (1596), and communications are attempted with the remote database (1598 and 1600). If a busy signal occurs (1604), the status is set the busy (1602). If no connection can be made (1608), then the status is set to the error (1606). If connection is made (1608), then the login (1610) and buyer ID (1612) are sent to the remote computer, and a balance is expected in return (1614). If the balance is not received (1618), then the status is set to the error (1616). The dial frequent buyer database routine terminates (1624) after hanging up the phone (1620) and closing the communications port (1662).
Although a specific embodiment has been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is also intended to cover any adaptations or variations of the present invention. It is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | A computer system automates advertising and promotional campaigns. The computer system includes a magnetic stripe card reader, bar code reader, monitor, printer, keyboard, and touchscreen input device. Software executing on the computer manages the operations of these devices. The system displays advertisements and product or store locator maps, dispenses coupons, accepts product orders, and manages customer surveys. Customers are attracted to the system by promotional sweepstakes, thereby enhancing the effectiveness of the advertising and surveys. A frequent shopper campaign also attracts customers to the system. | 6 |
TECHNICAL FIELD
The present application relates to controllers and control circuits for controlling an internal combustion engine, including a gas fired internal combustion prime mover used for driving a generator for generating electrical power.
BACKGROUND
Modern internal combustion engines are commonly controlled by a control circuit, which typically includes a microprocessor and programmed instructions to control the speed and other parameters of the running of the engine. In motor vehicles (e.g., cars and trucks) the internal combustion engines are operated according to an engine management system of hardware and software programmed by the manufacturer of the vehicle. After market modifications of the engine management circuits and software are sometimes carried out to achieve desired performance results or variations on the operation of the basic engine characteristics.
Similarly, engines (prime movers) used in electrical power generation systems are controlled and monitored by electronic circuits and programmed instructions running in the circuits. Inputs such as engine revolutions per minute (RPM), operational temperatures, pressures, fuel and air intake rates and concentrations of certain exhaust gases can all be used in addition to the operator's inputs to control and drive an engines.
Existing engine controllers and control circuits (collectively “engine controllers”) come in a variety of configurations. Many engine controllers are prone to environmental effects due to the adverse physical conditions in which the engine controllers are disposed. For example, engine controllers can be subjected to temperature extremes and other conditions such as high humidity, contamination and vibration. Modern circuitry in engine controllers can be susceptible to damage from such environmental effects and the reliability or life of an engine controller can suffer as a result. The end result of a failed engine controller can vary from non-optimal engine operation to catastrophic damage to the engine and associated equipment or even personal injury to engine operators. In some applications space is at a premium and an engine controller must occupy as little space as possible, which factors into the design of the controller in some applications. Additionally, economics are a factor that needs to be taken into consideration in the design of engine controllers so that the overall commercial engine and control system is built to conserve design, materials and manufacturing costs thereof.
Accordingly, a number of motives for improving engine controllers inform the present disclosure of an engine controller, especially an engine controller for a prime mover of an electrical generator or an engine used for co-generation of power and heat in a multifunctional system design.
SUMMARY
This disclosure is directed to controllers and control circuits for controlling an internal combustion engine, including a gas fired internal combustion prime mover used for driving a generator for generating electrical power. This design can be used for engine controllers for internal combustion engines used to drive electrical generators (feeding an electrical load, e.g., grid, AC or DC bus and associated loads).
Aspects of the invention include a controller for controlling engine speed of a prime mover engine in an electrical generation system, including a housing for containing a plurality of electrical parts of said controller; an engine speed processor that senses a movement of said prime mover engine and generates a first engine speed signal; an input speed processor that receives said first engine speed signal and generates a second engine speed signal corresponding at least in part to said first engine speed signal; an engine metering circuit that receives said second engine speed signal and relates said second engine speed signal to a clock signal and stores engine revolutions (RPM) and other data relating to the speed of said engine in at least one memory storage unit; a digital signal processor (DSP) controller coupled to said engine metering circuit by at least one multi-pin connection so as to permit said DSP to access said at least one memory storage unit on said engine metering circuit; and a host communication interface receiving signals from said DSP over a communication bus and further providing an output control signal for controlling the speed of said engine.
IN THE DRAWINGS
For a fuller understanding of the nature and advantages of the present invention, reference is made to the following detailed description of preferred embodiments and in connection with the accompanying drawings, in which:
FIG. 1 illustrates an exemplary architecture for generation, transformation and delivery of electrical power to a load;
FIG. 2 illustrates a representation of an engine controller;
FIG. 3 illustrates an exemplary engine metering circuit and components;
FIG. 4 illustrates an engine speed processor;
FIG. 5 illustrates an input speed processor;
FIG. 6 illustrates a host communication interface; and
FIG. 7 illustrates a representation of an engine controller.
DETAILED DESCRIPTION
As stated earlier, improvements in engine controller design can offer better durability, life span, efficiency and economy of an engine and/or engine-generator system. Such systems are employed for example in motor-generator pairs or in electric and heat co-generation systems. A particular but non-limiting use of the present engine controller is for engines operated at or substantially at wide-open throttle, a method of operation found by the present applicants to offer effective use of internal combustion engines in the above applications.
FIG. 1 illustrates a motor-generator and other (e.g., solar, battery) power generation system 10 . The motor-generator 100 outputs alternating current (AC) electrical power, which is converted to direct current (DC) electrical power in AC-to-DC Converter (ACDC) 102 . Solar collector generation system 110 generates DC electrical power output, which may be transformed or conditioned as needed in DC-to-DC Converter (DCDC) 112 . The DC outputs from ADC 102 and DDC 112 are delivered to a common DC bus 120 . A DC-to-AC Converter (DCAC) 130 transforms the DC power from the common bus 120 to AC electrical power provided to a load 140 . The load 140 may be an electrical grid, customer facility, industrial or residential infrastructure, or an islanding load.
FIG. 2 illustrates an architecture for an internal combustion engine controller 20 according to one or more embodiments of the invention. Some components of controller 20 will be discussed in further detail below.
An engine speed processor or circuit 30 is employed to generate an engine speed signal 32 corresponding to the rotational (e.g., revolutions per minute or equivalent) speed of the internal combustion prime mover (engine). The engine speed signal 32 is provided from engine speed processor or circuit 30 to an input speed processor or circuit 40 , which in turn outputs an engine speed input signal 42 for use in other portions of the controller 20 . Engine metering circuit 50 receives numerous signals at its input bus or input pin interface including the engine speed input signal 42 . A shared data bus 52 and a shared address (ADDR) bus 54 are disposed between the engine metering circuit 50 and a digital signal processor (DSP) controller or circuit 60 . DSP controller 60 processes the inputs relating to engine performance and speed from the other components and sensors of the system and outputs a CAN bus signal(s) 62 sent through a host communication interface circuit 70 to a host controller as host controller signal 72 .
FIG. 3 illustrates a detail of engine metering circuit 50 , which receives an input ESS 2 42 representing engine speed as mentioned herein. Engine metering circuit 50 can be generally viewed as a collection of interconnected components, including a clock generator 51 , a speed signal pulse (+n) component 55 , both of which provide a signal to counter 53 , which in turn provides an output signal to frequency (RPM) converter 57 . FPGA engine metering circuit 50 is then coupled to DSP controller 60 as mentioned above.
FIG. 4 illustrates an exemplary arrangement of engine speed processor or circuit 30 according to one or more embodiments of the present invention. Those skilled in the art will appreciate that equivalent and similar embodiments aside from the illustrative embodiments of the current examples can be implemented without loss of generality. Various implementations may depend on the specific applications at hand, design constraints, and other factors. Such other configurations and examples are meant to be reasonably comprehended by the scope of the present claims.
FIG. 4 illustrates a circuit configuration for an engine speed signal generator 30 , which is part of the controller system 20 . A two-pin input sensor or interface connector P 1 is directly or indirectly coupled to an engine speed sensor. Power to circuit 30 is supplied at V 1 and V 2 , which may be received in the form of a 15 Volt supply from a power supply bus or similar voltage reference source. A pair of balanced input resistors R 1 , R 2 are disposed as shown between P 1 and op amp A 1 . A first RC loop comprising resistor R 4 and capacitor C 1 is coupled to a first input (−) of op amp A 1 . A second RC loop comprising resistor R 3 and capacitor C 2 (grounded through G 1 ) is coupled to a second input (+) of op amp A 1 . Capacitors C 3 and C 5 are disposed between voltage input points V 1 and V 2 and ground points G 2 and G 3 , respectively. The output of op amp A 1 representing a first engine speed signal (ESS 1 , 32 ) is delivered through capacitor C 4 to input speed processor circuit 40 .
FIG. 5 illustrates an engine input speed processing circuit 40 , which is part of the controller system 20 . The circuit 40 takes first engine speed signal ESS 1 , 32 , which is referenced in the previous figures, through an input resistance R 5 . An output of R 5 is fed into a first (+) input of op amp A 2 . The second input (−) of op amp A 2 is coupled to ground G 4 through resistance R 6 . A 2 is further fed from source voltages V 3 and V 4 , which are coupled to capacitors C 6 and C 7 . An output of op amp A 2 is delivered to a first diode D 1 through resistor R 8 . A second diode D 2 is coupled to ground at G 5 . The outputs of diodes D 1 and D 2 are connected and coupled back to ground G 5 through resistor R 9 as well as being coupled to the input of Schmitt trigger inverter A 3 through resistor R 10 . Inverter A 3 provides improved signal conditioning between the analog and digital portions of the controller circuit. Inverter A 3 delivers an output ESS 2 , 42 of circuit 40 , which is a second signal indicative of a speed of the engine. This second engine speed signal (ESS 2 ) is usable as a speed input (SPEED_IN) signal for use in the FPGA circuit 50 below.
The FPGA processing circuit 50 is an integrated circuit (IC) having a multi-pin input/output circuit interface with the other components of controller 20 . One input received by FPGA is the second engine speed signal ESS 2 , 42 , described earlier and indicative of a rotational speed of the prime mover engine that is the subject of the present disclosure. Other electronic signals, clocking inputs and so on are also provided to engine metering circuit 50 .
In an aspect, one mechanical rotation of a prime mover engine causes the speed sensor to generate a number “Q” of output electrical pulses, which can be over 100 such pulses. The number (Q) can then be divided by four (4) so as to ascertain the number of output pulses in a quarter-turn of the prime mover engine. This quarter-turn periodicity can then be correlated with clock counts, and, in an aspect to calculate the revolutions per minute (RPM) of the engine. Those skilled in the art will appreciate that other techniques for revolution counting and clocking and speed processing are possible, which are comprehended by this invention, and that this is but one exemplary technique for doing so.
The engine metering circuit 50 , is coupled by one or more electronic busses to digital signal processor (DSP) controller circuit 60 , which allow DSP 60 to access memory storage units or addresses on circuit 50 . Engine metering circuit 50 may comprise a field programmable gate array (FPGA) circuit in one embodiment. In another embodiment, engine metering circuit 50 may comprise a reduced instruction set circuit (RISC).
In an example, provided here for the sake of illustration, two busses connect engine metering circuit 50 and DSP controller circuit 60 . The first is a Data Bus 52 and the second is an address bus 54 . The engine metering circuit 50 is configured to measure the engine speed and store that speed in a register (e.g., memory unit). The DSP controller circuit 60 can read the contents of this register through Data Bus 52 and Address Bus 54 . Other information in the circuit 50 storage registers includes digital I/O status, AC line frequency, and circuit 50 program RPM data. In one configuration, the DSP controller circuit 60 comprises a TMS320 family DSP controller chip from Texas Instruments, or similar DSP chip. The DSP controller circuit 60 can be programmable with machine executable instructions such as a reduced instruction set allowing signal processing functions thereon. In an aspect, the DSP circuit 60 is coupled to the FPGA engine metering circuit 50 by way of the aforementioned buses 52 and 54 . DSP controller 60 delivers CAN bus signal(s) 62 , which include in some embodiments signals over a controller area network (CAN) bus. In an example, the CAN bus is compliant with ISO1050 described at, e.g., www.ti.com/lit/ds/symlink/iso1050.pdf.
FIG. 6 illustrates an exemplary host communication interface circuit 70 , which is part of controller system 20 . This portion of the controller receives CAN bus inputs (CAN Rx and CAN Tx) that receive and transmit signals from and to DSP controller 60 according to the suitable CAN signaling protocol (e.g., ISO1050). The CAN bus inputs are provided to respective pin connections on ISO1050 circuit (chip) P 2 . Other inputs to circuit P 2 are voltage inputs V 5 and V 6 , which are isolated from grounds G 6 and G 7 by capacitors C 8 and C 9 , respectively. Circuit P 2 is further grounded at ground connections G 8 and G 9 as shown. Circuit P 2 provides CAN outputs to a pair of two-pin Headers P 4 and P 5 , which in an embodiment provides a CAN Low (CANL) signal to Header P 4 and inductor I 2 , and a CAN High (CANH) signal to Header P 5 and inductor I 1 as shown. Headers P 4 and P 5 are grounded through resistors R 11 and R 12 , respectively, which are both in turn coupled to ground G 10 through capacitor C 11 . Here, a header acts as a connector, and typically is a male connector. I 1 and I 2 can comprise one part in some embodiments, which is a common mode choke.
A four-pin Header P 3 taps into the outputs of inductors I 1 , I 2 , and is further coupled to a voltage V 7 , across capacitor C 10 . The I 1 and I 2 output taps connected to four-pin Header P 3 are further connected to respective pins of a multi-pin CAN input/output (I/O) communication connector 74 . CAN I/O 74 is furthermore connected to ground G 11 . Finally, CAN I/O connector 74 provides an output communication signal (OCS) 72 which is used to control the speed of the prime mover engine-generator pair. Ground connection G 11 on the figure indicates that the physical connector body is grounded.
FIG. 7 illustrates an internal engine controller system 80 and circuitry according to an embodiment of the invention. The system 80 is used to control the operation, speed and other functional parameters of an engine-generator pair (e.g., 820 , 830 ) used to generate electrical power to a load 860 . Those skilled in the art would appreciate that equivalent implementations are possible by rearranging certain parts of the illustrated embodiment, which are comprehended by the attached claims. Also, the illustrated engine controller represents a simplification of detail that would be understood by those skilled in the art. For example, digital signal processing (DSP) and other controllers, amplifiers and processing units themselves include sub-components and circuits and logic blocks that are not illustrated in the present drawing but are understood to be a part thereof. These details can be modified and specifically called out parts could be substituted with similar or equivalent parts as necessary for a given application without loss of generality.
As described earlier, an engine or generator or shaft RPM sensor (generally, a speed sensor) 825 senses the rotational speed of an engine 820 and/or generator 830 . The speed sensor 825 provides a signal corresponding to engine speed to speed sensing amplifier 860 , which in turn provides an amplified engine speed signal to a signal conditioner 870 . The output of signal conditioner 870 is provided to an engine speed measurement circuit 820 , which may be implemented as a field programmable gate array (FPGA) architecture, but may also be implemented in other (e.g., RISC) configurations. The output of speed measurement FPGA 820 comprises a speed feedback signal 821 .
Engine controller 80 includes a host microcontroller unit (MCU) 810 having a processor, and a digital signal processing (DSP) controller 800 and other engine speed measuring and signal handling components that receive an output power command or signal 814 and generate an engine speed command 812 . It is noted that those of skill in the art can substitute the exemplary DSP in this embodiment with other architectures, e.g., general processor, graphics processor, etc.
The engine speed command and speed feedback signal 821 are provided to comparator 808 of DSP controller 800 . The output of comparator 808 is delivered to a PID 804 which amplifies a speed error signal and generates an output current command 806 for use by an inverter grid connection controller 802 .
Electrical generator 830 provides AC electrical power through AC/DC converter (ADC) 840 and controllable DC/AC inverter 850 to load 860 .
Therefore, the engine speed is used, among other factors, to control an inverter by way of the above control circuit 80 so as to optimize the running of engine 820 and generator 830 and inverter 850 , especially when engine 820 is operated in a full throttle mode or wide open throttle (WOT) mode of operation.
The present invention should not be considered limited to the particular embodiments described above, but rather should be understood to cover all aspects of the invention as fairly set out in the present claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable, will be readily apparent to those skilled in the art to which the present invention is directed upon review of the present disclosure. The claims are intended to cover such modifications. | A system and method for controlling an internal combustion engine and electrical inverter system for powering a load, including controlling the operation of a spark-ignited internal combustion engine prime mover used in generation of electrical power by way of a generator. A microprocessor (e.g., DSP) controlled circuit taking engine speed input from an engine speed signal is used to control the operation of the internal combustion engine prime mover so that it is preferably operated substantially at wide open throttle. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is related to telescopically extendable, vertical weight bearing members, and more particularly to a vertical holding member such as for clothing or garments.
2. Prior Art
It is common in the clothing industry to have a plurality of racks arranged in various areas with clothes such as shirt, pants and coats arranged on opposite sides of the clothing rack. Generally these racks are comprised of tubular structural members which upstand from the floor and include adjustable means such as a spring-loaded pin which can be depressed to move an upper bracket upwardly or downwardly to another pre-drilled aperture in an outside tubular structure to main the rack in a predetermined position.
While not specifically disclosed for such an application, U.S. Pat. Nos. 2,892,647; 2,952,485 and 2,415,663 show various mechanisms for retaining a structural upper section relative to a support portion which is typically sitting on the floor. U.S. Pat. No. 5,016,846 also shows a device for a hospital table.
What is desired in the marketplace, is a vertically adjustable support member, which can be telescopically movable to infinite incremental positions, yet is simple in construction, has the ability to maintain a great deal of vertical load, and is easily adjustable between the various vertical heights.
SUMMARY OF THE INVENTION
The objects of the invention have been accomplished by providing a mechanical stand assembly for supporting objects, where the stand comprises an upper base section and a support member. The support member includes a telescopic tube projecting therefrom and within the upper base section and further comprises a locking mechanism for maintaining the support member at various incremental heights. The locking mechanism includes a locking jaw which is pivotably mounted within the stand, and has a frictional surface for engagement with a locking surface within the upper base section. The locking jaw and the locking surface are vertically offset so as to form an over center locking arrangement when downward vertical force is applied to the support member, yet with free upward vertical movement to adjust the vertical height.
In another aspect of the invention, the objects were accomplished by providing a mechanical stand assembly for supporting objects, where the stand comprises an upper base section, a support member, and an actuator assembly. The support member is cooperably attached to the upper base section allowing vertical movement there between. The actuator assembly comprises a locking member which is mounted to the stand assembly and which fixes the support member in various vertical positions, and an actuator member which moves the jaw into and out of locked engagement, thereby allowing for an infinite number of incremental vertical height positions for the support member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a three-dimensional perspective view of a typical double-sided rack, which could be used for hanging clothing articles for display purposes.
FIG. 2 is a side view of the rack shown in FIG. 1, partially broken away, where the upper section is shown in the locked position.
FIG. 3 is an enlarged view of the locking mechanism shown when in the fully open uninhibited position.
FIG. 4 is a side view of the locking mechanism shown in FIG. 3
FIG. 5 is an enlarged view of the locking mechanism when in the locked position.
FIG. 6 is an enlarged view of the locking mechanism shown when in an unlocked position.
FIG. 7 is a side-view of a clothing rack showing the bracket sections at different vertical heights.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference first to FIG. 1, the clothing rack assembly is shown generally by reference 10 as including a base section 12 , which upstands from a lower base section or floor support member, shown generally at 16 , which is used to stabilize the clothing rack assembly 10 in the vertically upright position. It should be appreciated that the floor support member 16 , could include any configuration of a base, but as depicted herein, is comprised of a plurality of individual floor feet sections, shown at 18 , having floor pad sections 20 . The clothing rack assembly 10 further includes independently movable upper support members such as 24 and 26 , which include bracket support members 28 and 30 .
With respect now to FIGS. 1 and 2, the upper base section 12 and upper support member 24 , 26 will be described in greater detail. The upper base member 12 is comprised of two side by side tubular members 40 and 42 which are identical in nature, and therefore only one such article will be described in detail. The tubular member 40 is preferably constructed from a metal extruded member such as a rectangular tube and includes a lower end section at 44 which can be attached to the floor base section 16 by known means such as through fasteners, brackets or by a welded structure. At the opposite end of the tubular member 40 is an opening 46 profiled to receive one of the upper support members such as 26 , as will be described in further detail herein. Finally, the upper base section 40 includes an inner contour such as at 50 which is profiled to slidably receive either of the upper base members 24 or 26 , as will be described in greater detail herein. The upper base member 12 further includes a strap or band section 48 to rigidify the two tubular members 40 and 42 together.
With respect now to FIG. 2, the upper support member such as 24 will be described in greater detail. It should be understood that as both members 24 and 26 are identical, only one such devise will be described. As shown in FIG. 2, the upper support member 24 is comprised of a tubular section 52 , an upper pushbutton actuator 54 , a linkage member 56 , and a locking jaw 58 . Extending from the upper support member 24 is the lateral support bar 28 , as described above to hang garments.
With respect now to the linkage mechanism, the pushbutton member 54 , is comprised of a body member 62 having an outer peripheral surface 64 profiled to be received within an inner contour 66 of the tubular column, with an upper lip 68 to prevent over-actuation of the pushbutton actuator 54 . The pushbutton actuator 54 further includes an opening at 70 extending upwardly through a lower face 72 of the pushbutton member, which is profiled to receive the linkage rod 56 . It should be appreciated to one of ordinary skill in the art that the pushbutton actuator and the linkage member could be attached by known means, such as by threading or by press-fit or through an epoxy.
Meanwhile, the linkage rod 56 includes a press or sweat fit collar at 74 which is opposed from a fixed inner wall 76 having a compression spring 78 positioned between the collar 74 and the inner wall 76 . It should also be appreciated that an aperture is positioned at 80 through the inner wall 76 allowing the uninhibited extension and movement of the linkage rod through the upper plate 76 . As should be appreciated, the compression spring 78 spring-loads the collar 74 upwardly, and therefore the linkage rod 56 and resultantly, the push-button actuator 54 , are in a normally spring-loaded position upwardly.
With reference now to FIGS. 3-6, the locking jaw 58 is shown as a metallic cylindrical shaped member, having side surfaces 82 and 84 , where a reduced thickness section 86 is provided to received the linkage rod 56 as will be described herein. The locking jaw 58 further includes a pin-receiving aperture at 90 and a further pin-receiving aperture at 92 . Preferably, the outer circumferential surface 94 of the locking jaw is proved with a frictional surface and in the preferred embodiment of the invention, has been knurled as at 96 and has been hardened through a subsequent heat-treating process. For ease of process, in the preferred embodiment of the invention, the entire circumferential surface is knurled. As shown in FIG. 3, assembly of the locking jaw 58 to the tube member is as follows.
The locking jaw 58 is attached to an inner section of the tube member 52 by way of a spring point 98 , which is interferingly positioned through apertures 100 in the tube member 52 . It should be appreciated that opposite ends of the sporing pin 98 will be interferingly fit in apertures 100 in opposite sides of the tube member 52 , yet will be profiled relative to the aperture 90 on the locking jaw, to allow the locking jaw to freely rotate about the pin member 98 . The linkage rod 56 extends through the entire length of the tube member 52 and includes a lower end section at 104 having a pin member 102 which is interference fit within aperture 92 of the locking jaw 58 . Once again, it should be understood that the pin 102 be profiled to allow rotation of the linkage rod relative to the pin yet be interference fit within the aperture 92 of the locking jaw 58 . This could be accomplished by a number of means known within the art, that is by including an interference fit pin member having an outer head which is larger than the aperture at the end of the linkage rod, or could include a threaded member including a headed section to retain the linkage rod 56 to the locking jaw 58 . As shown, a peripheral section 94 of the locking jaw 58 is positioned adjacent to an opening 106 in the tubular member 52 so it can be moved from a position extending outside the periphery of the tubular member 52 , (FIG. 3) to a position extending inside the tubular member 52 by way of actuation of the pushbutton actuator 54 (FIG. 6 ).
With reference now to FIGS. 5 and 6, the operation of the telescopic device will be described in greater detail. With respect first to the open position shown in FIG. 6, it should be appreciated that with the push-button actuator 54 in the activated state, that is when the push-button is engaged such that the linkage rod 56 is fully extended, the locking jaw 58 rotates in a clockwise sense about the pivot pin 98 as viewed in the position of FIG. 4 . It should be appreciated that the locking jaw 58 , in this position, is not in engagement with the inside wall 50 of the outer tube member 40 and therefore due to the sliding fit between the inner and outer tubular members, 40 and 52 , of the upper support member and the vertical base portion 40 , the upper support member 26 can be moved to virtually any incremental vertical position telescopically, only being limited by the overlapping length of the tubular members 40 and 52 . However, with reference to FIG. 5, when the pushbutton 54 is disengaged, that is when the spring is allowed to move the pushbutton upwardly, thereby retracting the linkage rod 56 also upwardly, the locking jaw 58 rotates in a counter-clockwise sense, thereby bringing the outer peripheral surface 96 into engagement with the inner surface 50 of the outer tubular member 40 . It should be appreciated that due to the over-centered nature of the pin 98 and frictional engagement contact surface, that is the offset Y 1 , (FIG. 5) a downward vertical load on the bracket 28 , will cause the locking jaw 58 to tend to bite in further into the inner surface 50 thereby tightening the inner 52 and outer 40 tubular members together. It should be appreciated that the device as shown herein, shows an easy mechanism for adjusting the height of such support structures which can be moved through any virtual incremental number of vertical locations.
Also advantageously, shown in FIG. 7, the rack of the present invention can be positioned at different vertical heights for different articles of clothing, for example one side could be at one vertical height for such clothing articles as topcoats or raincoats while the opposite side could be used for short jackets, or shirts. So is the case even when fully loaded, as the actuator 54 is easily accessible to the user. The user can simply grasp the support member 24 with one hand, and depress the button 54 , and move the support member 54 upwardly or downwardly as is required for the display. To ensure that the hangers, and the clothing which they hold, does not slip off the brackets 28 , end caps 110 prevent such slippage. | A mechanical stand for vertically supporting objects is disclosed which includes an upper base section comprised of a tubular structure, having a telescopically movable upper support member, which in the preferred embodiment of the invention could be used as a rack member or a shelf structure. The upper support member is comprised of a tubular member cooperatively profile with the tubular structure of the upper base section to be slidably received therein. The upper support member includes a pushbutton actuator which is operatively connected to a linkage member, which in turn is connected to a locking jaw, whereby actuation of the pushbutton member disengages the locking jaw from the inner surface of the upper base member, allowing various incremental telescopic locations of the upper support member. | 0 |
This is a continuation of application Ser. No. 08/159,069 filed on Nov. 29, 1993 and abandoned, which is a continuation of application Ser. No. 07/940,255filed on Sep. 1, 1992 , abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to inflatable type modular occupant restraint systems for passenger vehicles or, as it is more commonly known, an air bag restraint system. Such a system may be installed in an automobile or other vehicle, at least in part on the steering wheel for the protection of the driver and also in the dashboard or passenger side instrument panel for passenger protection in the event of a collision. More particularly, this invention relates to an improvement in a means for controlling the initial deployment of the air bag cushion.
2. Description of Related Art
An air bag restraint system module typically includes a canister, which has an open side and encloses an inflator and at least part of an air bag, and a cover which conceals the module from view. When an air bag module is designed for the driver side of a vehicle the module is located in the steering wheel behind a cosmetic cover which is an integral part of the steering wheel design. When the air bag module is designed for the passenger side of a vehicle, the container may be located just behind the vehicle dashboard, cosmetic cover, or passenger side instrument panel (hereinafter referred to as "dashboard") and the cover may form an integral part of the vehicle dashboard.
When the vehicle is involved in a collision, a crash signal initiates operation of the inflator to cause the air bag cushion to deploy. The inflator produces an inert gas (e.g., nitrogen) which is directed under pressure into the air bag cushion to force the air bag cushion out of the container and through the opening provided by rupturable tearseams in the steering wheel cover, or tearseams or a hinged cover in the dashboard, and into the passenger compartment of the vehicle. As the air bag cushion is directed into the passenger compartment, it is inflated by the continued flow of gas produced by the inflator. An untethered driver side air bag cushion deploys to fill the space between the steering wheel and the driver's head and upper torso. On the passenger side the air bag cushion is directed between the windshield and the occupant to fill the space between the windshield and the occupant's head and upper body. During the early stages of the air bag cushion's deployment, it is preferable to expand the air bag cushion between the steering wheel or dashboard of the vehicle and the occupant's torso in order that the momentum of the moving occupant can be initially absorbed from the occupant's torso. After the initial contact the air bag cushion still provides protection to the head and upper body of the occupant during a collision.
Tethers have been used to guide the deployment of an air bag cushion for motor vehicle occupant protection. Air bag cushions are commercially available with tethered driver side and passenger side air bag cushions wherein the tethers are attached by fastener members to the impact absorbing part of the air bag cushion and to the air bag cushion near the gas inlet opening. During high energy collisions a tethered air bag cushion is positioned to receive the initial impact from the vehicle occupant's head and upper torso.
SUMMARY OF THE INVENTION
An object of this invention is to provide a means for quickly moving the air bag cushion into place between the occupant's torso and the steering wheel during deployment of the air bag cushion.
Another object of this invention is to provide a means for quickly moving the air bag cushion into position between the occupant's torso and the instrument panel during deployment of the air bag cushion.
Another object of this invention is to provide a means for deploying the air bag cushion such that the initial contact is made between the air bag cushion and the occupant's torso.
Another object of this invention is to provide a means for reducing the momentum of the deploying air bag cushion.
Another object of this invention is to provide a means for lowering the deployment angle of the air bag cushion.
Another object of this invention is to provide a means for moving the air bag into the proper position to absorb the momentum of the occupant's torso.
These and other objectives of the invention, which will become apparent from the following description, have been achieved by a novel tether system for use with automotive air bag cushions. The tethers of this invention are folded and attached upon themselves at one or more locations by a rupturable fastener means which will release when a sufficient amount of tension is applied to the tether.
The air bag cushion used with the tether system of this invention comprises a first portion, having a front surface and a back surface. This first portion is disposed opposite the occupant of a vehicle when the cushion is deployed. A second portion of the air bag cushion is attached to the first portion and terminates in a third portion defining a gas inlet opening for the air bag cushion. At least one tether having a first end and a second end, and a first edge and a second edge, with the first end of each tether attached to the back surface of the first portion of the air bag cushion and the second end of each tether is attached adjacent the third portion of the air bag cushion. Each of the tethers are folded upon themselves to form at least a first tether section and a second tether section. Each of the first tether sections are joined to the respective second tether sections at least at one spaced contact point by rupturable attachment means.
BRIEF DESCRIPTION OF THE DRAWINGS
With this description of the invention, a detailed description follows with reference being made to the accompanying figures of drawing which form part of the specification, in which like parts are designated by the same reference numbers, and of which:
FIG. 1 is a side plan view of a passenger side air bag cushion containing tethers with tearseams illustrating the air bag cushion in a partially deployed condition before the rupturable attachment means have released;
FIG. 2 is a side plan view of the air bag cushion and tether illustrating the air bag cushion in a fully deployed condition after the rupturable attachment means of the tether have released;
FIG. 3 is a top plan view of the tether of this invention illustrating the stitching arrangement for rupturable fastener means;
FIG. 4 is a top plan view of an alternate tether for use with this invention illustrating the stitching arrangement for the rupturable fastener means;
FIG. 5 is a top plan view of the air bag cushion illustrating one possible tether arrangement;
FIGS. 6a, 6b, and 6c are a sequence of side plan views of the air bag cushion illustrating the operation of the tethers of this invention during deployment of the air bag cushion;
FIG. 7 is a side plan view of a tether illustrating an alternate way of attaching the rupturable attachment means; and
FIG. 8 is a side plan view of a driver side air bag cushion containing tethers with tearseams illustrating the air bag cushion in a partially deployed condition before the rupturable attachment means have released.
DETAILED DESCRIPTION OF THE INVENTION
As best seen in FIG. 1, an air bag deployment control device shown generally at 10 is provided for directing the deployment of an air bag cushion 12 from a module canister 14 toward a vehicle occupant. A tether 16 having a first end 18 attached to the back surface 20 of the air bag cushion first portion 22, and a second end 24 attached adjacent a gas inlet opening 26 provided for receiving a gas from an inflator 28. The tether 16 is folded upon itself to form at least a first section 30 and a second section 32. The tether first section 30 is attached to the tether second section 32 at least at one location by rupturable fastener means 34. Additionally, the folded tether 16 may include a tether third section 36 formed between the tether first end 18 and the first rupturable fastener means 34a, and a tether fourth section 38 between the first rupturable fastener means 34a and the tether second end 24. Upon deployment of the air bag cushion 12 from the canister 14 the expansion of the cushion 12 is halted momentarily by the shortened tether 16 causing, it is believed, the air bag cushion to pivot around the tether second end 24. As tension is applied to the tether 16 by the expanding cushion one of the rupturable fastener means 34 releases thereby allowing the cushion first portion 22 to proceed out of the canister 14 until the tether 16 again reaches the maximum length permitted by the rupturable fastener means 34.
The canister 14 for use with the tether of this invention includes any canister known in the art for use with a passenger side air bag restraint system or an air bag module known in the art for use with a driver side air bag restraint system. The tether of this invention was used with a passenger side canister 14 which includes a pair of first walls 40a and 40b (top and bottom respectively when viewed from above) and a pair of second walls 42a and 42b (left and right respectively when viewed from above) that define respectively a top opening 44 and a bottom opening 46 as shown in FIGS. 1 and 5. An air bag inflator 28 is held between a diffuser 48 and a cap 50 attached to the bottom opening 46 of the canister 14. Adjacent the inflator 28 and attached thereto is an air bag cushion 12 having a first portion 22 disposed in front of the occupant of the vehicle when the air bag cushion 12 is deployed. An air bag cushion second portion 52 is attached to the first portion 22 and terminates in a third portion 54 defining a gas inlet opening 26 for the air bag cushion. The air bag cushion first portion 22 has a front surface 56 which faces the occupant during deployment of the air bag cushion 12 and a back surface 20 which faces the interior of the air bag cushion 12. The air bag cushion 12 used with this invention can be any air bag cushion known in the art.
The tether 16 of this invention includes a first end 18, a second end 24, a first edge 58, and a second edge 60, as shown in FIG. 3. The tether 16 first end 18 is attached to the back surface 20 of the air bag cushion 12 by any suitable means such as stitching or the like. Preferably a box stitch 62, as shown in FIG. 3, is used. The tether second end 24 is attached to the air bag cushion 12 adjacent the air bag cushion third portion 54, preferably with a box stitch 62. Also, the tether second end 24 can be attached securely to the canister 14 adjacent the location where the air bag cushion third portion 54 is attached to the canister 14. Preferably the tether second end 24 is attached to the bottom canister first wall 40b by appropriate fastening means such as rivets, bolts, or the like. The tether 16 is folded upon itself to form at least a first section 30 and a second section 32. The first section 30 is attached to the second section 32 by rupturable fastener means 34. The rupturable fastener means 34 of this invention is any suitable attachment means which will release when tension is applied to the tether 16 at the first end 18 and the second end 24. The rupturable fastener means 34 must be such that it will release without resulting in the tearing of the tether. Further, the rupturable fastener means 34 must be such that it will fail under cold operating conditions (approximately -30° C.), while still being able to provide momentary resistance to applied force under hot operating conditions. The preferred rupturable fastener means for use with this invention is a rupturable stitch, preferably a lock stitch. The stitch may span the entire distance from the tether first edge 58 to the tether second edge 60 or any portion of the distance in between the first edge 58 and the second edge 60. In place of a rupturable stitch a hook and loop type fastener such as a Velcro® fastener may be used. The rupturable fastener means 34 are placed at a number of spaced locations along the length of the tether 16. Alternatively a rupturable stitch or a hook and loop type fastener such as a Velcro® 64 may be run the length of the tether 16 as shown in FIG. 7.
The tether 16 can be made from any suitable flexible material having sufficient strength so as not to fail under the forces of the deploying air bag cushion. Material used in the manufacture of the air bag cushion can be used in the manufacture of the tether. Materials suitable for use in this invention are woven or knit fabrics made from nylon, polyester, polyamide fibers, or other suitable materials. Natural fibers or fibers subject to structural degradation by molds or bacteria should not be used. Further, materials not approved for use in automotive vehicle interiors should not be used. Thread used in the stitching of the rupturable stitch can be made from any suitable fiber made from nylon, polyester, polyamide fibers, or the like. As with the material used for manufacture of the tether 16, natural fibers or fibers subject to structural degradation by molds or bacteria should not be used for the rupturable fastener means 34.
Reinforcement of the tether 16 where the rupturable fastener means 34 are located may be necessary to provide appropriate structural integrity to the tether material. These reinforcements can be made from any material suitable for providing structural integrity to the tether 16.
A single tether 16 or a single pair of narrow tethers 16 of the type shown in FIG. 3 can be used. Multiple pairs of tethers 16 can be used, however, one pair of tethers 16 is preferred as shown in FIG. 5. The number of tethers 16 used is determined by the particular application. Tether panels 65 as shown in FIG. 4 may also be used. Again, as with the narrow tethers 16 single or multiple tether panels 65 may be used. When two pairs of narrow tethers 16 or tether panels 65 are used the tethers 16 are oriented as shown in FIG. 1 with the first set of tethers 16 and the second set of tethers 16b. Each of the tethers 16 are folded about a fold line 66 and multiple rupturable fastener means 34 are used to attach the two sections as shown in FIGS. 3 and 4. When a tether panel, as shown in FIG. 4 is used either a rupturable fastener means 34 sewn as a rupturable "V" stitch 35 or straight stitch 35a can be used. When a lock stitch is used as the rupturable fastener means 34 with a single pair of narrow tethers 16 it is preferable to use two rows of lock stitches for the first stitches 34a and a single row of lock stitches for subsequent rupturable stitches. The number and type of stitches actually used is determined by the particular application.
To assemble an air bag cushion with the tethers of this invention the tethers can have the rupturable fastener means attached and the tether can then be installed in the air bag cushion in a manner similar to the installation of a conventional tether. Also, the tether can be installed in the air bag cushion without the rupturable fastener means and then the rupturable fastener means can be affixed to the tether. It is preferable to affix the rupturable fastener means prior to installation of the tether in the air bag cushion. The air bag cushion with the tether of this invention is then installed in a canister or attached to a module housing by means known in the art. When the tether second end is attached to the canister the tether with the rupturable fastener means is attached to the air bag cushion and the tether second end is attached to the canister and the air bag cushion is installed by means known in the art. The air bag restraint system with the tether of this invention can then be installed behind the dashboard of the passenger compartment of the a vehicle or in the steering wheel of a passenger vehicle.
A signal from a crash sensor (not shown) triggers the generation of gas by the inflator. The gas flows into the air bag cushion from the inflator through the air bag cushion gas inlet. The expanding air bag cushion ruptures the tearseam of the module cover or opens the hinged cover and starts to deploy into the vehicle passenger compartment. The air bag cushion deploys to the maximum amount permitted by the tether truncated due to the rupturable fastener means as shown in FIG. 6a. It is believed that the truncated tether causes the air bag cushion to pivot around the tether second end 24. As tension is applied to the tether by the deploying air bag cushion the first rupturable fastener means releases permitting the deploying air bag cushion to expand to a point shown in FIG. 6b. Again, it is believed that the truncated tether causes the air bag cushion to pivot further about the tether second end 24. This process continues until all of the rupturable fastener means have released and the air bag cushion is fully deployed as shown in FIG. 6c.
Thus, in accordance with the invention, there has been provided a means for quickly moving the air bag cushion into place between the occupant's torso and the instrument panel during deployment. There is also provided a means for deploying the air bag cushion such that the initial contact between the air bag cushion and the occupant is at the occupant's torso. There has also been provided a means for moving the air bag cushion into the proper position to better absorb the momentum of the occupant's torso. There has also been provided a means for reducing the momentum of the deploying air bag cushion. Additionally, there has been provided a means for lowering the deployment angle of the air bag cushion.
With this description of the invention in detail, those skilled in the art will appreciate that modification may be made to the invention without departing from the spirit thereof. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments that have been illustrated and described. Rather, it is intended that the scope of the invention be determined by the scope of the appended claims. | A guide device for directing the deployment of an automotive air bag cushion toward the torso of an occupant by means of a tether which is folded and attached to itself at a number of locations by rupturable seams. As the air bag cushion deploys the truncated tether or tethers cause the cushion to rotate about a point where the cushion is attached to the canister thereby moving the cushion in a downward direction. The cushion is thereby moved into position in front of the occupant's torso more quickly than an air bag cushion equipped with a tether without tearseams. | 1 |
[0001] This application claims the priority of U.S. Provisional Application Serial No. 60/269,465, filed Feb. 16, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to traffic barricades generally. It finds particular application in conjunction with molded plastic barricades and will be described with particular reference thereto.
[0003] A traffic barricade is typically a portable or fixed device having from one to three rails with appropriate markings. It is used to control traffic by closing, restricting, or delineating all or a portion of the right-of-way.
[0004] The Manual on Uniform Traffic Control Devices (MUTCD) classifies barricades as belonging to one of three types: Type I, Type II, or Type III.
[0005] Type I or Type II barricades are intended for use in situations where traffic is maintained through the temporary traffic control zone. They may be used singly or in groups to mark a specific condition, or they may be used in a series for channelizing traffic. Type I barricades normally would be used on conventional roads or urban streets and arterials. Type II barricades have more retroreflective area and are intended for use on expressways and freeways or other high-speed roadways.
[0006] Type III barricades are used at a road closure. They may extend completely across a roadway or from curb to curb. Where provision is made for access of authorized equipment, vehicles, and/or local traffic, it is often necessary to move the barricade between a position blocking traffic and a position permitting traffic.
[0007] Barricades are often heavy and cumbersome to erect and move. Moreover, once erected, barricades manufactured from wood and metal are often completely destroyed when impacted by a vehicle. They can also heavily damage the vehicle striking them. More importantly, they can injure the vehicle's occupants or a road worker in the vicinity. On the other hand, the known lightweight plastic barricades, which would cause less damage to a vehicle or passengers, are disadvantageous because they are destroyed by impact of a vehicle.
[0008] The present invention contemplates a new, improved barricade which overcomes the above mentioned difficulties and others while providing better and more advantageous results.
BRIEF SUMMARY OF THE INVENTION
[0009] In accordance with one embodiment of the present invention, a barricade is provided. The barricade includes a base including first and second elongate support members which define sockets and a ridge adjacent the first socket. An upright member is supported in a substantially upright position by the base, the upright member including a first leg member which is supported adjacent a first end by the first socket, and a second leg member which is supported adjacent a first end by the second socket. The ridge allows the upright member to deflect upon impact by a vehicle. Signaling means are attached to the barricade member for providing an instruction or warning to vehicular traffic.
[0010] In accordance with another embodiment of the present invention, a barricade is provided. The barricade includes a base which supports an upright member in a generally vertical orientation. The base includes two removably interlocking sections. Each interlocking section includes a socket for closely receiving a distal end of the upright member and a resilient, deformable area adjacent the socket, the deformable area deforming when the barricade is subjected to an impact, permitting the upright member to deflect somewhat and then return to a generally vertical orientation when the impact is removed.
[0011] One aspect of the present invention resides in an easily erected, portable barricade which resists damage upon impact with a vehicle.
[0012] Another aspect of the present invention is the provision of a traffic barricade which reduces the hazard posed to vehicle occupants or road workers if the barricade is hit by a vehicle.
[0013] Still another aspect of the present invention resides in a lightweight barricade upright which does not require external bracing and resists toppling.
[0014] Other aspects of the present invention will become apparent to those skilled in the art upon reading and understanding of the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention may take physical form in certain parts and arrangements of parts, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention.
[0016] [0016]FIG. 1 is a perspective view of a molded traffic barricade according to the present invention;
[0017] [0017]FIG. 2 is an enlarged elevational view of an upright of the barricade of FIG. 1;
[0018] [0018]FIG. 3 is an enlarged cross sectional view taken along line III-III of FIG. 2;
[0019] [0019]FIG. 4 is a top plan view of the barricade of FIG. 1;
[0020] [0020]FIG. 5 is an enlarged cross sectional view taken along line V-V of FIG. 4;
[0021] [0021]FIG. 5A is an enlarged cross sectional view taken along line V-V of FIG. 4 showing the leg member deflected;
[0022] [0022]FIG. 6 is enlarged cross sectional view taken along line VI-VI of FIG. 4;
[0023] [0023]FIG. 7 is a side elevational view of the barricade of FIG. 1; and
[0024] [0024]FIG. 8 is a perspective view of a molded barricade with reflective panels.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] With reference to FIG. 1, a traffic barricade A includes a base 10 and an upright member 12 supportively engaged with the base 10 , which extends generally perpendicular from the base. The base 10 in the illustrated embodiment includes two interlocking sections 10 A, 10 B, allowing the barricade A to be assembled and disassembled quickly. The base is placed on the ground or other generally horizontal surface on which the barricade is to be positioned. The sections 10 A and 10 B together form a generally rectangular-shaped member having four interconnected sides, which each contact the ground and support the upright member from tipping forwardly, rearwardly or to the sides. It is to be appreciated that the interlocking sections may be replaced by a single section which defines a rectangle, or by 3, 4, or more sections which interlock together. Additionally, the base may be circular, oval, or square-shaped, or the like.
[0026] As will become apparent in the discussion below, base 10 also includes a pair of opposed enlarged areas 16 A, 16 B. Preferably, as shown in FIG. 1, the generally U-shaped section 10 A includes a central portion or he elongate support member 17 A and two legs 18 A, 19 A, attached one at either end of the central portion, leg 18 A being slightly longer than leg 19 A. Correspondingly, the generally U-shaped section 10 B includes a central portion or elongate support member 17 B and two legs 18 B, 19 B, attached one at either end of the central portion, leg 18 B being slightly longer than leg 19 B. The central portion 17 A, 17 B and optionally the legs 18 A, 18 B are hollow tubes.
[0027] The enlarged areas 16 are formed in each of central portions 17 , 17 ′ of interlocking sections 10 A and 10 B, respectively, on opposite sides of the base. The enlarged areas are thus of increased cross sectional area relative to the adjoining portions of the central portion 17 A, 17 B. The enlarged areas preferably each define a socket (discussed below) for receiving a respective distal end of the upright member 12 . Additionally, enlarged areas 16 further include integral surface undulations or ridges 20 which permit upright member 12 to deflect slightly in the x direction. The sections 10 A and 10 B of the base are hollow tubular members, made of a suitable conventional thermoplastic material, such as by blow molding. However, the thickness of the tubular wall remains the same in the undulating regions. Those skilled in the art will appreciate that enlarged areas 16 may alternately be comprised of other materials permitting the upright member 12 to deflect, such as rubber, resilient plastics, and the like.
[0028] With reference now to FIG. 2, upright member 12 is shown as a substantially continuous, U-shaped, piece having a pair of legs 21 , 22 a central portion 24 , which interconnects legs 21 , 22 , and opposed ends 26 . The opposed ends are shaped to be closely received by corresponding sockets 28 (FIG. 5) disposed in the enlarged areas 16 of the base 10 . Upright member 12 is preferably of a relatively rigid construction so that it does not bend significantly in the wind or upon slight impact. The upright member may include protrusions and indentations functioning as integrally formed structural supports. As best shown in FIG. 3, these structural supports can include a pair of spaced ribs 30 separated by a channel-shaped groove 32 . The structural supports 30 , 32 run substantially the length of upright member 12 . As illustrated in FIG. 2, structural supports 30 , 32 do not extend to the opposed ends 28 of the upright member 12 . This allows the lower end of the leg members to flex slightly, upon a substantial impact, such as that of a vehicle. However, alternate embodiments could include shaped upright ends. In addition, those skilled in the art will appreciate that structural support can be functionally provided by other means such as a channel receiving a steel bar or other rigidity enhancing mechanism without departing from the spirit of the invention.
[0029] With reference now to FIG. 3, a cross section taken along line III-III of FIG. 2 is illustrated. A rigid light unit mount 36 extends away from an upper portion 24 of the upright member 12 . The mount 36 is preferably formed by compression molding the front and back walls of a flange atop the upright member. As is evident, the light unit mount 36 includes an attachment point 38 for fixing a light, reflector, or other device (not shown). In the illustrated embodiment, the attachment point 38 is an eye for receiving an attachment mechanism or bolt (not shown). Further, the attachment mechanism or bolt is preferably protected or recessed within a housing 40 defined within the mount 36 . When the bolt head is located within the housing 40 , unauthorized removal of the bolt, and hence the light unit, is more difficult.
[0030] As noted, FIG. 3 illustrates ribs 30 and separating channel indentation 32 . Additional longitudinal strength is added by applying a different compression mold to opposite sides of upright member 12 . Thus, ribs 30 ′ and channel indentation 32 ′ do not necessarily constitute a mirror image to ribs 30 and channel 32 .
[0031] In one embodiment, the upright member can be blow molded and then compression formed to assume the shape illustrated in FIGS. 2 and 3.
[0032] With reference now to FIG. 4, the top plan view illustrates interconnecting joints 44 between base sections 10 A, 10 B. Additionally, it should now be apparent that enlarged portions 16 slightly increase the overall width of the base 10 .
[0033] With reference now to FIG. 5, a cross sectional view along the line V-V of FIG. 4 further illustrates the interface between the upright member 12 and the base 10 . End 26 extending from the upright member 12 seats firmly within socket 28 defined by enlarged portion 16 . The socket 28 includes an opening 46 , formed in an upper surface 47 of the wall of the enlarged area 16 . The base of the socket 28 may be defined by a lower surface 48 of the wall of the enlarged area 16 . The base of the socket defines a seat 50 bordered by an annular ridge 52 integrally formed into the socket 28 . Tapered corners 56 of ridge 52 permit end 26 to deflect in the direction of arrows A and B while maintaining contact with seat 50 , as shown in FIG. 5A. In the process, the undulations 20 on one side become compressed, while those on the other side open out slightly to accommodate the movement of the end 26 . Thus, the undulations 20 in the top surface 47 of the enlarged area 16 advantageously provide support for the upright member ends 26 while allowing slight deflections in the x direction. This construction also allows the upright member to slide out of the base 10 upon impact with a vehicle. Desirably, the ends 26 cooperating in the resilient enlarged area 16 permit the upright member 12 to deflect, rather than to fail, in response to, for example, wind gusts. Moreover, it is believed that the undulations 20 allow the upright member 12 to be pushed out of or ejected from the sockets 28 while resisting tearing of the surrounding wall of the base 10 as by a sudden impact of a vehicle. The undulations 20 create a bellows effect in the material of the base. They also facilitate the elimination of an additional support for the upright member which would otherwise be required to prevent damage around the sockets.
[0034] With reference now to FIG. 6, a cross sectional view along the lines VI-VI of FIG. 4 illustrates the connection between the base sections 10 A. 10 B which permit assembly and disassembly of the base 10 . In the illustrated embodiment, base section 10 B includes and end 60 with locking indentations 62 . Upon urging end 60 into opening 64 of base section 10 A, end 60 deflects a cooperatively shaped projection 66 which seats closely with the locking indentation 62 on the end 60 . Those skilled in the art will appreciate that the illustrated interlocking mechanism is but one of many available to achieve the desirable goals of permitting the base 10 to be assembled and disassembled repeatedly.
[0035] Referring now to FIG. 7, it can now be appreciated that the upright member 12 is displaced on the base 10 in the x direction. In other words, the upright member 12 , hence the enlarged portions 16 are offset from the center of the base 10 . Thus, the barricade has a front end 68 and a rear end 69 . As is also now apparent, upright member 12 is configured to be supported only by the sockets 28 (FIG. 5) within enlarged areas 16 , thus no angled supports or braces are required to support the upright member 12 perpendicularly as is typical in the art.
[0036] With reference now to FIG. 8, cross members or reflective panels 70 may be attached to the barricade A as desired. The panels 70 signal an instruction or warning to vehicular traffic, such as arrows indicating that the traffic should turn to the left or right, or a written warning, such as ROAD CLOSED. It is within the skill of those of ordinary skill in the art to affix panels 70 to the upright member 12 at desired locations with suitable conventional fasteners, such as screws, bolts, jacknuts, and the like. Moreover, additional resistance to inadvertent deflection or toppling can be provided by filling a blow molded void or cavity defined by the base 10 with sand or other ballast. Alternately or in addition, sand bags or the like may be placed over base 10 to increase stability.
[0037] In yet another alternative embodiment, sections 10 A and 10 B are not interlocked but are spaced from each other at ends 60 .
[0038] The invention has been described with reference to the preferred embodiment. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. These modifications and alterations include continued variety in the size of the illustrated components, both in width and height, presence or absence of a light fixture, manufacturing techniques used, and attachment devices employed between various components as illustrated. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A traffic barricade includes a base which supports an upright member. The base includes two removably interlocking sections, each having an enlarged portion. The enlarged portions defines a socket for closely receiving a tab extending from the upright member. A deformably resilient material surrounds the socket, permitting the upright member to deflect slightly and return to a substantially perpendicular orientation relative to the base. The upright member incorporates integral structural supports which permit the barricade upright member to maintain an upright member orientation without additional external support mechanisms. | 4 |
FIELD OF THE INVENTION
[0001] The present invention is a method for detecting the end point of plasma etching process, especially by using a matrix.
BACKGROUND OF THE INVENTION
[0002] Generally in the semiconductor processes, the process of Reactive Ion Etch (RIE) is used to etch imperceptible patterns on the silicon wafers. RIE includes a step of putting a wafer with photo-resist patterns into a reactive chamber with plasma. Plasma includes etching gas, which can be vertically decomposed in a RF (Radio Frequency) field. Therefore, the reactive ion in the etching plasma can leave the wafer surface accerlatively. The accelerated reactive ion includes the materials not covered by the photo-resist patterns on the wafer surface. Therefore, the volatile etching species will be produced. During the above etching process, one or multiple layers' materials or thin films can be removed. For example, the removed materials could be silicon oxide, polysilicon, silicon nitride, or metallic aluminum.
[0003] When a thin film not covered by the photo-resist pattern is etched, the volatile species will be merged into the plasma. Therefore, when the process of RIE comes to the end point, the etching gas will be decreased but the volatile etching species will be increased. These increased or decreased amount in the plasma could be traced back to decide whether the process of reactive ion etch goes to the end point or not. The FIG. 1 of U.S. Pat. No. 4,246,606 or 4,263,089 introduce a device with end point detecting method, wherein a photoelectric cell is utilized for transferring from the emission intensity of plasma to an electric current or voltage, and then the emission intensity of plasma is measured to decide every stage of the plasma etch process by the electric current or voltage.
[0004] There are many improvements of end point detecting method in the progress of semiconductor process. For example, in the U.S. Pat. No. 5,690,784, when a coated substrate is etched by plasma, there is a beam going through another monitor substrate with the same coating. The emission intensity of the beam will be changed during the process of etching. So we may decide whether the coated substrate comes to the end point of the process of REI or not by comparing the beam intensity with an expected value or a reference value. Further more, in the U.S. Pat. No. 5,160,576, the light produced by plasma discharge can go through a folded filter mirror to easily detect the end point by reducing the noises. And there still are other improvements of end point detecting method, just like U.S. Pat. Nos. 5,288,367, 4,936,967, 4,345,968, 4,687,539, 5,837,094, etc.
[0005] In the end point detecting method of reactive plasma etching, the process stability is very important. Usually there is a simple algorithm can decide the end point. This algorithm includes the delay time to bypass the unnecessary unstable duration produced by plasma at the radio frequency power-on. And then, the end point signal is averaged by the time during the stable duration. Finally, compare the average signal with the present signal level to decide the end of the process. At this moment, the emission of interested plasma species' single wavelength could be detected. There were several skills used to get better detecting efficiency of end point, which mainly enhance the mathematics to improve the average signal. For example, U.S. Pat. No. 5,565,114 calculates the summarized average intensity of plasma emission spectrum at first, and then calculates the difference or ratio of summarized average values to decide whether the etching process comes to the end point. However, this kind of skill can only be used in the stable processes or some unstable processes with guaranteed tolerance.
[0006] The much more complex methods include detecting two kinds of emission wavelengths concurrently. These methods are especially useful for detecting a weak emission in plasma. Usually the ratio between the two intensities of different wavelengths is used to detect the end point. However, due to the unstable characteristic of plasma, sensitive electrical instruments that surround the etching machine, and the sustaining changes of chamber's states, all these noises produced from every source will be pick up by the end point detecting device easily. Therefore, if the simple algorithm is used, then the computer system will misjudge an end point because a change of intensity from the RF power sudden surge or a polymer material. The other noises would come from the improper grounding, unstructured touching of chambers' components, the aging and lacking of electrical shielding components, contamination of chambers or wafers, or arcing in the plasma.
[0007] The instability of plasma is a very difficult problem to be overcome, but the other noise sources can be minimized by some mathematics methods, just like the time average. For the best result of time average, a long time is taken to calculate from the signal. This is impractical in the real process, and the improvement of manufacturing will be delayed by this solution very obviously.
SUMMARY OF THE INVENTION
[0008] According to the disadvantages of the conventional end point detecting methods, the main objective of the present invention is to compare an end point matrix with a referenced end point matrix to detect the end point.
[0009] Another objective of the present invention is to detect the intensity changes of two kinds of plasma species before and after etching by different wavelengths, and then to reduce different noise sources.
[0010] Another objective of the present invention is to quickly detect the end point by using matrix calculation.
[0011] According to the present invention, a method for detecting the end point comprises steps of: provide a reference end point matrix in the plasma etching process firstly. Secondly, detect the illuminant intensities of at least two kinds of plasma species within different wavelengths at the beginning of etching, and combine the illuminant intensities of the plasma species within different wavelengths for the elements of an initial matrix. Thirdly, detect the illuminant intensities of at least two kinds of plasma species within different wavelengths during the process of etching, and combine the illuminant intensities of these two kinds of plasma species within different wavelengths for an etching matrix corresponding to the initial matrix. Finally, calculate the initial matrix and the etching matrix to get an end point matrix, which etching matrix equals to the multiplication of the initial matrix and the end point matrix, and detect whether the etching process comes to the end point or not by comparing the end point matrix with the reference end point matrix.
[0012] The present invention may best be understood through the following description with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 shows the intensities of CN plasma before and after etching process within different wavelengths; and
[0014] [0014]FIG. 2 shows the intensities of another Si plasma before and after etching process within different wavelengths.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Some embodiment examples of the present invention will be well described as below. However, the present invention could also be used at some other embodiment except following description, and the field of the present invention will not be limited and would be based on the claims of the present invention.
[0016] The present invention provides an end point detecting method by using matrix. The main steps is: detecting the illuminant intensities of at least two plasma species within different wavelengths at the beginning of etching, and combining the illuminant intensities of these two kinds of plasma species within different wavelengths for the elements of the initial matrix. Then detect the illuminant intensities at least two plasma species within different reflecting wavelengths during the process of etching, and combine the illuminant intensities of these plasma species within different wavelengths for the elements of the etching matrix. And then calculate the initial matrix and etching matrix to get the end point matrix, where the etching matrix equals to the multiplication of the initial matrix and the end point matrix. Then detect whether the etching process comes to the end point or not by comparing the end point matrix with the reference end point matrix.
[0017] The different rows of the initial matrix and etching matrix present the different types of plasma species, and every element of every column includes the intensity of plasma within different illuminant wavelengths. Further more, the initial matrix and the etching matrix also include a plasma parameters column, where every element presents the plasma parameter of the plasma etching process. The illuminant intensities detection of plasma species will use the charge couple device (CCD) matrix of the optical channel analyzer.
[0018] The steps of getting the reference end point matrix are as follows. In plasma etch process test, detect a first matrix at the beginning of etching, where the first matrix includes the illuminant intensities of at least two kinds of plasma species within different wavelengths before etching process. Secondly, detect a second matrix after the etching process is completed, where, corresponding to the first matrix, the second matrix includes the illuminant intensities of the two or more kinds of plasma species within different wavelengths after the etching process. By calculating the first matrix and the second matrix, we may get the reference end point matrix, where the second matrix equals to the multiplication of the first matrix and the reference end point matrix.
[0019] Here is an embodiment example of end point detecting algorithm according to the present invention. Please refer to FIG. 1. We may observe the different emission plasma species during the plasma etching process. Every kind of plasma has its own characteristic emission wavelength λ. Depending on above reacting mechanism, the intensity of λ will be changed by the plasma etching time (B) and the endpoint arriving time (A). Therefore, if the intensity of λ is stronger, then the intensity difference B-A would be plus, which presents the plasma species i locate at the j th state; if B-A is minus, which presents plasma species i do not locate at the j th state and with weaker emission intensity.
[0020] Because most of the noise factors exist concurrently, therefore it is not very assured to detect the end point by observing only one or two changes of the emission wavelengths. There is an expanding and rigid method that can really reflect the real time situation of the chamber during the plasma etching process, i.e. monitoring the end point by multiple plasma species and their wavelengths concurrently. Based on above concept, we define an end point matrix X that can meet the following formula:
BX=A,
[0021] where matrix B and A include the illuminant intensities of every kinds of plasma species within different wavelengths at the beginning and ending time of etching process. Every element of the matrix row presents the intensity of different wavelength j of every kind of plasma species i.
B = [ b 11 b 12 ⋯ b 1 x b 21 b 22 ⋯ b 2 x ⋮ ⋮ ⋰ ⋮ b x 1 b x 2 ⋯ b xx ] , A = [ a 11 a 12 ⋯ a 1 x a 21 a 22 ⋯ a 2 x ⋮ ⋮ ⋰ ⋮ a x 1 a x 2 ⋯ a xx ] ,
X = [ x 11 x 12 ⋯ x 1 x x 21 x 22 ⋯ x 2 x ⋮ ⋮ ⋰ ⋮ x x 1 x x 2 ⋯ x xx ]
[0022] In general condition, matrix X should be unchangeable (just like the ratio B/A should be a constant for the two wavelengths example). The relationship of intensity changes between A and B would follow the fundamental molecular reaction dynamics and the spectrum rules. However, the external conditions, just like the interruptions of polymers on the chamber's walls or the gas contamination, would also force to the change of intensity's background of A or B. Of course, the ratio of X is changeable. Therefore, the matrix X can be used to be the index of the condition change of the end point.
[0023] [0023]FIG. 1 and FIG. 2 show the general plasma emission spectrums before and after etching process respectively. For example, there are several emission wavelengths of CN plasma detected in FIG. 1, and every wavelength would have its own intensity change after etching process. We may find a lower intensity at λ=3860A after etching, but there is a higher intensity at λ=5146A before etching. In general dielectrics etching but except the CN plasma, different F, CF2, O, and CO plasma can be used for detecting. FIG. 2 shows a better description for the present invention. The silicon emission intensity will be enhanced at λ=2880A after etching, but the intensity will be reduced at λ=5043A after etching. In the typical polysilicon etching process, different H, Br, O, F, SiF, SiCl plasma can also be used for detecting except Si and Cl plasma. Therefore, if using the polysilicon etching as a practical example, the end point matrix can be written as:
B = [ Cl 3851 b Cl 3852 b Cl 3861 b Cl 4372 b Si 2880 b 0 0 0 SiF 3360 b SiF 4400 b SiF 7770 b 0 SiCl 2514 b SiCl 2820 b SiCl 2871 b 0 ] ,
A = [ Cl 3851 a Cl 3852 a Cl 3861 a Cl 4372 a Si 2880 b 0 0 0 SiF 3360 a SiF 4400 a SiF 7770 a 0 SiCl 2514 a SiCl 2820 a SiCl 2871 a 0 ] ,
X = [ x 11 0 0 0 x 21 x 22 x 23 0 x 31 x 32 x 33 0 x 41 x 42 x 43 x 44 ]
[0024] The 4×4 matrixe shown above is the end point matrix, which are combined by 4 kinds of plasma species (Cl, Si, SiF, and SiCl) with maximum emission wavelengths. The lower labels of matrix A's and matrix B's elements present the detected emission wavelengths. The upper labels of matrix A's and matrix B's elements present the intensity after etching process. Some elements are 0 in the matrix X. This is the characteristic of matrix A and matrix B. The characteristics of elements in the matrix X depend on the arrangements of the elements in matrix A and matrix B.
[0025] In the plasma etching producing testing process, if the matrix X, which is calculated after the matrix A and matrix B, are completed to measure, then it can be used as a reference end point matrix X ref of polysilicon etching process. And then, in general polysilicon etching process, we only need to detect every element of matrix B at the beginning of etching process, and detect every element of matrix A during etching process, therefore the end point matrix X could be able to get by formula BX=A. Finally, we may judge the etching process comes to the end point or not by comparing the end point matrix X with the reference end point matrix X ref .
[0026] The most advantage of the end point detecting method of the present invention is, there are multiple kinds of plasma species within multiple wavelengths can be detected and modified concurrently. The changes of external conditions would be separated in every element of the matrix X. Under suitable fluctuation criteria or tolerance, the end point detecting should be more exact than the other traditional methods.
[0027] About the concurrent detection of emissions with multiple wavelengths for multiple kinds of plasma species, the light emitted from plasma will be connected to and received by the charge coupled device (CCD) matrix of optical channel multi-analyzer (OMA) with all spectrum analysis. The changes of intensities and the elements of matrix can be quickly analyzed by the computer and be decided when the process will come to the end point at a suitable time.
[0028] The most important feature of the present invention is the illuminant emission spectrum within the plasma species. The same method can be expanded to the other plasma parameters that detected at the same time. In the matrix method of the present invention, t he reaction of plasma would be the most useful parameter in the RF impedance changes of possible touch points in the end point detection. Therefore, based on the matrix after etched, the matrix would probably be:
A = [ Cl 3851 a Cl 3852 a Cl 3861 a Cl 4372 a Si 2880 a 0 0 0 SiF 3360 a SiF 4400 a SiF 7770 a 0 V 1 a V 2 a V 3 a V 4 a ]
[0029] Where Vi of the last row in above matrix have different plasma parameters, which could probably include the chamber pressure, the running amount of reactive gas, the RF power, the RF impedance, the RF matching capacitance, and the peak-to-peak voltage.
[0030] The end point detecting method by matrix of the present invention is able to detect the intensity changes of at least two kinds of plasma species within different wavelengths before and after etching, so the present invention can reduce the noise produced by a single wavelength of a single plasma very efficiently. Furthermore, corresponding to the time average, the calculation of matrix can quickly judge whether the plasma etching process comes to the end point or not indeed. This is really great for end point detecting.
[0031] While the invention has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. | A method for detecting the end point of plasma etching process by using matrix comprises a step of detecting a beginning matrix including emitting intensities and/or other plasma parameters of at least two different plasma species during beginning etching process. Then, a step of detecting an etching matrix is performed in which the etching matrix includes emitting intensities and/or other plasma parameters of the at least two different plasma species at the etching reaction. An end point matrix is then computed by using the beginning as well as etching matrices and compared to a reference end point matrix to decide whether the end point is reached. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2014 205 036.7 filed Mar. 18, 2014, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to an endoscopic instrument for the connection to an operation robot, with an instrument housing, with a shank which connects to the instrument housing, and with at least one instrument part arranged on a distal side of the shank, wherein the instrument part and/or the shank are movable relative to the instrument housing and for this are each actively connected to a control means (a control).
BACKGROUND OF THE INVENTION
[0003] Operation robots are nowadays applied with an increasing number of surgical operations. Such an operation robot is known for example from US 2009/0234371 A1. This operation robot comprises several robot arms, at whose distal ends an endoscopic shank instrument is arranged each case, wherein this instrument is controlled by the operator from a console and serves for observing and/or manipulating on or in the body of a patient to be treated, depending on the type of instrument.
[0004] The instruments which are provided for manipulation comprise an instrument head which a tool arranged thereon, at their respective distal shank end. Known instruments are provided with an instrument head which can be bent relative to the shank, wherein the tool or a tool carrier with the tool and provided on the instrument head can also be bent (angled) with respect to the instrument head. Instruments which additionally comprise an instrument shank which can be rotated about their longitudinal axis are also widespread.
[0005] It is common to apply pull cables which are led through the shank into an instrument housing arranged at the proximal shank end, as control means, for the control of the rotation of the instrument shank and for the control of the bending of the instrument head as well as for the control of the tool or for actuating the instrument head and the tool. There, in the instrument housing, the pull cables are each non-positively coupled in movement to a rotatable actuation roller which is controlled by way of a rotatory drive motor. The actuation rollers are arranged next to one another in a common plane normal to their rotation axis. The drive motors which serve for actuating the pull cables are arranged in a drive unit which is releasably connectable to the instrument housing.
[0006] Typically, the number of actuation rollers which are arranged in the instrument housing and which is determined by the number of degrees of freedom of movement of the instrument head, has a significant influence on the size of the instrument housing. Moreover, various cable deflections which are necessary in the instrument housing moreover also have an additional disadvantageous influence on the dimensions of the instrument housing and increase the assembly effort on manufacture of the instrument. Thus, the instrument housing is already relatively large with an instrument, in whose instrument housing only four actuation rollers are arranged. This size of the instrument housing has been shown to be disadvantageous if several of these shank instruments are to be applied together in a restricted space, as is the case with single-port operations for example, with which the shank instruments are simultaneously led to the region of operation via a common body opening.
SUMMARY OF THE INVENTION
[0007] Against this background, it is an object of the invention to provide an endoscopic instrument of the type described above, which has a constructionally simplified movement coupling of the control means for the control of at least one instrument part arranged distally of the shank, and/or of the shank, to a drive unit, and which permits the creation of a compact instrument housing.
[0008] The endoscopic instrument according to the invention is such an instrument which is used in combination with an operation robot. It comprises an instrument housing, onto which the shank connects at the distal side which is to say distally. At least one instrument part is arranged at the distal side of the shank usefully designed as a hollow shank. With regard to this instrument part, it can e.g. be the case of a tool or an instrument head serving as a tool carrier. The instrument part and/or the shank are movable relative to the instrument housing. In this context, one preferably envisages the instrument part being pivotable relative to the shank and to the instrument housing which is connected thereto, and the shank is rotatable about its longitudinal axis relative to the instrument housing. Several instrument parts can further preferably be arranged at the distal side of the shank and these are pivotable relative to one another and relative to the shank. Inasmuch as this is concerned, if hereinafter one speaks of the instrument part, this is also to be understood as several instrument parts.
[0009] The instrument part and/or the shank are actively connected to control means which are actuatable in the instrument housing, for the movement control. Usefully, a pull means which is led from the instrument part through the shank into the instrument housing is provided as control means, at least for the instrument part which is arranged at the distal side of the shank. The actuation of the control means for the instrument part and/or for the shank is effected via drive motors which are actively connected thereto and are arranged in a drive unit of the instrument which is connectable to the instrument housing, and subject the control means to a pulling force for movement control of the instrument, if with regard to the control means, it is the case of a pull means.
[0010] The basic idea of the invention lies in coupling the control means which are actively connected to the instrument part arranged distally of the shank and/or to the shank, in each case via a translatorily movable coupling element which is coupled in movement to these means, to a linear drive unit which can be connected onto the instrument housing at the outer side. The coupling element is preferably arranged in the instrument housing such that it projects out of the instrument housing.
[0011] In combination with the pull means which are preferably used for the control of the instrument part arranged at the distal side of the shank, this means that a translation of the coupling element which is produced by the linear drive unit can be transmitted directly onto the pull means given a suitable design. Accordingly, the actuation rollers which until now are to be arranged in the instrument housing are no longer necessary, which leads to a considerable gain in space in the instrument housing, which is to say the creation of a comparatively small instrument housing, wherein the number of the individual components which were necessary until now for the movement transmission of the drive motor onto the control means can be significantly reduced.
[0012] The instrument housing is advantageously designed in an essentially completely closed manner for the protection of the control means which are located therein, so that a part of the coupling element is to be led through an outer wall of the instrument housing. For this, usefully an opening corresponding to the movement path of the coupling element is formed on the outer wall of the instrument housing. The connection of the linear drive unit to the instrument housing and thus the coupling of the linear drive movement to the coupling element are usefully releasable in a repeated manner, in order to be able to separate the linear drive unit from the remaining instrument for cleaning or maintenance purposes for example.
[0013] The coupling element is preferably arranged on a track-guided pull slide (carriage) in the instrument housing. A linear guide, in which the pull slide is displaceably guided, is accordingly preferably provided in the instrument housing. E.g. hollow profile rails or two guide strips which are aligned parallel to one another can serve as track guidance for the pull slides in a manner which is simple with regard to the design. The track guide is usefully aligned in the movement direction of the pull means. The pull slide which is led in the track guide is directly connected to the control means, in a particularly space-saving manner.
[0014] The linear drive unit which can be coupled to the coupling element can be formed by a fluidically actuatable cylinder or by a linear motor which can be coupled to the coupling element in a direct manner via a coupling device which is connected thereto. A linear drive unit which comprises at least one rotatory drive motor, subsequent to which a gear designed for the conversion of the rotation movement of the motor shaft into a translation movement is arranged, is however preferably provided. An electric motor is preferably provided as a drive motor, but a fluidically actuated motor can also be used as the case may be.
[0015] With regard to the gear which is arranged subsequently to the drive motor, it is preferably the case of a rack-and-pinion gear, whose rack is coupled in movement to a coupling device which is positively connectable to the coupling element on the instrument housing side. In this case, a pinion meshing with the rack is usefully arranged on the motor shaft of the drive motor, on the drive side. The linear drive unit advantageously comprises an essentially closed housing, in which at least the rack-and-pinion gear arranged subsequently to the drive motor, and the coupling device coupled in movement thereto are arranged. Hereby, usefully at least one opening is formed on an outer wall of the housing which lies in the connection direction of this housing to the instrument housing, through which opening the positive connection of the coupling element arranged on the instrument housing side to the coupling device on the linear drive side can be effected.
[0016] The rack of the rack-and-pinion gear is preferably coupled in movement to a drive slide (drive carriage) which is track-guided in the linear drive unit and on which the coupling device is formed. The rack can preferably be connected to the drive slide in a direct manner or be formed directly on the drive slide. A guide track for the drive slide and which is arranged in the linear drive unit is usefully aligned corresponding to the movement path of the coupling element provided on the instrument housing side. Usefully, an opening is formed on an outer wall facing the instrument housing, on the preferably envisaged housing of the linear drive unit, through which opening the coupling device formed on the drive slide at least partly projects out of the housing, in order to permit a coupling of the coupling element to the coupling device.
[0017] The coupling element, in a constructionally simple manner, is a projection projecting out of the instrument housing, wherein a recess for the positive receiving of the projection is formed on the coupling device. The projection which is provided on the part of the instrument housing and the recess which is formed on the coupling device on the liner drive side are hereby usefully arranged in a manner such that the projection engages into the recess formed on the coupling device, on connection of the linear drive unit to the instrument housing, wherein a reference travel of the drive slide can be necessary for this as the case may be.
[0018] The coupling element is advantageously resiliently mounted on the slide in the connection direction of the instrument housing and the linear drive unit, in order to permit the engagement of the projection into the recess of the coupling device after a reference travel of the drive slide. This design permits the evasion of the projection when the projection arranged on the instrument housing side, and the recess formed on the coupling device arranged on the linear drive side are not arranged in a congruent manner on connection of the linear drive unit to the instrument housing, wherein the projection after a reference travel of the drive slide locks into the recess in a manner impinged by spring force. A further measure which is advantageous in this respect lies in the fact that the regions adjacent the recess forming guide ramps for the coupling element, on the drive slides, so that the reference travel of the drive slide is not inhibited by the projection.
[0019] In particular, if with regard to the instrument part arranged at the distal side, it is the case of an instrument part pivotable relative to the shank, preferably at least one pull cable is provided for this instrument part as a control means. Thus, two pull cables acting antagonistically upon the instrument part can be fastened on the instrument part in a direct or indirect manner, and these pull cables are led through the shank into the instrument housing, where they are coupled in movement in each case to a coupling element able to be coupled to a drive motor of the linear drive unit.
[0020] However, a design with which only one pull cable, whose two ends are connected to the instrument part in an antagonistically acting manner, is provided as a control means for the instrument part arranged at the distal side of the shank is preferred. In this case, only one coupling element coupled in movement to the pull cable and, on the part of the linear drive unit, only one drive motor are required for the movement control of the instrument part arranged at the distal side of the shank in this case. The pull cable is hereby advantageously guided in the instrument housing in a deflection roller guide, wherein the movement coupling of the pull cable to the coupling element is envisaged in a region between the shank and a deflection roller which is distanced furthest in the pull direction from the instrument part which is to be controlled.
[0021] The coupling of movement of the pull cable to the coupling element is advantageously effected via a pull slide. Thus, the pull cable is preferably connected to a pull slide on which the coupling element is formed and which can be displaced in the pull direction of this pull cable. The pull slide is usefully guided in a guide track which is arranged in a manner corresponding to the pull direction of the pull cable, in the instrument housing.
[0022] A section of the pull cable is preferably formed by a pull rod. In this context, one envisages both ends of the pull cable being fastened at both ends of the pull rod. The pull cable is preferably fastened on the pull slide on the section formed by the pull rod, wherein the connection of the pull cable to the pull slide is favorably not designed in a rigid manner. Instead, the pull rod is advantageously resiliently mounted on the pull slide on two projections which are distanced to one another in the pull direction of the pull cable, in order to protect the pull cable from an overload.
[0023] The shank for the control of its rotation movement is preferably coupled in movement to a pinion which in the instrument housing meshes with a rack coupled in movement to a coupling element, despite the fact that a pull cable which is coupled in movement to a coupling element in the described manner could be used as a control means for the control of the rotation movement of the shank.
[0024] The coupling element is advantageously designed on a pull slide which is connected to the rack. Hereby, the coupling element, with which it is preferably the case of a projection, is arranged at a side of the rack which is away from the toothing and projects out of the instrument housing in the already described manner.
[0025] As has been already noted, the instrument according to the invention can comprise several movable instrument parts on the distal side of its shank. In a preferred design, the instrument according to the invention as movable instrument parts comprises an instrument head pivotably arranged at the distal end of the shank, and a tool carrier pivotably arranged on the instrument head relative to the instrument head. Further preferably, with regard to the tool arranged on the tool carrier it is the case of a jaw tool, so that two jaw parts which are pivotable relative to one another are arranged on the tool carrier. Advantageously, the instrument head, the tool carrier and the two jaw parts of the tool are each coupled in movement to a pull cable as control means, wherein the individual pull cables in the already described manner can be coupled via a coupling element which is coupled in movement thereto and is led out of the instrument housing, in each case to a drive motor of a linear drive unit connectable to the instrument housing.
[0026] The invention is hereinafter explained in more detail by way of embodiment examples which are represented in the drawing. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In the drawings, shown in a schematically simplified manner, and in different scales in each case:
[0028] FIG. 1 is a perspective plan view showing an endoscopic instrument for the connection to an operation robot, without a linear drive unit;
[0029] FIG. 2 is a perspective bottom view showing the endoscopic instrument according to FIG. 1 without a linear drive unit;
[0030] FIG. 3 is a perspective bottom view showing a proximal end region of the instrument according to FIG. 1 , without a linear drive unit;
[0031] FIG. 4 is a perspective bottom view showing a proximal end region according to FIG. 3 , omitting a part of the instrument housing;
[0032] FIG. 5 is a view according to FIG. 4 , with a linear drive unit connected on the instrument housing;
[0033] FIG. 6 is a perspective plan view showing the linear drive unit according to FIG. 5 ;
[0034] FIG. 7 is a perspective representation showing a coupling element which is provided on the instrument side, in the condition coupled to a drive motor of the linear drive unit;
[0035] FIG. 8 is a perspective individual representation showing the coupling element according to FIG. 7 ;
[0036] FIG. 9 is a perspective representation showing a further embodiment of the coupling element;
[0037] FIG. 10 is a perspective representation, in a first view, showing the coupling element which is shown in FIG. 8 , with an arrangement on a pull slide;
[0038] FIG. 11 is a perspective representation, in a second view, showing the coupling element represented in FIG. 8 , with the arrangement on a pull slide;
[0039] FIG. 12 is a perspective representation, in a third view, showing the coupling element which is shown in FIG. 8 , with an arrangement on a pull slide;
[0040] FIG. 13 is a perspective representation showing a drive train of the linear drive unit according to FIG. 6 ;
[0041] FIG. 14 is a lateral view showing the endoscopic instrument according to one of the preceding figures;
[0042] FIG. 15 is a perspective bottom view showing the instrument according to FIG. 14 ; and
[0043] FIG. 16 is a detail view from FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] With regard to the endoscopic instrument represented in the drawing, it is the case of a shank instrument with a shank 2 which is designed as a hollow shank and on which an instrument head 4 is arranged at the distal side. An instrument housing 6 , into which a proximal end region of the shank 2 engages and there in a mounting device 8 ( FIGS. 4 and 5 ) is rotatably mounted relative to the instrument housing 6 , is provided at the proximal side of the shank 2 .
[0045] It is evident from FIGS. 5 , 14 and 15 that the instrument head 6 is pivotably articulated on the shank 2 via a joint pin 10 and is pivotable in a plane transverse to the longitudinal extension of the shank 2 . A tool carrier 12 is articulated on the instrument head 4 at the distal side via a joint pin 14 , in a manner such that the tool carrier 12 can pivot in a plane normal to the pivot plane of the instrument head 4 . The tool carrier 12 carries a jaw tool with two jaw parts 16 and 18 which are pivotable relative to one another.
[0046] The movement control of the instrument head 4 , of the tool carrier 12 which is articulated thereon, and of the jaw parts 16 and 18 is effected via three pull cables 20 , 22 and 24 , wherein the instrument head 4 , the tool carrier 12 and the two jaw parts 16 and 18 are each coupled in movement to one of the pull cables 20 , 22 and 24 in an antagonistically acting manner, which is not evident from the drawing.
[0047] The pull cables 20 , 22 and 24 are led through the shank 2 into the instrument housing 6 and there are each tensioned by way of a deflection roller arrangement. Hereby, the pull cable 24 merely wraps one deflection roller 26 which is arranged in the proximal end region of the instrument housing 6 . The pull cable 22 on a deflection roller pair 28 which is arranged in the instrument housing 6 proximally of the proximal shank end, and on a deflection roller pair 30 arranged laterally distanced thereto, leads to a deflection roller 32 which is arranged next to the deflection roller 26 and around which it wraps. In a similar manner, the pull cable 24 is guided on a deflection roller pair 34 arranged in the instrument housing 6 proximally of the proximal shank end, and on a deflection roller pair 36 arranged laterally distanced thereto, to a deflection roller 38 which is arranged next to the deflection roller 26 and around which it wraps.
[0048] The deflection roller pairs 28 , 30 , 34 and 36 are mounted together on a mounting body 40 which is arranged on a base plate 42 of the instrument housing 6 . The base plate 42 forms a part of the outer wall of the instrument housing 6 . A mounting body 44 which is likewise arranged on the base plate 42 and at its side which is away from the base plate 42 is provided with three recesses 46 , 48 and 50 , in which the defection rollers 26 , 32 and 38 are rotatably mounted on a common mounting pivot 52 ( FIG. 16 ) serves for mounting the deflection rollers 26 , 32 and 38 .
[0049] The pull cable 20 in the region between the defection roller pair 30 and the defection roller 32 is guided in the instrument housing 6 parallel to the longitudinal extension of the shank 2 . The pull cable 24 is likewise led parallel to the longitudinal extension of the shank 2 , in the region between the deflection roller pair 36 and the defection roller 38 . This also applies to the pull cable 22 which is guided in the instrument housing between the pull cables 20 and 24 . The pull cables 20 , 22 and 24 are each subjected to a pull force in this region, for the control of the instrument head 4 , the tool carrier 12 as well as the jaw parts 16 and 18 , and this will be dealt with in more detail hereinafter.
[0050] A section of the pull cable 20 is formed by a pull rod 52 , in the region between the deflection roller pair 30 and the deflection roller 32 . In a similar manner, a section of the pull cable 22 is also formed by a pull rod 56 , and a section of the pull cable 24 in the region between the deflection roller pair 36 and the deflection roller 38 is formed by a pull rod 58 .
[0051] The pull cable 20 in the region of the pull rod 54 is fastened on a pull slide 60 , which in the instrument housing 6 is guided in a guide track 62 aligned parallel to the guiding of the pull cable 20 and formed by two guide strips 64 and 66 which are arranged on the base plate 42 of the instrument housing 6 . The guide strips 64 and 66 as well as the pull slide 60 are designed for forming a swallowtail guide.
[0052] A guide strip 68 is arranged on the base plate 42 of the instrument housing 6 , on the side of the guide strip 66 which is away from the guide strip 64 , in a manner distanced to the guide strip 66 . The guide strip 68 together with the guide strip 66 forms a guide track 70 which is designed as a swallowtail guide, in which a pull slide 72 , on which the pull cable 22 is fastened via the pull rod 56 is linearly guided.
[0053] A further guide strip 74 is arranged on the base plate 42 at the side of the guide strip 68 which is away from the guide strip 66 , in a manner distanced to this guide strip 68 . The guide strip 74 together with the guide strip 68 forms a guide track 76 in the form of a swallowtail guide for a pull slide 78 . The pull cable 24 is fastened on the pull slide 78 via the pull rod 58 .
[0054] The construction of the pull slides 60 , 72 and 78 is evident from the FIGS. 7 , 10 - 12 as well as 16 , in which the pull slide 60 is represented by way of example. The pull slides 72 and 78 are constructionally identical to the pull slide 60 .
[0055] The pull slides 60 , 72 and 78 each comprise a hollow-rail-like base body 80 with an essentially U-shaped cross section. The pull slides 60 , 72 and 78 each lie on the base plate 42 of the instrument housing 6 , via a flat base 82 formed on the base body 80 . Walls 84 and 86 extend normally to the flat sides of the base 82 , on the two longitudinal sides of the base 82 . The outer sides of the walls 84 and 86 which are away from one another are each provided with bevellings for forming the swallowtail guide. The wall 86 extends beyond a flat side of the base 82 which faces the base plate 42 of the instrument housing 6 . An elongate rail 88 is formed there on the wall 86 , and this rail extends beyond the wall 86 in the longitudinal direction of this wall 86 at its two ends.
[0056] As is particularly evident from FIGS. 2 and 3 , the rail 88 of the pull slide 60 engages into an elongate opening 90 which is formed on the base pate 42 of the instrument housing 6 and which is formed on this base plate 42 in the region of the guide track 62 . In a manner corresponding to this, the rails 88 of the pull slide 72 engage into an opening 92 formed in the region of the guide track 70 , and the rail 88 of the pull slide 78 engages into an opening 94 formed in the region of the guide track 76 . The openings 90 , 92 and 94 are in each case designed longer than the rails 88 of the pull slides 60 , 72 and 78 , in order to permit a linear displacement of the pull slides 60 , 72 and 78 .
[0057] In each case a fastening block 96 for fastening the pull rods 54 , 56 and 58 of the pull cables 20 , 22 and 24 is arranged on the flat side of the bases 82 of the pull slides 60 , 72 and 88 , said flat side being away from the base plate 42 of the instrument housing 6 (see in particular FIG. 16 ). The fastening blocks 96 each comprise two projections 98 and 100 which are distanced to one another in the longitudinal direction of the pull sides 60 , 72 and 78 respectively and which project normally to the flat sides of the base 82 . The two projections 98 and 100 are each provided with a bore which extends through the projections 98 and 100 in the longitudinal direction of the fastening block 96 . The pull rods 54 , 56 and 58 on the respective pull slides 60 , 72 and 78 are led through the bores of the projections 98 and 100 , wherein the pull rods 54 , 56 and 58 in the intermediate space between the projections 98 and 100 are surrounded by two helical springs 102 and 104 which are arranged next to one another, as well as a fixation sleeve 106 arranged between the helical springs 102 and 104 . The pull rods 54 , 56 and 58 are fastened on the fastening block 96 of the respective slide 60 , 72 and 78 via this arrangement of the helical springs 102 and 104 as well as of the fixation sleeve 106 , wherein the helical springs 102 and 104 form an overload protection for the pull cables 20 , 22 and 24 .
[0058] It is evident from FIG. 12 that an opening 108 extending transversely to the longitudinal extension of the wall 86 through this wall is formed on the wall 86 of the pull slides 60 , 72 and 78 . A coupling element 110 which can be coupled to a drive motor of a linear drive unit 146 connectable to the instrument housing 6 is led through the opening 108 , wherein this is yet explained in more detail hereinafter.
[0059] The coupling element 110 is represented in FIG. 8 and a further coupling element 112 is represented FIG. 9 . Both coupling elements 110 and 112 have a positive-fit body in the form of a projection 114 , on which a spring element 116 connects with regard to the coupling element 110 , and a spring element 118 connects with regard to the coupling element 112 . The spring element 116 of the coupling element 110 has a spring body which is shaped in a meandering manner, whereas the spring element 118 of the coupling element 112 has an annular spring body.
[0060] The arrangement of the coupling elements 110 on the pull slides 60 , 72 and 78 is such that the positive fit body 114 of the coupling element 110 is led through the opening 108 formed on the wall 86 and projects at the outer side of the base plate 42 of the instrument housing 6 which is away from the pull slides 60 , 72 and 78 respectively, whereas the spring element 116 of the coupling element 110 is supported in a frame 120 formed on the wall 86 .
[0061] The shank 2 at its proximal end which projects into the instrument housing 6 proximally of the mounting device 8 is surrounded by a toothed ring 112 ( FIGS. 4 and 5 ). The toothed ring 122 is connected to the shank 2 in a rotationally fixed manner. A pull slide 124 is displaceably arranged transversely to the longitudinal extension of the shank 2 , between the toothed ring 122 and the base plate 42 of the instrument housing 6 . Hereby, the pull slide 124 is guided in a guide track 126 which is formed by guide strips 128 and 130 . The pull slide 124 comprises a base 132 , via which it lies on the base plate 42 of the instrument housing 6 . Walls 134 and 136 extend normally to the flat sides of the base 132 , on the two longitudinal sides of the base 132 . The outer sides of the walls 134 and 136 which are away from one another are each provided with bevellings for forming a swallowtail guide. The inner sides of the guide strips 128 and 130 which face one another comprise corresponding bevellings, in a manner corresponding to this. A rack 138 which is meshed by a toothed ring 122 is formed on an upper side of the wall 134 which away from the base 132 .
[0062] The wall 136 of the pull slide 124 extends beyond a flat side of the base 132 which faces the base plate 42 of the instrument housing 6 . An elongate rail 140 which extends beyond the wall 136 in the longitudinal direction of the wall 136 at its two ends is formed on the wall 136 there.
[0063] The rail 140 of the pull slide 124 engages into an elongate opening 142 which is formed on the base plate 42 of the instrument housing 6 and which is formed on the base plate 42 in the region of the guide track 126 ( FIGS. 2 and 3 ). The opening 142 is aligned normally to the openings 90 , 92 and 94 . The opening 142 is designed longer than the rail 140 of the pull slide 124 , in order to permit a linear displacement of the pull slide 124 .
[0064] An opening extending transversely to the longitudinal extension of the wall 136 and through this is formed on the wall 136 of the pull slide 124 , as with the pull slides 60 , 72 and 78 , but is not evident from the drawing. The coupling element 112 which is represented in FIG. 9 and which can likewise be coupled to a drive motor of a linear drive unit connectable to the instrument housing 6 is led through this opening.
[0065] The arrangement of the coupling element 112 on the pull slide 124 is such that the positive-fit body 114 of the coupling element 112 is led through the opening formed on the wall 136 , and projects at the outer side of the base plate 42 of the instrument housing 6 , said outer side being away from the pull slide 124 , whereas the spring element 118 of the coupling element 112 is supported in a frame 144 formed on the wall 136 .
[0066] As has already been noted, a linear drive unit 146 can be connected onto the instrument housing 6 . The connection of this linear drive unit 146 onto the instrument housing 6 is effected via a housing part 148 of the linear drive unit 146 which can be connected to the instrument housing 6 by way of a clip connection. The housing part 148 is designed in an open manner at its side which faces the instrument housing 6 .
[0067] The housing part 148 at the side which is away from the instrument housing 6 is closed by a base plate 150 , whose dimensions correspond to the dimensions of the base plate 42 of the instrument housing 6 . Two fastening clips 152 which positively and peripherally engage the housing part 148 connected to the instrument housing 6 are arranged on the instrument housing 6 on two side walls which are away from one another, for the releasably connection of the housing part 148 to the instrument housing 6 . Two projections 154 which engage into holes 156 formed on the base plate 42 of the instrument housing 6 and which project in the direction of the instrument housing 6 are formed on the base plate 150 of the housing part 148 , for simplifying the assembly of the instrument housing 6 and the housing part 148 .
[0068] It is particularly evident from FIG. 15 that four guide rails 158 , 160 , 162 and 164 which are aligned parallel to the longitudinal extension of the shaft 2 and parallel to one another are arranged on the flat side of the base plate 150 of the housing part 148 of the linear drive unit 146 , said flat side being away from the instrument housing 6 . The guide rails 158 and 160 form a guide track 166 , in which a drive slide 168 is linearly displaceably guided. The guide rails 160 and 162 form a guide track 170 , in which a drive slide 172 is linearly displaceably guided. A guide track 174 for a drive slide 176 is formed by the guide rails 162 and 164 .
[0069] The drive slides 168 , 172 and 176 are designed in a constructionally identical manner. Their design is evident from FIGS. 7 and 13 , in which the drive slide 168 is shown in an exemplary manner. The drive slides 168 , 172 and 176 are designed in an essentially cuboid manner, wherein at their longitudinal sides which are away from one another they comprise a wedge-like recess 178 extending over the entire length of the drive slide 168 , 172 or 176 . The recesses 178 in combination with a corresponding profiling on the inner sides of the guide rails 158 , 160 , 162 and 164 which face one another, serve for forming a swallowtail guide. An elongate hole 180 aligned in the longitudinal direction of the drive slide 168 , 172 and 176 is moreover formed on the drive slides 168 , 172 and 176 respectively. A longitudinal side of the elongate hole 180 is provided with a toothing and forms a rack 182 .
[0070] A bearing block 184 which carries three electrically operated, rotatory drive motors 186 , 188 as well as 190 is supported on the sides of the guide rails 158 , 160 , 162 and 164 which are away from the base plate 150 of the housing part 148 . The arrangement of the drive motors 186 , 188 and 190 on the bearing block 184 is such that a motor shaft 192 of the drive motor 186 engages into the elongate hole 180 formed on the drive slides 168 , a motor shaft 192 of the drive motor 188 engages into the elongate hole 180 formed on the drive slide 172 and a motor shaft 192 of the drive motor 190 engages into the elongate hole 180 formed on the drive slide 176 . A pinion 194 which meshes with the rack 182 in the elongate hole 180 of the related drive slide 168 , 172 and 176 is arranged in each case on the ends of the motor shafts 192 of the drive motors 186 , 188 and 190 .
[0071] A coupling device 196 is arranged next to the elongate hole 180 , on the flat side of the drive slides 168 , 172 and 176 which is away from the drive motors 186 , 188 and 190 . The coupling device 196 is formed by an elongate rail 198 which extends at both longitudinal ends of the drive slides 168 , 172 and 176 beyond this. A prominence 200 with two side surfaces tapering to one another at a shallow angle is formed in the region of the middle of the rail 198 at the side which is away from the drive slides 168 , 172 and 176 . A recess 202 extending in the direction of the drive slides 168 , 172 and 176 is formed in the region of the middle of the prominence 200 .
[0072] The coupling devices 196 of the drive slides 168 , 172 and 176 engage into three elongate openings 204 , 206 and 208 which are formed on the base plate 150 of the housing part 148 . Hereby, the prominences 200 with the recess formed therein in the housing part 148 project in a freely accessible manner in the direction of the instrument housing 6 .
[0073] Apart from the four guide rails 158 , 160 162 a well as 164 , two further guide rails 210 and 212 aligned normally to the guide rails 158 , 160 , 162 and 164 and parallel to one another are arranged on the flat side of the base plate 150 of the housing part 148 of the linear drive unit 146 , said flat side facing away from the instrument housing 6 . The guide rails 210 and 212 form a guide track 214 , in which a drive slide 216 is linearly displaceably guided.
[0074] The drive slide 216 is designed in a constructionally identical manner to the drive slides 168 , 172 . A bearing block 218 carrying an electrically operated rotatory drive motor 220 is supported on the sides of the guide rails 210 and 212 which are away from the base pate 150 of the housing part 148 . The bearing block 218 together with the bearing block 184 forms a common construction unit.
[0075] The arrangement of the drive motor 220 on the bearing block 218 is such that a motor shaft of the drive motor 220 engages into the elongate hole 180 formed on the drive slide 216 , which is not evident from the drawing, wherein a pinion arranged at the end of the drive shaft meshes with the rack 182 in the elongate hole 180 .
[0076] Next to the elongate hole 180 , a coupling device 196 with an elongate rail 198 and with prominence 200 having a recess 202 and arranged on said rail is arranged on the flat side of the drive slide 216 which faces away from the drive motor 220 . This coupling device 196 of the drive slide 216 engages into an elongate opening 222 which is formed on the base plate 150 of the housing part 148 and which is aligned normally to the openings 204 , 206 and 208 , wherein the prominence 200 with the recess 202 formed thereon projects in the housing part 148 in the direction of the instrument housing 6 in a freely accessible manner.
[0077] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
APPENDIX
[0078]
[0000]
List of reference numerals
2
shank
4
instrument head
6
instrument housing
8
bearing device
10
joint pin
12
tool carrier
14
joint pin
16
jaw part
18
jaw part
20
pull cable
22
pull cable
24
pull cable
26
deflection roller
28
deflection roller pair
30
deflection roller pair
32
deflection roller
34
deflection roller pair
36
deflection roller pair
38
deflection roller
40
mounting body
42
base plate
44
mounting body
46
recess
48
recess
50
recess
52
bearing pivot
54
pull rod
56
pull rod
58
pull rod
60
pull slide
62
guide track
64
guide strip
66
guide strip
68
guide strip
70
guide track
72
pull slide
74
guide strip
76
guide track
78
pull slide
80
base body
82
base
84
wall
86
wall
88
rail
90
opening
92
opening
94
opening
96
fastening block
98
projection
100
projection
102
helical spring
104
helical spring
106
fixation screw
108
opening
120
coupling element
112
coupling element
114
projection
116
spring element
118
spring element
120
frame
122
toothed ring
124
pull slide
126
guide track
128
guide strip
130
guide strip
132
base
134
wall
136
wall
138
rack
140
rail
142
opening
144
frame
146
linear drive unit
148
housing part
150
base plate
152
fastening clips
154
projection
156
hole
158
guide rail
160
guide rail
162
guide rail
164
guide rail
166
guide track
168
drive slide
170
guide track
172
drive slide
174
guide track
176
drive slide
178
recess
180
elongate hole
182
rack
184
bearing block
186
drive motor
188
drive motor
190
drive motor
192
motor shaft
194
pinion
196
coupling device
198
rail
200
prominence
202
recess
204
opening
206
opening
208
opening
210
guide rail
212
guide rail
214
guide track
216
drive slide
218
bearing block
220
drive motor
222
opening | An endoscopic instrument for the connection to an operation robot. The endoscopic instrument includes an instrument housing, to which a shank with at least one instrument part arranged at the distal side of the shank connects distally. The instrument part and/or the shank are movable relative to the instrument housing and for this are each actively connected to control. The control can be coupled, via a translatorily movable coupling element coupled thereto and projecting out of the instrument housing, to a linear drive unit which can be connected to the instrument housing at the outer side. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority of U.S. provisional application Ser. No. 60/803,301 filed on May 26, 2006, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to sleeve-and-insert type packaging. More particularly, the invention relates to a novel insert for a sleeve-and-insert type package that is suitable for use as an integral blister card or a receiving tray.
BACKGROUND OF THE INVENTION
A sleeve-and-insert type of package is a package wherein a substantially planar member is housed within an enclosure from which it may be partially or fully removed to gain access to items held on one or more surfaces of the planar member. The planar member may be identified by several alternative names including but not limited to an “insert,” a “card,” an “insert card,” a “slide card,” and a “sliding element.” These terms will be used interchangeably herein.
Sleeve-and-insert type packaging is useful for a variety of purposes; including the sale and distribution of items that may be juxtaposed permanently or temporarily in some manner with respect to the insert. A sleeve-and-insert type of package is particularly useful as a so-called “unit-dose packaging system.” In a unit-dose packaging system medicaments such as pills are removably held to the planar member in individual, or unit doses, typically within a blister. In alternative embodiments unit-doses, such as held in syringes, patches, inhalers, pouches, and the like, are mounted to a tray. Unit dose packaging systems are useful as a means for dispensing an individual, or a unit dose of a medicament. Such systems are even more useful when they have the added features of providing resistance to the package being opened by a child, while at the same time facilitating ease of opening, closing and general use by older individuals whose manual dexterity may have decreased with age. These two features are typically referred to as “child-resistant” and “senior-friendly,” respectively.
Preventing or inhibiting undesired partial or full removal of the inner slide card from the sleeve/shell is important in helping facilitate resistance to child tampering and use by seniors. In addition, preventing or inhibiting widespread access to the items held by the sliding element is important to child-resistance. Thus, it will be appreciated that it is useful to have a unit dose package with additional novel features that prevent or inhibit the undesired access of items held by the inner card.
Because decreased cost and increased ease of manufacturing are desirable, it will likewise be appreciated that it is beneficial to have a child-resistant and senior-friendly unit dose package that is efficient to operate, is durable and sturdy, and simple to construct, thereby reducing the cost and inefficiencies of manufacture.
SUMMARY OF THE INVENTION
The present invention overcomes the shortcomings of the prior art by providing features that improve the ease of manufacturing, lower the cost of manufacturing, improve the ease of use, and improve the child-resistance features of an individual insert card as well as sleeve-and-insert package as a whole. These features include a monolithically formed slide card, blisters integral to the slide card, blisters integral to the slide card that are detachable, a detachable locking panel attached to the slide card, improved locking elements, features that increase the durability of the locking elements, ribs that improve the strength and durability of the slide card, ribs that improve the strength of the sleeve, and ribs that interfere with unintended access to the blisters such as by a child trying to bite their way through the sleeve and/or slide card.
According to one aspect of the invention, an improved locking panel with at least one reinforcement element to inhibit deformation hingedly extends from the base panel. In another embodiment, at least two locking panels hingedly extend from the base panel. According to a further aspect of the invention two adjacent locking panels are separated from one another, by a cut line or a slot or a similar means for separation. According to an additional aspect of the invention, the base panel has at least one reinforcement elements to inhibit deformation of the base panel. According to still an additional aspect of the invention, the base panel has an arrangement of one or more ribs.
In accordance with another aspect of the invention, the base panel includes a raised grip configured to improve access and withdrawal of the slide card from a sleeve. In accordance with still a further aspect of the invention, either the locking member or the base panel includes a fold-resisting abutment for improving lockability between the sleeve and card. In accordance with still another aspect of the invention, at least one fold-over panel is hingedly connected to the base panel, and either or both of the base panel and fold-over panel has at least one rib. In accordance with one more aspect of the invention, a fold-over panel is hingedly connected to the base panel. There the base panel and fold-over panel have complementary, cooperating ribs for nesting or interlocking the folded panels.
Also taught herein are insert cards comprising a monolithically formed base panel with at least one hingedly attached locking panel that includes at least one engaging edge. There, at least one blister is integrally formed within the base panel to define a blister opening configured to receive an item that is stored by the blister. Other features of the exemplary insert cards include a seal over the blister opening and at least one rib extending from the base panel. In some embodiments the rib is positioned proximate to the perimeter of the base panel but the ribs may be located anywhere on the insert card.
Additional features of some insert cards include an abutment that inhibits a face-contacting relationship between the base panel and locking panel, wherein at least a portion of the perimeter of the abutment is curved. Further, the base panel can include an extended grip portion for easier access once the insert card has been released from the sleeve. In other embodiments, the blisters are detachable for ease of use. In some of those embodiments the blisters are detachable so as to define a center bar that allows the insert card to fully function within the sleeve even after blisters are removed. In still other embodiments, the locking panel is detachable from the base panel.
Further described and taught herein are insert cards that include one or more hingedly attached fold-over cards. In those embodiments the fold-over cards can include features such as ribs, blisters, abutments, posts, and combinations and the like, that interface, interlock, or otherwise cooperate with one or more similar features of the base panel to nest the folded panels, lock the folded panels, or keep the folded panels spaced apart.
In addition to the insert cards described, taught and claimed herein, a packaging system that incorporates the insert cards is described, taught and claimed. The exemplary system includes a releasably lockable sleeve, as taught in previous applications filed by the present applicant, configured to receive an insert card described, taught or claimed herein. Further, the description includes a method of using the insert cards described, taught and claimed herein. Additional embodiments include insert cards wherein the items are not held to the base panel by blisters but by other means for securing, including clips, ties, receiving inserts, tabs, locking posts, tape, hook and loop fasteners, ribs, springs, combinations thereof, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 2 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 3 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 4 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 5 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 6 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 7 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 8 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 9 is a side elevation view of the exemplary slide card of FIG. 8 .
FIG. 10 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 11 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 12 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
FIG. 12 a is a cross-section elevation view of the ribs of exemplary folded cards, of FIG. 12 .
FIG. 13 is a plan view of an exemplary embodiment of a slide card, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as an illustration, specimen, model or pattern. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
For the purposes of teaching and illustration, and not limitation or restriction, the illustrated embodiments of the present invention reference pharmaceutical products such as medicaments in the form of tablets, pills and the like. It is contemplated that the present invention is not limited to the pharmaceutical-related goods referenced with the illustrated embodiments, but is applicable to any small, delicate, sensitive, or portable item. Accordingly, the present invention can be used with all nature of small and portable items that the user may want to hold and store in a releaseably lockable container and dispense in a regulated manner. Further, the present invention is not limited to the blister packs referenced with the illustrated embodiments, but is applicable to any tray, card, rack, pack, pouch, and the like to which an item of any sort may be held, stored, attached, secured or otherwise associated with the item.
Referring now to FIG. 1 , an exemplary embodiment of a slide card 100 is shown. The slide card 100 is primarily for use with a releaseably lockable sleeve, as taught in one or more prior applications or patents filed by the present applicant, and includes a base panel 110 and a locking panel 115 . The locking panel 115 includes an engaging edge 118 . The base panel 110 is connected to the locking panel 115 by a hinge 120 . The base panel 110 has formed cavities or blisters 125 for receiving an item. In the exemplary embodiment, the blisters 125 are integrally formed with the base panel 110 and a seal, such as a foil or paper substrate, is attached to the base panel 110 to enclose the item within each blister 125 . The items are thereby held in place within the blisters 125 until being removed by known methods.
The slide card 100 can be made of any material including paper or plastic, formed by manufacturing processes including thermo-forming or die-pressing. The hinge 120 can be formed in any configuration by forming a fold line, score line, cut line, perforation lines, or any combination thereof, and the like. The locking panel 115 is pivotable about the hinge 120 such that it can engage a locking element in the sleeve, and thereby inhibit undesired removal of the slide card 100 from the sleeve. In the embodiment shown in FIG. 1 , the slide card 100 is a thermo-formed plastic blister card used to hold medicaments.
In the exemplary embodiments shown in FIGS. 2-4 , the slide cards 200 , 300 , 500 include multiple locking panels 215 , 315 , 515 , respectively. The locking panels 215 of the slide card 200 are each defined by a hinge 220 and separated from one another by a cut line 230 . Similarly, the locking panels 315 are defined by a hinge 320 and separated from one another by a cutout 330 . The cutout may also be termed a slot. The illustrated locking panels 515 are triangular shaped and connected to the base panel 510 along respective hinges 520 . Alternative embodiments can include locking panels of alternative shape and additional number.
Each of the locking panels 215 , 315 , 515 on the respective slide cards 200 , 300 , 500 are independent from one another. Thereby, each of the locking panels independently engages a respective locking element of a related sleeve. Thus, to release the slide card from the sleeve, it is considered that one or more release mechanisms may be used to release the locking panels from their respective locking elements. For example, a single release mechanism may be used that releases each of the locking panels substantially simultaneously. Alternatively, each of the locking panels may have its own release mechanism. It is increasingly difficult to release the slide card from the sleeve as the number of release mechanisms that are required to be substantially simultaneously triggered to release the slide card from the sleeve increases. Accordingly, increasing the number of release mechanisms that are required to release the slide card improves the child resistance of the package.
Slide cards taught by the present invention may have at least one rib 235 , 335 , 535 . A rib, as taught by the present invention, is a raised member extending from a plane that is the surface of a base panel or the locking panel, or both. Ribs can extend in either direction, that is, upwardly or downwardly with respect to a surface of the panel, or both. The rib or a section of a rib may serve multiple purposes including, but not limited to, providing a barrier to a portion of the base panel (for example, forming a barrier around an item placed on the base panel), providing a barrier to resist application of a perpendicularly applied force (for example, crushing or biting), serving as a gripping structure to facilitate grasping of a base panel or locking member, and serving as structural reinforcement against deformation of the base panel or the locking panel, or both.
Certain embodiments of slide cards include at least one rib. Another advantage of the rib(s) taught herein is the increased rigidity to the slide card. The rib or ribs may be thermoformed or pressed into the slide card, or may be separately attached to the slide card. Referring to FIGS. 2 and 3 , a U-shaped rib 235 , 335 extends around the perimeter of the base panel 210 , 310 , respectively.
Turning now to FIG. 4 , there is shown an alternative embodiment in the form of a T-shaped rib 535 that extends along an edge and longitudinally along the substantial center of the base panel 510 . The slide card 500 further includes elongated ribs 536 that substantially align with respective locking panels 515 and are offset from the longitudinal portion of the rib 535 . Referring to FIG. 5 , an L-shaped rib 735 extends around a portion of the perimeter of the base panel 710 . The slide card 700 further includes a longitudinal rib 736 to provide rigidity to a portion of the base panel 710 , which is offset from the rib 735 . Alternative embodiments (not shown) provide a slide card that includes a series or pattern of ribs which increase the rigidity of areas of the base panel and the locking panel, respectively.
It should be noted that the ribs are not limited to the locations, shapes, arrangements, or patterns described herein. Rather, the locations, shapes, arrangements, or patterns of the ribs are determined in order to increase the rigidity of the slide card, to accommodate the placement of blisters and other features, and provide other beneficial features. For slide cards that are thermoformed, a certain amount of rigidity is helpful to prevent or inhibit the slide card from curling or twisting after being formed. The ribs can be arranged to accommodate a desired blister layout or configuration, such as the layouts described herein. Accordingly, the location of ribs may be adapted to provide rigidity or other features without interfering with or obstructing the other elements of the slide card.
The ribs can be strategically located to provide beneficial features. For example, the ribs can be located to provide a child resistance feature, for example, such that the ribs prohibit biting into the card to access articles in the blisters. The location of each rib can provide additional functional benefits when the slide card is used in combination with a sleeve or outer carton. For example, disposing a rib at an end of the slide card, which corresponds with the open end of a sleeve, provides an end closure to the open end of the sleeve. Thereby, when the slide card is received in the sleeve, the rib protects the slide card and items contained therein from dust, pests, and unintended access. In the embodiments shown herein, the end of the slide card that corresponds to the open end of a sleeve is the end opposite the locking panel.
In certain embodiments, a slide card 100 is designed for being enclosed in a sleeve that includes a catch flap, as taught in previous applications filed by the present applicant. The catch flap is disposed at the open end of the sleeve such that, as the slide card 100 is pulled from the sleeve, the folded locking panel 115 , 215 , 315 , 515 , of the slide card engages the catch flap, thereby preventing the slide card from being fully removed from the sleeve. If the slide card is inserted into the sleeve such that the side of the slide card from which the blisters protrude is adjacent to the wall of the sleeve that the catch flap is hingedly connected, the blisters may inadvertently interfere with the removal of the slide card. Specifically, the catch flap may engage one or more of the blisters, thereby preventing the slide card from being removed from the sleeve. In this case, ribs 235 , 335 , 535 , 735 extend the length of the slide card to act as a bridge or as rails to prevent the blisters from engaging the catch flap as the slide card is removed from the sleeve. Here, also, but not necessarily, the rail portion of the ribs has a height that is no less than the height of blisters, allowing the catch flap to slide along the rails and not engage the blisters. The height of the rails and of the blisters is referenced relative to the base panel 210 , 310 , 510 , 710 .
As shown in FIGS. 6 and 7 , certain embodiments of slide cards 1100 , 1300 include a raised grip 1140 , 1340 that is disposed at the end of the base panel 1110 , 1310 , respectively. The raised grip 1140 , 1340 can be formed in a manner similar to the ribs 1135 , 1335 . The size and shape of the raised grip 1140 , 1340 is an ergonomic design decision, such that the raised grip 1140 , 1340 facilitates access by the intended user. For example, the slide card 1100 , 1300 can be captured between a user's thumb and finger, wherein the user's thumb contacts the convex surface and the user's finger contacts the opposite concave surface. In the embodiments shown in FIGS. 6 and 7 , the raised grip 1140 , 1340 is integral to the rib 1135 , 1335 . However, in alternative embodiments, the raised grip 1140 , 1340 may be detached or offset from the rib 1135 , 1335 or the rib 1135 , 1335 may be omitted.
Referring now to FIGS. 8 and 9 , the ability of the locking panel 1515 of a slide card 1500 to be engaged by an aperture or panel that forms a part of the locking arrangement of the system's sleeve or shell (not shown), is enhanced by biasing the locking panel 1515 away from a substantially parallel condition with respect to the base panel 1510 . Fold-resisting features serve this purpose. The hinge 1520 serves as a fold-resisting mechanism to bias the locking panel 1515 . The amount of bias in the hinge 1520 may be controlled by additional manufacturing techniques including varying the thickness of the hinge 1520 or otherwise varying the degree to which a line forming the hinge 1520 is weakened to permit bending.
The base and locking panels 1510 , 1515 of the slide card 1500 further include fold-resisting abutments 1545 , 1550 that prevent the locking panel 1515 and base panel 1510 from being placed into a substantially parallel condition or face contacting arrangement with respect to one another. Although one fold-resisting abutment on either the locking panel 1515 or the base panel 1510 is sufficient to serve as a fold-resisting mechanism or element, more than one fold-resisting abutment may be used on either one or both panels 1510 , 1515 . The use of opposing fold-resisting abutments 1545 , 1550 on respective base 1510 and locking 1515 panels, provides the advantage of being able to minimize the height of each fold-resisting abutment 1545 , 1550 while still achieving desirable fold resistance. Although each abutment may take many forms, an embossed abutment may be easily manufactured in a suitable substrate, particularly a substrate formed of plastic, paper, or a combination thereof, or other suitable materials.
The illustrated fold-resisting abutments 1545 , 1550 are proximate to the hinge 1520 . Specifically, the fold-resisting abutment 1545 is disposed on the base panel 1510 and the fold-resisting abutment 1550 is disposed on the locking panel 1515 such that, when the locking panel 1515 is folded along the hinge 1520 , the fold-resisting abutments 1545 , 1550 contact one another to provide support to the hinge 1520 or otherwise maintain the proper locking angle of the locking panel 1515 . In the exemplary embodiment, the fold-resisting abutment 1545 has a shape similar to a bubble or otherwise has a substantially semi-circular cross section. The fold-resisting abutment 1550 has a substantially rectangular cross section. It is noted that, in alternative embodiments, the fold-resisting abutments may have any size or shape that facilitates supporting the locking panel and hinge.
The fold-resisting abutment 1550 shown in FIG. 8 includes a curved edge E that is proximal to the engaging edge 1518 . The edge E of the fold-resisting abutment 1550 is curved such that the locking panel 1515 resists buckling along the engaging edge 1525 . In addition, the fold-resisting abutment 1550 increases the rigidity of the locking panel 1515 to resist bending over the fold-resisting abutment 1545 . In other words, the locking panel 1515 may tend to fold at the edge E where the support of the fold-resisting abutment 1550 ends. The curvature of the curved edge E also resists the tendency of the locking panel 1515 to fold along a straight line and thus resists the undesired possibility of collapsing. With reference now to FIG. 9 , a side elevation view of the slide card 1500 is shown. The locking panel 1515 is shown partially pivoted about the hinge 1520 with respect to the base panel 1510 to a position wherein it can engage one or more locking elements in a sleeve or shell to help form a locking arrangement.
Turning now to FIG. 10 , a slide card 1700 includes a center bar 1755 defined by longitudinal and transverse lines of demarcation. Transverse lines of demarcation 1762 extend from the longitudinal lines of demarcation 1760 to define tear-away units 1765 . Each tear away unit 1765 is defined from a portion of the base panel 1710 and includes a blister 1725 . The center bar 1755 permits continued access to and use of the slide card 1700 within a sleeve as units 1765 are detached from the base panel 1710 . In the exemplary embodiment, the center bar 1755 is located in the center of the base panel 1710 . However, in alternative embodiments, the bar may be located in any suitable position. For example, the bar may be located adjacent to a longitudinal edge of the slide card 1700 .
Referring to FIGS. 11-13 , embodiments of a slide card including a fold-over panel are shown. Beginning with FIG. 11 , a slide card 1900 includes a fold-over panel 1970 . The fold-over panel 1970 is connected to the base panel 1910 by a hinge panel 1975 . Specifically, the hinge panel 1975 is hingedly connected to the panels 1910 , 1970 along fold lines F. In this embodiment, the hinge panel 1975 includes an aperture P. The aperture P reduces the stress at the hinge panel 1975 . It is contemplated that a hinge may be defined by one or more apertures P and that the fold lines F may be omitted. The apertures P may be any suitable size or shape that facilitates reducing stress in a portion of the slide card between the base panel and the fold-over panel. It is further contemplated that the aperture P may be omitted and the fold lines may extend across the slide card to define a hinge panel. In alternative embodiments, it is contemplated that formed hinges or soft creasing may be used as a hinge.
With regard to FIGS. 12 and 12 a, a slide card 2000 includes a fold-over panel 2070 connected to the base panel 2010 by a hinge panel 2075 . Specifically, the hinge panel is connected to the panels 2010 , 2070 along fold lines F. The base panel 2010 and the fold-over panel 2070 include U-shaped ribs 2035 a, 2035 b, respectively. The U-shaped ribs 2035 a, 2035 b correspond to one another such that, as the fold-over panel 2070 is folded to be substantially parallel to the base panel 2010 , the ribs 2035 a on the base panel 2010 align and are in contact with the ribs 2035 b on the fold-over panel 2070 . Specifically, the ribs 2035 a, 2035 b are substantially similar in shape and are positioned substantially symmetrically about the hinge panel 2075 . As shown in FIG. 12 a, the ribs 2035 a, 2035 b can be designed to matingly engage such that the slide card 2000 is maintained in the folded arrangement described above. The design of the ribs 2035 a, 2035 b is not limited to that shown in FIG. 12 a, but include any corresponding cross-sections that facilitate maintaining the folded arrangement. For example, the cross-sections may be a protrusion and recess combination or each of the cross-sections may be defined by a common diagonal plane. In yet other embodiments, either set of ribs are wider and longer in order to receive the other set. In that configuration, the ribs are nested and the folded panels achieve a thinner profile.
With reference to FIG. 13 , a slide card 2300 includes multiple fold-over panels 2370 a, 2370 b connected to the base panel 2310 by hinge panels 2375 a, 2375 b, respectively. Specifically, the hinge panels 2375 a, 2375 b are connected to the base panel 2310 and to a respective fold-over panel 2370 a, 2370 b along the fold lines F. In the exemplary embodiment, the hinge panel 2375 b is wider than the hinge panel 2375 a such that the fold-over panel 2370 a can be folded onto the base panel 2310 , as described above, and the fold-over panel 2370 b can subsequently be folded onto the fold-over panel 2370 a. Thereby, the ribs 2335 a of the fold-over panel 2370 a are in contact with the ribs 2335 c of the base panel 2010 , and the ribs 2335 b of the fold-over panel 2370 b are in contact with the outside surface of the fold-over panel 2370 a.
Alternative embodiments of the present invention include a slide card having a peelable backing, not shown. The peelable backing facilitates removal of items and can include foil or a combination of foil and tissue or kraft paper, and is sealed to the back of the blister. Frangible lines, such as perforated, cut, or score lines, are added to the peelable backing to define tabs which are peelable to expose the article within a blister. In this embodiment, a peel initiation area is located along the edge or perimeter of the slide card. In alternative embodiments, wherein a more child resistant peelable backing is desired, a peel initiation area may be located toward the center of the slide card. Advantageously, the slide card includes a stationary body member that may be engaged to grip the slide card before or after the tabs have been peeled away. It should be noted that the peelable backing can be incorporated into alternative embodiments, such as shown in FIG. 10 . In that case, the center bar 1755 is, in effect, a stationary body member and, when a tear away unit 1765 is removed a small angled cut line defines the peel initiation location of a peelable backing.
It must be emphasized that the law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims. | An improved insert card is provided. The various embodiments include improved hinges, locking tabs, ribs, detachable base panel with center bar, grips, fold-resisting abutments, and fold-over panels. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for steering a light beam onto a desired target, and more specifically relates to an apparatus for steering a laser beam onto a target in a laser imaging system.
2. Description of the Prior Art
Beam steering apparatus typically include one or more mirrors which redirect, or "steer", a beam emitted by a stationary laser such that a terminal portion of the beam strikes a desired target. The precise location of the laser beam and an angle of incidence of the beam on the target is determined by the relative position of the mirrors.
FIGS. 5(a) and 5(b) show a typical prior art beam steering apparatus 500. The apparatus 500 includes a shaft 510, a first bracket 520 and a second bracket 550 adjustably connected to the shaft 510. A first mirror mount 530 is adjustably connected to the first bracket 520 and a second mirror mount 560 is adjustably connected to the second bracket 550. Mirrors (not shown) are attached to mounting points 533 and 561 respectively formed on the first mirror mount 530 and the second mirror mount 560. The relative angles between the reflective surfaces of the mirrors 540, 570 are adjusted by manipulating knobs 521, 522 located on the first bracket 520, knobs 531, 532 located on the bracket 530, and knobs 551, 552 located on the second bracket 550.
Another approach to steering a light beam is to physically change the position and angular orientation of the light source. For example, in the case of a laser light source, the laser could be physically moved relative to a fixed mirror.
A problem with the prior art beam steering apparatus is that adjustment of the beam is complicated and requires a large amount of space around the apparatus in which to maneuver to effect the desired adjustment.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an apparatus for steering a beam in which a point of incidence of the beam is adjustable in two orthogonal directions and an angle of incidence of the beam is adjustable in two orthogonal directions.
Another object of the present invention is to provide an apparatus which allows the above-described adjustments to be performed with a minimum number of tools and within a minimal space.
A beam steering apparatus in accordance with the present invention is superior to the above-described prior art beam steering apparatus in that adjustment of a redirected beam is greatly simplified and can be effected in a confined space with a minimum number of tools.
The apparatus includes a base, an input block adjustably connected to the base, and an output block adjustably connected to the base. An input mirror is connected to the input block, and an output mirror is connected to the output block. The input mirror is positioned to receive a beam and to redirect the beam to the output mirror, and the output mirror is positioned to further redirect the beam such that a terminal portion of the beam strikes a target. The terminal portion of the beam is adjustable in a first orthogonal direction by sliding the input block relative to the base, and the terminal portion of the beam is adjustable in a second orthogonal direction by sliding the output block relative to the base. Because the position of the beam can be adjusted in two orthogonal directions by sliding the input and output blocks relative to the base, the adjustment is greatly simplified over the prior art apparatus.
Also in accordance with the present invention, the input mirror is rotatably connected to the input block and the output mirror is rotatably connected to the output block. An angle of incidence of the beam relative to the target is adjustable in a first plane by rotating the input mirror relative to the input block, and is adjustable in a second plane by rotating the output mirror relative to the output block. Because the angle of incidence of the beam can be adjusted in two orthogonal directions by rotating the input and output mirror relative to the input and output blocks, the adjustment is greatly simplified over the prior art apparatus.
Also in accordance with the present invention, an input block locking screw is adjustably connected to an upper surface of the input block such that the input block locking screw may be loosened from above the input block using a first tool. The input block also includes an adjustment hole for receiving the first tool such that the first tool may be used as a lever to slidably adjust the input block relative to the base. In addition, an output block locking screw and adjustment hole are similarly provided on the output block. Because the input and output block locking screws and adjustment holes are positioned on upper surfaces of the input and output blocks, the amount of space necessary to adjust the position of these blocks is greatly reduced over the prior art apparatus. Further, because the input and output blocks may be positioned using the same tool used for loosening the locking screws, the number of tools necessary to adjust the apparatus is reduced.
Also in accordance with the present invention, the input and output mirrors are attached to rotatable shafts such that an angle of incidence of the output beam relative to the target is adjustable by rotation of the shafts. A locking screw is provided on the upper surface of the input block for securing the input mirror shaft to the input block. Similarly, a locking screw is provided on the side surface of the output block for securing the output mirror shaft to the output block. Holes are formed in the input mirror shaft and output mirror shaft which are formed to receive a second tool used to adjust the locking screws. As such, the rotated position of input mirror and output mirror may be adjusted using a single tool.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 shows a perspective view of the beam steering device according to the present invention;
FIG. 2 shows a top view of the beam steering device of FIG. 1;
FIG. 3(a) shows an exploded perspective view of the input block of the beam steering device shown in FIGS. 1 and 2;
FIG. 3(b) shows a section view of the input block indicating an adjustment of the input block relative to the base.
FIG. 4 shows a reverse exploded perspective view of the output block of the beam steering device shown in FIGS. 1 and 2; and
FIGS. 5(a) and 5(b) show front and side views, respectively, of a prior art beam steering apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An apparatus 1 for steering a light beam 5 from a light source 3 to a target 9 in accordance with the present invention is shown in FIGS. 1-4.
Referring to FIG. 1, the apparatus 1 includes a base 10, an input block 20 connected to the base 10, an input mirror 35 connected to the input block 20, an output block 40 connected to the base 10, and an output mirror 65 connected to the output block 40.
In a preferred embodiment, the apparatus 1 is incorporated into a laser imaging system (not shown) which is manufactured by the assignee of the present invention and disclosed in co-pending U.S. application Ser. No. 08/080,014, entitled "Laser Imaging System for Inspection and Analysis of Sub-Micron Particles" Attorney Docket Number M-2466-US!, incorporated herein by reference. In the laser imaging system, the light source 3, which can be a gas laser, is mounted in a fixed relationship with the apparatus 1 and generates a beam 5. The beam 5 is directed in the vertical (y-axis) direction and reflected by the input mirror 35 toward the output mirror 65. The output mirror 65 then redirects the laser beam 5 to a target 9, which can be a workpiece or other object being examined by the laser imaging system. As used herein, the portion of the laser beam 5 which strikes the target 9 is referred to as a terminal portion 7.
The base 10 includes an upper surface 11 which defines a linear groove 12. The groove 12 is aligned in a direction corresponding to the x-axis direction (FIG. 1). In a preferred embodiment of the present invention, the base 10 is approximately 4.51 inches long, 2.15 inches wide and 0.50 inches thick. The groove 12 is approximately 1.75 inches wide (measured in the z-direction in FIG. 1). The base 10 is preferably machined aluminum and includes four or more threaded holes (not shown) formed on the upper surface 11 in the groove 12 for securing the input block 20 and the output block 40. In addition the base 10 includes one or more holes 13 for receiving a fastener such that the base 10 can be connected the above-mentioned laser imaging system.
As best shown in FIG. 3(a), the input block 20 is a six-sided fixture having a width (measured in the z-direction in FIG. 1) which fits within the groove 12 such that the input block 20 is slidable along the groove 12. The input block 20 includes a lower surface 21 facing the groove 12, a pair of side surfaces 22, and a upper surface 23. The input block 20 defines a through-hole 24 formed between the side surfaces 22 for receiving an input mirror assembly 30, described below. In addition, the input block 20 defines a pair of slots 25 which extend from the upper surface 23 to the lower surface 21. A pair of input block locking screws 26 are inserted through the slots 25 and connected to two of the threaded holes (not shown) which are formed in the base 10. When the input block locking screws 26 are loosely mounted in the threaded holes, the input block 20 is slidable in the groove 12 over a range defined by the slots 25. Conversely, when the input block locking screws 26 are tightened, the input block 10 is fixedly connected to the base 10. As shown in FIG. 3(b), an adjustment hole 29 is provided through the input block 20 such that an end of an Allen wrench 90, which is used to tighten the input block locking screws 26, may be used as a lever to adjust the position of the input block 20 relative to the base 10. To facilitate this adjustment, a web 91 is formed midway along the hole 29 and a counter bore 14 is provided in the upper surface 11 of the base 10 under the adjustment hole 29 for receiving an end of the Allen wrench 90.
The input block 20 also defines a pair of threaded holes 27 extending from the upper surface 23 and intersecting the through-hole 24. A pair of mirror assembly locking screws 28 are received in the holes 27 and are used to fixedly connect the input mirror assembly 30 to the input block 20, as described below.
The input block 20 is preferably formed from aluminum and is approximately 1.75 inches wide, 1.50 inches long and 1.00 inches high.
The input mirror 35 is connected to an input mirror assembly 30. The input mirror assembly 30 includes a shaft 31 having a semi-cylindrical first end 32 and a cylindrical second end 33. A diameter of the input mirror shaft 31 is selected such that the input mirror is rotatably received in the through-hole 24 formed in the input block 20. The semi-cylindrical first end is formed such that when the input mirror 35 is connected, a plane of the mirror intersects the axis of the shaft 31. In addition, an adjustment hole 34 is formed adjacent the second end 33.
When the input mirror assembly 30 is mounted on the input block 20, the input mirror 35 extends from one side surface 22 of the input block 20, and the second end 33 extends from the other side surface 22. The input mirror assembly 30 is rotatable relative to the input block 20 when the input mirror locking screws 28 (described above) are in a loosened position, and the input mirror assembly 30 is rigidly secured to the input block 20 when the input mirror locking screws 28 are in a tightened position. When the locking screws 28 are loosened, preferably using an Allen wrench (not shown), the same Allen wrench may then be inserted into the adjustment hole 34 and used as a lever to adjust the rotated position of the input mirror assembly 30.
The input mirror shaft 31 preferably has a diameter of approximately 0.625 inches a length of 2.69 inches. Finally, the preferred material for the input mirror 35 is commercially available from Melles Griot of Irvine, Calif. under part number 01 MFG 001, and is 5 mm square and 1 mm thick. The input mirror 25 is connected to the input mirror shaft 31 using silicon adhesive.
As best shown in FIG. 4, according to the preferred embodiment, the output block 40 includes a body portion 41 having a width (measured in the z-direction in FIG. 1) which fits within the groove 12 such that the output block 40 is slidable along the groove 12. The body portion 41 includes a lower surface 42 facing the groove 12, a side surface 43 and an upper surface 44. The body portion 41 defines a horizontal through-hole 48 having an axis aligned in the z-direction (FIG. 1) through which the beam 5 is directed, described below. The body portion 41 also defines a pair of slots 45 formed through the upper surface 44. A pair of output block locking screws 46 secure the output block 40 to the base 10 when the output block locking screws 46 are in a tightened position, and allow the output block 40 to slide relative to the base 10 along the slots 45 when the output block locking screws 46 are in a loosed position. Finally, an adjustment hole 49 is formed in the output block and functions similar to the adjustment hole 29 of the input block 20 (discussed above).
The output block 40 also includes a cantilever portion 50 which is integrally formed with the upper surface 44 of the body portion 41. The cantilever portion 50 extends along the upper surface 44 and from the side surface 43 of body portion 41. The cantilever portion 50 defines a through-hole 51, which is formed in the y-direction (FIG. 1), for receiving an output mirror assembly 60, as described below. A horizontal output mirror locking screw receiving hole 52 is formed in an end of the cantilevered portion 50 and intersects the through-hole 51. An output mirror locking screw 53 is received in the output mirror locking screw receiving hole 52 and secures the output mirror assembly 60 as described below.
The output block 40 is preferably formed from aluminum with the body portion being 1.75 inches wide, 1.60 inches long and 1.00 inches high, and the cantilever portion 0.97 inches wide, 2.70 inches long and 0.57 inches high.
In the preferred embodiment of the present invention, the above-mentioned output mirror 65 is connected to an output mirror assembly 60. The output mirror assembly 60 includes an output mirror shaft 61 having a semi-cylindrical first end 62 to which is connected the output mirror 65, and a cylindrical second end 63. The output mirror shaft 61 has a diameter which allows it to rotate around its axis when received into the through-hole 51 formed in the cantilever portion 50 of the output block 40. The output mirror 65 is a planar mirror disposed parallel to the axis of the shaft 61. The semi-cylindrical first end 62 is cut such that when the output mirror 65 is mounted to the first end 62, a surface of the output mirror 65 intersects the axis of the shaft 61. When the output mirror assembly 60 is mounted on the output block 40, the output mirror 65 extends from a lower surface 54 of the cantilever portion 50, and the second end 63 extends from an upper surface 55 of the cantilever portion 50. Further, the output mirror 65 is positioned adjacent the horizontal through-hole 48 formed in the body portion 41 of the output block 40 for purposes described below. The output mirror assembly 60 is rotatable when the output mirror locking screw 53 (described above) is in a loosened position, and is rigidly secured when the output mirror locking screw 53 is in a tightened position. Finally, an adjustment hole 64 is formed adjacent the second end 63. The same Allen wrench used to loosen and tighten the locking screw 53 can be inserted into the adjustment hole 64 and used as a lever to adjust the rotated position of the output mirror assembly 60.
The output mirror shaft 61 is preferably 0.625 inches in diameter and has a length of 1.56 inches. Finally, the output mirror 65 is commercially available from Melles Griot of Irvine, Calif. under part number 01 MFG 001, and is 5 mm square and 1 mm thick, and is fastened to the output mirror shaft 61 using silicon adhesive.
Operation of the above-described apparatus 1 will now be described.
Referring to FIG. 1, with the apparatus 1 connected to the above-mentioned laser imaging system (not shown), the laser beam 5 is directed from a point below the apparatus 1 such that it travels along a vertical (y-axis) path and strikes the input mirror 35. The input mirror 35 and the output mirror 65 are relatively positioned such that the laser beam 5 is reflected by the input mirror 35 to the output mirror 65, and from the output mirror 65 toward the target 9. More specifically, the input mirror assembly 30 is rotated relative to the input block 20 such that the input mirror 35 is at an approximately 45° angle with respect to the x-axis and the y-axis, thereby redirecting the beam 5 from the y-axis direction to the x-axis direction (toward the output mirror 65). Similarly, the output mirror assembly 60 is rotated relative to the output block 40 such that the output mirror 65 is at an approximately 45° angle with respect to the x-axis direction and the z-axis direction, thereby redirecting the beam 5 from the x-axis direction to the z-axis direction (toward the target 9). Note that in the disclosed embodiment, the portion of the laser beam 5 located between the output mirror 65 and the target 9 travels through the through-hole 48 formed in the body portion 41 of the output block 40.
In accordance with one aspect of the present invention, the location of the incident portion 7 of the laser beam 5 is adjustable relative to the target 9 by sliding the input block 20 and the output block 40 relative to the base 10. That is, as the input block 20 is slid to the right (FIG. 1), the terminal portion 7 is adjusted downward along the y-axis direction, and when the input block 20 is slid to the left, the terminal portion 7 is adjusted upward along the y-axis direction. Similarly, as the output block 40 is slid to the right (FIG. 1), the terminal portion 7 is adjusted to the right along the x-axis direction, and when the output block 40 is slid to the left, the terminal portion 7 is adjusted to the left along the x-axis direction. A first Allen wrench is used to loosen and tighten the locking screws 26, 46 and is also used as a lever to adjust the position of the input block 20 and the output block 40 relative to the base 10.
In accordance with another aspect of the present invention, an angle of incidence of the laser beam 5 from the apparatus 1 to the target 9 is adjustable by rotating the input mirror assembly 30 relative to the input block 20 and the output mirror assembly 60 relative to the output block 40. That is, rotation of the input mirror assembly 30 relative to the input block 20 changes the angle of incidence in the Θ x direction. Similarly, rotation of the output mirror assembly 60 relative to the output block 40 changes the angle of incidence in the Θ y direction. A second Allen wrench is used to loosen and tighten the locking screws 28, 53 and is also used as a lever to adjust the rotated position of the input mirror assembly 30 and the output mirror assembly 60.
In accordance with another aspect of the present invention, the above-described adjustments are performed in a minimum amount of space and with only two tools. That is, adjustment of the input block 20 relative to the base 10 is performed by accessing the input block locking screws 26 from a position over the input block 20. Likewise, adjustment of the input mirror assembly 30 is performed by accessing the input mirror locking screws 28 from a position over the input block 20. Further, adjustment of the output block 40 relative to the base 10 is performed by accessing the output block locking screws 46 from a position over the output block 40. Finally, adjustment of the output mirror assembly 60 is performed by accessing the output mirror locking screw 53 from a position to the side of the output block 40.
Although the present invention has been described in considerable detail with reference to the preferred embodiment described above, other versions are possible. For example, the output mirror can be rotated such that the output beam is directed in an opposite direction along the z axis, thereby obviating the necessity of the through hole formed in the output block. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiment contained herein. | A beam steering apparatus including a base, an input block slidably connected to the base, and an output block slidably connected to the base. An input mirror is connected to the input block and an output mirror is connected to the output block. The input mirror is positioned to receive a light beam and to steer the light beam to the output mirror, and the output mirror is positioned to redirect the light beam to a target. The terminal portion of the light beam is adjustable in a first orthogonal direction by sliding the input block relative to the base, and in a second orthogonal direction by sliding the output block relative to the base. The input mirror is rotatably connected to the input block and the output mirror is rotatably connected to the output block. An angle of incidence of the output beam relative to the target is adjustable in a first plane by rotating the input mirror relative to the input block, and is adjustable in a second plane by rotating the output mirror relative to the output block. Adjustments of the input and output blocks relative to the base and rotation of the input and output mirrors relative to the input and output blocks, respectively, are performed in a minimum space and using a minimum number of tools. | 6 |
[0001] This is a Divisional of U.S. patent application Ser. No. 12/813,873 filed Jun. 11, 2010, now allowed, which is a Divisional of U.S. patent application Ser. No. 11/649,647 filed Jan. 4, 2007, now issued as U.S. Pat. No. 7,858,149, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/246,825 filed Oct. 7, 2005, now issued as U.S. Pat. No. 7,517,409, which is a Divisional of U.S. patent application Ser. No. 10/649,288 filed Aug. 27, 2003, now issued as U.S. Pat. No. 7,160,574 on Jan. 9, 2007, which claims the benefit of priority to U.S. Provisional Patent Application 60/406,602 filed Aug. 28, 2002, all of which are incorporated by reference.
FIELD OF INVENTION
[0002] This invention relates to repairing leaks in pipes, and in particular to methods, systems and apparatus for repairing leaks and providing barrier protective coatings in a single operation to the interior walls of small diameter metal and plastic pressurized pipes such as pressurized drain lines, hot water lines, cold water lines, potable water lines, natural gas lines, HVAC piping systems, and fire sprinkler system lines, and the like, that are used in multi-unit residential buildings, office buildings, commercial buildings, and single family homes, and the like.
BACKGROUND AND PRIOR ART
[0003] Large piping systems such as those used in commercial buildings, apartment buildings, condominiums, as well as homes and the like that have a broad base of users commonly develop problems with their pipes such as their water and plumbing pipes, and the like. Presently when a failure in a piping system occurs the repair method may involve a number of separate applications. Those repair applications may involve a specific repair to the area of failure such as replacing that section of pipe or the use of a clamping devise and a gasket.
[0004] Traditional techniques to correct for the leak have included replacing some or all of a building's pipes. In addition to the large expense for the cost of the new pipes, additional problems with replacing the pipes include the immense labor and construction costs that must be incurred for these projects.
[0005] Most piping systems are located behind finished walls or ceilings, under floors, in concrete or underground. From a practical viewpoint simply getting to the problem area of the pipe to make the repair can create the largest problem. Getting to the pipe for making repairs can require tearing up the building, cutting concrete and/or having to dig holes through floors, the foundation or the ground. These labor intensive repair projects can include substantial demolition of a buildings walls and floors to access the existing piping systems. For example, tearing out of the interior walls to access the pipes is an expected result of the demolition necessary to fix existing pipes.
[0006] There is usually substantial time-consuming costs for removing the debris and old pipes from the worksite. With these projects both the cost of new pipes and the additional labor to install these pipes are required expenditures. Further, there are additional added costs for the materials and labor to replumb these new pipes along with the necessary wall and floor repairs that must be made to clean up for the demolition effects. For example, getting at and fixing a pipe behind drywall is not completing the repair project. The drywall must also be repaired, and just the drywall type repairs can be extremely costly. Additional expenses related to the repair or replacement of an existing piping system will vary depending primarily on the location of the pipe, the building finishes surrounding the pipe and the presence of hazardous materials such as asbestos encapsulating the pipe. Furthermore, these prior known techniques for making piping repair take considerable amounts of time which results in lost revenue from tenants and occupants of commercial type buildings since tenants cannot use the buildings until these projects are completed.
[0007] Finally, the current pipe repair techniques are usually only temporary. Even after encountering the cost to repair the pipe, the cost and inconvenience of tearing up walls or grounds and if a revenue property the lost revenue associated with the repair or replacement, the new pipe will still be subject to the corrosive effects of fluids such as water that passes through the pipes.
[0008] Over the years many different attempts and techniques have been proposed for cleaning water type pipes with chemical cleaning solutions. See for example, U.S. Pat. Nos. 5,045,352 to Mueller; 5,800,629 to Ludwig et al.; 5,915,395 to Smith; and 6,345,632 to Ludwig et al. However, these systems generally require the use of chemical solutions such as liquid acids, chlorine, and the like, that must be run through the pipes as a prerequisite prior to any coating of the pipes.
[0009] Other systems have been proposed that use dry particulate materials as a cleaning agent that is sprayed from mobile devices that travel through or around the pipes. See for example, U.S. Pat. Nos. 4,314,427 to Stolz; and 5,085,016 to Rose. However, these traveling devices generally require large diameter pipes to be operational and cannot be used inside of pipes that are less than approximately 6 inches in diameter, and would not be able to travel around narrow bends. Thus, these devices cannot be used in small diameter pipes found in potable water piping systems that also have sharp and narrow bends.
[0010] Other repair type techniques for sealing and repairing pipes have included, for example, U.S. Pat. Nos. 5,622,209 to Naf; 4,505,613 to Koga; 4,311,409 to Stang; 3,727,412 to Marx et al.; and 3,287,148 to Hilbush.
[0011] Hilbush '148 describes a process for sealing laid gas pipes by blowing in a foamed sealing emulsion. The foam settles on the internal wall and condenses there. In the case of leaks, it tends to settle in larger quantities which makes this technique unsuitable for many applications. This method is expressly suited only to gas pipes; solid additions to the sealing emulsion are neither taught nor made obvious.
[0012] Marx, '412 describes a repair process in which the portion of the pipe with the leak is sealed at the front and rear ends. A specially stabilized emulsion is then pressed in which issues at the leak, is destabilized there and coagulates so that the leak is sealed. Actual solid sealing materials are not therefore pressed into the pipes and the vehicle is water, not gas.
[0013] Stang '409 describes the sealing of leaks in laid pipes by very fine substances having a high capillary action. The very fine and difficult to use substance is arranged externally at the leak and is watered there. The capillary pressure thus obtained counteracts the delivery pressure of the medium flowing in the pipe. The very fine insulating material must be laid onto the conduit from the exterior, after excavation of the leak.
[0014] Koga '613 describes a process and an apparatus for the internal repair of laid pipes by means of “plastic mist” conveyed in a gas stream. It is unclear whether actual leaks are also sealed with it. More importantly, this process does not appear to be able to immediately produce the plastic mist necessary to work.
[0015] Naf '209 describes s process where a sealant is introduced with water and is part of a water sealant mixture. The water sealant mixture fills a pipe resulting in adding multiple steps to the process of filling, setting up a hydraulic recirculating system, draining and drying the piping system. The water/sealant mixture may also flow from the leaking section creating water damage to the immediate area.
[0016] None of the prior art techniques describe a process where a barrier coating and leaks are sealed with a barrier coating application combined with a leak sealing operation.
[0017] Thus, the need exists for solutions to the above problems where providing a barrier coating and sealing leaks is accomplished in piping systems in a single operation.
SUMMARY OF THE INVENTION
[0018] A primary objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks of pressurized pipes in buildings without having to physically remove and replace the pipes, where the leaks are sealed and the barrier coating is applied in a single operation.
[0019] A secondary objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks, in a single operation in pipes by initially cleaning the interior walls of the pipes.
[0020] A third objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks, in a single operation in pipes by applying a corrosion protection barrier coating to the interior walls of the pipes that provides a barrier coating and seals leaks in one operation.
[0021] A fourth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks, in a single operation, in pipes in buildings in a cost effective and efficient manner.
[0022] A fifth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks, in a single operation, in pipes which is applicable to small diameter piping systems from approximately ⅜″ to approximately 6″ in diameter in piping systems made of various materials such as galvanized steel, black steel, lead, brass, copper or other materials such as PVC, and composites including plastics, as an alternative to pipe replacement or repair.
[0023] A sixth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation which is applied to pipes, “in place” or insitu minimizing the need for opening up walls, floors ceilings, or grounds.
[0024] A seventh objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, which minimizes the disturbance of asbestos lined piping or walls/ceilings that can also contain lead based paint or other harmful materials.
[0025] An eighth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where once the existing piping system is restored with a durable epoxy barrier coating the common effects of corrosion from water passing through the pipes will be delayed if not stopped entirely.
[0026] A ninth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, to clean out blockage where once the existing piping system is restored, users will experience an increase in the flow of water, which reduces the energy cost to transport the water. Additionally, the barrier epoxy coating leak sealant being applied to the interior walls of the pipes can create enhanced hydraulic capabilities again giving greater flow with reduced energy costs.
[0027] A tenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where customers benefit from the savings in time associated with the restoration of an existing piping system.
[0028] An eleventh objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where customers benefit from the economical savings associated with the restoration and in-place leak repair of an existing piping system, since walls, ceilings, floors, and/or grounds do not always need to be broken and/or cut through.
[0029] A twelfth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where income producing properties experience savings by remaining commercially usable, and any operational interference and interruption of income-producing activities is minimized.
[0030] A thirteenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where health benefits had previously accrued, as the water to metal contact will be stopped by a barrier coating thereby preventing the leaching of metallic and potentially other harmful products from the pipe into the water supply such as but not limited to lead from solder joints and from lead pipes, and any excess leaching of copper, iron and lead.
[0031] A fourteenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation where the pipes are being restored and repaired, in-place, thus causing less demand for new metallic pipes, which is a non-renewable resource.
[0032] A fifteenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, using a less intrusive method of repair where there is less building waste and a reduced demand on expensive landfills.
[0033] A sixteenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where the process uses specially filtered air that reduces possible impurities from entering the piping system during the process.
[0034] A seventeenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where the equipment package is able to function safely, cleanly, and efficiently in high customer traffic areas.
[0035] An eighteenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation where the equipment components are mobile and maneuverable inside buildings and within the parameters typically found in single-family homes, multi unit residential buildings and various commercial buildings.
[0036] A nineteenth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where the equipment components can operate quietly, within the strictest of noise requirements such as approximately seventy four decibels and below when measured at a distance of approximately several feet away.
[0037] A twentieth objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation where the barrier coating leak sealant material for application in a variety of piping environments, and operating parameters such as but not limited to a wide temperature range, at a wide variety of airflows and air pressures, and the like.
[0038] A twenty first objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation where the barrier coating leak sealant material and the process is functionally able to deliver turnaround of restored piping systems to service within approximately twenty four hours or less.
[0039] A twenty second objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation, where the barrier coating material is designed to operate safely under NSF (National Sanitation Foundation) Standard 61 criteria in domestic water systems, with adhesion characteristics within piping systems in excess of approximately 400 PSI.
[0040] A twenty third objective of the invention is to provide methods, systems and devices for repairing interior walls and sealing leaks in pipes, in a single operation where the barrier coating material is designed as a long-term, long-lasting, durable solution to pipe corrosion, pipe erosion, pinhole leak repair and related water damage to piping systems where the barrier coating extends the life of the existing piping system.
[0041] A twenty fourth objective of the invention is to provide methods, systems and devices for both cleaning and coating interiors and leak sealing, the interior of pipes having diameters of up to approximately 6 inches using dry particulates, such as sand and grit, prior to coating the interior pipe walls.
[0042] A twenty fifth objective of the invention is to provide methods, systems and devices for cleaning coating interiors and sealing leaks of pipes having diameters of up to approximately 6 inches in buildings, without having to section off small sections of piping for cleaning coating and leak sealing applications.
[0043] A twenty sixth objective of the invention is to provide methods, systems and devices for cleaning the interiors of an entire isolated piping system in a building in a single pass run operation.
[0044] A twenty seventh objective of the invention is to provide methods, systems and devices for barrier coating and leak sealing the interiors of an entire isolated piping system in a building in a single pass run operation.
[0045] The novel method and system of pipe restoration prepares and protects small diameter piping systems such as those within the diameter range of approximately ⅜ of an inch to approximately six inches and can include straight and bent sections of piping from the effects of water corrosion, erosion and electrolysis and sealing leaks in-place, thus extending the life of small diameter piping systems. The barrier coating used as part of the novel process method and system, can be used in pipes servicing potable water systems, meets the criteria established by the National Sanitation Foundation (NSF) for products that come into contact with potable water. The epoxy material also meets the applicable physical criteria established by the American Water Works Association as a barrier coating. Application within buildings ranges from single-family homes to smaller walk-up style apartments to multi-floor concrete high-rise hotel/resort facilities and office towers, as well as high-rise apartment and condominium buildings and schools. The novel method process and system allows for barrier coating and leak repair, in a single operation to potable water lines, natural gas lines, HVAC piping systems, hot water lines, cold water lines, pressurized drain lines, and fire sprinkler systems.
[0046] The novel method of application of an epoxy barrier coating leak sealant is applied to pipes right within the walls eliminating the traditional destructive nature associated with a re-piping job. Typically 1 system or section of pipe can be isolated at a time and the restoration of the system or section of pipe can be completed in less than one to four days (depending upon the building size and type of application) with water restored within approximately less than approximately 24 to approximately 96 hours. For hotel and motel operators that means not having to take rooms off line for extended periods of time. Too, for most applications, there are no walls to cut, no large piles of waste, no dust and virtually no lost room revenue. Entire building piping systems can be cleaned within one run through pass of using the invention. Likewise, an entire building piping system can be coated and leaks sealed within one single pass operation as well.
[0047] Once applied, the epoxy coating not only seals the leak but creates a barrier coating on the interior of the pipe in the same operation. The application process and the properties of the epoxy coating ensure the interior of the piping system is fully coated and leaks repaired. Epoxy coatings are characterized by their durability, strength, adhesion and chemical resistance, making them an ideal product for their application as a barrier coating and leak sealant on the inside of small diameter piping systems.
[0048] The novel barrier coating provides protection and extended life to an existing piping system that has been affected by erosion corrosion caused from internal burrs, improper soldering, excessive turns, and excessive water velocity in the piping system, electrolysis and “wear” on the pipe walls created by suspended solids. The epoxy barrier coating will create at least an approximately 4 mil covering to the inside of the piping system and will seal leaks spanning up to approximately 125 mils.
[0049] There are primarily 3 types of metallic piping systems that are commonly used in the plumbing industry—copper, steel and cast iron. New steel pipes are treated with various forms of barrier coatings to prevent or slow the effects of corrosion. The most common barrier coating used on steel pipe is the application of a zinc based barrier coat commonly called galvanizing. New copper pipe has no barrier coating protection and for years was thought to be corrosion resistant offering a lifetime trouble free use as a piping system.
[0050] Under certain circumstances that involved a combination of factors of which the chemistry of water and installation practices a natural occurring barrier coating would form on the inside of copper pipes which would act as a barrier coating, protecting the copper piping system against the effects of corrosion from the water.
[0051] In recent history, due to changes in the way drinking water is being treated and changes in installation practices, the natural occurring barrier coating on the inside of copper pipe is not being formed or if it was formed is now being washed away. In either case without an adequate natural occurring barrier coating, the copper pipe is exposed to the effects of corrosion/erosion, which can result in premature aging and failure of the piping system, most commonly referred to as a pinhole leak.
[0052] With galvanized pipe the zinc coating wears away leaving the pipe exposed to the effects of the corrosive activity of the water. This results in the pipe rusting and eventually failing.
[0053] The invention can also be used with piping systems having plastic pipes, PVC pipes, composite material, and the like.
[0054] The novel method and system of corrosion control by the application of an epoxy barrier coating and sealant can be applied to existing piping systems in-place, in the same operation.
[0055] The invention includes novel methods and equipment for providing barrier coating corrosion and a repair method for sealing leaks for the interior walls of small diameter piping systems in the same operation. The novel process method and system of internal leak repair and corrosion control includes at least three basic steps: Air Drying a piping system to be serviced; profiling the piping system using an abrasive cleaning agent; and applying the barrier coating leak sealant to selected coating thickness layers inside the pipes. The novel invention can also include two additional preliminary steps of: diagnosing problems with the piping system to be serviced, and planning and setting up the barrier coating leak repair project onsite. Finally, the novel invention can include a final end step of evaluating the system after applying the barrier coating leak repair and re-assembling the piping system.
[0056] A novel method and process of applying a barrier coating leak sealant to pipes to fix openings and cracks in the pipes, can include the steps of mixing an epoxy material to form a barrier coating leak sealant having a viscosity range of approximately 1,200 cps to approximately 60,000 cps at room temperature, applying the barrier coating leak sealant to interior walls of the pipes without dismantling all of the piping system, wherein the barrier coating leak sealant provides an interior barrier for protecting the interior walls of the pipes and sealing leak openings up to approximately 125 mils in diameter, and restoring the pipes of the existing piping system to service is less than approximately ninety six hours. A more preferable viscosity range is between approximately 10,000 cps to approximately 60,000 cps.
[0057] The method and process can further include the step of mixing an additional filler material with the barrier coating to further fill in the leak openings. The filler can be additional epoxy material. The additional filler material can be selected from the group consisting of: glass flakes, glass fibers, epoxy fibers, mica, clay, silica, cork, and plastics.
[0058] Approximately 100 to approximately 200 milliliters of unfilled epoxy can be used for pipes having a length of approximately 5 feet to approximately 30 feet, where the pipes are approximately ½ inch in diameter.
[0059] Approximately 100 to approximately 300 milliliters of unfilled epoxy can be used for pipes having a length of approximately 5 feet to approximately 30 feet, where the pipes are approximately ¾ inch in diameter.
[0060] Approximately 100 to approximately 400 milliliters of unfilled epoxy can be used for pipes having a length of approximately 5 feet to approximately 30 feet, where the pipes are approximately 1 inch in diameter.
[0061] Approximately 100 to approximately 500 milliliters of unfilled epoxy can be used for the pipes having a length of approximately 5 feet to approximately 30 feet, where the pipes are approximately 1¼ inch in diameter.
[0062] Approximately 100 to approximately 600 milliliters of unfilled epoxy can be used for pipes having a length of approximately 5 feet to approximately 30 feet, where the pipes are approximately 1½ inch in diameter.
[0063] Approximately 100 to approximately 700 milliliters of unfilled epoxy can be used for pipes having a length of approximately 5 feet to approximately 30 feet, where the pipes are approximately 2 inches in diameter.
[0064] The mixed epoxy having a viscosity of approximately 1200 to approximately 5000 cps has at least approximately 25% fillers.
[0065] The mixed epoxy having a viscosity of approximately 5001 to approximately 10000 cps has at least approximately 20% fillers.
[0066] The mixed epoxy having a viscosity of approximately 10001 to approximately 15000 cps has at least approximately 15% fillers.
[0067] The mixed epoxy having a viscosity of approximately 15001 to approximately 25000 cps has at least approximately 10% fillers.
[0068] The mixed epoxy having a viscosity of approximately 25001 to approximately 60000 cps has at least approximately 5% fillers.
[0069] The method and process can further include the step of applying and maintaining a positive pressure fluid, that can include air, throughout the pipes to set the barrier coating for a selected time of at least several minutes, wherein the positive pressure fluid is at a pressure level of at least approximately 1.5 PSI.
[0070] Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0071] FIG. 1 shows the general six steps that is an overview for applying the barrier coating leak sealant.
[0072] FIGS. 2A , 2 B, 2 C and 2 D shows a detailed process flowchart using the steps of FIG. 1 for providing the barrier coating leak sealant.
[0073] FIG. 3 shows a flow chart of the set up of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
[0075] This is a Divisional of U.S. patent application Ser. No. 12/813,873 filed Jun. 11, 2010, now allowed, which is a Divisional of U.S. patent application Ser. No. 11/649,647 filed Jan. 4, 2007, now issued as U.S. Pat. No. 7,858,149, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/246,825 filed Oct. 7, 2005, now issued as U.S. Pat. No. 7,517,409, which is a Divisional of U.S. patent application Ser. No. 10/649,288 filed Aug. 27, 2003, now issued as U.S. Pat. No. 7,160,574 on Jan. 9, 2007, which claims the benefit of priority to U.S. Provisional Patent Application 60/406,602 filed Aug. 28, 2002, all of which are incorporated by reference.
[0076] FIG. 1 shows the general six steps for a project overview for applying the barrier coating leak sealant to an existing piping system, which include step one, 10 program diagnosis, step two, 20 project planning, step three, 30 drying piping system, step four 40 , profiling the piping system, step five, 50 applying barrier coating leak sealant to the interior walls of the pipes in the piping system, and final step six 60 evaluation and return to operation of the piping system.
Step One—Problem Diagnosis 10
[0077] For step one, 10 , several steps can be done to diagnose the problem with a piping system in a building, and can include:
(a) Interview onsite engineering staff, property mangers, owners or other property representatives as to the nature of the current problem with the piping system. (b) Evaluation of local and on-site water chemistry being used in the piping system for hardness and aggressive qualities. (c) Engineering evaluation, if necessary, to determine extent of present damage to the wall thickness of the piping and overall integrity of the piping system. (d) Additional on-site testing of piping system, if necessary, identifying leaks or the nature or extent of leaking. (e) Corrosion control, leak sealing proposal development for client, including options for pipe and fitting replacement where necessary. After completion of step one, 10 , the project planning and setup step 20 can be started.
Step Two—Project Planning and Setup 20
[0084] For step two, 20 , several steps can be followed for planning and setup for restoring the integrity of the piping system in a building, and can include:
(a) Complete contract development with client, after the diagnosis contract has started. (b) Commence project planning with site analysis crew, project management team, and on-site engineering/maintenance staff. (c) Plan delivery of the equipment and supplies to the worksite. (d) Complete equipment and supply delivery to worksite. (e) Commence and complete mechanical isolation of the piping system. (f) Commence and complete set up of hosing and equipment.
Step Three—Air Drying—Step 1 Method of Corrosion Control and Leak Repair 30
[0091] For step three, 30 , the piping system to be prepared for the coating by drying the existing pipes, and can include:
(a) Piping systems are mapped. (b) Isolations of piping systems or pipe sections are prepared and completed. (c) The isolated piping system to receive the barrier coating leak sealant is adapted to be connected to the barrier coating equipment. (d) The isolated pipe section or system is drained of water. (e) Using moisture and oil free, hot compressed air, a flushing sequence is completed on the piping system to assure water is removed. (f) Piping system is then dried with heated, moisture and oil free compressed air. (g) Length of drying sequence is determined by pipe type, diameter, length complexity, location and degree of corrosion contained within the piping system, if any. (h) Exiting debris is captured with use of an air filter vacuum, drawing air, which is used simultaneously with compressor. (i) Inspections are completed to assure a dry piping system ready for the barrier coating and sealant.
Step Four—Piping System Profiling—Step 2 of Method of Corrosion Control and Leak Sealant 40
[0101] For step four, 40 , the piping system is to be profiled, and can include:
(a) Dried pipes can be profiled using an abrasive agent in varying quantities and types. The abrasive medium can be introduced into the piping system by the use of the moisture and oil free heated compressed air using varying quantities of air and varying air pressures. The amount of the abrading agent is controlled by the use of a pressure generator. (b) The simultaneous use of the air filter vacuum at the exit end, drawing air to assist the compressor, reducing the effects of friction loss in the piping system, enhancing the effects of the sanding and debris removal. (c) The abraded pipe, when viewed without magnification, must be generally free of all visible oil, grease, dirt, mill scale, and rust. Generally, evenly dispersed, very light shadows, streaks, and discolorations caused by stains of mill scale, rust and old coatings may remain on no more than approximately 33 percent of the surface. Also, slight residues of rust and old coatings may be left in the craters of pits if the original surface is pitted. (d) Pipe profiling is completed to ready the pipe for the application of the barrier coating leak sealant material. (e) Visual inspections can be made at connection points and other random access areas of the piping system to assure proper cleaning and profiling standards are achieved. (f) An air flushing sequence is completed to the piping system to remove any residuals left in the piping system from the profiling stage.
Step Five—Corrosion Control Epoxy Sealing Leak Repair and Protection of the Piping—Step 3 of the Method of Corrosion Control and Leak Repair 50
[0108] For step five, 50 , the piping system is barrier coated and leaks sealed and can include:
(a) Piping system can be heated with hot, pre-filtered, moisture and oil free compressed air to an appropriate standard for an epoxy coating application. (b) Piping system can be checked for leaks. (c) If leaks are identified or are suspect and the approximate size determined the operator may choose to apply the coating material without fillers, if the leak is determined to be >approximately 30 mils in width the operator can decide to add fillers to the coating material, prior to injection into the piping system. (d) Coating and leak sealing material can be prepared and metered to manufacturer's specifications using a proportionator. (e) The barrier coating leak sealant and fillers are placed into the epoxy carrying tube or injection device. (f) The coating and leak sealant material can be injected into the piping system using hot, pre-filtered, moisture and oil free compressed air at temperatures, air volume and pressure levels to distribute the epoxy barrier coating leak sealant throughout the pipe segment, in sufficient amounts to eliminate the water to pipe contact in order to create an epoxy barrier coating on the inside of the pipe and seal the leak in a single operation. During this wetting out stage a vacuum filter maybe used in conjunction with the compressor to assist the wetting out of the coating material. At all times, a neutral or positive pressure must be maintained on the inside of the pipe. (g) The coating can be applied to achieve a coating of at least approximately 4 mils and sealing leaks up to approximately 125 mils in size. (h) Once the epoxy barrier coating leak sealant is injected and the piping segment is wetted out warm, pre-filtered, moisture and oil free compressed air can be applied to create a positive pressure inside the pipe with a continuous positive pressure maintained of at least approximately 1.5 P.S.I. over the internal surface of the pipe to achieve the initial set of the epoxy barrier coating sealant takes place. After initial set and still maintaining positive pressure confirm that all valves and pipe segments support appropriate air flow indicating clear passage of the air through the pipe i.e.: no areas of blockage. Allow the barrier coating leak sealant to cure to manufacturer's standards. Positive pressure can be maintained until the epoxy has reached its “initial set.” The time depends on the epoxies pot life, the application temperature of the epoxy and the maintenance temperature and the actual film thickness of the epoxy, these factors all come into play when getting the epoxy to its initial set. For example, an epoxy having a 30 minute pot life, measured at room temperature, will need a positive pressure for at least approximately 30 minutes at no less then room temperature. Thus, a positive pressure should be maintained to at least the manufacturers specification of the epoxies pot life when measured at room temperature or until initial set is achieved.
Step Six—System Evaluation and Re-Assembly 60
[0118] The final step six, 60 allows for restoring the piping system to operation and can include:
(a) Remove all process application fittings. (b) Examine pipe segments to assure appropriate coating standards, check to ensure all leaks are sealed. (c) Re-confirm that all valves and pipe segments support appropriate air flow. (d) Install original valves, fittings/fixtures, or any other fittings/fixtures as specified by building owner representative. (e) Reconnect water system, and water supply. (f) Complete system checks, testing and evaluation of the integrity of the piping system. (g) Complete a water flush of system, according to manufacturer's specifications. (h) Evaluate water flow and quality. (i) Document piping layout schedule, and complete pipe labeling.
[0128] FIGS. 2A , 2 B, 2 C and 2 D show a detailed process flowchart using the steps of FIG. 1 for providing the barrier coating leak sealant. These flow chart figures show a preferred method of applying a novel barrier coating leak sealant for the interior of small diameter piping systems following a specific breakdown of a preferred application of the invention.
[0129] Components in FIG. 3 will now be identified as follows:
[0000]
IDENTIFIER
EQUIPMENT
100
395, 850, 1100, 1600 CFM Compressors Outfitted with
Aftercooler, Water separator, Fine Filter and Reheater
(if required)
200
Main Air Header and Distributor (Main Header)
300
Floor Manifold (optional)
400
Sander
500
Pre-Filter
600
Dust Collector System (Air Filter Vacuum)
700
Portable Epoxy Metering and Dispensing Unit
(Epoxy Mixer)
800
Epoxy Barrier Coating and Sealant
900
Epoxy Carrying Tube - Injection Device
[0130] Referring to FIG. 3 , components 100 - 900 can be located and used at different locations in or around a building. The invention allows for an entire isolated building piping system to be cleaned in one single pass through run without having to dismantle either the entire or multiple sections of the piping system. The piping system can include pipes having diameters of approximately ⅜ of an inch up to approximately 6 inches in diameter with the piping including bends up to approximately ninety degrees or more throughout the building. The invention allows for an entire isolated building piping system to have the interior surfaces of the pipes coated and leaks sealed in one single pass through run without having to dismantle either the entire or multiple parts of the piping system. Each of the components will now be defined.
100 Air Compressor
[0131] The air compressors 100 can provide filtered and heated compressed air. The filtered and heated compressed air employed in various quantities is used, to dry the interior of the piping system, as the propellant to drive the abrasive material used in cleaning of the piping system and is used as the propellant in the application of the epoxy barrier coating leak sealant and the drying of the epoxy barrier coating leak sealant once it has been applied. The compressors 100 also provide compressed air used to propel ancillary air driven equipment.
200 Main Air Header and Distributor
[0132] An off the shelf main header and distributor 200 shown in FIG. 3 can be one Manufactured By:Media Blast & Abrasives, Inc. 591 W. Apollo Street Brea, Calif. 92821.
[0133] The Main Header 200 provides safe air management capability from the air compressor for both regulated and unregulated air distribution (or any combination thereof) to the various other equipment components and to both the piping system risers and fixture outlets for a range of piping configurations from a single family home to a multi-story building. The air enters through the 2″ NPT inlet to service the pressure vessel. The main header 200 can manage air capacities ranging to approximately 1600 CFM and approximately 200 psi.
[0134] There are many novel parts and benefits with the Main Header and Distributor 200 . The distributor is portable and is easy to move and maneuver in tight working environments. Regulator Adjustment can easily and quickly manage air capacities ranging to approximately 1600 CFM and approximately 200 psi, and vary the operating airflows to each of the other ancillary equipment associated with the invention. The Air Pressure Regulator and the Method of Distributing the air allows both regulated and unregulated air management from the same equipment in a user-friendly, functional manner. The approximately 1″ Valving allows accommodation for both approximately 1″ hosing and with adapters, and hose sizes of less than approximately 1″ can be used to meet a wide variety of air demand needs on a job site. The insulated cabinet, surrounding air works dampens noise associated with the movement of the compressed air. The insulated cabinet helps retain heat of the pre-dried and heated compressed air, the pre-dried and heated compressed air being an integral part of the invention. The insulated cabinet helps reduce moisture in the pressure vessel and air supply passing through it. Finally, the valving of the pressure vessel allows for delivery (separate or simultaneous) of regulated air to the side mounted air outlet valves, the top mounted regulated air outlet valves as well as the top mounted unregulated air outlet valves.
300 Floor Manifold
[0135] An on off-the-shelf floor manifold 300 can be one Manufactured By: M & H Machinery 45790 Airport Road, Chilliwack, BC, Canada
[0136] As part of the general air distribution system set up, the floor manifolds 300 can be pressure rated vessels designed to evenly and quietly distribute the compressed air to at least 5 other points of connection, typically being the connections to the piping system. Airflow from each connection at the manifold is controlled by the use of individual full port ball valves.
[0137] There are many novel parts and benefits to the Air Manifold 300 . The portability of manifold 300 allows for easy to move and maneuver in tight working environments. The elevated legs provide a stable base for unit 300 as well as keep the hose end connections off the floor with sufficient clearance to permit the operator ease of access when having to make the hose end connections. The threaded nipples placed at approximately 45° angle allow for a more efficient use of space and less restriction and constriction of the airline hoses they are attached to. Multiple manifolds 300 can be attached to accommodate more than 5 outlets. The manifolds can be modular and can be used as 1 unit or can be attached to other units and used as more than 1.
400 Pressure Generator System-Sander
[0138] A pressure generator sander 400 that can be used with the invention can be one Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo Street Brea, Calif. 92821.
[0139] The pressure generating sander system 400 can provide easy loading and controlled dispensing of a wide variety of abrasive medium in amounts up to approximately 1.3 US gallons at a time. The pressure generator sander can include operational controls that allow the operator to easily control the amount of air pressure and control the quantity of the abrasive medium to be dispersed in a single or multiple application. The abrasive medium can be controlled in quantity and type and is introduced into a moving air steam that is connected to a pipe or piping systems that are to be sand blasted clean by the abrasive medium. The sand can be introduced by the pressure generator sander system 400 by being connected to and be located outside of the piping system depicted in FIG. 3 . The novel application of the sander system 400 allows for cleaning small pipes having diameters of approximately ⅜″ up to approximately 6″.
[0140] Table 1 shows a list of preferred dry particulate materials with their hardness ratings from 1 to 10 (being the hardest), and grain shapes that can be used with the sand generator 400 , and Table 2 shows a list of preferred dry particulate particle sieve sizes that can be used with the invention.
[0000]
TABLE 1
PARTICULATES
Material
Hardness Rating
Grain Shape
Silicon Carbide
10
Cubical
Aluminium Oxide
9
Cubical
Silica
5
Rounded
Garnet
5
Rounded
[0141] Table 1 shows the hardness and shapes of the typical types of particulates used in the cleaning and sanding process. Based on the MOH scale of hardness it is found that a 5 or higher hardness particulate be used in this process. A particulate such as silicon carbide is recommended over a softer garnet particulate when used to clean and profile harder metal pipes, such as steel, were the metal is a softer, such as copper it can be cleaned and profiled with a less hard particulate such as garnet.
[0000]
TABLE 2
PARTICULATE SIZE
SIEVE SIZE OPENING
U.S. Mesh
Inches
Microns
Millimeters
4
.187
4760
4.76
8
.0937
2380
2.38
16
.0469
1190
1.19
25
.0280
710
.71
45
.0138
350
.35
[0142] Table 2 describes the various standards for measuring particulate size. In the cleaning and profiling stage an operator will decide to use particulate of various sizes depending on the size of pipe, the type of piping material i.e. steel or copper and the degree and type of build up inside the pipe. In a copper pipe situation it is common to use a 24/25 mesh size. When cleaning a heavily encrusted steel pipe an operator might use a small particulate such as a 45 or 60 mesh to bore a hole through the build up with our getting clogged up. As the opening inside the pipe increases by cleaning, larger particulate sizes can be used.
[0143] There are many novel parts and benefits to the use of the Pressure Generator Sander System 400 . The portability allows for easy to move and maneuver in tight working environments. The sander 400 is able to accept a wide variety of abrasive media in a wide variety of media size. Variable air pressure controls in the sander 400 allows for management of air pressures up to approximately 125 PSI. A mixing Valve adjustment allows for setting, controlling and dispensing a wide variety of abrasive media in limited and controlled quantities, allowing the operator precise control over the amount of abrasive medium that can be introduced into the air stream in a single or multiple applications. The filler lid incorporated as part of the cabinet and the pressure pot allows the operator to load with ease, controlled amounts of the abrasive medium into the pressure pot. The pulse button can be utilized to deliver a single sized quantity of the abrasive material into the air stream or can be operated to deliver a constant stream of abrasive material in to the air stream. All operator controls and hose connections can be centralized for ease of operator use.
500 Abrasive Reclaim Separator Module (Pre-Filter)
[0144] An off-the-shelf pre-filter that can be used with the invention can be one Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo Street Brea, Calif. 92821
[0145] During the pipe profiling stage, the Pre-Filter 500 allows the filtering of air and debris from the piping system for more than two systems at a time through the 2-approximately 2″ NPT inlets. The cyclone chamber/separator captures the abrasive material and large debris from the piping system, the byproducts of the pipe profiling process. The fine dust particles and air escape through the approximately 8″ air and dust outlet at the top of the machine and are carried to the dust collection equipment 600 , which filters, from the exhausting air, fine particulates, that may not have been captured with the Pre-Filter 500 .
[0146] There are many novel parts and benefits to the Pre-Filter 500 . The pre-filter has portability and is easy to move and maneuver in tight working environments. The Dust Drawer with Removable Pan allows for easy clean out of the abrasive media and debris from the pipe. The Cyclone Chamber/Separator slows and traps the abrasive media and debris from the piping system and air stream and prevents excess debris from entering into the filtration equipment. The 2-approximately 2″ NPT Inlets allows a full range of air filtration from two separate riser or piping systems. Use of the approximately 8″ or greater flex tube as an expansion chamber results in reducing the air pressure of the air as it leaves the Pre-filter 500 and reduces the potential for back pressure of the air as it departs the Pre-filter and enhances the operational performance of the air filter vacuum 600 . When used in conjunction with the air filter vacuum 600 , the Pre-filter 500 provides a novel way of separating large debris from entering the final stage of the filtration process. By filtering out the large debris with the Pre-filter 500 this promotes a great efficiency of filtration of fine particles in the final stages of filtration in the air filter vacuum 600 . The approximately 8″ air and dust outlet to the air filter vacuum 600 from the Pre-filter 500 permits the compressed air to expand, slowing it in velocity before it enters the air filter vacuum 600 , which enhances the operation of the air filter vacuum 600 . Process cost savings are gained by the use of the Pre-filter 500 by reducing the impact of filtering out the large amounts of debris at the Pre-filter stage prior to air entering the air filter vacuum 600 . This provides for greater operating efficiencies at the air filter vacuum 600 a reduction in energy usage and longer life and use of the actual fine air filters used in the air filter vacuum 600 .
600 Dust Collection Filter—Air Filter Vacuum
[0147] An off-the-shelf example of an air filter vacuum 600 used with the invention can be one Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo Street, Brea, Calif. 92821.
[0148] During the pipe profiling stage, the air filter vacuum or dust collector 600 is the final stage of the air filtration process. The dust collector 600 filters the passing air of fine dust and debris from the piping system after the contaminated air first passes through the pre-filter 500 (abrasive reclaim separator module).
[0149] During the drying stage the filter 600 can be used simultaneously with compressor 100 aids in drawing air through the piping system. During the sanding or cleaning stage the filter 600 can be used with compressor 100 the filter 600 assists by drawing air through the piping system. The filter 600 can be used simultaneously with the compressor 100 to create a pressure differential in the piping system which is used to reduce the effects of friction loss and assists in a pulling action within the pipe during the drying and sanding or cleaning stages as well as the coating stage. The filter 600 can be capable of filtering air in volumes up to approximately 1100 CFM.
[0150] There are many novel parts and benefits to the Air Filter 600 . The air filter has portability and is easy to move and maneuver in tight working environments. The Dust Drawer with Removable Pan allows for easy clean out of the abrasive media and debris from the filtration chamber. The 8″ flexible duct permits the compressed air to expand and slow in velocity prior to entering the dust collector 600 , enhancing efficiency. The sliding air control exit vent permits use of a lower amperage motor on start up. The reduced electrical draw enables the dust collector 600 to be used on common household electrical currents while still being able to maintain its capacity to filter up to approximately 1100 CFM of air. The air filter 600 keeps a flow of air running over the epoxy and enhancing its drying and curing characteristics. The dust collector 600 creates a vacuum in the piping system, which is used as method of checking for airflow in the piping system.
[0151] The air filter 600 can be used simultaneously with compressor 100 to reduce the effects of friction loss, enhancing drying, sanding, epoxy injection and drying.
700 Portable Epoxy Metering and Dispensing Unit
[0152] A metering and dispensing unit 700 used with the invention can be one Manufactured by: Lily Corporation, 240 South Broadway, Aurora, Ill. 60505-4205.
[0153] The Portable Epoxy Metering and Dispensing Unit 700 can store up to approximately 3 US gallons of each of A and B component of the two mix component epoxy, and can dispense single shots up to approximately 14.76 oz, in capacities up to approximately 75 US gallons per hour.
[0154] The unit 700 can be very mobile and can be used both indoors and outdoors, and it can operate using a 15 Amp 110 AC electrical service i.e.: regular household current and approximately 9 cubic feet (CFM) at 90 to 130 pounds per square inch. The unit 700 requires only a single operator.
[0155] The epoxy 800 used with the unit 700 can be heated using this unit to its recommended temperature for application. The epoxy 800 can be metered to control the amount of epoxy being dispensed.
[0156] There are many novel parts and benefits to the Epoxy Metering and Dispensing Unit 700 , which include portability and is easy to move and maneuver in tight working environments. The heated and insulted cabinet, all epoxy transit hoses, valves and pumps can be heated within the cabinet. The Top filling pressurized tanks offers ease and access for refilling. Epoxy 800 can be metered and dispensed accurately in single shot or multiple shots having the dispensing capacity up to approximately 14.76 ounces of material per shot, up to approximately 75 gallons per hour.
[0157] The position of mixing head permits a single operator to fill the portable epoxy carrying tubes 900 in a single fast application. The drip tray permits any epoxy overspill at the time of filling to be contained in the drip tray, containing the spill and reducing cleanup. The epoxy carrying tube hanger allows the operator to fill and temporarily store filled epoxy tubes, ready for easy distribution. The pump and heater combination allows for the epoxy to metered “on ratio” under a variety of conditions such as changes in the viscosity of the epoxy components which can differ due to temperature changes which effect the flow rates of the epoxy 800 which can differ giving the operator an additional control on placement of the epoxy 800 by changing temperature and flow rates. Unit 700 provides greater operator control of the characteristics of the epoxy 800 in the process.
800 Epoxy Barrier Coating Leak Sealant
[0158] A preferred epoxy barrier coating that can be used with the invention can be one Manufactured by: CJH, Inc. 2211 Navy Drive, Stockton, Calif. 95206. The barrier coating product used in this process can be a 2-part thermo set resin with a base resin and a base-curing agent.
[0159] The preferred thermo set resin is mixed as a two-part epoxy that is used in the invention. When mixed and applied, it forms a durable barrier coating leak sealant on pipe interior surfaces and other substrates. The barrier coating leak sealant provides a barrier coating that protects those coated surfaces from the effects caused by the corrosive activities associated with the chemistry of water and other reactive materials on the metal and other substrates and seal leaks in the pipe.
[0160] The epoxy barrier coating sealant can be applied to create a protective barrier coating and leak sealant to pipes ranging in size approximately ⅜″ to approximately 6″ and greater. The barrier coating can be applied around bends intersections, elbows, tee's, to pipes having different diameters and make up. The barrier coating leak sealant can be applied to pipes in any position e.g.: vertical or horizontal and can be applied as a protective coating leak sealant to metal and plastic type pipes used in fire sprinkler systems and natural gas systems. At least an approximately 4 mils coating layer can be formed on the interior walls of the pipes. The barrier coating leak sealant protects the existing interior walls and can also stop leaks in existing pipes which have small openings and cracks, and the like, of up to approximately 125 mils in size.
[0161] Although the process of application described in this invention includes application of thermo set resins other types of thermo set resins can be used.
[0162] For example, other thermo set resins can be applied in the process, and can vary depending upon viscosity, conditions for application including temperature, diameter of pipe, length of pipe, type of material pipe comprised of, application conditions, potable and non potable water carrying pipes, and based on other conditions and parameters of the piping system being cleaned, coated and leaks sealed by the invention.
[0163] Other thermo set type resins that can be used include but are not limited to and can be one of many that can be obtained by numerous suppliers such as but not limited to: Dow Chemical, Huntsmans Advances Material, formerly Ciba Giegy and Resolution Polymers, formerly Shell Chemical.
[0164] A preferred viscosity range of the mixed as-applied epoxy used in this process, before fillers are introduced, when measured at room temperature, 25° C., is in the range of approximately 1,200 centipoises (cps) to approximately 60,000 centipoises (cps), and preferably in a narrower range of 10,000 to 60,000 centipoises (cps.)
[0165] The preferred pot life, measured at room temperature is at least approximately 30 minutes.
[0166] Fillers used in the process preferably can contain a mixture of low and high aspect ratio particles, acicular shaped particles, and plate like particles.
[0167] Fillers preferably made of the same epoxy material that comprises the barrier coating were used. Other materials may also be used include: glass flakes, glass fibers, epoxy fibers, mica, clay, silica, cork and plastics. The particle size and distribution of the fillers were noted as follows in Table 3
[0000]
TABLE 3
US Sieve Size
Inches
Millimeters
Microns
#8
trace
.0937
2.38
2380
#10
trace
.0787
2.00
2000
#12
.6%
.0661
1.68
1680
#16
21.6%
.0469
1.19
1190
#20
41.2%
.0331
.841
841
#30
21.6%
.0234
.595
595
#40
6.0%
.0165
.420
420
[0168] Table 3 shows the approximate breakdown of the size and % content of the size of fillers contained in the filler mix. For example, about 41.2% of the filler passed through a #20 size sieve or were approximately 0.841 millimeters in size. Only a trace amount of fillers passed through #8 sieve and were larger in size i.e. 2.38 millimeters, when compared to the size of the filler particles that passed through a #20 size sieve. The composition of mix of the various sizes of fillers were found to provide a wide range of opportunity for the fillers to fill the holes or cracks of various sizes that can be found in the piping system, up to approximately 125 mils in size.
[0169] Table 4 lists the amounts of epoxy needed for different length pipes and different diameter pipes.
[0000]
TABLE 4
UNFILLED EPOXY QUANTITY expressed in Milliliters
Pipe Dimension
Length (ft)
½″
¾″
1″
1¼″
1½″
2″
5
100
100
100
100
100
200
10
100
100
200
200
200
300
15
100
200
200
300
300
400
20
200
200
300
300
400
500
25
200
300
400
400
500
600
30
200
300
400
500
600
700
[0170] Referring to Table 5, a five foot length of piping having a ½ inch inside diameter would use approximately 100 milliliters of the novel unfilled epoxy.
[0171] A 30 foot long section of piping having an inside diameter of approximately 2 inches would use approximately 700 milliliters of the novel unfilled epoxy.
[0000]
TABLE 5
Viscosity of
RATIO of Filler to
Mixed EPOXY (cps)
Mixed Epoxy by Volume
1,200-5,000 cps
at least approximately 25% filler
5,001-10,000 cps
at least approximately 20% filler
10,001-15,000 cps
at least approximately 15% filler
15,001-25,000 cps
at least approximately 10% filler
25,001-60,000 cps
at least approximately 5% filler
[0172] Table 5 lists the viscosity ranges in centipoises, and the amount of filler that is mixed into the unfilled epoxy. For example, an epoxy having a viscosity of approximately 1200 to 5000 cps would have at least approximately 25% fillers.
[0173] An epoxy having a viscosity of approximately 25,001 to approximately 60,000 cps would have at least approximately 5% fillers.
[0174] Differences in viscosity were noted and primarily related to diameter and length of pipe. It was found that a lower viscose epoxy i.e. 1,200 cps to 5,000 cps provided the operator the ability to coat and seal leaks over a longer distance in a small diameter pipe. For example, a pipe of ½ inch or less in diameter over 100 feet in length. A more viscose epoxy say in the range of 25,001 cps to 60,000 cps provided the operator the ability to coat and seal leaks in larger diameter pipes say for example 2″ and greater in diameter and to seal small leaks without out same quantity of fillers as required with a lower viscose epoxy.
[0175] Although the novel invention can be applied to all types of metal pipes such as but not limited to copper pipes, steel pipes, galvanized pipes, and cast iron pipes, the invention can be applied to pipes made of other materials such as but not limited to plastics, PVC (polyvinyl chloride), composite materials, polybutidylene, and the like. Additionally, small cracks and holes in plastic type and metal pipes can also be fixed in place by the barrier coating leak sealant.
[0176] Although the preferred applications for the invention are described with building piping systems, the invention can have other applications such as but not limited to include piping systems for swimming pools, underground pipes, in-slab piping systems, piping under driveways, various liquid transmission lines, tubes contained in heating and cooling units, tubing in radiators, radiant in floor heaters, chillers and heat exchange units, and the like.
[0177] While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Methods and systems for cleaning, coating and sealing leaks in existing pipes, in a single operation. A piping system can be cleaned in one pass by dry particulates forced and pulled by air throughout the piping system by a generator and a vacuum. Pipes can be protected from water corrosion, erosion and electrolysis, extending the life of pipes such as copper, steel, lead, brass, cast iron piping and composite materials. Coatings can be applied to pipes having diameters up to approximately 6″. Leak sealants of at least approximately 4 mils thick can cover insides of pipes, and can include novel mixtures of fillers and epoxy materials, and viscosity levels. A positive pressure can be maintained within the pipes during applications. Piping systems can be returned to service within approximately 96 hours. | 5 |
This claims the benefit of U.S. Provisional Patent Application Serial No. 60/214,338, filed Jun. 27, 2000 and hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates generally to poured concrete wall forms and, more particularly, to connecting hardware for panels coupled together and used to construct the concrete wall form.
It is well known in the art to use prefabricated reusable panels to construct a wall form for a poured concrete wall. Typically, two spaced opposed parallel sets of forms are erected in order to pour concrete therebetween and form a wall. Each form is constructed of a number of adjacent interconnected panels. Tie rods are used to maintain the spacing between the opposed forms constructed of the panels.
Typically, each panel has a marginal frame projecting rearwardly from a back face of the panel to include a flange along the spaced side edges of the panel. The flanges are adapted to be positioned in an abutting relationship with the flange of an adjacent panel to construct the concrete wall form. Holes in the flanges of the adjacent panels can be aligned to receive there through the shank of a pin or a bolt. The pin or bolt may pass through the ends of the ties and commonly are held in position by wedges which are driven through a slot in the shank of the pin or bolt. As the wedges are driven into the slot, the abutting flanges of the adjacent panels are drawn together. The pins and wedges offer a simple mechanism for effectively coupling the panels together.
After the concrete has been poured and the wall has set, the pins and wedges are removed from the panels during the dismantling of the wall form by dislodging the wedges from the slots and sliding the pins from the holes to release the adjacent panels.
In the construction of a concrete wall form, a large quantity of hardware is necessary to connect the adjacent panels together. Typically, the workers performing the construction of the wall form carry a large bucket of the pins and wedges with them to join the adjacent panels together. During such operations, the loss of the attachment hardware is appreciable, especially during inclement weather as it is difficult for a worker wearing gloves to handle the pins and wedges. Furthermore, the wall forms are commonly constructed in excavated areas, such as ditches and trenches, for a poured concrete wall in a residential basement or below ground floor of a commercial building. The workers commonly move around on scaffolding when constructing the concrete wall forms. As such, the work space for constructing a wall form and for the workers to maneuver and manipulate the associated hardware is extremely tight and limited. Therefore, the installation of the pins and wedges is even more difficult and retrieval of any lost hardware is very problematic. As such, the cost of labor and materials has increased accordingly due to these problems.
One prior art solution aimed at some of these problems has been to permanently connect at least some of the hardware to the panels. Each panel has numerous sets of such devices. Problems frequently arise because one or more sets of the hardware permanently affixed to the panels breaks or requires repair thereby taking that particular panel out of service until it is repaired. Furthermore, the addition of the attachment hardware commonly adds significant weight to each panel thereby placing a greater burden on the workers for transporting, installing and manipulating the panels in constructing and disassembling the wall form.
Moreover, a particular contractor may have an inventory of panels which are not compatible with the panels having permanently affixed hardware thereby requiring the contractor to entirely discard the current supply of panels and associated hardware in favor of the panels having a specific attachment hardware design. While such systems may minimize the occurrence of lost pins and/or wedges, they include other drawbacks. Very often, specialized tooling is required for the installation, repair and/or use of known attached systems thereby minimizing the universal application and use of such systems.
When the concrete is poured between the spaced forms and assembled panels, the hydrostatic forces generated by the poured concrete tend to spread the opposed forms apart, but these outward or spreading forces are held in check by the form tie rods. In addition, the concrete expands as it sets creating greater spreading forces on the panels. The pin joining the adjacent panels together is subject to significant pulling forces by the tie rod and an opposed force by the frame or rail on the panel. These forces can make removing the pins from the panels and the tie rods very difficult often requiring a number of repeated blows from a sturdy sledge hammer or the like to dislodge the pin and/or wedge from the panels. The hammering can damage known attachment hardware and/or mushroom the point of the pin causing interference with its operation. The workers frequently damage or destroy the pins during disassembly of a form which significantly shortens the life of the attached hardware and associated panel.
Another problem common with attached hardware is that liquid from the poured concrete frequently splashes onto the rear sides of the forms and the associated hardware. When the concrete spills or splashes onto the attachment hardware, it naturally sticks to the attachment hardware as it sets up and makes disengaging the pin and wedge more difficult. The spilled concrete also fouls the associated hardware thereby minimizing its usefulness.
Therefore, there is a need for attachment hardware for concrete wall form panels that is durable, easy to engage between the adjacent form panels, easy to remove after the concrete has set, that is easily and conveniently installed and disassembled by the workers in the field and does not significantly increase the weight of the panel and is compatible with standard pin and wedge systems.
SUMMARY OF THE INVENTION
These and other objectives of the invention have been attained by a system for releasably coupling adjacent panels to construct a wall form for a poured concrete wall. The system includes a pin assembly which can be selectively attached to a mount on each of the walls near the holes in the marginal frame of the panels.
The system, according to a presently preferred embodiment of this invention, includes a pin which is movably mounted to one of the panels approximate each hole. The pin is movable between an engaged position in which the pin projects through each of the aligned holes in the adjacent panels, a stowed position in which the pin is withdrawn from each of the holes and a retracted position in which the pin is spaced from the frame to provide access for the standard pin and wedge attachment hardware when the pin of this system is not in use. The pin has a stem and a shank which are threadably coupled together as a two piece unit. The stem has an enlarged head on one end thereof and the shank has a slot which extends there through transverse to the longitudinal axis of the pin and a tapered region which is adapted to project through the holes in the frames of the panels. The tapered region on the pin is longer than known pin designs to assist in the removal of the pin from the tie rod during disassembly of the wall forms.
The pin assembly includes the two-piece pin and a carrier. The pin is housed within a throughbore of the carrier. The throughbore is in a casing of the carrier which is situated between a generally rectangular or oval lower slide and an upwardly projecting impact mast. The bore in the casing has an enlarged seat which is adapted to receive the head of the stem of the pin when the pin is housed in the casing with the shank projecting forwardly from the carrier. In one embodiment, the pin is free to rotate relative to the carrier in the bore of the casing. The upwardly projecting impact mast provides access for a worker to strike the carrier with a hammer to dislodge the pin from the tie rods and holes in the panels when disassembling the concrete wall forms.
The mount in one embodiment includes a base and a retainer. The slide of the carrier is captured between spaced channel side walls in a channel of the retainer for sliding the carrier and pin in the channel relative to the retainer. The bottom surface of the slide has a well and the confronting surface of the channel has a pair of detents. Each detent is biased to project from the bottom surface of the channel. The detents and the well cooperate to retain the carrier and the pin in the stowed and engaged positions, respectively, as the carrier and pin slide relative to the retainer. The retainer also has four extensions each of which project from a corner of the retainer and have an aperture there through.
The retainer is selectively mounted to the base which is welded or otherwise secured to the back face of each of the panels proximate the hole in the frame of the panel. The base has four notches which are adapted to retain a head of a fastener which projects through one of the apertures in the retainer to selectively bolt or secure the retainer to the base. The system also includes a standard wedge which is inserted into the slot of the pin when the pin is in the engaged position and projecting through the aligned holes in the adjacent panels.
In another embodiment specifically designed for use on steel ply wall forms, the mount includes the retainer and a pair of spaced preferably steel mount bars. The retainer is mounted by studs or other mechanical fasteners to the mount bars.
As a result of the system according to this invention, a simple and cost effective attachment mechanism to overcome the problems of previously known attachment hardware for poured concrete wall panel forms is provided. Specifically, the pin is selectively attached to the panel and is movable with the carrier between the stowed and engaged positions so that the likelihood of dropped and lost pins during the assembly and disassembly of the wall forms is eliminated. Furthermore, the system is robust and can readily withstand impact blows on the impact mast to dislodge the pin from the engaged position when the wall form panels are being disassembled. Moreover, impact directly on the tip of the pin will also result in dislodging the pin and sliding the pin and carrier from the engaged position toward the stowed position. Due to the configuration of the tapered region of the pin in one embodiment, removal of the pin from the tie rod and holes in the adjacent panels is significantly easier and more convenient. Further, if the pin is damaged, it can be easily replaced by unscrewing the shank from the stem and replacing the specific parts as required without costly service or extensive down time.
The pin and carrier can be moved to the retracted position thereby providing access to the aligned holes of the adjacent panels so a standard pin and wedge or other attachment hardware mechanism may be used without interference from the invention of this system. Moreover, the entire carrier, pin and retainer can be selectively attached or removed from the base or mount bars for use as desired by the poured wall contractor. Moreover, this system can be readily provided as original equipment with the base plate welded or secured to the panels and the carrier, retainer and pin selectively attached thereto. Likewise, the panels can be retrofit to include the base or mount bars and selectively secured components of the system for use as required. The operational interaction between the carrier and the retainer will not be fowled by splashed or spilled concrete because the components of the system which interact with one another are concealed or captured. Furthermore, the slide and carrier are preferably non-metallic, more preferably nylon, so that concrete which splashes onto the hardware does not adhere to it.
BRIEF DESCRIPTION OF THE DRAWINGS
The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a plan view of a concrete wall form panel according to one embodiment of this invention with a number of base plates of the attached pin system mounted thereto;
FIG. 2 is an exploded perspective view of components of the attached pin system for poured concrete wall panels according to one embodiment of this invention;
FIG. 3 is a perspective view of the system mounted to a panel which is being joined to an adjacent panel;
FIGS. 4A-4C are cross-sectional side views of the attachment hardware system according to a presently preferred embodiment of this invention in various configurations;
FIG. 5 is an exploded perspective view of an alternative embodiment of the pin and retainer of this invention;
FIGS. 6A and 6B are sequential cross-sectional views of adjacent panels being disassembled and the disengagement of the tie rod from the pin assembly;
FIG. 7 is a perspective view of a pair of adjacent panels coupled together by a standard pin and wedge system and the attached pin system of this invention in a retracted position;
FIGS. 8A-8C are top plan views of an alternative embodiment of this invention in engaged, stowed and retracted positions, respectively;
FIG. 9 is a cross-sectional view taken along line 9 — 9 of the embodiment of FIG. 8A;
FIG. 10 is a perspective view of a shank of a pin according to the embodiment of FIGS. 8A-9;
FIG. 11 is a top plan view of a further alternative embodiment of this invention; and
FIG. 12 is a back elevational view of the embodiment of FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a presently preferred embodiment of an attachment system 10 for a poured concrete wall form panel 12 is shown. The attachment system 10 includes a pin assembly in which a pin 14 is comprised of two pieces including a generally cylindrical stem 16 having an enlarged disk-shaped head 18 on one end and threads 20 on an opposite end. A second portion of the pin 14 is a shank 22 which has a slot 24 extending transversely through the longitudinal axis of the shank and a tip 26 on one end. Opposite of the tip 26 is a threaded hole 28 in which to threadably receive the threads 20 on the stem 16 for coupling the stem 16 and the shank 22 of the pin 14 together.
Referring to FIG. 3, the shank 22 of the pin 14 is sized for insertion through a hole 30 in a flange 32 of the panel 12 used for constructing a concrete wall form. The hole 30 in the flange 32 is aligned with a similarly configured hole 30 a in a flange 32 a of an adjacent panel 12 a. The flange 32 a may include a bushing 34 seated in the hole 30 a and the diameter of the bushing 34 permits movement of the shank 22 of the pin 14 there through. One embodiment of a concrete wall form panel 12 , 12 a which is compatible with this invention is disclosed in U.S. patent application Ser. No. 09/232,414 filed Jan. 15, 1999, which is hereby incorporated by reference in its entirety.
As is well known in the art, a tie rod 35 having a hole 37 proximate an end thereof extends between the adjacent panels 12 , 12 a of the concrete wall form to maintain the spacing between the opposed panels (not shown) forming a cooperating wall form (not shown). The flanges 32 , 32 a may include a notch or cut-out 36 sized and configured to accommodate the tie rod 35 seated in the notch 36 so that the flanges 32 , 32 a of the adjacent panels 12 , 12 a can be juxtaposed in face-to-face abutting relationship.
A wedge 38 according to a presently preferred embodiment of this invention is well known in the art and includes a generally planar piece of steel or other appropriate metal which is dimensioned to fit within the slot 24 in the shank 22 of the pin 14 . The wedge 38 has a tapered configuration so that a narrow end 40 of the wedge 38 passes into and through the slot 24 and a broad end 42 of the wedge 38 is wider than the slot 24 and is thereby prevented from passing through the slot 24 . Wedges, as disclosed in U.S. Pat. No. 5,904,875, assigned to the assignee of this invention and hereby incorporated by reference, could be utilized with this invention.
When the adjacent panels 12 , 12 a are positioned with the respective holes 30 , 30 a in the flanges 32 , 32 a being generally aligned, the pin 14 is projected through the hole 30 in the panel 12 to which the attachment hardware system 10 is mounted in an engaged position as shown in FIG. 4 A. The hole 37 of the tie rod 35 may then be slipped onto the shank 22 of the pin 14 and then the shank 22 inserted into the hole 30 a in the opposite flange 32 a at which time the narrow end 40 of the wedge 38 is inserted into the slot 24 and hammered or forced into place thereby drawing the panels 12 , 12 a together and releasably coupling and binding them together forming a concrete wall form.
The shank 22 of the pin 14 preferably includes an extended length tapered region 23 (see FIGS. 6 A and 6 B). In one embodiment, the shank 22 is about 2.446 inches long and the tapered region 23 includes a first portion 25 proximate the head 18 and about 0.985 inches long (L 2 ) and forming an angle of about 91.056° with respect to the plane of the head 18 . The tapered region 23 includes a second portion 27 adjacent the first portion 25 extending about 1.064 inches in length (L 3 ) and forming an angle of about 93.242° with respect to the plane of the head 18 . The advantages of the tapered region 23 are detailed herein below.
The pin 14 is housed in a throughbore 44 of a carrier 46 , as shown particularly in FIG. 2 . The throughbore 44 is in a casing 48 of the carrier 46 which is situated between a lower slide 50 and an upwardly projecting impact mast 52 . Although the slide 50 is shown in a generally rectangular shape, it may preferably have an oval cross-sectional configuration. Preferably, the impact mast 52 , casing 48 and slide 50 are cast or integrally formed together to provide a more robust and sturdy carrier 46 .
The bore 44 in the casing 48 has an enlarged seat 54 in which the head 18 of the stem 16 of the pin 14 is received. The stem 16 is inserted into the throughbore 44 and ultimately threaded into the hole 28 in the shank 22 of the 14 pin to thereby assemble the two-piece pin 14 with the carrier 46 . Preferably, the head 18 of the pin 14 is concealed within the casing 48 to prevent concrete or other debris from fowling interaction between the pin 14 and the carrier 46 . In one embodiment as shown in FIGS. 1-4C, the pin 14 is free to rotate relative to the carrier 46 within the bore 44 for convenient alignment of the slot 24 in the shank 22 of the pin 14 and access for insertion and removal of the wedge 38 . Alternatively, as shown in FIG. 5, the seat 54 in the throughbore 44 of the carrier 46 may include a notch 56 into which a lug 58 on the stem 16 is inserted to orient the pin 14 relative to the carrier 46 and thereby prevent rotation.
The impact mast 52 of the carrier 46 includes three faces; namely, forward and rear sloped faces 60 , 62 which are on opposite sides of a top face 64 . The forward and rear sloped faces 60 , 62 provide impact surfaces for a hammer or other tool utilized by a worker to dislodge the pin 14 from the adjacent panel 12 a. The sloped faces 60 , 62 also offer a convenient location for manipulating the carrier 46 and pin 14 to and between the engaged position as shown in FIG. 4A, a stowed position as shown in FIG. 4B and a retracted position as shown in FIG. 4 C. The configuration of the impact mast 52 and sloped faces 60 , 62 , 64 provides convenient access to a worker for striking the impact mast 52 with clearance relative to the flange 32 of the panel 12 when the pin 14 is in the engaged position. It should be readily understood that an alternate design or configuration for the impact mast 52 may be provided within the scope of this invention.
As shown particularly in FIG. 2, the slide 50 of the carrier is inserted between a pair of spaced channel sidewalls 66 forming a channel 68 in a retainer 70 . Each channel sidewall 66 has an inwardly turned lip 72 which captures the slide 50 for movement in the channel 68 to and between the engaged, stowed and retracted positions of the carrier 46 . A bottom surface 74 of the slide 50 has a generally oval-shaped well 76 formed therein.
As shown particularly in FIGS. 2 and 4 A- 4 C, a bottom wall 82 of the channel 68 has a stowed detent 84 and an engaged detent 86 formed therein. Each detent 84 , 86 includes a tab 78 cantilevered from the bottom wall 82 with a U-shaped slot 80 in the bottom wall 82 surrounding three sides of the tab 78 . A boss 79 is formed on the distal end of each tab 78 and is sized and configured to be seated within the well 76 in the bottom surface 74 of the slide 50 . The detents 84 , 86 cooperate with the well 76 to retain the carrier 46 and the pin 14 in the stowed and engaged positions, respectively, as the carrier 46 and pin 14 slide relative to the retainer 70 . Each boss 79 is biased upwardly to engage the well 76 when positioned appropriately. The detents 84 , 86 can be manually disengaged from the well 76 by moving the carrier 46 and pin 14 in the retainer 70 . Although not shown in FIG. 4C, a detent may also be provided in the channel 68 to retain the pin 14 and carrier 46 in the retracted position. It should be readily understood that alternate designs or configurations for the detents 84 , 86 could be provided within the scope of this invention.
A stop 88 is provided at a back edge of the channel to join the channel sidewalls 66 together and prevent the carrier 46 from sliding rearwardly out of the retainer 70 . The retainer 70 also includes four extensions 90 each of which project from a corner of the retainer 70 and have an aperture 92 there through. A downwardly directed lip 94 is also provided along the front edge of the retainer 70 .
Preferably, the retainer 70 and carrier 46 are molded or otherwise formed from Zytel® (ST801BK010) a nylon resin commercially available from Dupont (www.dupont.com). The pin 14 is preferably 4140 fully hardened alloy steel which, in combination with the preferred nylon resin of the carrier 46 and retainer 70 , provide a robust and durable system 10 capable of withstanding the frequent and high impact blows commonly required during installation and disassembly of the wall forms. Moreover, concrete splashed onto the retainer 70 and carrier 46 will not adhere to these components avoiding the need to frequently scrape or remove hardened concrete which often results in damage to the components.
The retainer 70 is selectively mounted or secured to a base 96 which is welded or otherwise secured to the back face of the panel 12 near one of the holes 30 as shown in FIG. 1 . The retainer 70 and base 96 provide a mount for the pin assembly. The base 96 has four notches 98 which are adapted to retain a head 100 of a fastener 102 such as a bolt or the like. The fastener 102 projects through one of the apertures 92 in the retainer 40 and is secured by a nut 104 . The head 100 of each fastener 102 is inserted into the open mouth 106 of the respective notch 98 in a direction generally parallel to the plane of the base 96 as shown in FIG. 2 . The base 96 includes two generally parallel channels 108 on the bottom surface thereof. The two aligned notches 98 proximate the top of the base as shown in FIG. 2 are joined together by one of the channels 108 and the two lower notches 98 are likewise joined by the other channel 108 . The heads 100 of the fasteners 102 are recessed in the channels 108 relative to the bottom of the base 96 .
In this way, the bases 96 can be provided on the panel 12 with the retainer 70 , carrier 46 and pin 16 being selectively mounted to each of the bases 96 on the panel 12 as required. Alternatively, the panels 12 may be retrofit to have the bases 96 added thereto by welding or similar mounting techniques and the retainer 70 , carrier 46 and pin 14 can then be selectively mounted to the base 96 as required.
Referring to FIGS. 6A and 6B, the advantageous feature of the extended tapered region 23 of the pin assembly according to this invention will now be described. The marginal flange 32 , 32 a of each of the adjacent panels 12 , 12 a typically has a length represented by L 1 as shown in FIG. 6 A. The extended tapered region 23 of the pin 14 has the first portion 25 adjacent the head 18 having a length represented by L 2 and the second portion 27 having a length represented by L 3 . When the panels 12 , 12 a are assembled together with the wedge 38 inserted in the slot 24 of the pin 14 as shown in FIG. 6A, the tie rod 35 is positioned on the pin 14 in the first portion 25 . After the concrete has been poured and cured, significant stresses and forces are experienced by the pin 14 and tie rod 35 . Disassembly of the panels 12 , 12 a and removal of the pin 14 from the flanges 32 , 32 a and the tie rod 35 from the pin 14 requires the user to overcome these forces and dislodge the pin 14 from the marginal flange 32 , 32 a and the tie rod 35 from the pin 14 . Currently, during disassembly of the forms as the adjacent panels 12 , 12 a are separated from one another, a tapered portion 29 of a standard pin 31 (see FIG. 7) is concealed within the flange 32 a of the adjacent panel 12 a and the tip 33 of the pin 31 is likewise concealed within the hole 30 a of the adjacent flange 32 a. Therefore, the tie rod 35 remains seated on the generally cylindrical shaft 39 of the standard pin 31 and it is difficult for an operator to dislodge the pin 31 from the tie rod 35 because of the stresses. Further, the user does not have access to the tip 33 of the pin 31 to strike it with a hammer and dislodge it from the tie rod 35 because the tip 33 of the pin 31 is concealed within the flange 32 a.
The extended tapered region 23 of the pin 14 of this invention advantageously promotes the disassembly of the pin 14 from the tie rod 35 . Specifically, as shown in FIG. 6B, when the marginal flanges 32 , 32 a of the adjacent panels 12 , 12 a are separated, the tie rod 35 is positioned in the extended tapered region 23 of the pin 14 and most likely on the second portion 27 thereof. In this configuration, separation of the tie rod 35 from the pin 14 is promoted because the tie rod 35 will naturally slide or eject the pin 14 because of the stresses promoting the translation of the tie rod 35 on the tapered region 23 of the pin 14 toward the tip 26 . Moreover, the tip 26 of the pin 14 is exposed or accessible for a tool or hammer to impact the pin 14 and further promote the disengagement of the tie rod 35 from the pin assembly.
Referring to FIG. 7, one advantage of the system 10 according to this invention is the capability of moving the pin assembly from the engaged or stowed positions (FIGS. 4A and 4B, respectively) to the retracted position (FIGS. 4 C and 7 ). When in the retracted position, ample clearance is available for access to the holes 30 , 30 a for use of the standard pin 31 and wedge 38 to couple the panels 12 , 12 a together as an alternate latching mechanism. Specifically, the standard pin 31 is inserted into the hole 30 a and projects through the hole 30 in an opposite direction to the pin 14 . As such, the pin 14 in the retracted position remains conveniently mounted to the panel 12 for subsequent use while the alternate latching mechanism is utilized as desired. While the retracted position as shown in FIGS. 4C and 7 is linearly aligned with respect to the hole 30 and the stowed and engaged positions, it could be oriented off-axis, non-linearly or otherwise within the scope of this invention.
Referring to FIGS. 8A through 10, an alternative presently preferred embodiment of an attachment system 110 for a poured concrete wall form panel is shown. Specifically, this embodiment is designed for use on steel ply wall forms of the type disclosed in U.S. Pat. Nos. 3,204,918; 3,362,676; and 5,265,836, each of which are incorporated by reference herein. As is well known in the art, so called steel ply wall form panels typically include a perimeter steel frame with flanges and a plywood panel inserted therein.
The attachment system 110 includes a pin assembly in which a pin 114 is comprised of two pieces including a generally cylindrical stem 116 having an enlarged disk-shaped head 118 on one end and threads 120 on an opposite end. A second portion of the pin 114 includes a generally planar shank 122 which has a slot 124 extending transversely through the longitudinal axis of the shank 122 and a tip 126 on one end. A hole 127 is included in the shank 126 between the slot 124 and the tip 126 as is well know for inclusion on pins for use with steel ply wall forms. Opposite of the tip 126 is a barrel 129 with a threaded axial hole 128 in which to threadably receive the threads 120 on the stem 116 for coupling the stem 116 and the shank 122 of the pin 114 together. A generally circular disk 130 is included between the shank 122 and the barrel 129 . A pair of lobes 132 are diametrically spaced on the barrel 129 and project from one face of the disk 130 .
The pin 114 is housed in a throughbore 144 of a carrier 146 , as shown particularly in FIG. 9 . The throughbore 144 is in a casing 148 of the carrier 146 which is situated between a lower slide 150 and an upwardly projecting impact mast 152 . The slide 150 is preferably oval in a cross-sectional configuration. Preferably, the impact mast 152 , casing 148 and slide 150 are cast or integrally formed together to provide a more robust and sturdy carrier 146 .
The bore 144 in the casing 148 has an enlarged seat 154 in which the head 118 of the stem 116 of the pin 114 is received. The stem 116 is inserted into the throughbore 144 and ultimately threaded into the hole 128 in the shank 122 of the 114 pin to thereby assemble the two-piece pin 114 with the carrier 146 . Preferably, the head 118 of the pin 114 is concealed within the casing 148 to prevent concrete or other debris from fowling interaction between the pin 114 and the carrier 146 . In the embodiment as shown in FIGS. 8A-10, the pin 114 is inhibited from rotation relative to the carrier 146 within the bore 144 . The seat 154 in the throughbore 144 of the carrier 146 includes a pair of notches 156 into which the lobes 132 projecting from the disk 130 are inserted to orient the pin 114 relative to the carrier 146 and thereby prevent rotation.
The impact mast 152 of the carrier 146 is similar to the embodiment shown in FIGS. 2-5 in that it includes three faces; namely, forward and rear sloped faces 160 , 162 which are on opposite sides of a top face 164 . Additionally, the carrier 146 and pin 114 are translated to and between the engaged position as shown in FIG. 8A, a stowed position as shown in FIG. 8B and a retracted position as shown in FIG. 8 C.
As shown particularly in FIGS. 8A through 9, the slide 150 of the carrier 146 is inserted between a pair of spaced channel sidewalls 166 forming a channel 168 in a retainer 170 . Each channel sidewall 166 has an inwardly turned lip 172 which captures the slide 150 for movement in the channel 168 to and between the engaged, stowed and retracted positions of the carrier 146 . A bottom surface 174 of the slide 150 has a generally oval-shaped well 176 formed therein. A bottom wall 182 of the channel 168 has a stowed detent 184 and an engaged detent 186 formed therein. Each detent 184 , 186 includes a tab 178 cantilevered from the bottom wall 182 with a U-shaped slot 180 in the bottom wall 182 surrounding three sides of the tab 178 . A boss 179 is formed on the distal end of each tab 178 and is sized and configured to be seated within the well 176 in the bottom surface 174 of the slide 150 . The detents 184 , 186 cooperate with the well 176 to retain the carrier 146 and the pin 114 in the stowed and engaged positions. It should be readily understood that alternate designs or configurations for the detents 84 , 86 could be provided within the scope of this invention. Preferably, the retainer 170 and carrier 146 are molded or otherwise formed from Zytel® (ST801 BK010) a nylon resin commercially available from Dupont (www.dupont.com).
A stop 188 is provided at a back edge of the channel 168 to join the channel sidewalls 166 together and prevent the carrier 146 from sliding rearwardly out of the retainer 170 . The retainer 170 also includes four extensions 190 each of which project from a corner of the retainer 170 and have an aperture 192 there through. A downwardly directed lip (not shown) is also provided along the front edge of the retainer 170 .
The retainer 170 is selectively mounted or secured to a base which includes a pair of spaced generally parallel, preferably steel mount bars 196 which are welded or otherwise secured to the frame and/or back face of the steel ply wall form panel near one of the holes in the flange. The retainer 170 and mount bars 196 provide a mount for the pin assembly. Mounting studs 198 or other appropriate mechanical fasteners are inserted into the apertures 192 to secure the retainer 170 to the mount bars 196 as shown in FIG. 8 A. The mount bars 196 are preferably permanently mounted to the steel ply wall form panel and the retainer 170 may be removably or permanently mounted to the mount bars 196 .
A further alternative embodiment of this invention is shown in FIGS. 11-12. This embodiment is similar to that of FIGS. 8A-10 with the exception that the retainer 270 is modified so that two of the extensions 290 a on one side of the retainer 270 are oriented perpendicularly relative to the remaining two extensions 290 of the retainer 270 . This configuration of the retainer 270 is particularly useful for installation adjacent to a flange (not shown in FIGS. 11-12) of the steel ply wall form panel. The mounting studs, screws or other fastener 198 in the perpendicularly oriented extensions 290 a are fastened to the flange while the fasteners 198 in the other extensions 290 are fastened to the mount bars 196 or back face of the panel.
From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof. | A sliding pin is selectively mounted to the back of a poured concrete wall form panel for use in combination with a standard wedge for coupling adjacent panels of the concrete wall form together. The pin when attached to the panel conveniently slides relative to the panel to and between engaged, stowed and retracted positions. Furthermore, the pin is captured within a carrier and is rotatable for convenient access to the slot in the shank of the pin. The components of the system are durable to withstand impact blows by a hammer or other tool, do not require specialized hardware for their use and will not be fouled by splashed concrete or other debris. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This is a Continuation-in-part application of the joint inventors' application Ser. No. 519,578 filed Aug. 2, 1983 and now abandoned.
FIELD AND BACKGROUND OF THE INVENTION
This invention concerns a process and a machine for the production of a package made up of threads assembled by multidirectional weaving i.e. deposit of thread about a network of rods; and susceptible to serve as a framework in the manufacture of a body made of composite material.
Such frameworks are utilized, after impregnation with a suitable binder and subsequent hardening of the binder, for the purpose of obtaining components capable of withstanding very high mechanical and thermal stresses, for example, those used for the structural components of satellites, re-entry bodies, or rotor hubs for rotary winged aircraft.
A manual process is already known from U.S. Pat. No. 4,218,276 (AVCO), for creating three-dimensional structures, consisting of upwardly pointed vertical and parallel needles, held apart by two reeds arranged at right angles. Over the needle points a layer of fabric is then placed, and against it is pressed a plate equipped with holes corresponding to the needles, the points of which penetrate the fabric which is pressed downwardly by the plate. This operation is repeated by rotating the reeds until the required stack thickness is obtained, after which the stack is removed from the machine. Then, filamentary reinforcements are introduced into the holes made in the stack so as to form a three-dimensional structure. In order to put this process into operation, it is therefore necessary to have available layers of fabric manufactured in advance and trimmed to the dimensions required for each specific product. Moreover, while this U.S. patent proposes the creation of so-called three-dimensional structures in which rigid components such as metallic needles are arranged vertically, it can be seen that such structures cannot be obtained by the simultaneous deposit of threads on those needles. Instead, bonded layers are formed first, after which they are stacked up and then penetrated by the needles.
Likewise known, from U.S. Pat. No. 4,183,232, to the present applicant, is a three-dimensional weaving machine for the production of hollow, rotating woven frames. Into a network of rods, held parallel to the generating lines of the body to be created by means of gratings, there are introduced and woven on a fixed plane, on the one hand, circumferential threads by unwinding in concentric circles parallel threads, and on the other, radial threads by knitting by means of a needle, of a thread in the form of a chain. In this process, the rods can be metal pins which, at the end of the weaving, are removed and replaced, through a lacing arrangement, by threads which provide longitudinal filling.
The process known from U.S. Pat. No. 3,955,602 makes it possible to create pieces of simple geometric shape, such as, essentially, parallelepiped blocks in which the threads deposited on a single plane emerge on either side of a network of vertical pins with an overlap, requiring, on this account, the use of a thread locking device. U.S. Pat. Nos. 3,955,602; 4,183,232 and 4,218,276 discussed above are incorporated here by reference.
In general, the processes according to the prior art require specific tooling for the piece to be made to the extent that the weaving is linked to the separation or pitch of the vertical pins. Consequently, they do not permit rapid and economical changes in the woven pieces.
Moreover, most of the known processes for the creation of woven pieces of three dimensions require the installation of a substantial number of thread bobbins, and consequently, the manipulation of same in order to pass from one piece to another.
Finally, the essential problem to be resolved in the weaving of structures of the type considered lies in the fact that the threads to be introduced in a network of pins or rods must be deposited in such a way that no residual tension will be retained in them.
In fact, the accumulated tensions would finally deform the network and prevent continued production, by shutting down the respective machine, for example. This problem is usually resolved, either empirically, through the skill of the operator, or by the use of pin-holding equipment with introduction of the threads under tension and threading each thread into a needle.
SUMMARY OF THE INVENTION
The present invention makes it possible to remedy the disadvantages of the processes and equipment of the prior art. Its objective is a process which consists, in an initial phase of production, of creating a network of rigid rods, parallel but not joined together, of depositing at one end of said stationary network a single thread following a twisting route zigzagging between the terminal portions of the rods, with the thread forming successive layers superimposed on each other on planes transverse to the direction of the rods, of compressing these layers of thread as they are formed, this compression being accompanied by a sliding of said layers along the rods, and if necessary, of the subsequent replacement of the rods by means of threads in a final lacing phase.
The compression with sliding of the layers of thread along rods is accomplished preferably by the intermittent application of pressure on each new layer completed, the overall assembly of superimposed layers being held at its base by a supporting surface which moves away in a continuous motion from the thread-deposit area in order to make room for the new layers of thread to be deposited.
It is desirable that the thread be deposited without tension in the network of rods, and to this purpose it is delivered by mechanical thrust, on demand, in a direction generally parallel to the direction of the rods.
The thread can be deposited in windings oriented in the layers, superimposed alternately, first in one direction and then in another, crossing the first, for example, perpendicular to it (in this case, these two directions form a trirectangular trihedron with the direction of the rods).
Thus, the process according to the invention makes it possible to perform the weaving in three dimensions of shaped pieces of complex design and any dimensions, by the deposit in the free spaces of the rods which define one direction of the piece to be produced, and with a thread following any direction at right angles to the preceding one, This thread comes from a single bobbin and it is reeled mechanically from above the rods (which are assumed to be arranged vertically), at the level of the top of the rods and parallel to their long direction. When a layer of thread is deposited, it is compressed at the same time that the component intended to hold the piece during the course of production is shifted in order to permit the deposit of the next layer. When the directions perpendicular to the rods have been materialized by the thread according to this method of thread deposition or weaving, these rods are removed in the course of a terminal operation called lacing, and they are replaced by a thread, preferably according to the process described in U.S. Pat. No. 4,393,669, to the present applicant. U.S. Pat. No. 4,393,669 is also incorporated here by reference.
Likewise, rods formed from a material remaining in the piece can also be used, examples of these being pulp-extruded rods, and therefore, in this case, it is evident that the lacing operation is not applicable. In this case the rods remain as part of the thread package.
By virtue of this process, it is possible to change at will, in each layer, the direction of the thread deposited at the top of the rods, in accordance with the stresses to which the woven piece or package is likely to be subjected. This is not the case in the known processes, in which, in general, the precise direction of the thread is dictated by the methods of operation of the process used.
In addition, the process according to the invention, makes it possible to eliminate any system for stopping the threads introduced perpendicularly into the network of rods, and this leads, therefore, to the construction of a very simple machine.
Finally, the arrangement provides for a single bobbin which facilitates monitoring of the reeling out of the thread. In the prior art, it is generally necessary to provide several bobbins in order to feed the needles which make it possible to introduce the threads into a given layer, these bobbins being equipped with devices for reeling the thread and for applying tension, and even for braking movement of the thread, in order to cause a given quantity of thread to arrive at each one of the bobbins for the creation of a layer, and without tension, so as not to deform the network of rigid pins or rods. The process according to the invention makes it possible to avoid these requirements.
The invention also concerns a machine which makes it possible to use the previously-described process. This machine comprises, arranged on top of each other in a stationary housing, an assembly of three horizontal frames, which do not rotate but are independently movable vertically, among which, the intermediate frame has a set of horizontal plates provided with orderly perforations of regular design and intended to receive rigid rods of equal length which are thus held in a regular vertical network. The upper frame is equipped, by means of a displacement mechanism in accordance with two horizontal crossing directions, which are preferably perpendicular, with a shuttle which is thus movable in any direction on a horizontal plane, located slightly above the top of the network or rods, and capable of depositing on the top of same a thread which follows a winding path. The lower frame is equipped with a horizontal stopping plate, not perforated, subjacent to the network of rods. It is understood that the machine just described will meet the requirements if the rods are made from material remaining in the piece, such as paste-extruded materials, for example. In this case, the initial operation of weaving or thread deposition is the only operation necessary in order to obtain a three-dimensional weave. This same machine will likewise meet the requirements in cases in which--after the weaving has been performed on rods which are to be replaced by threads--it might be desired, for reasons of convenience of production, for example, to carry out the final operation of lacing at a different work station. But it might be useful for the same machine to perform the final phase of lacing, as well. In this case, it is advisable that the machine be equipped with a lacing device, in addition in order to make it possible to replace the rods with threads, after the initial thread deposition or weaving is completed. This lacing accessory consists, preferably, of an upper device to actuate a lacing needle, and a lower device for introduction of the lacing thread, these devices being installed in the respective mechanisms of displacement in two crossing horizontal directions, mounted, respectively, on the upper frame and on the intermediate frame.
Advantageously, the machine's shuttle includes means for pulling and pushing the thread, capable of ensuring the delivery of the thread without tension, and consisting of two rollers between which the thread is held, and one of which is put into rotation by a motor. These rollers, push the thread, after it is deposited, into a vertical thread-guide.
In addition, the machine is preferably equipped with a perforated horizontal plate, capable of descending over the network of rods, so that the rod ends then penetrate these perforations, thus compressing the layers of woven thread in said network. This perforated plate can be installed on the upper frame, above the shuttle, which is moved away from the rods from time to time in order to permit said perforated plate to descend onto the layers of deposited thread.
Below the network of rods, the stopping plate can consist of a disk driven in rotation around its vertical axle, and comprising a vibrating bar which ensures, by sweeping under all the rods in turn, the longitudinal position of the rods at a constant average height, despite the frictional downward pull they are subjected to by the thread package in the course of production.
It is desirable to combine with the machine according to the invention, a numerical control device to pilot and synchronize, according to a pre-established program, all of the operations of its movable parts, especially those of its shuttle, which define the configuration of the winding paths for deposit of the thread which form the successive layers of the package.
BRIEF DESCRIPTION OF THE DRAWINGS
The description which follows, with reference to the attached drawings by way of example and without limitation thereto, makes it possible to understand clearly how this invention can be put into practice.
FIG. 1 represents, schematically, in vertical section, a multidimensional thread depositing machine according to the invention. The left side shows the thread depositing phase and the right half shows the lacing phase;
FIG. 2 represents, in perspective, a top view of the network of rods and of the thread package being produced therein, in addition to the shuttle and its displacement mechanism;
FIG. 3 shows, on a larger scale, detail III of FIG. 1;
FIG. 4 is a sectional view taken along line IV--IV of FIG. 3;
FIG. 5 shows schematically a sectional view taken along line V--V of FIG. 4, showing at the same time the lower perforated plate which supports the thread package in the course of production, and the upper perforated plate, lowered in position in order to compress the package; and
FIG. 6 shows schematically and in exploded perspective, the lower part of the machine, and more particularly the vibrating device used in the thread depositing phase.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, no importance should be attributed to the fact that the number of rods of the network varies from one figure to the other. It is done this way for the simple reason of convenience of representation and understanding. In practice, the number and the arrangement of the rods are selected in accordance with the conformation and dimensions of each thread package to be produced.
The machine represented in FIG. 1 comprises a housing 1, in which are installed, between its base 1a and its roof 1b, several stationary vertical threaded pins 2 (at least three), along which three horizontal frames, 3,4, and 5 can move. To this end, each one of these frames is provided with its own motor (not shown) in order to drive in rotation, by means of a chain 6, nuts engaged on the aforesaid threaded pins (only one of these nuts 6a of the single frame 4 has been shown, with the corresponding portion of chain 6). Each frame can thus be moved, at will, either upwardly or downwardly under the control of that motor.
In other words, each frame 3, 4 and 5 has its own chain 6 which is movable by a motor. Each frame 3, 4 and 5 also has its own set of nuts 6a, each threaded onto one of the threaded rods 2, and each rotatable by movement of the chain 6. When the motor is driven to move the chain, each of the nuts 6a of the respective frame rotates to raise or lower that frame. Since the chain for each plate is rotatable independently of the chain for any other plate, the frames are movable independently of each other.
The upper frame 3 is equipped with a perforated plate 7, and by means of a displacement mechanism 8 providing crossing movement, a shuttle 9 which performs the deposit of a thread 10 in a network 14 of rigid metal rods 11, held vertically in a regular distribution by perforated plate 12 and 13 (the number of plates 13 depends on the height of the piece to be produced), carried by intermediate frame 4. The perforations of plates 7, 12 and 13 are arranged according to gridlines (straight, as shown in this illustration, or oblique), in such a way that rods 11 of network 14 which crosses them causes the appearance among them of channels which cross each other at a certain angle, in this case a right angle, into which the thread 10 is deposited by shuttle 9, according to alternating perpendicular changes of direction. The lower most perforated plate 13 is attached to lower frame 5 by means of clamps 51.
Mechanism 8 which causes the displacements of shuttle 9 comprises a horizontal guide bar 15, along which the shuttle can move, actuated by a motor 16 through the medium of a transmission belt located inside the guide bar 15 (FIG. 2). The guide bar 15 is itself movable in a perpendicular horizontal direction, and its ends roll along guide rails 17,18 attached to upper frame 3, under the action of transmission belts 19,20 driven by a motor 21, likewise secured to frame 3. Shuttle 9 can thus move in two perpendicular horizontal directions 22 and 23, and therefore it can be moved successively to any point on the horizontal plane limited by rails 17,18.
Shuttle 9 (FIG. 3) consists of a carriage 24, which slides along guide bar 15 and is equipped with a small step motor 25 and two rollers 26 and 27 between which the thread 10 is clamped. Roller 26 is driven in rotation by motor 25, while roller 27 is mounted for idle rotation. By command of motor 25, thread 10 is pushed more or less rapidly into vertical thread-guide tube 28, attached to plate 42 of carriage 24, and passing between the upper ends of rods 11 of the network 14, in order to deposit the thread on top of the network in accordance with the winding path selected.
In order to make a thread package of specific shape on the machine described, rods 11 are first of all engaged through perforated plates 12,13 in order to arrange them in a regular network 14 offering the shape desired (in this case, it is a cylindrical shape of circular or polygonal section). Since frame 3 is placed at such a height that the thread-guide tube 28 of shuttle 9 will penetrate into the upper part of network 14 (FIG. 3), the shuttle is moved by its mechanism 8 along a winding course the turns of which are oriented in accordance with one of the directions of the orthogonal channels of network 14, parallel to the directions of displacement 22,23 of shuttle 9. At the same time, the shuttle's motor 25 is put in operation, so that thread 10, coming out of bobbin 29, is deposited on the top of the network or rods in accordance with that winding path between the upper ends of the latter (FIG. 4). Deposit of the thread without tension is accomplished by means of a speed of output of the thread from the shuttle, synchronized with the speed of displacement of said shuttle.
When a layer C of thread has been deposited, the next layer C is deposited in superimposition on top of it, in accordance with the other direction 22 or 23. Upon the completion of each layer, shuttle 9 is caused to move to one side, and the downward displacement of frame 3 is ordered so as to cause the perforated plate 7 (FIG. 5) to come down onto network 14, for the purpose of compressing the mass 30 made up of all of the layers C produced. In order to ensure easy penetration of rods 11 into the perforations 31 of plate 7, the ends of the rods are ground to a point and the perforation openings are flared, as shown. In a parallel manner, frame 4 is caused to descend from a distance approximately equal to the thickness of one layer, so that mass 30 will descend gradually, held by perforated plate 12 attached to frame 4 and compressed by perforated plate 7, attached to frame 3. After each operation of compression, in which perforated plate 7 always descends to the same level, it is caused to rise again (by the upward movement of frame 3), up to a likewise fixed level, sufficient to make room for shuttle 9 between said perforated plate and the ends of rods 11, so it can return to that space in order to effect the deposit of a new layer of thread after having reabsorbed the space required by its movement to one side prior to the compression.
It will be recalled that the frames 3 and 4 each have their own drive chain 6 and threaded nuts 6a for effecting upward and downward movement of each frame. It should also be understood that the rods 11 can slide with respect to the perforated plates 12,13. This sliding, however, is impeded by the fact that the rods have thread 10 wrapped around them. Friction between the rods and the threads tend to make the rods move along with the woven mass 30. A relative movement between the rods and the woven mass 30 is effected using a mechanism connected to the lower frame 5 as will be discussed below. It should also be remembered that the left hand side of FIG. 1 shows the mechanism during a weaving stage when the woven mass 30 is being formed while the right half shows a lacing stage.
The rods are linked by friction to the mass 30 as noted above, and they are therefore pulled downward at the time of the descent of frame 4. In order to compensate for this effect, under the network of rods there is provided and carried by frame 5 (of adjustable height), a disc 32, driven in rotation under the effect of a motor gear reducer 46, through the medium of a chain 48 and a toothed gear 50, equipped with a vibrating bar 33 (FIG. 6), seated in the disc 32 by a pair of vertical-action vibrators 44 (one shown) which are connected under disc 32. The rotation of the rotating assembly 32, 33 and 44, allows bar 33 to sweep under all the rods in the set of rods which it strikes successively and causes them to rise, thus cancelling the descent caused by the descent of frame 4. Therefore, rods 11 retain a constant overlap with respect to the last layer deposited, thus permitting the deposit of the next layer under the the same conditions as the preceding layer. At the end of the thread laying operation, frame 4 is located near frame 5, and perforated plates 13, suspended by chains 34 attached to frame 4, have consequently become juxtaposed.
The mass 30 is then completed and can be transferred, as applicable, either to a binder impregnation station, or to another machine or work station in order to carry out the terminal phase of lacing (if used). But the machine covered by the invention can also carry out this terminal phase in order to produce the three-dimensional mass 30a. To this end, the machine is equipped with a lacing accessory 35 (already described in the applicant's U.S. Pat. No. 4,393,669 incorporated here by reference) consisting of an upper device 35a (FIGS. 2 and 3 of U.S. Pat. No. 4,393,669 and an upper device 35b (FIG. 7 of the same patent). These devices are shown together in the right-hand portion of FIG. 1 of the present application. The upper device 35a is installed on frame 3 through the medium of a displacement mechanism 36a providing for two orthogonal directions, similar to mechanism 8 of shuttle 9. The same is true for lower device 35b, the displacement mechanism 36b of which is mounted on frame 4. These lacing assemblies are removable.
In the lacing phase, frame 4 which carries the woven piece by means of its perforated plate 12 (the lift called for in the weaving phase having been eliminated) is raised to a height to allow a sufficient space below for the descent of rods 11a, displaced by woven mass 30. The frame is lifted correspondingly to a position in which its perforated plate 7 rests on the top of woven mass 30. According to the assertions of the already cited U.S. Pat. No. 4,393,669, the upper device 35a causes a long needle 41 to descend successively plumb with each rod 11, so as to remove it and cause it to fall to 11a under frame 4, onto disc 32 (while it remains held by perforated plates 13, now reassembled and held at the top of columns 38). At each descent, the aforesaid needle threads lower into device 35b a thread 39 coming from a bobbin 40 and pulls it in a loop through woven mass 30 in replacement of the rod it has just forced out, thus transforming mass 30 into a three-dimensional mass 30a. Naturally, the displacement mechanisms 36a and 36b are controlled correspondingly in the same way so that the lacing devices 35a and 35b will constantly be opposite each other and will successively be plumb with each rod of network 14.
Control of the various movable components of the machine, especially displacement mechanisms 8, 36a and 36b (equipped with step motors), is effected in synchronization, in each phase of operation, by means of a numerical control device of a classic programmable type well known to technicians and not forming a part of the present invention, into which there is introduced a program corresponding to the characteristics of structure, shape and dimensions of the thread package or woven piece to be produced.
It is understood that, through the choice of this program, it is possible to obtain the deposit of the thread by shuttle 9 in each layer, in accordance with any desired winding path among rods 11 of the network.
Moreover, these rods can be arranged in a transverse section of any shape and geometric disposition. It is also possible to obtain pieces of any shape, solid or hollow, or even deformable if the path for deposit of the thread is selected to that end in each transverse layer.
This numerical control is a standard numerical control designed to control milling machines and capable of operating three shafts simultaneously, and of controlling the output (all or nothing) which might be required in the program for production of the package. Such a control is commercially available for milling machines and can be used for the present invention.
The lower frame is movable only by manual control of the operator accomplished by pressing a respective button (not shown) on the numerical control unit.
All of the functions involved in the deposit of the thread, i.e.,:
rotation of the plate 32 which supports the vibrating bar 33, and start-up of the vibrator;
descent of the intermediate frame 4 by the thickness of one layer;
descent of the upper frame 3 in order to compress the layers of thread deposited;
lifting up of the upper frame 3; and
simultaneous rotation of the three step motors, i.e., the two shuttle displacement motors and the motor which thrusts the thread;
are the result of instructions from the program which defines a thread package and the re-entry into numerical control.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | The invention concerns the production of three-dimensional thread packages. Vertical rods (11) are maintained in a stationary arranged network by engagement through perforated plates (12,13). A thread (10) is deposited from above this network by a shuttle (9) in a sinuous path between upper end portions of the rods (11). The layers of thread thus formed in succession, supported by the perforated plate (12) which undergoes a descending movement, are compacted by a perforated plate (7) which is lowered upon the finishing of each layer. A lacing arrangement (35) replaces the rods (11) by threads after the thread laying phase. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from and is a continuation of U.S. patent application Ser. No. 13/966,991 filed on Aug. 14, 2013, which application is a continuation of and claimed priority from U.S. patent application Ser. No. 13/743,860 filed on Jan. 17, 2013, which application was a continuation of and claimed priority from U.S. patent application Ser. No. 13/542,073 filed on Jul. 5, 2012, which application claimed priority from and was a continuation of U.S. patent application Ser. No. 13/030,990 filed on Feb. 18, 2011 (now U.S. Pat. No. 8,291,648), which application claimed priority from provisional U.S. Pat. App. No. 61/305,746 filed on Feb. 18, 2010, all of which applications are incorporated by reference herein in their entireties.
FIELD OF INVENTION
The present invention relates to methods and apparatuses for providing a portable structure to any type of terrain. More specifically, the invention provides a rapid response emergency multi-purpose unit for providing shelter and services to difficult terrain.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
No federal funds were used to develop or create the invention disclosed and described in the patent application.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
Not Applicable
AUTHORIZATION PURSUANT TO 37 C.F.R. §1.171 (d)
A portion of the disclosure of this patent document contains material which is subject to copyright and trademark protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever.
BACKGROUND
Many times it is difficult or impossible to provide the appropriate medical care or other services to remote areas and/or areas having difficult terrain, such as mountains, jungles, and the like. The uneven terrain causes difficulty in erecting any sort of covered structure. The difficult terrain also prevents land vehicles from reaching those areas. Accordingly, an apparatus that is transportable and provides some shelter to remote areas during times of emergency is needed.
SUMMARY OF THE INVENTION
The portable structure will be well suited for many applications that may include but not limited to a triage hospital, decontamination facility, radiation free sanctuary, temporary housing or billeting, relief station, command center during a disaster, morgue, repair facility, communications center, forward observation facility, rescue and recovery facility, and staging area.
The portable structure may be insulated, and may be transported to any disaster area and in a matter of minutes. It may provide a full array of services for any natural disaster, terrorist attack, or other necessities. The portable structure may be fully operational within minutes, providing an insulated, clean, lighted, heated or cooled environment, which may be fully equipped, allowing the staff to perform on-site activities immediately. Depending on the size specified, this portable structure may be fully functional with ninety minutes.
It is an object of the portable structure to provide a rapid response emergency multi-purpose unit that may be towed to a site or deployed from the air.
It is another object of the portable structure to provide a portable structure that may be leveled on any type of uneven terrain.
All elements that will provide the physical equipments and services for an entire portable structure will be contained in a mobile transport container pod that may be transported by ground, sea or air.
The pod will be constructed with appropriate material and design such that the pod, once deployed and the equipment correctly positioned, will be become the nucleus of the entire portable structure.
The pod will be constructed in a manner that the components for the portable structure will be off-loaded and erected in a logical and predetermined manner and method.
The virgin pod is weather and water proof, and hermetically sealed to minimize contamination, damage, or pilferage to the critical elements contained in the pod during storage and deployment.
The pod will vary in size, shape, dimensions, and weight based on the special-ordered equipment and services requested by the client(s). The pod may have portable or retractable axle/wheel/tire assemblies allowing the pod, when the axle wheel/tire assemblies are deployed, to be transported on land.
The pod may be loaded and secured on a ship in a manner similar to the manner in which cargo containers are loaded on to container ships.
The pod may be loaded into cargo aircraft.
The pod may be airlifted by helicopter or other suitable means.
The pod, when deployed to a disaster location, may be placed on the ground whether the ground is level or uneven, hilly or flat, or is covered with snow or other liabilities.
Other objects of the portable structure will become apparent to those skilled in the art in light of the present disclosure.
BRIEF DESCRIPTION OF THE FIGURES
In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limited of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.
FIG. 1 provides a perspective view of the pod with the slide outs extended and the pod leveling screws deployed.
FIG. 2A provides a cutaway view of one embodiment of a leveling screw, leveling screw block, and leveling screw pad engaged with one another.
FIG. 2B provides a perspective view of the embodiment of the leveling screw pad shown in FIG. 2A .
FIG. 2C provides a perspective view of one embodiment of a pod with two leveling screws fully retracted.
FIG. 2D provides a perspective view of one embodiment of a pod with two leveling screws partially extended.
FIG. 3 provides a perspective view of the pod without the slide outs extended, wherein the pod base is expanded for use on soft terrain.
FIG. 4 provides a perspective view of one embodiment of the interior portion of one slide out.
FIG. 5 provides a top view of one embodiment of the pod before the slide outs have been extended showing the relative dimensions of some elements thereof.
FIG. 6 provides an top view of one embodiment of the pod after the slide outs have been extended showing the relative dimensions of some elements thereof.
FIG. 7 provides a cutaway side view of one embodiment of the pod showing the relative dimensions and arrangement of some elements thereof.
FIG. 8A provides a top view of a first arrangement of the generator and HVAC components within the pod.
FIG. 8B provides a top view of a second arrangement of the generator and HVAC components within the pod.
FIG. 9A provides a top view of one arrangement of the generator and HVAC components within the pod.
FIG. 9B provides a cutaway side view of the arrangement of the generator and HVAC components shown in FIG. 9A .
FIG. 9C provides an external side view of the pod have exterior access panels.
FIG. 10 provides a top view of the pod with the catwalk extended.
FIG. 11 provides an end view of the pod with the catwalk extended.
FIG. 12 provides a top view of the pod with the catwalk extended and shows two ground rails in relation thereto.
FIG. 13 is an end view of one embodiment of a vertical rail roller of a vertical rail section engaged with a ground rail.
FIG. 14 is a perspective view of an embodiment of a ground rail having an extended base for use with soft material.
FIG. 15A provides a perspective view of one embodiment of a ground rail engaged with a ground rail support.
FIG. 15B provides an end view of one embodiment of a ground rail engaged with a ground rail support.
FIG. 16 provides a perspective view of one embodiment of a sleeve connector and a pin.
FIG. 17A provides a side view of a sleeve connector engaged with two vertical rail sections using two pins.
FIG. 17B provides a perspective view of a sleeve connector and vertical rail section prior to engagement there between.
FIG. 18 provides a perspective view of two fully constructed uprights engaged with two ground rails and affixed to one another via a plurality of cross members.
FIG. 19 is a detailed view of one embodiment for attaching the cross member to the upright.
FIG. 20 is an end view of one embodiment of the suit frame having a plurality of horizontal and vertical cables.
FIG. 21 is a side view of one embodiment of an outside floor support.
FIG. 22 is a side view of one embodiment of an inside floor support.
FIG. 23 is an end view of one embodiment of an outside floor support showing the floor support sleeve and clamp.
FIG. 24 is a perspective view of one embodiment of an outside floor support showing the floor support sleeve and clamp as removed from one another.
FIG. 25 is a perspective view of one embodiment of an outside floor support with the floor support sleeve and claim engaged with one another.
FIG. 26 is a top view of one embodiment of a floor grid showing outside and inside floor supports.
FIG. 27 is a perspective view of one embodiment of a suite frame having a center floor member affixed to the vertical cables 28 b.
FIG. 28 is a perspective view of one embodiment of an equalizer that may be used to adjust the position of the floor supports.
FIG. 29 is a side view of a plurality of equalizers installed between vertical rail sections adjacent inside and outside floor supports.
FIG. 30 is a side view of one embodiment of the suite frame erected on uneven terrain.
FIG. 31 is a side view of one embodiment of the suit frame erected and attached to a pod.
FIG. 32 is a simplified depiction of one embodiment for the control panel for the portable structure.
FIG. 33 is a perspective view of one embodiment of the vertical cable and treatment area supports.
FIG. 34A is an end view of one embodiment of the suite showing one arrangement for treatment areas along the center vertical cables.
FIG. 34B is a top view of one embodiment of the suite showing one arrangement for treatment areas along the center vertical cables.
FIG. 34C is a top view of one embodiment of the floor plan of the suite showing one arrangement for treatment areas within the suite.
FIG. 35 is a side view of one embodiment of HVAC ductwork that may be used within the suite.
FIG. 36 is a side view of one embodiment of the arrangement of HVAC ductwork within the portable unit.
FIG. 37 is a top view of one embodiment of the arrangement of HVAC ductwork within the portable unit.
FIG. 38 is a top view of one embodiment of the arrangement of the lighting fixtures within the suite.
FIG. 39 is a side view of one embodiment of the arrangement of the various control centers, control panel, and generators for the portable unit.
FIG. 40A is a perspective view of the mesh covering that may be placed over the suite frame in certain embodiments.
FIG. 40B is a top view of the mesh covering that may be placed over the suite frame in certain embodiments.
FIG. 41 is a perspective view of one embodiment of one section of the cocoon material that may be placed over the mesh covering.
FIG. 42 is a top view of an embodiment of the suite having two access doors and two suite canopies.
FIG. 43 is an end view of one embodiment of a suite access door and suite canopy.
FIG. 44 is a perspective view of an embodiment of a cocoon canopy section.
FIG. 45 is an end view of one embodiment of a suite access door and suite canopy.
DETAILED DESCRIPTION -
LISTING OF ELEMENTS
ELEMENT DESCRIPTION
ELEMENT #
Generator
2
HVAC
4
Control panel
6
Breaker panel
7
Exterior access panel
8
Water control center
9
Portable structure
10
Pod
12
Slide out
13
Leveling screw
14
Leveling screw block
14a
Leveling screw pad
14b
Leveling screw retainer
15
Side port
15a
Bottom port
15b
Pod base
16
Pod access door
17
Shelving
18
Catwalk
19
Ladder
19a
Suite frame
20
Ground rail
21
Ground rail support
21a
Support pad
21b
Vertical rail section
22
Vertical rail roller
22a
Arch support
23
Upright
24
Fixture
24a
Fixture aperture
24b
Cross member
25
Tab
25a
Sleeve connector
26
Pin
26a
Aperture
26b
Outside floor support
27a
Inside floor support
27b
Center floor member
27c
Horizontal cable
28a
Vertical cable
28b
Floor support sleeve
29a
Floor support clamp
29b
Floor support platform
29c
Floor support arm
29d
Equalizer
29e
Suite
30
Treatment Area Support
31
Treatment Area
32
Light Source
33
Electrical Conduit
34
Electrical Outlet
35
HVAC Ductwork
36
Mesh Covering
38
Cocoon Section
40
Suite Access Door
42
Suite Canopy
44
Cocoon Canopy Section
46
Floor Sheet
48
DETAILED DESCRIPTION
1. Description of Illustrative Embodiment
Before the various embodiments of the present invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements 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 of being carried out in various ways. Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “front”, “back”, “up”, “down”, “top”, “bottom”, and the like) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as “first”. “second”, and “third” are used herein and in the appended claims for purposes of description and are not intended to indicate or imply relative importance or significance.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, FIG. 1 illustrates a first embodiment of a pod 12 having two slide outs 13 , which are shown in the extended position in FIG. 1 . The dimensions of the pod 12 and slide outs 13 will vary depending on the specific embodiment of the portable structure 10 , and therefore do not limit the scope of the portable structure 10 as disclosed and claimed herein. In one embodiment of the portable structure 10 shown in FIGS. 5 and 6 , the slide outs 13 are approximately three feet wide and the pod 12 is eight feet wide. Accordingly, when the slide outs 13 are extended the overall width of the pod 12 is 14 feet. It is contemplated that the entire length of the pod 12 may be from twelve to forty five feet. However, the portable structure 10 is in no way limited by any dimensions of the pod 12 , and the preceding are for illustrative purposes only.
Each corner of the pod 12 may be equipped with a pod leveling screw 14 having a leveling screw pad 14 b attached to one end thereof as shown in FIGS. 2A , 2 C, and 2 D. A laser level (not shown) and computer (not shown) in communication with a rotational power source (not shown) may be used to continually adjust the leveling screws 14 so that the pod 12 remains level through any settling that may occur upon deployment. The size of the leveling screw pads 14 b will vary depending on the rigidity of the surface on which the pod 12 is placed. A portion of the leveling screw 14 may be engaged with the leveling screw block 14 a , and the leveling screw block 14 a may be securely engaged with the pod 12 . A leveling screw retainer 15 may be placed at each bottom corner of the pod 12 and secured thereto. The leveling screw retainer 15 may be formed with a side port 15 a for inspecting the leveling screw 14 and/or leveling screw pad 14 b . The leveling screw retainer 15 may also formed with a bottom port 15 b through which the leveling screw pad 14 b may pass when deployed.
The pod leveling screws allow users to vary the distance between the pod 12 and the leveling screw pad 14 b , which rests upon the surface on which the pod 12 is deployed. In this manner, the user may level the pod 12 and extremely uneven terrain. Pod leveling screws 14 may also be positioned out the outer corners of the slide outs 13 for additional structural support. Other arrangements of leveling screws 14 , leveling screw pads 14 b , and/or leveling screw retainers 15 exists, and any structure and/or method that allows a user to adequately level the pod 12 may be used without limitation.
All the components of the portable structure 10 may be configured to fit within the pod 12 . Accordingly, the pod 12 may be delivered to the site at which it is needed, and the portable structure 10 may them be deployed from the materials contained within the pod 12 , which is described in detail below. In assembling the portable structure 10 , the pod 12 is first placed in the area in which services are needed and then the pod 12 is leveled. It is contemplated the pod 12 will most typically be of the dimensions and weight such that a helicopter may deliver the pod 12 to the area in which it is needed. Alternatively, the pod 12 may be configured as a trailer to a land vehicle.
An embodiment of a pod 12 having an expanded pod base 16 is shown in the embodiment in FIG. 3 . This embodiment would be especially useful on surfaces that are extremely soft or if the rigidity of the surface is unknown. Alternatively, the size of the leveling screw pads 14 b could be increased to reduce the pressure they exert on the surface on which the pod 12 is deployed.
The precise layout, equipment, and equipment placement within the portable structure 10 will vary from one embodiment to the next. In the embodiment shown in FIG. 4 , shelving 18 may be positioned on the interior surface of one of the slide outs 13 . As shown in FIG. 7 , a portion at one end of the pod 12 may be designated for positioning some of the working elements of the portable structure 10 , such as a generator 2 , control panel 6 , and other mechanical and/or electrical systems or controls. For convenience, a pod access door 17 may be positioned adjacent the area designated for working elements, as shown in FIGS. 5-7 . Top views of two alternative arrangements of a generator 2 and HVAC 4 layout is shown in FIGS. 8A and 8B . As is apparent to those skilled in the art, HVAC ductwork 36 spans the distance from the HVAC 4 to other areas of the portable structure 10 requiring heating and/or cooling.
In certain embodiments, it may be beneficial for the pod 12 to be equipped with exterior access panels 8 for some of the mechanical and/or utility machinery. As shown in FIGS. 9A-9C , these panels may be placed adjacent the HVAC 4 , control panel 6 , and or the generators 2 . The precise dimensions of the pod 12 and slide outs 13 vary, and the configuration of the HVAC 4 , generators 2 , control panel 6 , and/or exterior access panels 8 may vary without departing from the spirit and scope of the portable structure 10 .
After the pod 12 is positioned and leveled, the catwalk 19 may be extended. Although not shown in the figures herein, it is contemplated that many applications of the portable structure 10 will include a plurality of cables attached to various portions of the catwalk 19 to increase the robustness and stability thereof. The catwalk 19 runs perpendicular to the longest side of the pod 12 in the embodiment shown in FIGS. 10 and 11 and is positioned on the end of the pod 12 opposite the generator 2 , HVAC 4 , and/or other mechanical and electrical controls. A ladder 19 a may also be positioned adjacent the catwalk 19 for access to the upper exterior of the portable structure 10 as shown in FIG. 31 . Typically, the length of the catwalk 19 is equal to the width of the suite frame 20 , which is described in detail below.
To begin construction of the suit frame 20 , ground rails 21 may extend from the pod 12 spaced from one another by an amount equal to the length of the catwalk 19 , as shown in FIG. 12 . The distal ends of the ground rails 21 may be affixed to one another by a cross brace (not shown) to add strength to the suite frame 20 . The ground rails 21 will be positioned below the cat walk 19 and may form the foundation for additional elements of the suite 30 . If the terrain is uneven, ground rail supports 21 a may be used to ensure each ground rail 21 will not be dislodged from the desired position. The ground rail supports 21 a (as shown in FIGS. 15A and 15B ) may be adjustable for height and may have ground pads 21 b of varying size depending on the rigidity of the surface on which the ground rail supports 21 a are placed. The ground rails 21 and/or ground rail supports 21 a (if so equipped) support the suite 30 , and therefore must be constructed of a suitably robust material, such as steel, iron, metal alloys, polymer materials, or any other suitable material known to those skilled in the art.
Two embodiments of ground rails 21 are shown in FIGS. 13 and 14 . The embodiment in FIG. 13 is shown engaged with a vertical rail roller 22 a , which is described in detail below. The embodiment of a ground rail 21 shown in FIG. 14 includes an enlarged base section to reduce the pressure the ground rail 21 places on the area in which it is deployed. This embodiment of a ground rail may be especially useful when the ground rails 21 are placed adjacent a soft surface, such as snow or mud.
After the ground rails 21 are placed, a laser level (not shown) and computer (not shown) may be used to determine the elevation at various points along the ground rails 21 that would yield a surface that is level and substantially the same elevation as the floor of the pod 12 . Alternatively, the ground rail supports 21 a may be adjusted such that each ground rail 21 is level and at a constant elevation with respect to a reference point on the pod 12 . It is contemplated that such elevation will be slightly less than that of the floor of the pod 12 . Once these values are determined, the first upright 24 , which will be the upright 24 that is furthest from the pod 12 , is constructed. The upright 24 generally forms a U-shape, as shown in FIG. 18 . Together with the ground rails 21 , the uprights 24 may comprise the suite frame 20 . Two uprights 24 attached to one another through a plurality of cross members 25 are shown in FIG. 18 . A more detailed view of how each cross member 25 may be affixed to a vertical rail section 22 is shown in FIG. 19 . However, other connection structures and/or methods may be used other than those shown without departing from the spirit and scope of the portable structure 10 .
Each upright 24 may be comprised of at least two vertical rail sections 22 having a vertical rail roller 22 a at the lower end thereof. As shown in FIG. 13 , the vertical rail roller 22 a may engage the ground rail 21 in such a manner that once the upright 24 is constructed, it may be motivated along the ground rail 21 through the interface between the ground rail 21 and the vertical rail roller 22 a . A number of vertical rail sections 22 make up each side of an upright 24 , and each side may be connected to one another through an arch support 23 , which forms the curved portion of the upright 24 . The arch supports 23 may be flexible, rigid, or semi-rigid, depending on the specific application of the portable structure 10 . In the event that the ground rails 21 are not first leveled, a computer (not shown) and laser level (not shown) may be used to measure and compute the quantity and length of vertical rail sections 22 to use for each upright 24 to ensure a level floor surface.
Adjacent vertical rail sections 22 of one upright 24 may be joined to one another through the sleeve connector 26 and a plurality of pins 26 a in the first embodiment, which is best shown in FIGS. 16-17B . Two adjacent vertical rail sections 22 are shown engaged with one sleeve connector 26 in FIG. 17A , and one vertical rail section 22 positioned adjacent a sleeve connector 26 prior to insertion of a pin 26 a is shown in FIG. 17B . A sleeve connector 26 may be placed over the adjacent ends of two vertical rail sections 22 on one side of an upright 24 . Corresponding apertures 26 b in the sleeve connector 26 (best shown in FIG. 16 ) and vertical rail sections 22 are oriented so that a first pin 26 a may pass through the sleeve connector 26 and the top vertical rail section 22 and a second pin 26 a may pass through the sleeve connector 26 and the bottom vertical rail section 22 .
Because of the design of the vertical rail rollers 22 a and the ground rails 21 , during the construction of the suite frame 20 as each upright 24 is assembled according to the proper dimensions, that upright 24 is moved away from the pod 12 to make room adjacent the pod 12 for assembly of the next upright 24 . Accordingly, the upright 24 furthest from the pod 12 is the first upright 24 assembled, and the upright 24 adjacent the pod 12 is the final upright 24 assembled.
The horizontal space between adjacent uprights 24 may vary from one embodiment of the portable structure 10 to the next and therefore in no way limits the scope of the portable structure 10 . Each upright 24 may be separated from the next upright 24 by equal amounts throughout the entire suite frame 20 , or the distances between adjacent uprights 24 may vary. The distance between adjacent uprights 24 is determined by the dimensions of the cross members 25 used, one embodiment of which is shown in detail in FIG. 19 . This embodiment of cross members 25 uses tabs formed in the cross member 25 and corresponding fixtures 24 a affixed to the upright 24 having fixture apertures 24 b formed therein. As previously mentioned, FIG. 19 represents but one of an infinite number of ways that the cross members 25 may be secured to the uprights 24 , and is therefore in no way limiting to the scope of the portable structure 10 .
In one embodiment of the portable structure 10 each upright 24 will be separated from the next by six feet, and the position of each vertical rail roller 22 a with respect to the ground rail 21 will be fixed by at least one set screw (not shown) for each vertical rail roller 22 a . The first upright 24 that is constructed (i.e., the upright 24 furthest from the pod 12 ) may have mesh covering 38 and/or a cocoon section 40 , described in detail below, over the end thereof to seal that end of the suite 30 from the environment. The last upright 24 that is constructed (i.e., the upright 24 closest to the pod 12 ) may have a special mesh covering 38 and/or cocoon section 40 that correspond with the pod 12 in such a manner as to create a smooth transition between the suite 30 and the pod 12 , as well as ensuring that both the pod 12 and the suite 30 are sealed and protected from the external environment of the portable structure 10 .
In the embodiment shown in FIG. 20 , a plurality of vertical cables 28 b and horizontal cables 28 a may be used to strengthen the suite frame 20 . The precise position of each horizontal and vertical cable 28 a , 28 b may vary from one embodiment of the portable structure 10 to the next, and is therefore in no way limiting. Horizontal cables 28 a connect each end of the arch support 23 in each upright 24 in the embodiment shown in FIG. 20 . Additional horizontal cables 28 a connect corresponding vertical rail sections 22 for added support. Vertical cables 28 b may be affixed to the arch support 23 and extend to the floor level or beyond, depending on the specific application of the portable structure 10 .
As will be apparent to those skilled in the art, a leveling operating floor in the suite frame 20 may be ensured through one of two methods. In the first method, the ground rails 21 are leveled with respect to the pod 12 by adjusting the height of the ground rail supports 21 a . In the second method, the number of vertical rails sections 22 on any given upright 24 is adjusted to compensate for changes in terrain on which the ground rails 21 rest.
As each upright 24 is constructed a mesh covering 38 may be positioned over each upright 24 . One embodiment of what the mesh covering 38 may comprise is shown in FIGS. 41A and 41B . The mesh covering 38 in FIG. 41A is shown in the shape of an upright 24 , while the mesh covering 38 in FIG. 41B is shown in a planar orientation. The material from which the mesh covering 38 is constructed is preferably light weight, such as a plastic or polymer, but any material known to those skilled in the art may be used without limitation.
Outside floor supports 27 a , one embodiment of which is shown engaged with a vertical rail 22 in FIG. 21 , may be affixed to vertical rail sections 22 so that the outside floor support 27 a extends inward from the vertical rail section 22 . The position of the outside floor support 27 a on the vertical rail section 22 may be determined by the laser level (not shown) and computer (not shown) to ensure that all outside floor supports 27 a form a level plane. Each outside floor support 27 a may include a floor support sleeve 29 a , at least one floor support platform 29 c , at least one floor support arm 29 d , and at least one floor support clamp 29 b.
The floor support arm 29 d may be rigidly affixed at one end thereof to the floor support platform 29 c and rigidly affixed at the opposite end thereof to the floor support clamp 29 b . The floor support clamp 29 b may be pivotally engaged with the floor support sleeve 29 a , as indicated by the arrangement shown in FIGS. 23 and 25 . One embodiment of the floor support sleeve 29 a and floor support clamp 29 b are shown separated from one another for clarity in FIG. 24 . Accordingly, the outside floor supports 27 a may be configured so that as more force is placed downward onto the floor support platform 29 c , the floor support clamp 29 b is pressed against the vertical rail section 22 with increasing force. That is, as the floor support platform 29 c experiences downward force, the floor support arm 29 d experiences a downward force, which in turn causes the floor support clamp 29 b to pivot inward toward the vertical rail section 22 with increasing force. Other embodiments for the outside floor supports 27 a exist but are not pictured herein, and any structure known to those skilled in the art that will cause the floor support clamp 29 b to place greater force on the vertical rail section 22 as more weight is placed on the floor support platform 29 c may be used without limitation. Furthermore, any structure and/or method that will securely affix an outside floor support 27 a to a vertical rail section 22 may be used with the portable structure 10 without limitation, including but not limited to set screws (not shown), welds, chemical adhesion, and/or combinations thereof.
A side view of one embodiment of an inside floor support 27 b is shown affixed to a vertical cable 28 b in FIG. 22 . The inside floor support 27 b may be affixed to the vertical cable 28 b in the same manner as the outside floor support 27 a is affixed to a vertical rail section 22 . However, in the embodiment pictured in FIG. 22 each inside floor support 27 b includes two floor support platforms 29 c and two floor support arms 29 d extending from a common floor support sleeve 29 a in opposite directions.
One embodiment of a floor grid comprised of a plurality of outside and inside floor supports 27 a , 27 b is shown from the top view in FIG. 26 . The inside floor supports 27 b may be affixed to the center floor member 27 c in addition to a vertical cable 28 b for additional strength. The center floor member may be formed as a rigid or semi-rigid rod (or tensioned cable) that extends the length of the suit frame 20 and is affixed at either end to the vertical cables 28 b of the two terminal uprights 24 . The outside floor supports 27 a may be affixed to vertical rail sections 22 . Adjacent outside or inside floor supports 27 a , 27 b within a given row may be connected to one another to provide additional strength to the floor grid through any structure and/or method suitable for the particular application, including but not limited to cables, plates, rods, and/or combinations thereof. After all the outside and inside floor supports 27 a , 27 b have been positioned and leveled with respect to one another, the floor sheet 48 may be extended onto the floor support platforms 29 c of the outside and inside floor supports 27 a , 27 b . The floor sheet 48 may be configured as a singular unit or in several panels that may be affixed to one another. It is contemplated that the floor sheet 48 will be rigid or semi rigid depending on the spacing and side of the floor support platforms 29 c . The specific area of the floor support platforms 29 c may vary from one embodiment to the next, and the optimal dimensions vary depending on the orientation of the suite frame 20 . However, it is contemplated that many applications will require floor support platforms 29 c have an area between two square inches and five hundred square inches.
As mentioned, a floor grid layout may include center floor member 27 c that may be affixed to the vertical cables 28 b to provide more support for the floor sheet 48 . Additional vertical cables 28 b may be affixed to the arch support 23 , and additional center floor members 27 c may be affixed to those vertical cables 28 b to increase the load-bearing capabilities of the floor. One embodiment of the suite frame 20 is shown in perspective in FIG. 25 , wherein each arch support 23 includes one vertical cable 28 b affixed thereto, and one horizontal cable 28 a affixed thereto. The embodiment in FIG. 25 also includes a center floor member 27 c . A horizontal cable 28 b may also be affixed to corresponding vertical rail sections 22 on opposite sides of each upright 24 for additional support.
To ensure that neither the outside and inside floor supports 27 a , 27 b slip downward as weight is placed upon the floor support platforms 29 c , an equalizer 29 e (one embodiment of which is shown in FIG. 28 ) may be positioned below each outside and inside floor support 27 a , 27 b . The equalizer 29 e may be used in place of a sleeve connector 26 to connect two vertical rail sections 22 whose junction is located immediately below either an outside or inside floor support 27 a , 27 b , one such arrangement is shown in FIG. 29 . The embodiment of an equalizer 29 e shown in FIG. 28 is threaded at each end to accept a threaded end of a vertical rail section 22 , and is configured with a movable sleeve on the outer portion. As the central portion of the equalizer 29 e is rotated, the ends of the two vertical rail sections 22 engaged with the equalizer 29 e will be moved closer or further from one another depending on the direction of rotation. This allows for precise adjustments in the leveling of the inside and outside floor supports 27 a , 27 b during settling of the portable structure 10 . The equalizers 29 e may be adjusted when the floor sheet 48 is extended or before the floor sheet 48 has been positioned on the floor support platforms 29 c.
An illustrative embodiment of a suite frame 20 is shown constructed over an uneven surface in FIG. 30 , and the suite frame 20 affixed to the pod 12 is shown in FIG. 31 . As previously described, to account for the uneven terrain, the number of vertical rail sections 22 on each side of each upright 24 may be adjusted, or the ground rail supports 21 a may be adjusted. As shown in FIG. 30 , the uprights to the left of the figure have a greater number of vertical rail sections 22 on each side than those towards the right of the figure. The laser level (not shown) and computer (not shown) may be used to determine the number of vertical rail sections 22 needed to ensure the top of the suite frame 20 is substantially level. However, even if the suite frame 20 is not absolutely level, the equalizers 29 e in cooperation with the outside and inside floor supports 27 a , 27 b allow the user to ensure that the floor sheet 48 may be adjusted for an absolutely level work surface. Each upright 24 may be separated from the next upright 24 by equal amounts throughout the entire suite frame 20 , or the distances between adjacent uprights 24 may vary.
After the suite frame 20 is fully assembled and leveled, and the floor sheet 48 has been extended on the floor support platforms 29 c , a plurality of cocoon sections 40 may be positioned over the mesh covering 38 to protect the suite 30 from a variety of hazards. The cocoon sections are fully described in U.S. patent application Ser. No. 12/716,039, which is incorporated by reference herein in its entirety. Each cocoon section 40 , one embodiment of which is shown in FIG. 41 may be made from a material or combination of materials that alone or in combination provide resistance to water, environmental pollutants, radiation, industrial pollutants, electromagnetic waves, and abrasion. Furthermore, each cocoon section 40 may be configured to provide heat and/or cooling to the suite 30 as needed, and each cocoon section 40 may be configured to absorb mechanical energy from the impact of various hazards such as ice, hail, failing rocks, and the like through the use of inflatable layers. Each cocoon section 40 is typically flexible and preformed so that each cocoon section 40 fits over a specific portion of the suite frame 20 .
One embodiment of the suite 30 is shown from above in FIG. 42 and in perspective in FIG. 44 , wherein the suite 30 includes two suite canopies 44 on each side of the suite 30 . Inside each suite canopy 44 a suite access door 42 may be positioned to provide access to the interior of the suite 30 from the surrounding environment. The suite access doors 42 may be sliding-type doors to conserve space and for less complexity, such as those shown in FIG. 43 . A cocoon canopy section 46 is shown in FIG. 44 . A suite canopy 44 may be integrated into an adjacent cocoon section 40 . The suite canopy 44 and the suite access door 42 positioned therein is shown from the exterior thereof in FIG. 45 . Although not shown, the end of the suite 30 furthest from the pod 12 may include a suite access door 42 and a ladder (not shown) to directly access the exterior terrain surface adjacent that end of the suite 30 .
The portable structure 10 is shown with the suite 30 constructed and attached to the pod 12 in FIG. 31 . As shown the portable structure 10 may be deployed on uneven terrain. The dimensions of the suite 30 , suite frame 20 , pod 12 , and various elements thereof may be different than those indicated by the scale in FIG. 31 , and are therefore in no way limiting to the scope of the portable structure 10 . The surface of the floor sheet 48 may be coplanar and level with respect to the bottom surface of the pod 12 so that ingress/egress from one to the other is simple and efficient. It is contemplated that when the portable structure 10 is deployed on uneven terrain, the end of the pod 12 to which the suite 30 connects should be facing down slope, as is shown in FIG. 31 . For additional strength exterior cables (not shown) may be anchored to the terrain at one end, draped over the exterior of each cocoon section 40 , and subsequently anchored to the terrain at the opposite end of the exterior cable (not shown).
Once the portable structure 10 is fully deployed and assembled, the interior layout may be arranged for an infinite number of situations. The optimal arrangement will depend on the purpose for which the portable structure 10 is deployed. One possible arrangement for the interior of the suite 30 is shown in FIGS. 34A-34C . In this arrangement the interior of the suite 30 is arranged with a plurality of bunks forming different treatment areas 32 . Each treatment area 32 may be suspended from the floor sheet 48 using a plurality of treatment area supports 31 , which may be affixed to vertical cables 28 b as shown in FIG. 33 . Treatment area supports 31 may be configured as any rigid or semi rigid member that will bear the weight of an average human plus a nominal amount for clothing, equipment, and the like. The treatment area supports 31 may be attached to the vertical cables 28 b using any structure and/or method known to those skilled in the art, including but not limited to clamps, rivets, chemical adhesion, and/or combinations thereof. Additional vertical cables 28 b may be used to connect adjacent treatment area supports 31 to one another, as may angled cables (not shown) affixed to a vertical cable 28 b at one end and to either end of the treatment area support 31 at the opposite end.
An end view of one section of treatment areas 32 is shown in FIG. 34A , from which it is clear that the first embodiment allows the treatment areas 32 to be positioned above and below one another. A top view of the center section of treatment areas 32 is shown in FIG. 34B , which shows that the vertical cables 28 b along the center of the suite frame 20 may have treatment areas 32 on either side thereof. One row of treatment areas 32 may be positioned along each side of the uprights 24 , as shown schematically in FIG. 34C . The optimal treatment area 32 structure will vary from one embodiment to the next, but it is contemplated that most applications will require a lightweight, rigid or semi-rigid surface approximately six feet long and at least two feet wide. Alternatively, the treatment areas 32 may be configured as cots, wherein two rigid members connected by a patient support unrolled so that the two rigid members rest upon two treatment area supports 31 . More treatment areas 32 may be added in the same amount of space if the treatment areas 32 are smaller, and therefore the size of the treatment area 32 is in no way limiting to the scope of the portable unit 10 . A number of sections of treatment areas 32 is shown from above in FIG. 35C .
The interior of the suite 30 may be an entirely climate-controlled, protected area that is impervious to the elements and other hazards as listed above. An HVAC 4 , which may be placed in the pod 12 , may be in fluid communication with the suite 30 through HVAC ductwork 36 . As shown in FIG. 35 , in one embodiment the HVAC ductwork 36 increases in cross-sectional area from one end to the next such that the HVAC ductwork 36 may telescope. A side view of one embodiment of HVAC ductwork 36 connecting the HVAC 4 in the pod 12 to the interior of the suite 30 is shown in FIG. 36 , with FIG. 37 providing a top view thereof. As shown, two parallel runs of HVAC ductwork 36 may span the length of the suite 30 with various outlets (not shown) at certain portions to deliver conditioned air (either heated or cooled, which also may be humidified or dehumidified) to the interior of the suite 30 . The exact arrangement of the HVAC ductwork 36 will vary depending on the dimensions of the portable structure 10 and the size of the HVAC 4 , and is therefore in no way limiting in scope.
The interior of the suite 30 may also be illuminated by artificial light sources 33 . One arrangement of artificial light sources 33 for the interior of the suite 30 is shown in FIG. 39 , which also shows one arrangement for electrical outlets 35 and electrical conduit 34 connecting the light sources 33 and/or electrical outlets 35 with the generator 2 in the pod 12 . The light sources 33 and the electrical outlets 35 may hang from cables (not shown) attached to the uprights 24 . It is contemplated that having light sources 33 and/or electrical outlets 35 near each treatment area 32 will be most desirable, and therefore the arrangement of light sources 33 and/or electrical outlets 35 will vary for each embodiment of the portable structure 10 and is in no way limiting to its scope. It is also contemplated that in many embodiments it will be beneficial for the portable structure 10 to include exterior lights, which are not shown herein for purposes of clarity.
One arrangement of a control center, which may be used to monitor and control various systems and/or conditions relevant to the portable structure 10 , is shown in FIG. 39 . As shown, the arrangement in FIG. 39 may be positioned within the pod 12 at the end of the pod 12 furthest from the suite 30 . Because the portable structure 10 may include electrical outlets 35 , generators 2 , HVAC 4 , potable water, light sources 33 , a conditioned air supply, and multiple treatment areas 32 , the various systems of the portable structure 10 must be monitored and controlled. Accordingly, it is contemplated that at least one control panel 6 and breaker panel 7 will be required. Furthermore, at least one water control center 9 will be required for any portable structure 10 that includes a water system, such as the embodiments pictured herein. Multiple parameters internal and external to the portable structure 10 may be monitored and controlled, which parameters include but are not limited to, multiple potable water supply systems and quantities, multiple electrical system loading, electrical system switches, potable water system temperatures, electrical draw on multiple electrical systems, air temperature and humidity internal and external to the portable structure 10 , fuel supply, generator load and temperature, level of pod 12 , level of floor sheet 48 , temperature of cocoon sections 40 , cocoon heat, light level, air thermostat, external light level, level of suite frame 20 , and waste tank level. One layout of certain parameters that may be monitored is shown in FIG. 32 .
The optimal dimensions and/or configuration of the pod 12 , suite frame 20 , suite 30 , and/or cocoon sections 40 will vary from one embodiment of the portable structure 10 to the next, and are therefore in no way limiting to the scope thereof. The various elements of the portable structure 10 may be formed of any material that is suitable for the application for which the portable structure 10 is used. Such materials include but are not limited to metals and their metal alloys, polymeric materials, cellulosic materials, and/or combinations thereof. Furthermore, the scope of the portable structure 10 is in no way limited by the specific shape and/or dimensions of the pod 12 , suite frame 20 , suite 30 , and/or cocoon sections 40 or the relative quantities and/or positions thereof.
Having described the preferred embodiment, other features, advantages, and/or efficiencies of the portable structure 10 will undoubtedly occur to those versed in the art, as will numerous modifications and alterations of the disclosed embodiments and methods, all of which may be achieved without departing from the spirit and scope of the portable structure 10 as disclosed and claimed herein. It should be noted that the portable structure 10 is not limited to the specific embodiments pictured and described herein, but are intended to apply to all similar apparatuses for providing services and/or shelter in an expedient manner. Modifications and alterations from the described embodiments will occur to those skilled in the art without departure from the spirit and scope of portable structure 10 .
2. General Description and Method of Use
A general description of the several elements of the portable structure 10 and how those elements may be assembled will now be described. However, the following description and method of construction is merely illustrative, and therefore will be different from one embodiment of the portable structure 10 to the next. Accordingly, the precise steps within the method of construction and various embodiments of the portable structure 10 are not meant to be limiting with respect to the scope of the claims herein.
First, the pod 12 of the portable structure 10 is positioned so the large back access door (not shown, but on the end of the pod 12 that is adjacent the suite 30 when fully deployed) faces down slope, after which the user may enter the pod 12 via a pod access door 17 and start the generator(s) 2 . If a night operation, the user may also turn on interior lighting (not shown) and deploy the outside flood light system (not shown). The user then activates the pod leveling screws 14 , which may be controlled by a laser level (not shown), computer (not shown), and rotational power source (not shown) so the pod 12 is level. The leveling screws 14 may also be adjusted manually. Contained within the pod 12 may be all the elements to construct the suite 30 .
An access panel storage area (not shown, but which may be positioned above or below the large back access door) houses the strong and lightweight, specially designed ground rails 21 and other lower-section elements of the suite frame 20 . The user then opens the access panel and removes the ground rails 21 and assembles them on the ground, whether the ground is even or uneven, in the configuration desired. The user then anchors the ground rails 21 to the ground utilizing the specially designed anchor rods (not shown) and anchors or the ground rail supports 21 a so that their position is fixed.
A second access panel storage area (not shown) houses the strong and lightweight vertical rail sections 22 and cables that will be used to erect each upright 24 that will engage the ground rails 21 . This access panel may be positioned adjacent the catwalk 19 . Alternatively, one large access panel storage area may be used to hold all elements used to construct the suite frame 20 . Accordingly, as long as the pod 12 includes storage areas of sufficient size to hold all elements of the suite frame 20 , the storage areas may be configured in any manner without limitation.
Once the ground rails 21 are in place, and before any uprights 24 are assembled, the following is initiated: (1) a lap top computer (not shown) connected to a plug-in laser level measuring instrument (not shown) are both activated; (2) the laser level measuring instrument (not shown) is used in conjunction with the laptop computer to establish and save the “level” elevations for the suite frame 20 ; (3) the specially designed software will calculate the combination of various color coded components, locations, and elevations necessary for each upright 24 , and the number of vertical rail sections 22 needed, once in the final position, so that the suite frame 20 will be level. A different method may be used if the ground rail supports 21 a are used to level the ground rails 21 .
Throughout the deployment and construction of the portable unit 10 , the personnel may receive guidance from the laptop, which may also provide instructions as to the correct manner in the deployment and assembly of the suite 30 and suite frame 20 .
Using the ladder 19 a , the user climbs on top of the pod 12 and opens the access door (not shown) and then expands the catwalk 19 . Next, the specially designed strong and light weight vertical rail sections 22 may be removed along with the specially designed arch supports 23 , cross members 25 , center floor members 27 c , outside and inside floor supports 27 a , 27 b , and cables 28 a , 28 b . The vertical rail sections 22 having the specially designed vertical rail rollers 22 a may be positioned adjacent the ground rails 21 . The specially designed cocoon sections 40 and mesh covering 38 that will add rigidity to the structure may be removed from the pod 12 .
The various elements then may be assembled per instruction. First, two vertical rail rollers 22 a are affixed to two vertical rail sections 22 unless such vertical rail sections 22 have already been outfitted with vertical rail rollers 22 a . Next, two outside floor supports 27 a are placed on the two vertical rail sections 22 . Additional vertical rail sections 22 are then connected on each side of the upright 24 using sleeve connectors 26 and pins 26 a or an equalizer 29 e.
Once each side of the upright 24 is constructed to the specified height (as determined by the computer), the arch support 23 is connected to both sides. Next, a horizontal cable 28 a and corresponding cable brackets (not shown) are installed at each end of the arch support 23 . A vertical cable 28 b and corresponding cable bracket (not shown) is placed at the top of the arch support 23 . The next upright 24 is assembled in the same manner, and after two uprights 24 have been assembled, they are affixed to one another with cross members 25 . Also, a portion of the mesh covering 38 may be placed over the furthest upright 24 . With the exception of the outside and inside floor supports 27 a , 27 b , ground rails 21 , vertical rail rollers 22 a , and other elements located below the floor sheet 48 , the assembly work is done from on top of the pod 12 .
As each upright 24 is assembled, the bottom vertical rail section 22 having the vertical rail roller 22 a attached thereto rests in/on the respective ground rail 21 . As each new upright 24 is erected, it is attached to the last upright 24 assembled via a plurality of cross members 25 and it, with the previous uprights 24 , rolls down the ground rails 21 away from the pod 12 . Once each new upright 24 is erected, a mesh covering 38 and a cocoon section 40 may be secured to that specific upright 24 .
Once the cocoon sections 40 and/or mesh covering 38 is secured to the upright 24 , that upright 24 is moved forward away from the pod 12 , utilizing a winch system (not shown), on the ground rails 21 . The process continues on the next upright 24 and until the entire suite frame 20 , mesh covering 38 , and cocoon sections 40 are assembled and erected.
The first upright 24 will also have an “end section” installed. A specially designed guidance system advances the completed uprights in a precise manner along the entire length of the ground rails 21 . Once the suite frame 20 is assembled and erected and is secured to the ground rails 21 , the inner floor elements may be installed.
The first step in installing the floor is to laser the correct elevations for a level floor. This ensures that the elevation of the floor is level no matter what the topography on which the portable structure 10 rests. The pod 12 may be anchored to the uneven ground, and slopping down, but because the floor elevation is laser leveled, the interior floor of both the suite 30 and the pod 12 are level.
Once the laser level has established the proper floor elevation with respect to each vertical rail section 22 , the user may then position and secure the specially designed outside floor supports 27 a on the vertical rail sections 22 . Next the user may laser the elevation of the specially designed inside floor supports 27 b and center floor member 27 c with respect to the vertical cables 28 b . Then the inside floor supports 27 b and center floor member 27 c may be secured in position on each vertical cable 28 b . After the outside and inside floor supports 27 a , 27 b have been leveled and secured, the floor sheet 48 is extended and rests upon the floor support platforms 29 c of the outside and inside floor supports 27 a , 27 b . If the floor sheet 48 is modular, a specially designed tape may be used to cover all the joints, cracks, and seams to ensure a closed environment.
At this point, the cocoon sections 40 may be activated to provide the necessary protection to ensure a hermetically safe environment within the suite 30 . The suite 30 and pod 12 now function as a portable structure 10 that is able to be erected on an uneven surface and have a hermetically sealed environment with a level and flat floor on which to conduct emergency operations. With the portable structure 10 complete and sealed, the HVAC 4 , lighting systems, treatment areas 32 , and electrical systems are rapidly deployed and the portable structure 10 is up and running.
The portable structure 10 may consist of the following the items listed below, which are approximate in size and scope, pending the engineering design and the desired size and scope required for the specific application.
A pod 12 of approximately thirty six feet in length may contain at least the following: a working area adjacent the end of the pod 12 that will be connected to the suite 30 ; catwalk 19 and ladder 19 a ; uprights 24 and the elements required to assemble them; cocoon sections 40 ; mesh covering 38 ; ground rails 21 ; floor sheet 48 ; HVAC 2 ; generators 2 ; breaker panels 7 ; water control center 9 : HVAC ductwork 36 ; light fixtures 37 : electrical conduit 34 ; and electrical outlets 35 . When assembled the portable structure 10 will offer the insulated, hermitically controlled environment, for all circumstances, i.e., air-conditioned or heated, lighted, and sheltered from all the elements including the sun, rain, wind, snow, and/or ice.
Each cocoon section 40 is constructed of material that is incredibly strong, insulated, and durable. Each cocoon section 40 may be made of a plurality of modular units of approximately 20 feet in length and may be erected in sections. When the cocoon sections 40 are attached to one another they may be deployed over a suite frame 20 of twenty feet, forty feet, sixty feet, or any other length desired to accommodate the disaster or other need. Cocoon sections 40 may be fabricated to other lengths as well, and the specific length thereof is in therefore no way limiting.
The portable structure 10 may be erected large enough to accommodate forty people, sixty people, or more as the design specification require. The portable structure 10 may be fully functional and able to accept response teams, people or patients in a matter of ninety minutes or less, depending on the size of the portable structure.
Each portable structure 10 will be specifically outfitted to accommodate the specific mission of various agencies. For certain applications, some items may remain in the pod 12 throughout construction of the suite 30 and while the portable structure 10 is in use. For example, if the portable structure 10 is used as a triage facility, the following list is an example of some items that may remain inside the pod 12 : a control center that monitors lighting, heating, cooling, water supply levels, discharge water levels, etc.; at least one generator 2 sized to provide all the electric needs; an HVAC with the associated controls; a reservoir providing potable water supply; a reservoir to collect discharge/waste water; pharmaceutical supplies and first aid supplies; a refrigerated chest for accommodating IV fluids; cabinets for other medical supplies; cabinet for uniforms, clothing, masks, gloves, etc.; sink and drains for washing purposes; a chemical toilet; a shower facility; hazardous waste receptacles; sharps and needle receptacles; sleeping and resting area, and any other supplies suitable for the particular application for which the portable structure is designed.
Other items that may be placed within the portable structure 10 that will be utilized in the portable structure 10 once erected include but are not limited to: a triage stretcher and sled; lighting units to illuminate the suite 30 ; HVAC ductwork 36 ; electrical outlets 35 ; waste containers; IV poles and other necessary equipment for the specific application of the portable structure 10 .
The pod 12 may also have suitable apparatus and hooks (not shown) allowing the pod 12 to be air lifted to inaccessible disaster areas via helicopter. In another embodiment, the pod 12 is outfitted with a retractable axle and wheel assembly to transport the pod 12 via roadways as indicated in FIG. 11 .
The portable structure 10 affords emergency response personnel the ability to respond rapidly to any area, under any circumstances, day or night, winter or summer, heat, rain, snow or ice, and in a matter of minutes. Utilizing the portable structure 10 will provide a new dimension to the quality of care and the time-critical activity that is necessary to address the immediate threat or to treat and save lives on-site before transporting to another area. One of the most important features of the portable structure 10 is the ability to be utilized for an indefinite period of time in multiple scenarios. It may be used repeatedly for many years with the same assurance in quality response to any scenario.
All dimensions shown, described, indicated, or otherwise presented herein are for illustrative purposes only, and in no way limit the scope of the portable structure 10 . It should be noted that the present disclosure is not limited to the specific embodiments pictured and described herein. Modifications and alterations from the described embodiments will occur to those skilled in the art without departure from the spirit and scope of the portable structure. | The portable structure will generally have a pod from which a suite frame and suite may be deployed. The suite will allow personnel to administer to many critical demands and activities. The portable structure may be deployed upon any terrain, whether level or uneven, rigid or soft, and both the pod and the suite may be leveled independently. Additionally, the portable structure may incorporate at least one cocoon section wherein the cocoon section comprises at least one interior layer contacting a mesh covering placed over the suite frame, at least one thermal layer affixed to the interior layer, wherein the thermal layer includes heat adding and heat removal members capable of removing or adding heat to the mesh covering or a substance adjacent the at least one thermal layer and at least one exterior layer affixed to the thermal layer. | 4 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to flush toilets which include a device for controlling odor, and more particularly to those flush toilets having an exhaust fan or blower as the odor control device, which blower removes odorous gases from within the toilet bowl.
2. Description of Related Art
A variety of devices have been devised over the years for removing odorous air or gases from toilets, and from the space surrounding the toilet referred to as a water closet.
Deodorants
One approach to solving the odor removal problem around toilets, particularly in public or business establishments, is to place solid bars of deodorant within or adjacent the toilet. Alternatively, various misting devices have been developed which are mounted on the wall adjacent the toilet to periodically spray a mist of a deodorizing liquid into the air. While both the solid and the liquid deodorizers do help mask the undesirable odor, the odor is typically still detectable in the air even with strongly scented deodorants, and thus this approach is only marginally effective.
Ceiling Exhaust Fans
Another approach to solving the odor removal problem around toilets is to mount a suction blower in the ceiling of the room containing the toilet such as a bathroom. A wall mounted switch controls the suction blower to exhaust odorous gases present in the bathroom to the exterior of the building. This approach works to a degree, but has some serious shortcomings. For example, the odorous gases are allowed to circulate. throughout the air in the bathroom prior to being removed and exhausted. Therefore, the person using the toilet must smell the odorous gases in the air which can be quite unpleasant. Secondly, this approach necessitates removing most or all of the air from the bathroom to remove the odorous gases, which is a quantity of air at least equal to that contained in the bathroom, typically two to three times as much. The air contained in the bathroom is typically heated air in the winter, which must be replaced with more heated air causing an increase in the heating and/or electric bill. In the summer, this air might be cooled air such as in an air conditioned building, which air must be replaced with more cooled air causing an increase in the electric bill for air conditioning.
Toilets With Built-in Air Flow Devices
Electrically Powered Blowers: The more effective odor control systems remove odorous gases directly from the toilet bowl, which gases are exhausted to the sewer system down-stream of the water trap and siphon seal in the toilet bowl. One approach is to provide an electrically powered suction blower within the structure of the toilet. The odorous gases are withdrawn from the bowl by the suction blower through an intake port or manifold and suitable exhaust conduit. A one-way valve is typically positioned in the exhaust conduit to prevent the backflow of sewer gases into the toilet. The electric suction blower necessitates the availability of an electrical wall socket or another source of electricity. Examples of such toilets with built-in suction blowers which deposit the odorous gases into:the sewer pipe include U.S. Pat. Nos. 6,073,275 issued to Klopocinski, and 4,103,370 issued to Arnold. In some odor control systems, the odorous gases are withdrawn from the toilet bowl, passed through a charcoal filter, and returned to the room with or without additional deodorizing. Such a system is shown in U.S. Pat. No. 3,594,826 issued to Maurer.
Other Air Flow Devices: Toilets with built-in air flow devices other than electrically powered suction blowers have been designed. In U.S. Pat. No. 2,309,925 issued to Schotthoefer is disclosed a toilet having an air flow device which uses falling drops of water to produce a downdraft of air which draw away odorous gases from within the toilet bowl.
Toilets With Separate External Blower Systems
An alternative to having an electrically powered suction blower built into the structure of the toilet is to provide a separate external blower system. The odorous gases are withdrawn from the toilet bowl by the external suction blower through an intake port or manifold and suitable exhaust conduit. The odorous gases are typically exhausted back into the bathroom after an attempted deodorizing, or into a separate exhaust conduit leading outside the building. Examples of external blower systems for toilets include U.S. Pat. Nos. 6,052,837 issued to Norton et al., and 5,875,497 issued to Lovejoy. Both of these patented devices use a special seat which includes an intake manifold for withdrawing the odorous gases from within the toilet. A problem with such external suction blower systems is that they exhaust the supposedly deodorized gases back into the bathroom. Such requires periodic replacement of deodorizer blocks or liquid deodorizer and is only marginally effective in deodorizing the odorous gases. If the odorous gases are to be exhausted to the exterior of the building, a separate exhaust duct must be constructed into the building, since such external suction blower systems are typically not connectable directly to the sewer pipe without major modifications to the toilet.
There is a need for an odorless toilet which does not require electricity to operate, and for a ventilation system to retrofit existing toilet designs and installed toilets for odor removal which requires no electricity to operate.
SUMMARY OF INVENTION
1. Advantages of the Invention
One of the advantages of the present invention is that it utilizes the same water source necessary to operate the toilet, capturing water flow energy which is normally wasted to eliminate odorous gases from the toilet.
Another advantage of the present invention is that no external or internal source of electricity is required, such as a wall socket or batteries, thus presenting no electrical shock hazard and not requiring periodic replacement of batteries.
A further advantage of the present invention is its adaptability to most standard toilet designs, being manufactured as an integral part of the toilet, or as a retrofit or add-on such as in the form of a kit for preexisting toilet designs and for toilets already installed.
Yet another advantage of the present invention is its ability to extract and store energy from the flow of water during flushing and refilling of the flush water tank, the energy being available for later use when the water flow has stopped after the tank has refilled.
Another advantage of the present invention is its ability to capture odorous gases before they exit the toilet to disperse into the air in the bathroom.
A further advantage of the present invention is the elimination of exhausting a large volume of heated or air conditioned air from the bathroom during use.
Yet another advantage of the present invention is the elimination of the need to cut holes in walls and ceiling for installing an exhaust fan, wall switches, and the associated electrical wiring.
These and other advantages of the present invention may be realized by reference to the remaining portions of the specification, claims, and abstract.
2. Brief Description of the Invention
The present invention comprises a ventilation system for removing odors from a water closet or toilet, and a self-contained venting toilet which incorporates the ventilation system. The toilet is of the type having a water supply tank, and a bowl with a hollow flush ring manifold adjacent the top of the bowl. The flush ring manifold includes an inlet opening and a plurality of flushing water discharge openings facing inwardly into the bowl. A flushing conduit connects the bowl to the tank. A discharge conduit connects the bowl with a siphon outlet which connects to a sewage waste drain. The discharge conduit includes an odor trap to prevent odors from passing from the sewage waste drain back to the bowl. A water control mechanism controls the supply of water under pressure from an external water supply pipe and the level of flushing water within the tank. A flushing mechanism includes a valve controlled outlet to the flushing conduit and the flushing ring manifold, adapted to discharge the water contained in the tank into the bowl. A seat pivotally is mounted on the bowl for movement between a horizontal position over the bowl and an elevated substantially vertical position at the rear of said bowl and adjacent the tank.
The ventilation system is adapted to exhaust gases and odors from within the bowl to the siphon outlet and into the sewage waste drain. The ventilation system includes an exhaust conduit communicating between the bowl and the siphon outlet. A blower assembly is operatively connected to and powered by the supply of water from the external water supply pipe when the water control mechanism is allowing the flow of water under pressure from the external water supply pipe to refill the level of flushing water within the tank. The. blower assembly is interposed along the exhaust conduit to induce a flow of air within the exhaust conduit toward the siphon outlet and into the sewage waste drain.
A preferred version of the ventilation system includes a fluid motor which is connected to the water supply pipe to extract kinetic energy taken from the flushing water flowing through the water supply pipe when the water control mechanism is allowing the flow of water under pressure from the external water supply pipe to refill the level of flushing water within the tank. The fluid motor is operatively connected to an energy storage device to supply kinetic energy to the energy storage device while tank of the toilet is being refilled following flushing. The kinetic energy is stored as potential energy by one or more spiral clock springs in the energy storage device, which is operatively connected to power the fan of the blower assembly through a gear box. The energy storage device includes a release mechanism which locks the releasing of the stored potential energy until release thereof is desired. The release mechanism can be operatively connected to the flushing mechanism for actuation when the flushing mechanism is actuated, or the release mechanism can be actuated by a lever accessible externally of the toilet, but separately from the flushing mechanism. This allows operation of the ventilation system even when flushing water is not flowing through the water supply pipe following flushing of the toilet by utilizing the stored potential energy within the energy storage device. A one-way valve is interposed along the exhaust conduit to prevent the flow of air within said exhaust conduit away from the siphon outlet and back into the bowl.
The preferred version of the ventilation system is incorporated into a preferred version of the self contained venting toilet, the toilet having a pair of elongate intake manifolds integral with and adjacent the top of the bowl. The intake manifolds extend at opposite sides of the bowl around at least a portion of the periphery of the bowl, the intake manifolds each having a plurality of intake holes along the length thereof. The exhaust conduit communicates with the bowl through the intake manifolds.
The above description sets forth, rather broadly, the more important features of the present invention so that the detailed description of the preferred embodiment that follows may be better understood and contributions of the present invention to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and will form the subject matter of claims. In this respect, before explaining at least one preferred embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the following description or as illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are shown in the accompanying drawings wherein:
FIG. 1 is substantially a perspective front quarter view of a self contained venting toilet incorporating the ventilation system of the present invention;
FIG. 2 is substantially a perspective front quarter view of the toilet corresponding to FIG. 1, but with the seat cover and the toilet seat elevated to a vertical position showing the intake manifolds of the ventilation system at the top periphery of the bowl;
FIG. 3 is substantially a perspective view of the toilet approaching side elevation;
FIG. 4 is substantially a lateral vertical sectional view taken on the line 4 — 4 if FIG. 3 showing the, relationship of the intake manifolds to the bowl, the seat, and the seat cover;
FIG. 5 is substantially a partial longitudinal sectional view of the toilet showing the configuration of the ventilation system in the toilet;
FIG. 6 is substantially atop plan view of the toilet with the seat cover elevated to the vertical position and the seat down partially covering the intake manifolds and the top periphery of the bowl;
FIG. 7 is substantially a lateral vertical sectional view taken on the line 7 — 7 of FIG. 6 showing the mating of the outer periphery of the seat to the manifold;
FIG. 8 is substantially a lateral vertical sectional view taken on the line 8 — 8 of FIG. 3 showing the ventilation system, and the connection to the siphoned discharge passage;
FIG. 9 is substantially a rear perspective view of the odorless toilet with the cover removed from the tank to show the conventional flushing components and the ventilation fan assembly;
FIG. 10 is substantially a side perspective view corresponding to FIG. 9;
FIG. 11 is substantially a side perspective view of the ventilation fan assembly; and
FIG. 12 is substantially a longitudinal vertical sectional view taken on the line 12 — 12 of FIG. 11 showing the details of the water motor, the clock spring motor assembly, the gear box, and the suction blower.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a self-contained venting toilet wherein odors are removed by an integral ventilation system which needs no electricity to operate. An intake manifold is provided around the periphery of the bowl, together with an exhaust conduit communicating between this manifold and a suction blower installed in the tank portion of the toilet powered by a spring motor which is rewound each time the toilet is flushed. The exhaust conduit leads to the sewer system or to an exhaust duct leading outside of the buildings.
Standard Toilet Components
Basic Toilet: Referring to FIGS. 1-3, the self-contained venting toilet 20 of the present invention includes an integral porcelain or ceramic member 23 having a base 26 , a central hollow pedestal section 29 forming a downward extension of the bowl section 32 , and a water tank section 35 . Bowl section 32 includes a hollow flush ring 38 having an inlet opening 41 and a plurality of flushing water discharge openings 44 facing inwardly into bowl section 32 . A water trap 47 formed in bowl section 32 and base 26 extends to a siphoned discharge passage 50 and a toilet discharge outlet 53 to a sewer waste drain 56 . A removable tank cover 59 of porcelain or ceramic material is disposed on top of tank section 35 . A seat 62 and a seat cover 65 are pivotally mounted to the bowl section 32 with a pivotable flush control lever 68 which extends forwardly from the tank section 35 . The base 26 is secured to the floor 71 by a plurality of bolts 74 which can be covered by a base cover (not shown) such as made of plastic.
Flushing Components: The flushing components and mechanisms of the toilet are basically standard as shown best in FIGS. 5, 8 , 9 , and 10 . They include a flush arm 80 connected to the flush control lever 68 for movement therewith. A flapper valve 83 is pivotally connected to and covers a flush water outlet 86 within water tank section 35 . A chain 89 connects the flapper valve 83 to the flush arm 80 to allow uncovering of the flush water outlet 86 to selectively release flushing water 92 from the tank section 35 . A hose 95 is connected to water tank section 35 and to flush ring 38 at inlet opening 41 to route the flushing water 92 from water tank section 35 into flush ring 38 and out through flushing water outlet openings 44 into bowl section 32 , water trap 47 , siphoned discharge passage 50 , toilet discharge outlet 53 , and into sewer waste drain 56 of the sewer system (not shown). Flushing water 92 is replenished in tank section 35 from a water supply pipe 98 having a valve 99 interposed there along which connects from a source of pressurized water to a float controlled water flow control valve 101 having a float 102 to control the water level within tank section 35 .
Flushing Operation
Toilet 20 is flushed by pressing the flush control lever 68 which pivots the flush arm 80 to lift and open the flapper valve 83 by means of chain 89 . This releases flushing water 92 from the tank section 35 through hose 95 into flush ring 38 for delivery through flushing water discharge openings 44 and then through the bowl section 35 and water trap 47 to siphoned discharge passage 50 and toilet discharge outlet 53 into sewer waste drain 56 . The flapper valve 83 closes when most of the flushing water 92 has drained from tank section 35 , and the water is replenished from the water supply pipe 98 through the water flow control valve 101 until float 102 rises to the desired level.
Modifications for the Vented Toilet
The self-contained venting toilet 20 includes modifications from that of a standard toilet which permit ventilation of the bowl section 35 .
Manifolds and Riser Tube: A first modification to the self-contained venting toilet 20 from a standard toilet is the addition of a pair of arcuate intake manifolds 104 and 107 which are mounted opposite one another on flush ring 38 of the bowl section 32 . A plurality of intake ports 110 and 113 are arranged around the intake manifolds 104 and 107 adjacent an outer edge 116 of seat 62 . The seat 62 may be arranged to bear directly on the intake manifolds 104 and 107 , or may be positioned in the usual manner on a plurality of somewhat compressible pads 119 affixed to seat 62 . Respective rear portions 122 and 125 of intake manifolds 104 and 107 terminate in downwardly extending conduits 128 and 131 and a riser tube 134 .
Ventilation Fan Assembly: Another modification to the self-contained venting toilet 20 from a standard toilet is the addition of a ventilation fan assembly 135 disposed within water tank section 35 .
Fluid Motor: Ventilation fan assembly 135 includes a standard fluid motor 136 having a housing 137 . Fluid motor 136 is connected to a pipe 138 which connects water flow control valve 101 thereto to receive flushing water 92 from water supply pipe 98 . A power output shaft 139 of a vaned disk 140 of fluid motor 136 extends therefrom such that when flushing water 92 flows through fluid motor. 136 , vaned disk 140 through power output shaft 139 supplies power for ventilation fan assembly 135 when flushing water 92 is flowing therethrough for discharge through pipe 138 into water, tank section 35 . Valve 99 can be used to control the amount and pressure of flushing water 92 to fluid motor 136 to control the rotational speed thereof. An overpressure valve 141 includes a housing 142 which threadably connects to fluid motor 136 , and which communicates with the flushing water 92 which flows therethrough. When the pressure builds to a predetermined level, a spring-loaded check member 144 opens to allow the flushing water 92 to exit fluid motor 140 through an overpressure pipe 145 .
Clock Spring Motor Assembly: Ventilation fan assembly 135 further includes an energy storage device in the form of a clock spring motor assembly 146 , which includes a housing 149 which is bolted to fluid motor 136 . Disposed within housing 149 is at least one spiral clock spring 152 which has an outer end 155 affixed to a tubular spring housing 158 rotationally disposed within housing 149 on an output shaft 161 supported by a pair of bushings 164 connected to housing 149 . Clock spring 152 further includes an inner end 167 having a socket 168 which is affixed to a stub shaft 170 connected to the output shaft 143 of fluid motor 136 by a key 171 for rotation therewith. A lock pawl 173 having a bent engaging end (not shown) and an elongate lever end 174 is pivotally mounted to housing 149 , being spring-loaded by means of a torsion spring 176 to extend through a hole 179 through housing 149 to individually engage a plurality of peripheral holes 182 through tubular spring housing 158 to restrain rotation thereof during winding of clock spring 152 . Lock pawl 173 is configured such that the engaging end disengages from spring housing 158 when lever end 174 is raised and to reengage when lowered.
Gear Box: Ventilation fan assembly 135 further includes a planetary gear box 185 having a housing 186 which is bolted to housing 149 . Gear box 185 includes a large outer gear 188 having an input socket 189 to which output shaft 161 is connected using a key 171 . A plurality of planet gears 191 interconnect outer gear 188 and a sun gear 192 having an output shaft 193 within gear box 185 , output shaft 193 which extends from housing 186 . Planet gears 191 rotationally interconnect outer gear 188 to sun gear 192 with output shaft 161 to produce an increase in revolutions between the input socket 189 and output shaft 161 of between about one to two and one to fifty.
Suction Blower: Ventilation fan assembly 135 further includes a squirrel cage or centrifugal suction blower 194 having a housing 197 which is bolted to gear box 185 . Housing 197 includes an intake 200 connected to riser tube 134 and an exhaust 203 connected to an outlet conduit 204 , with a central rotor chamber 206 . A vaned rotor 209 is rotationally disposed within rotor chamber 206 by means of a shaft 212 of vaned rotor 209 which is supported on a pair of bushings 215 connected to housing 197 . Shaft 212 is connected to output shaft 161 of gear box 185 so as to be powered thereby. The use of the gear box 185 allows vaned rotor 205 to spin at a higher speed than without which provides added air drag to extend the amount of time and odorous gases moved before clock spring 152 unwinds.
Toilet Seat: Another modification to the self-contained venting toilet from a standard toilet is the addition of a rearwardly extending lever arm 216 to seat 62 , which extends through a hole (not shown) through ceramic member 23 below water tank section 35 , with a resilient grommet 217 disposed in the hole around arm 216 . Lever arm 216 is pivotally connected to seat 62 through a limited range of included angles of between about zero degrees and one-hundred-eighty-degrees. This allows lever arm 216 to remain in a generally horizontal position as seat 62 is raised to a vertical position and lowered to a horizontal position, but tilts lever arm 216 upwardly when weight is applied to the horizontal seat 216 and compresses pads 119 such as when a person sits thereon.
Mounting and Connection of the Ventilation Fan Assembly
Ventilation fan assembly 135 is mounted within tank section 35 of ceramic member 23 using a mounting bracket 218 . Lock pawl 173 extends through a resilient grommet 219 disposed in a rectangular hole 220 through water tank section 35 . Lever arm 216 of seat 62 is connected to lever end 174 of lock pawl 173 by a rod 221 secured to lever arm 216 which extends through a seal (not shown) into water tank section 35 for vertical movement therewith such as by nuts (not shown) threaded thereon, and to lever end 174 lock pawl 173 but only to move upwardly, such as by a washer (not shown) secured therebelow. Therefore, when lever arm 216 rises in response to a person sitting on seat 62 , lever end 174 of lock pawl 173 is also raised. However, when lever arm 216 is not raised, lever end 174 can still be raised without also raising lever arm 216 . This permits actuation of ventilation assembly 137 even when a person is not sitting on seat 62 . Riser tube 134 extends from outside of tank section 35 through a seal 222 , to prevent leakage of flushing water 92 , and communicates with intake 200 of centrifugal fan assembly 194 . The output of the fan assembly 135 is delivered from output 203 through conduit 204 into air inlet 227 of base 26 which communicates with siphoned discharge passage 50 past water trap 47 leading to toilet discharge outlet 53 and sewer waste drain 56 . The outlet conduit 204 is provided with a one-way or check valve 230 providing for one-way passage of exhausted gases away from the bowel section 32 in a direction toward the toilet discharge outlet 53 and sewer waste drain 56 . Check valve 230 can be of any of a variety of suitable designs, the design shown being a ball type check valve having a cylindrical housing 233 with an inlet 236 , and an outlet 239 . A lightweight ball 242 is disposed within an inner chamber 245 of check valve 230 , inlet 236 having a seat 248 of matching radius to ball 242 . A compression spring 243 retains ball 242 against seat 248 while fan assembly 135 is stopped. Ball 242 lowers against spring 243 under the air pressure generated by the fan assembly 135 such that gases are free to move past ball 242 . Loss of fan pressure allows spring 243 to reseat ball 242 which results in closure of the valve 230 , which prevents any passage of gases from the sewer waste drain 56 back through the fan assembly 135 and the riser tube 143 where they can emerge into the room via the intake manifolds 104 and 107 under the seat 62 .
Operation of the Vented Toilet
Initial Winding of Clock Spring Motor: Vented toilet 20 is initially operated to store energy in clock spring motor assembly 146 by actuating flush control lever 68 , which pivots the flush arm 80 to lift and open the flapper valve 83 to drain the flushing water 92 from water tank section 35 . This causes float 102 to drop, signaling water flow control valve 101 to open, starting the flow of flushing water 92 through water supply pipe 98 . The flushing water 92 flowing through water supply pipe 98 powers fluid motor 136 rotates the vaned disk 140 and the power output shaft 143 , which winds spiral clock spring 152 of the clock spring motor assembly 146 . Lock pawl 173 is engaged with tubular spring housing 158 to prevent clock spring 152 from unwinding. When clock spring 152 is completely wound, a process which takes less time than the time to refill water tank section 35 , the rotor of fluid motor 136 cannot rotate further and the water pressure builds within fluid motor 136 until pressure relief valve 141 opens to allow the remaining flushing water to bypass fluid motor 136 and flow directly into water tank section 35 . This winding process occurs during every flushing of toilet 20 to keep clock spring 152 wound for subsequent ventilation cycles.
Using the Ventilation System: Ventilation fan assembly 135 can be actuated either by a person sitting on seat 62 , or by actuating lock pawl 173 . When a person sits on seat 62 , this causes pads 119 to compress under the weight of the person applied to seat 62 , which causes seat 62 to tilt forwardly a slight amount which tilt is transmitted and amplified by the length of lever arm 216 into an upward movement which actuates pawl 173 through rod 221 . In either case, actuation of lock pawl against the bias of torsion spring 176 releases tubular spring housing 158 to rotate on output shaft 161 thereof to drive sun gear 188 of gear box 185 . The outer gear 192 , planetary gears 191 , and sun gear 193 produce an increased rotational speed at output shaft 193 which is connected to vaned rotor 209 of blower 194 . Odorous gases are drawn from bowl section 32 through intake ports 110 and 113 of the respective intake manifolds 104 and 107 , through the respective conduits 128 and 131 , riser tube 134 , and into blower 194 . The odorous gases are expelled by blower 194 through exhaust 203 through conduit 204 and check valve 230 , air inlet 227 of base 26 , siphoned discharge passage 50 , toilet discharge outlet 53 , and out through sewer waste drain 56 . Check valve 230 prevents exhausted odorous gases and other sewer gases from moving backwardly from sewer waste drain 56 toward bowel section 32 . Blower 194 of ventilation fan assembly 135 stops running either when clock spring 152 is unwound, or when the person rises from seat 32 , which allows pawl 173 to be biased by torsion spring 176 against tubular spring housing 158 .
CONCLUSION
It can now be seen that the present invention solves many of the problems associated with the prior art. The present invention utilizes the existing source of water necessary to operate a toilet to eliminate odorous gases from toilets, capturing water flow energy which is normally wasted. The present invention requires no external or internal source of electricity such as a wall socket or batteries needing periodic replacement are required, and presenting no electrical shock hazard. The present invention is adaptable to most standard toilet designs, either manufactured as an integral part of the toilet, or as an add-on or kit for preexisting toilet design and toilets already installed. The present invention has the ability to extract and store energy from the flow of water during flushing and subsequent refilling of the flush water tank for later use when there is no water flow. The present invention has the ability to capture odorous gases before having a chance to enter the bathroom or other room wherein the toilet is located. The present invention eliminates the exhausting a large volume of heater or air conditioned air during use. The present invention eliminates the need to cut holes in walls and in the ceiling for an exhaust fan, wall switches, and the associated electrical wiring.
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 presently preferred embodiments of this invention. The specification, for instance, makes reference to toilets. However, the present invention is not intended to be limited to toilets. Rather it is intended that the present invention can be used with urinals and other such devices which use water and which contain odorous gases. While the ventilation fan assembly is shown as being actuatable by both the sitting of a person on the toilet, and independently by moving the end of the pawl which extends through the tank other ways of actuating can be used. For example, the pawl can be connected to the flush control lever by the appropriate mechanism for actuation when a person flushes the toilet. Likewise, while a centrifugal suction blower is preferred due to the efficiency and compactness thereof, the present invention can be used such as with axial suction blowers, and other types of blowers. Also, while a ball type one-way valve is shown other such one-way valves can be used such as those using a resilient flap which covers an air flow hole. Finally, while the odorous gases are shown to be exhausted to the sewer system, such gases could be exhausted to a conduit leading to the outside of the building, particularly where the ventilation system is an add-on to an existing installed toilet. The energy storage device can be other than of the clock spring motor type shown. For example, potential energy can be stored such as in rubber bands, other types of springs, and even as water in a separate tank which is filled during refilling of the flushing tank, such separate tank which feeds a water motor or turbine by opening a valve therebetween to power the blower. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given. | A venting toilet having a conventional ceramic bowl and flushing tank arrangement includes a water powered odor exhaust system which withdraws gases from the toilet bowl. A suction blower powered by a water motor through which the refill water to the toilet tank flows following flushing is arranged to draw odorous gases from the toilet bowl through a pair of intake manifolds built into the top of the bowl below the seat. The odorous gasses are delivered to the sewer system downstream of the water trap. An energy storage device containing a clock spring wound by the water motor, and a gear box are connected between the water motor and the suction blower, allow operating of the suction blower to draw odors from the toilet bowl even when the toilet has finished refilling. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the recovery of non-ferrous metals, particularly aluminum, from dross resulting from secondary melting and remelt operations.
2. Discussion of the Prior Art
Dross is a material which forms on the surface of molten non-ferrous metals during remelting and metal holding and handling operations when the molten metal is in contact with a reactive atmosphere, such as air. Dross normally consists of metal oxides entraining a considerable quantity of molten free (un-reacted) metal, and for economic reasons it is desirable to extract the free metal before discarding the residue.
The traditional processes for recovering the free metal generally involve one or several of the following steps:
1. Cooling of the dross using either a mechanical cooler or a dross room (where the dross is spread out over a floor).
2. Transportation of the cooled dross to a dross treatment plant.
3. Crushing and screening of the cooled dross, followed by elimination (usually by dumping) of the fine fraction which consists mainly of oxides and which may be dangerous and disadvantageous to handle in subsequent steps.
4. Heating of the larger dross fractions in the presence of a molten salt bath in order to remelt the metallic fraction and cause the resulting molten droplets to coalesce.
Step 4 is normally carried out in a rotary furnace. The dross fractions and salt mixture are charged and heated to a temperature above the melting point of the metal using direct flame burners. The furnace is then rotated at a suitable rate of speed to obtain a tumbling or cascading action of the mixture. Examples of such processes are disclosed for example in U.S. Pat. No. 3,676,105 to McLeod et al, U.S. Pat. No. 3,789,024 to Murphy et al, and U.S. Pat. No. 4,030,914 to Papafingos et al, all of which disclose the use of salt mixtures as fluxes.
All salt mixtures normally used in Step 4 are selected to be molten at the operating temperatures in order to protect the molten metal surface, and sufficient quantities must be added to completely cover the molten metal. The salt mixtures most frequently used are chloride-based in order to have a sufficiently low melting point, but frequently have added fluoride salts, such as cryolite. The fluoride salts are added for various reasons including improving the fluidity and wettability of the molten salt, and improving the solubility of oxides in the molten salt mixture. A typical salt mixture consists of a 50:50 mixture of NaCl and KCl to which a small quantity (for example 5 wt. %) of a fluoride salt, such as cryolite, is added.
Disadvantageously, the molten salts generate salt fumes which are corrosive both within the plant and in the external environment, and the residual salt cake containing dross impurities is very polluting because the salts are water soluble and are readily leached out of dump sites.
Processes have been proposed which use some form of heating by direct plasma means (Dube et al, U.S. Pat. No. 4,952,237; Lindsay, U.S. Pat. No. 4,997,476; Drouet, U.S. Pat. No. 5,245,627) or by an indirect electrical method (Montanga, U.S. Pat. No. 3,999,980) to permit heating of the dross to temperatures sufficient to melt and release the molten metal without using molten salt fluxes to protect the furnace charge. These methods work by controlling the furnace atmosphere to protect the charge from reaction with excessive amounts of oxidizing gases (oxygen, water, carbon dioxide) during processing, thus making it possible obtain acceptable recoveries. However, these methods do not allow all of the metal trapped in the dross oxide layers to be completely released by heating alone and the recoveries, particularly from drosses generated in secondary melting and remelting processes, are lower than desirable. Recoveries may be as much as 6% less in these processes than processes based on conventional molten salt treatment methods and the resulting economic penalty can be severe.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved process for the recovery of non-ferrous metals, and particularly aluminum, from drosses containing such metals arising from secondary melting and handling operations.
Another object of the invention is to improve the percentage recovery of metal from dross recovery processes that do not rely primarily on the use of molten salt baths.
According to one aspect of the invention, there is provided a process of recovering a non-ferrous metal from a dross containing the metal, comprising: introducing into a rotary furnace the dross and a fluoride compound which becomes substantially molten only above the melting point of the metal; heating the dross and fluoride compound to a maximum temperature above the melting point of the metal using a heating means that substantially maintains a non-oxidizing atmosphere in the furnace; rotating the furnace continuously, intermittently or in a reciprocal fashion until the dross reaches the maximum temperature; removing the molten metal thereby separated from a solid dross residue; and removing the solid dross residue from the furnace. The fluoride compound is such that it remains in the dross during the process and avoids making the dross "sticky" or "mushy" (i.e tending to clump or form a paste rather than a dry solid).
Most preferably, the process involves the use of a fluoride compound having a melting point or melting range high enough that the process may be carried entirely without causing the fluoride compound itself to become substantially molten.
A characteristic of the present invention is the use of a fluoride salt that does not, during the process, generate molten or fluid material that causes the dross to become sticky or to coalesce. Whilst this may be accomplished by using any fluoride salt at a very low concentration, it is a preferred and surprising feature of the present invention that a fluoride salt may be used that alone does not become molten or fluid at the process temperatures required to melt and coalesce the metal. The term "fluoride salt" includes mixtures of different fluoride salts, and it is known that, in the case of salt mixtures, melting can occur over a wide range of temperatures, and such mixtures may include small portions that melt at very low temperatures. Nevertheless, such mixtures of salts are not excluded from the preferred embodiment of this invention unless the compositions are such that the mixtures become fluid or molten at the process temperatures.
The heating of the dross is preferably carried out using a plasma generated by a plasma generating means, although other heating means that prevent the introduction of oxidizing gases into the furnace may be used, e.g. "external" electrical heating devices that introduce heat through the furnace wall. So-called "reduced oxygen" burners may be usable in heating the dross, except where such burners introduce other reactants such as water vapour into the furnace. Burners such as oxy-carbon burners which do not introduce water into the furnace are useable, since residual oxidizing gases can react with the dross without significant loss in recoverable metal. However the preferred heating is carried out by means which do not introduce any oxidizing gas into the furnace and therefore achieve a non-oxidizing atmosphere within the furnace without sacrificing any recoverable metal.
Suitable plasma generating means include, for example, direct current (DC) arcs generated between consumable (usually graphite) or non-consumable (water- or gas-cooled) electrodes, transferred arcs in which the arc is struck between an electrode and the load to be heated or between two electrodes, or contained arcs in which plasma is directed by a flow of gas from a torch containing suitable electrodes. In particular, a contained arc plasma generator has been found especially useful for carrying out this invention as it allows for simple mechanical design of the apparatus. A particular apparatus for carrying out this invention using a contained arc plasma is found in U.S. Pat. No. 4,952,237 to Dube et al (the disclosure of which is incorporated herein by reference), although any rotary furnace designed for heating dross without using molten fluxes and using a plasma generating means can be used with the present invention. The plasma generating means is often combined with a gas source which delivers gas to the plasma to stabilize it and in some cases to direct it along a desired direction. Gases used for this purpose can include N 2 , H 2 , CO, CO 2 , air, Ar and CH 4 , as well as mixtures of these gases. In has been found particularly advantageous to use a gas that is non-reactive, and in particular, N 2 , Ar, or oxygen-depleted air produced when air is subject to a process such as pressure swing absorption (PSA) prior to use to remove most but not all the oxygen from it. However, gases containing free oxygen, or chemically combined but nevertheless reactive oxygen, are preferably not employed in the process. The amount of oxygen introduced by a plasma generator when an oxygen containing gas is used is slight and quickly reacts with a small amount of dross to create a non-oxidizing atmosphere within the furnace. Because there is an inevitable loss of recovery in these cases, a non-reactive gas is generally preferred. Gases or gas mixtures which generate water vapour are to be avoided however, and the presence of water vapour should be prevented for reasons of reactivity and environmental contamination.
The dross treated in the present invention consists essentially of metal and metal oxides, where the oxides are in the form of layers or particles of substantial size. The metal is frequently trapped within oxide layers of substantial thickness. Because dross is formed at metal melting temperatures, it is free of contaminants such as paints, lacquers, etc. normally associated with metal scrap.
While the process of this invention is suitable for all non-ferrous metal drosses conventionally recoverable by the salt bath technique, it is particularly suitable for treating drosses of aluminum or aluminum alloys. The invention is moreover primarily concerned with drosses from mills and extruders that contain little or no metal salt compounds rather than drosses from primary sources.
When treating drosses of aluminum or aluminum alloys, a number of fluoride salts may be used, including NaF, AlF 3 , CaF 2 , K 3 AlF 6 , KF, LiF, MgF 2 , Na 3 AlF 6 and their mixtures. Cryolite, NaF, AlF 3 and mixtures of these salts including mixtures that form specific compounds themselves provide the best combination of features for the present invention. Cryolite is preferred and an inexpensive form of impure cryolite referred to as "recovered cryolite" is particularly preferred because of its relative ease of handling as well as its low cost. Recovered cryolite is a form of cryolite recovered from wastes from the Hall-Heroult process and it generally has a melting point of about 995° C. and contains about 87-90% by weight of Na 3 AlF 6 , about 2% by weight of Al 2 O 3 , about 1-1.5% by weight of Na 2 CO 3 and about 4% by weight of Na 2 SO 4 .
One of the important features of the process of the invention is that the amount of added fluoride salt may be surprisingly low, generally less than 8% F (i.e. weight of F calculated as a percent of the total load) and frequently much less than this. A preferred feature of the process is that the added salt does not become substantially molten during the process. If cryolite or recovered cryolite is used, generally only 0.4% F to 3.5% F are required (measured by percent by weight F). Larger amounts of cryolite do not bring any advantage and indeed may result in reduced recovery (tests may be carried out to determine an optimum range of addition for each fluoride salt or salt mixture employed). As noted earlier, salts that have a component that may melt are included within the scope of the preferred aspect of the invention if the salts nevertheless remain solid in appearance during the process. Cryolite, at least from some sources, is such a material. Tests have shown that cryolite may contain a small amount of "chiolite" since the material may be non-stoichiometric. This component has a low melting point but the material as a whole remains solid and dry in appearance throughout the process of the invention. While a number of fluoride salts are effective at enhancing the recovery of metal because of their particular interaction with the dross, in practical processes some of these salts are not preferred since they are volatile and either disappear from the furnace charge before they can be effective or being volatile can escape to the environment. Fluoride salts which become molten below the melting point of metal are generally not preferred for these reasons. This includes, for example, KAlF 4 which is effective for enhancing metal recovery but is too volatile to be a preferred salt for use in a commercial process.
This invention operates very effectively using fluoride salts only. Small amounts of chloride salt such as the levels that are introduced in dross obtained from secondary melting processes do not however affect the recovery of metal by this process and may be present in the charge. If chloride salts are added in excess of about 25 to 30% by weight of the dross, then the recovery of metal from the dross is actually substantially reduced because the dross becomes agglomerated and the metal cannot be released by the encasing dross. The preferred mode of operation is to avoid the presence of chloride salts altogether except those unavoidably introduced in dross obtained from secondary melting processes.
The enhanced recovery of the present process does not appear to be related to the mechanisms operating in other processes where salts are used. The fluoride salts of the present invention are not substantially molten during the process, and therefore do not provide a protective liquid coating on the metal droplets, nor can they act as solvents for oxide. Furthermore, there are no contaminating materials in the dross which can react with the fluoride salts to produce a protective or metal-releasing effect.
Although not wishing to be bound by a particular theory, it is believed that the present invention operates through the use of reactive fluoride salts which react with the oxide layer and metal to generate an interface that releases the oxide from the metal, and further reacts with the metal to change the surface tension and encourage coalescence. Chloride salts appear to be ineffective as reactive salts, and fluoride salts which react with metals to form Na or K ions are most effective at altering the surface tension and enhancing coalescence. This mechanism is operable at surprisingly low concentrations of fluoride salt, e.g. in amounts insufficient to coat the dross material. It is particularly surprising that a solid fluoride salt at these low concentrations can nevertheless react by solid-solid reactions (with the oxide) or solid-liquid reactions (with the molten metal) sufficient to make the present invention operative. Since cryolite appears to react as a solid to form Na in the metal, it is a particularly preferred salt and is effective at low concentrations. While the mechanism operates for a wide variety of fluoride salts, this surprising capability of operating with a salt that is substantially solid at the melting point of the metal, or more preferably substantially solid during the entire process of metal recovery, overcomes the environmental and operational problems associated with the volatility of salts having lower melting points.
The fluoride salt is generally introduced with the dross into the rotary furnace, which may be preheated. The dross and salt are processed under inert gas until the metal content of the dross is molten and can be removed. For example, in the treatment of drosses from aluminum or aluminum alloys, this requires heating the dross to a temperature of no more than 850° C., and preferably no more than about 750° C., during which time the fluoride salt remains a solid. Once the metal has been removed from the dross, further heating of the remaining solid (the dross residue) can be carried out, including heating to a temperature above the melting point of the fluoride salt, if so desired. Various reactive gases can also be introduced at this stage, if desired, for example to stabilized the residue for subsequent disposal.
The process of the invention has the advantage of improving the yields of recoverable metal from drosses without resorting to the use of molten salt fluxes. The fluoride additions are relatively small and no "salt cake" develops to be disposed of. The fluorides remain in the dross residue after the process is complete but are at low levels and the residue can be used in various secondary processes as a result. The residue can also be reacted with other chemicals (such as CaO) to convert the fluorides to insoluble form (e.g. CaF 2 ) for disposal in landfill.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a rotary furnace (except that the plasma torch has been omitted) which can be employed for the process of the present invention;
FIG. 2 is an end elevational view of the furnace of FIG. 1;
FIG. 3 is a longitudinal cross-section of a plasma torch of the type which may be used for the present invention; and
FIG. 4 is a graph showing the results obtained in Example 1, below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A furnace 10 in accordance with the present invention (except lacking a plasma torch) is shown in side view in FIG. 1 and in end elevation in FIG. 2. The furnace consists of a hollow steel cylinder 11 having its interior walls lined with a high temperature-resistant refractory layer 12. The walls of the cylinder taper inwardly at each longitudinal end and one end is closed by an end wall 13 while the other end has an opening 14 which is closable by a door mechanism shown generally at 15. The above structure forms an enclosed furnace chamber for treatment of the dross.
The cylinder 11 is rotatably and tiltably supported by a framework 16. The framework allows the cylinder to rotate on its longitudinal axis on rollers 17 and also permits it to tilt about pivots 18. The rotation is effected by a gear ring 19 rigidly connected to the cylinder and a chain (not shown) which passes around the gear ring and is driven by a motor (not shown) capable of rotating the cylinder either intermittently or continuously in either direction at speeds up to about 10 r.p.m. or even as high as 20 r.p.m. Tilting is effected by a motor 20 which rotates a threaded rod 21 connected between an upright gantry member 22 and a horizontal cradle member 23 via a threaded bracket 24. Rotation of the rod causes tilting of the cylinder 11 in either direction about pivot 18 preferably to an extent ranging up to about 30° above or below the horizontal.
The door mechanism 15 is supported by a framework 25 rigidly attached to the tiltable section of the main framework 16. The framework 25 comprises a door mount 26 vertically hinged at one side via a rotatable vertical shaft 27. A circular refractory lined door 28 is supported on the framework 25 by vertical pivots 29 which allow the door to tilt relative to the framework 25 so that the door can seat properly in the opening 14 in the cylinder 11. The door has four horizontal holes 30 which act as gas vents to permit escape of furnace gases to the exterior. The vents are covered by an annular channel 31 having an exhaust conduit 32.
The refractory-lined door 28 rotates with the cylinder, the door 28 is attached to the non-rotating framework 25 via a low friction annular bearing rotated under the annular channel 31. Escape of gases between the periphery of the opening 14 and the confronting periphery of the door is prevented by positioning a gasket of fibrous material around the furnace opening between the cylinder 11 and the door 28. The door is held closed by a cable and winch arrangement 33 which pulls the door into sealing contact with the cylinder 11, thus compressing the gasket.
The door 28 has a central hole 34 which receives an annular plasma torch mount 35. The walls defining the hole and the engaging parts of the mount form a ball-and-socket type of joint which permits the torch mount to be tilted relative to the longitudinal axis of the hole 34 (and consequently also relative to the central longitudinal axis of the cylinder 11). When a plasma torch is located in the mount 35, it seals the hole 34 against the release of gases but the mount permits the plasma torch to be tilted as required within the furnace. Generally the mount allows the plasma torch to be tilted by up to 15° either above or below the central longitudinal axis of the furnace.
A typical contained arc type of plasma torch 40 for use in the present invention is shown in FIG. 3. The torch comprises an elongated tube 41 having gas injection ports 42 located between front and rear electrodes 43 and 44, respectively. An arc 45 is struck between the front and rear electrodes and the gas is converted to plasma and ejected from nozzle 46. The plasma torch normally has a water jacket (not shown) to avoid overheating. The torch can be mounted in the furnace in the manner indicated above with the nozzle 46 projecting into the furnace.
The apparatus described above is operated in the following manner.
The furnace 10 is pre-heated either by means of a conventional heating device (e.g. a gas burner or an electric element) or by means of the plasma torch 40.
A dross charge is then prepared in a charging device (not shown) such as a shovel mounted on a fork-lift truck and specially adapted to fit within the furnace opening The door 28 is then opened and the furnace is tilted to the horizontal position by tilting motor 20. The furnace is charged with dross until the charge occupies about one quarter to one third of the total interior volume of the furnace. The weight of the load can be measured by means of four load cells 36 (FIG. 1).
The furnace is then further is then further charged with a fluoride salt in the desired ratio to the weight of the load. Preferably the fluoride salt used in recovered cryolite, and preferably it is charged at approximately 4% by weight of the load, although any charge ratio from 1% to 7% of recovered cryolite may be used, as previously stated.
The gasket of fibrous material is then installed around the furnace opening 14 and the door 28 is then closed and winch 33 operated to hold the door tightly closed.
The furnace is then tilted upwardly (door end high) by up to 30°. A higher tilting angle allows a larger dross charge to be handled because the molten metal, when formed, must not rise to the level of the door opening 14. However, the tilting angle should not be so high that a tumbling effect is prevented.
As the plasma torch is operated, the furnace is rotated at a continuous, or preferably intermittent, speed of less than 1 r.p.m. The rotation prevents a hot spot forming in the furnace lining 12 and also conveys the heat to the dross charge. The temperature of the dross charge is monitored either by thermocouples (not shown) buried in the furnace lining 12 and/or by means of a thermocouple mounted in the gas exhaust conduit 32. A high exhaust gas temperature indicates that the charge is ready or that the refractory layer is being overheated and that damage may result. A computer may be used to enable the speed of rotation of the furnace to be varied according to the temperature of the exhaust gas.
When the charge has been uniformly heated to a temperature above the melting point of the metal in the dross but below the temperature at which the fluoride salt becomes molten (generally a temperature in excess of 720° C.), the plasma output may be cut back (and optionally the plasma gas changed) and the speed of rotation of the furnace is increased until most of the metal has coalesced and separated from the solid dross residue. The rotation is then stopped and the molten metal is removed through one or more tap holes 37. The tilting and rotating capabilities of the furnace can be used to direct the molten metal towards one or other of the tap holes. The molten metal is poured into a drain pan (not shown) located under the furnace. The non-metallic impurities included in the dross remain in the furnace as a solid. It is removed by first opening the door to the furnace then tilting the furnace downwardly preferably by about 30 degrees. The non-metallic solid is then discharged into a crucible placed at the mouth of the furnace.
The process of the invention is further illustrated by the following Examples, which should not be viewed as limiting the scope of the present invention in any way.
Example 1
In this Example, a sample of dross generated from an alloying furnace in a remelt operation was treated to recover metal in a laboratory furnace, as follows.
A charge of 1 kg of dross was placed in a small indirectly-heated rotary furnace and processed under an argon atmosphere. An analysis of the dross by fire assay gave a metal content of 69% by weight. The dross was also found to contain 1.4% chlorides and 0.06% fluorides. In repeated tests, varying amounts of "recovered cryolite" were added and the dross was heated to 725° C. while rotating the furnace at 2 rpm. This operation took about 30 minutes. The rotational speed was increased to 5 rpm and the dross was heated for a further 20 minutes at 725° C.
After the test, the liquid metal and non-metallic residue were cooled in the furnace under an argon atmosphere. The metal recovery was compared to the dross metal content as measured by fire assay to obtain the recovery efficiency. This is plotted in FIG. 4 of the accompanying drawings.
These results show the operational range for the fluoride salt additive. The small scale of the test most likely exaggerated the observed effect, but the improvement resulting from fluoride additions is clear.
Example 2
In this Example, a thirty ton sample of dross from a similar source as the dross of Example 1 was processed in an industrial-size plasma dross furnace of the type shown in FIGS. 1 to 3.
The metal content of the dross determined by fire assay was found to be 65.5%, and the chloride and fluoride contents were 3.2% and 0.15%, respectively. In repeated tests, the dross was processed under air and nitrogen at two levels of recovered cryolite additions. The recovery efficiency is shown in Table 1 below. This full scale process test still demonstrates the improved recovery with the addition of recovered cryolite under either air or nitrogen, but further shows the advantage of using nitrogen in place of air as a plasma torch gas.
TABLE 1______________________________________ Cryolite addition RecoveryTorch gas (cryolite/charge) F efficiency______________________________________air 0% 0% 87.0%air 4% 0.96% 91.3%N.sub.2 1% 0.49% 90.8%N.sub.2 4% 1.96% 95.1%______________________________________
Example 3
In this Example, long term trials using drosses from the same source as the other Examples (total dross treated 500 to 1000 metric tons) were carried out in an industrial-size plasma dross furnace of the type shown in FIGS. 1 to 3 and also in a conventional rotary salt flux furnace using a conventional salt flux (NaCl-KCl-5% cryolite). Plasma dross furnace runs using air with no fluoride salt additions and N 2 with 4% recovered cryolite additions (1-96% F) were used. The average metal recovery from the dross over the period of the long term trials is shown in Table 2 below and indicates that the use of fluoride salt with the plasma processing results in increased recovery over the conventional rotary salt furnace.
TABLE 2______________________________________Process Average metal recovery______________________________________Air/plasma/ 62%no added fluoride saltRotary salt furnace 67%N.sub.2 /plasma/ 70%4% added cryolite______________________________________
Example 4
Laboratory tests were performed to determine the metal recovery efficiency for a variety of chloride and fluoride fluxes at very low concentrations. Two fluoride fluxes including one containing Na and three chloride fluxes (two of which contain small amounts of fluorides) were used. All salts were added at the rate of 1% by weight salt in the dross. The metal recovery is shown in Table 3 and shows that fluoride salts are much more effective than chloride salts at metal recovery by this process, and that Na based fluoride salts are more effective than other fluoride salts. The preferred recovered cryolite salt is the most effective.
TABLE 3______________________________________ MetalType Name F % Recovery______________________________________Fluoride AlF.sub.3 0.66 50.5%Fluoride Recovered 0.49 54.7% CryoliteChloride 50% KCl - 0.0 0% 50% NaClChloride A103-2 ™ 0.02 8.1% FluxChloride Promag S ™ 0.01 22.3% Flux______________________________________ Note: A103-2 ™ Flux: Estimated purity 85%, 47.5 KCl, 47.5 NaCl, 5% Na.sub.3 AlF.sub.6 - Promag ST ™ Flux: Estimated purity 85%, 40% KCl, 60% MgCl.sub.2, 1.4% | A process of recovering a non-ferrous metal from a dross containing the same. The process involves introducing into a rotary furnace the dross and a fluoride compound which becomes substantially molten above the melting point of the metal, heating the dross and fluoride compound to a maximum temperature above the melting point of the metal, using a heating device which substantially maintains a non-oxiding atmosphere in the furnace, rotating the furnace until the dross reaches the maximum temperature, removing the molten metal thereby separated from a solid dross residue and removing the solid dross residue from the furnace. The fluoride compound, which may be, for example, cryolite, recovered cryolite, AlF 3 or NaF, or a mixture thereof, is such that it remains in the dross during the process and does not make the dross become sticky. The use of the fluoride improves the rate of recovery of the metal content of the dross without producing environmental difficulties either during the heating operation or during the disposal or use of the dross residue. | 8 |
TECHNICAL FIELD
This invention relates to fiber optic receivers and wideband receiver amplifiers subject to relatively tight packaging constraints.
BACKGROUND
Many advanced communication systems transmit information through a plurality of parallel optical communication channels. The optical communication channels may be defined by a fiber optic ribbon interconnect (or fiber optic cable) formed from a bundle of glass or plastic fibers, each of which is capable of transmitting data independently of the other fibers. Relative to metal wire interconnects, optical fibers have a much greater response, they are less susceptible to interference, and they are much thinner and lighter. Because of these advantageous physical and data transmission properties, efforts have been made to integrate fiber optics into computer system designs. For example, in a local area network, fiber optics may be used to connect a plurality of local computers to centralized equipment, such as servers and printers. In this arrangement, each local computer has an optical transceiver for transmitting and receiving optical information. The optical transceiver may be mounted on a substrate that supports one or more integrated circuits. Typically, each computer includes several substrates that are plugged into the sockets of a common backplane. The backplane may be active (i.e., it includes logic circuitry for performing computing functions) or it may be passive (i.e., it does not contain any logic circuitry). An external network fiber optic cable may be connected to the optical transceiver through a fiber optic connector that is coupled to the backplane.
Fiber optic transceivers typically include a transmitter component and a receiver component. The transmitter component typically includes a laser, a lens assembly, and a circuit for driving the laser. The fiber optic receiver component typically includes a photodiode and a high gain receiver amplifier, which may be operable to perform one or more signal processing functions (e.g., automatic gain control, background current canceling, filtering or demodulation). For one-directional data transfer, a transmitter component is required at the originating end and a receiver component is required at the answering end. For bi-directional communication, a receiver component and a transmitter component are required at both the originating end and the answering end. In some cases, the transmitter circuitry and the receiver circuitry are implemented in a single transceiver integrated circuit (IC). The transceiver IC, photodiode and laser, along with the lenses for the photodiode and the laser are contained within a package that has a size that is sufficiently small to fit within a fiber optic communication device.
SUMMARY
In one aspect, the invention features a fiber optic receiver that includes an opto-electronic transducer, an adjustable response preamplifier circuit, and a mode selection circuit. The opto-electronic transducer is configured to generate an electrical data signal in response to a received optical data signal. The adjustable response preamplifier circuit is coupled to the opto-electronic transducer and is operable to amplify an electrical data signal generated by the opto-electronic transducer. The mode selection circuit is coupled to an output of the preamplifier circuit and is configured to transmit a mode control signal to the preamplifier circuit in response to a received control signal.
Embodiments of the invention may include one or more of the following features.
The mode selection circuit may be configured to transmit the mode control signal to the preamplifier circuit in response to a received data rate control signal or a received power mode control signal.
The mode selection circuit preferably is configured to modulate the mode control signal onto a common line coupled between the preamplifier circuit and the post-amplifier circuit. The mode selection circuit may be configured to modulate the mode control signal onto the common line as a single pulse or as a multiple pulse pattern. In some embodiments, the mode selection circuit is configured to modulate the mode control signal onto the common line as a time-varying signal.
The preamplifier circuit preferably comprises a mode detection circuit that is configured to generate a response control signal for adjusting the response of the preamplifier circuit based upon the mode control signal transmitted by the mode selection circuit.
In some embodiments, the mode detection circuit is configured to detect one or more mode control signal pulses modulated onto a common line coupled between the preamplifier circuit and the mode selection circuit. In these embodiments, the mode detection circuit may be configured to detect the one or more mode control signal pulses based upon a comparison of a common line voltage with a reference voltage.
In other embodiments, the mode detection circuit is configured to detect a time-varying mode control signal modulated onto a common line coupled between the preamplifier circuit and the mode selection circuit. In these embodiments, the mode detection circuit preferably comprises a frequency detector.
The preamplifier circuit may be configured to select one of multiple sets of operating parameters based upon the mode control signal transmitted by the mode selection circuit. For example, the preamplifier circuit may be configured to adjust one or more bandwidth response parameters in response to a bandwidth mode control signal transmitted by the mode selection circuit. Alternatively, the preamplifier circuit may be configured to adjust one or more supply current operating parameters in response to a power mode control signal transmitted by the mode selection circuit.
The mode selection circuit preferably is incorporated within a post-amplifier circuit.
In some embodiments, the fiber optic receiver may include a receiver optical sub-assembly (ROSA) comprising a fiber optic connector for coupling to a mating connector of a fiber optic cable. The preamplifier circuit may be incorporated within the ROSA. The ROSA and the post-amplifier circuit may be mounted on a common substrate.
Among the advantages of the invention are the following.
By transmitting the mode control signal from the mode selection circuit to the preamplifier, the adjustable response amplifier may be placed in the preamplifier stage within a receiver optical sub-assembly (ROSA). As a result, the fiber optic receiver may accommodate multiple operating modes (e.g., multiple bandwidth and power modes) while conforming to existing receiver optical sub-assembly (ROSA) size and pin count constraints. This feature enables the analog electrical data signals generated by the opto-electronic transducer to be amplified, filtered, and shaped optimally for data recovery, while allowing the receiver to be housed within a package sized to fit within fiber optic communication devices with significant size constraints.
Other features and advantages of the invention will become apparent from the following description, including the drawings and the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a diagrammatic view of a fiber optic receiver, which includes an opto-electronic transducer, a preamplifier circuit and a post-amplifier circuit, and a fiber optic cable carrying an optical data signal to the fiber optic receiver.
FIG. 2A is a diagrammatic cross-sectional side view of a fiber optic cable coupled by a pair of mating connectors to a receiver optical sub-assembly (ROSA) of the fiber optic receiver of FIG. 1 .
FIG. 2B is a diagrammatic cross-sectional end view of a header module of the ROSA of FIG. 2A taken along the line 2 B— 2 B.
FIG. 3 is a circuit diagram of the fiber optic receiver of FIG. 1 .
FIG. 4 is a circuit diagram of a post-amplifier mode selection circuit.
FIG. 5A is a diagrammatic view of a data rate control signal, a positive edge-triggered one-shot output signal, and a negative edge-triggered one-shot output signal, each plotted as a function of time.
FIG. 5B is a graph of voltage values on the data lines of the fiber optic receiver of FIG. 1 plotted as a function of time.
FIG. 6 is a circuit diagram of a preamplifier mode detection circuit.
FIG. 7 is a circuit diagram of an alternative post-amplifier mode selection circuit.
DETAILED DESCRIPTION
In the following description, like reference numbers are used to identify like elements. Furthermore, the drawings are intended to illustrate major features of exemplary embodiments in a diagrammatic manner. The drawings are not intended to depict every feature of actual embodiments nor relative dimensions of the depicted elements, and are not drawn to scale.
Referring to FIG. 1 , in one embodiment, a fiber optic receiver 10 includes an opto-electronic transducer 12 (e.g., a p-i-n photodiode), an adjustable response preamplifier circuit 14 , and a post-amplifier circuit 16 . In operation, a fiber optic cable 18 carries an optical data signal 20 to opto-electronic transducer 12 . In response to optical data signal 20 , opto-electronic transducer 12 generates an electrical data signal 22 , which is amplified by preamplifier circuit 14 . Preamplifier circuit 14 is configured to amplify electrical data signal 22 over a prescribed range of optical power for optical data signal 20 . The resulting pre-amplified electrical data signal 24 is further amplified by post-amplifier circuit 16 , which amplifies and shapes electrical data signal 24 so that data embedded in output signal 26 may be extracted by a conventional clock and data recovery circuit.
As explained in detail below, preamplifier circuit 14 has an adjustable response that may be set by a control signal 28 (e.g., a data rate control signal or a power mode control signal) that is received by post-amplifier circuit 16 . Post-amplifier circuit 16 transmits a corresponding mode control signal to preamplifier circuit 14 to optimize the performance of fiber optic receiver 10 for different operating conditions. For example, in one embodiment, when the data rate of the received optical data signal 20 is high, the cutoff frequency of preamplifier 14 may be set high (e.g., about 1.5 GHz to about 2.5 GHz), whereas when the data rate is low, the cutoff frequency of preamplifier circuit 14 may be set low (e.g., about 0.5 GHz to about 1.5 GHz). In this embodiment, the data rate of optical data signal 20 may be known a priori or may be extracted by a phase-locked loop or other techniques in the clock and data recovery circuit or in the post-amplifier circuit 16 . In some embodiments, both preamplifier circuit 14 and post-amplifier circuit 16 have adjustable responses.
As shown in FIG. 2A , in one embodiment, fiber optic cable 18 includes a cable connector 30 that couples to a mating receiver connector 32 of fiber optic receiver 10 . Cable connector 30 includes a socket 34 that is configured to slide over a protruding lip 36 of receiver connector 32 . An annular sleeve 38 is disposed about the distal end of fiber optic cable 18 and is configured to slide within a channel 40 defined within receiver connector 32 . Socket 34 has a pair of pins 42 , 44 that are slidable within vertical slots 46 , 48 of lip 36 . Socket 34 may be slid over lip 36 , with pins 42 , 44 aligned with slots 46 , 48 , until pins 42 , 44 reach the ends of slots 46 , 48 . Socket 34 then may be rotated to seat pins 42 , 44 in end extensions 50 , 52 of slots 46 , 48 . The process of seating pins 42 , 44 within end extensions 50 , 52 compresses a biasing mechanism 54 (e.g., a rubber o-ring) that urges socket 34 against receiver connector 32 , effectively locking cable connector 30 to receiver connector 32 . When properly seated within channel 40 , the one or more fibers of fiber optic cable 18 are aligned with a lens assembly 56 , which focuses optical data signals 20 onto opto-electronic transducer 12 .
Referring to FIG. 2B , opto-electronic transducer 12 and preamplifier circuit 14 are housed within a header module 58 of a receiver optical sub-assembly (ROSA) 60 , which is mounted on a substrate 62 (e.g., a printed circuit board or other support for passive and active components) of fiber optic receiver 10 . ROSA 60 and substrate 62 are contained within a receiver package 63 . Opto-electronic transducer 12 is mounted centrally within ROSA 60 to receive optical data signals that are carried by fiber optic cable 18 and focused by lens 56 . ROSA 60 also includes a plurality of insulated posts 64 , 66 , 68 , which define channels through which electrical connectors extend to couple substrate 62 to opto-electronic transducer 12 and preamplifier circuit 14 .
Other embodiments may use fiber optic connectors that are different from the bayonet-type connectors 30 , 32 to couple fiber optic cable 18 to receiver 10 . Receiver 10 may be housed within a standalone receiver package or may be housed together with a transmitter component in a transceiver package.
Referring to FIG. 3 , in one embodiment, preamplifier circuit 14 includes an adjustable response high gain amplifier 70 and a mode detection circuit 72 . Post-amplifier circuit 16 includes a high gain amplifier 74 and a mode selection circuit 76 . In some embodiments, mode selection circuit 76 may be implemented as a circuit that is separate from post-amplifier circuit 16 . In response to a received control signal 28 , mode selection circuit 76 generates a mode control signal, which is transmitted to preamplifier circuit 14 . In one embodiment, mode selection circuit 76 is configured to transmit the mode control signal over data lines 78 , 80 (i.e., data, data-bar). In another embodiment, mode selection circuit 76 is configured to transmit the mode control signal to preamplifier circuit 14 over a power line that is coupled between preamplifier circuit 14 and post-amplifier circuit 16 . In general, mode selection circuit 76 may be configured to transmit the mode control signal to preamplifier circuit 14 over one or more common lines that are coupled between preamplifier circuit 14 and post-amplifier circuit 16 . Mode detection circuit 72 is configured to detect the mode control signal that is transmitted by mode selection circuit 76 and to generate a response control signal 82 for adjusting the response (or signal processing characteristics) of amplifier 70 , including the bandwidth, gain, noise, and time response of amplifier 70 . Bias levels and passive element values (e.g., resistance, capacitance and conductance values) may be varied, as well as other techniques, to achieve a desired frequency and time domain characteristic behavior of amplifier 70 .
The response of amplifier 70 may be adjusted in different ways.
For example, the bandwidth response may be adjusted by varying the bias conditions of a variable transconductance transistor in the preamplifier circuit. Alternatively, the bandwidth response may be adjusted by varying the bias voltage applied to a varactor (voltage-variable capacitor) in the preamplifier circuit. The bandwidth response also may be adjusted by varying capacitance values or resistance values in low-pass filters coupled to the signal paths through the preamplifier circuit. The bandwidth response alternatively may be adjusted by varying the gain of an amplifier within preamplifier circuit 14 .
In some embodiments, the operating power parameters of amplifier 70 may be adjusted based upon response control signal 82 . For example, control signal 28 may correspond to a power mode signal (e.g., a power-up mode signal, power-down mode signal, or sleep or standby mode signal). In this case, mode selection circuit 76 transmits a power mode control signal to mode detection circuit 72 . In response, mode detection circuit 72 generates a power response control signal 82 that is configured to set the operating power mode of amplifier 70 .
Amplifier 70 may have a continuously variable response or a discrete variation in response. A continuously variable amplifier response may be achieved by incrementing or decrementing the amplifier characteristics based upon each pulse detection. Similar results may be achieved by counting each time a frequency is detected. The amplifier response also may be varied based upon pulse amplitude modulation or the actual frequency of the mode control signal.
Referring to FIG. 4 , in one embodiment, mode selection circuit 76 is configured to transmit the mode control signal as a single pulse modulation over data lines 78 , 80 . In this embodiment, mode selection circuit 76 includes a positive edge-triggered one-shot 84 , a negative edge-triggered one-shot 86 and a pair of pull down switches 88 , 90 , which are configured to selectively pull the voltages on data lines 78 , 80 close to ground potential. Positive edge-triggered one-shot 84 and negative edge-triggered one-shot 86 may be implemented in a conventional way (e.g., with NAND gates and inverters). Pull down switches 88 , 90 may be implemented by conventional transistors that are large enough to pull down the voltages on data lines 78 , 80 substantially below the reference voltage (e.g., close to ground potential).
As shown in 5 A and 5 B, in operation, control signal 28 may have a low value for a first mode of operation (Mode 1 ) that may correspond to a low data rate (or a first power mode), and a high value for a second mode of operation (Mode 2 ) that may correspond to a high data rate (or a second power mode). When the value of control signal 28 switches from low to high, positive edge-triggered one-shot 84 generates a pulse 92 that closes switch 88 , which pulls down data line 78 close to ground potential (V Gnd ). When the value of control signal 28 switches from high to low, negative edge-triggered one-shot 86 generates a pulse 94 that closes switch 90 , which pulls down data-bar line 80 close to ground potential (V Gnd ).
Referring to FIG. 6 , in one embodiment, preamplifier mode detection circuit 72 is configured to detect the single pulse modulations on data line 78 and data-bar line 80 based upon a comparison of the data line voltages with a reference voltage (V Ref ). The reference voltage has a value between ground potential and the normal operating range of electrical data signals 24 (e.g., V cc −0.5 volts to V cc −0.25 volts, where V cc corresponds to the positive supply voltage). Mode detection circuit 72 includes a pair of comparators 96 , 98 that have negative inputs coupled to the reference voltage and positive inputs coupled to data lines 78 , 80 , respectively. The outputs of comparators 96 , 98 are coupled through a pair of inverters 102 , 104 to the set (S) and reset (R) inputs of an SR latch 100 , respectively. In operation, the outputs of comparators 96 , 98 are low only when data lines 78 , 80 are pulled below the reference voltage. Accordingly, when data line 78 is pulled below V Ref , SR latch 100 is set to a value of 1. When data-bar line 80 is pulled below V Ref , on the other hand, SR latch 100 is set to a value of 0. In this way, the operating condition information contained in control signal 28 may be transmitted from post-amplifier circuit 16 to preamplifier circuit 14 in the form of a single pulse modulation on data line 78 or data-bar line 80 , or both. The response of amplifier 70 may be adjusted in one or more of the ways described above based upon the response control signal 82 produced at the output of SR latch 100 .
Other embodiments are within the scope of the claims.
For example, in some embodiments, mode selection circuit 76 may be configured to modulate the mode control signal onto one or more common lines coupled between preamplifier circuit 14 and post-amplifier circuit 16 as a multiple pulse pattern, rather than as a single pulse. In these embodiments, mode detection circuit 72 may include a decoder or other circuit configured to generate an appropriate response control signal 82 corresponding to the response mode specified by the multiple pulse mode control signal pattern.
In other embodiments, mode selection circuit 76 may be configured to modulate the mode control signal onto one or more common lines that are coupled between preamplifier circuit 14 and post-amplifier circuit 16 as a time-varying signal. For example, referring to FIG. 7 , in one embodiment, mode selection circuit 76 may include a pair of frequency controllers 110 , 112 , each of which is coupled to a respective adjustable frequency voltage source 114 , 116 . Voltage sources 114 , 116 are selectively coupled to data lines 78 , 80 by a pair of switches 118 , 120 and are configured to modulate a time varying mode control signal onto the data signals carried by lines 78 , 80 . In operation, frequency controllers 110 , 112 set the frequency of voltage sources 114 , 116 based upon the value (or state) of control signal 28 . The frequencies set by frequency controllers 110 , 112 may be the same or different. In accordance with this embodiment, a large number of different response modes may be selected to accommodate a corresponding number of different operating conditions. For example, four different response modes may be established by selectively setting each of voltage sources 114 , 116 to have one of two different frequencies (f 1 , f 2 ), as illustrated in Table 1 below.
TABLE 1 Data Rate Control Data Line 78 Data Line 80 Signal State Frequency Frequency Response Mode 1 f 1 f 1 R 1 2 f 2 f 1 R 2 3 f 1 f 2 R 3 4 f 2 f 2 R 4
In this embodiment, mode detection circuit 72 preferably includes a pair of frequency detectors that are configured to resolve the frequencies of the time-varying mode control signals modulated onto data lines 78 , 80 .
In some embodiments, mode selection circuit 76 may be configured to modulate the mode control signal onto one or more common lines that are coupled between preamplifier circuit 14 and post-amplifier circuit 16 as an amplitude modulated signal. In these embodiments, mode selection circuit 76 may include a pair of frequency sources that are capable of producing amplitude modulated output signals. Mode detection circuit 72 preferably includes a corresponding pair of amplitude demodulators that are configured to resolve the amplitude variations modulated onto the mode control signals transmitted by mode selection circuit 76 .
Still other embodiments are within the scope of the claims. | A fiber optic receiver that includes an opto-electronic transducer, an adjustable response preamplifier circuit, and a post-amplifier circuit is described. The opto-electronic transducer is configured to generate an electrical data signal in response to a received optical data signal. The adjustable response preamplifier circuit is coupled to the opto-electronic transducer and is operable to amplify an electrical data signal generated by the opto-electronic transducer. The post-amplifier circuit is coupled to an output of the preamplifier circuit and is configured to transmit a mode control signal to the preamplifier circuit in response to a received control signal. By transmitting the mode control signal from the post-amplifier to the preamplifier, the adjustable response amplifier may be placed in the preamplifier stage within a receiver optical sub-assembly (ROSA). As a result, the fiber optic receiver may accommodate multiple operating modes (e.g., multiple bandwidth and power operating modes) while conforming to existing receiver optical sub-assembly (ROSA) size and pin count constraints. | 7 |
[0001] The subject invention generally relates to a lignocellulosic composite material and a method for preparing the lignocellulosic composite material. The subject invention also generally relates to a binder resin having at least one of an insecticide and a fungicide therein for forming the composite material.
[0002] Composite materials, such as oriented strand board (OSB), medium density fiberboard (MDF), agrifiber board, particle board, flakeboard, and laminated strand board (LVL) are known in the art. Generally, these types of boards are produced by blending or spraying lignocellulosic particles or materials with a binder resin while the lignocellulosic particles are tumbled or agitated in a blender or like apparatus. Lignocellulosic particles generally refer to wood particles as appreciated by those skilled in the art. After blending sufficiently to form a uniform mixture, the particles are formed into a loose mat, which is compressed between heated platens or plates, or by steam injection between the two platens to cure the binder and bond the flakes, strands, strips, pieces, etc., together in densified form. Conventional processes are generally carried out at temperatures of from about 120 to 225° C. in the presence of varying amounts of steam, either purposefully injected into or generated by liberation of entrained moisture from the wood or lignocellulosic particles. These processes also generally require that the moisture content of the lignocellulosic particles be between about 1 and about 20% by weight, before it is blended with the binder resin to produce adequate physical properties of the composite material.
[0003] The lignocellulosic particles can be in the form of chips, shavings, strands, wafers, fibers, sawdust, bagasse, straw, wood wool, bamboo and the like, depending upon the type of composite material desired to be formed. When the particles are larger, the boards produced by the process are known in the art under the general term of engineered wood. These engineered woods include panels, plywood, laminated strand lumber, OSB, parallel strand lumber, and laminated veneer lumber. When the lignocellulosic particles are smaller, the boards are known in the art as particleboard and fiber board.
[0004] The engineered wood products were developed due to the increasing scarcity of suitably sized tree trunks for cutting lumber. Such products can have advantageous physical properties such as strength and stability. Another advantage of the engineered wood and particle boards is that they can be made from the waste material generated by processing other wood and lignocellulosic materials. This leads to efficiencies and energy savings from recycling processes, and saves landfill space.
[0005] Binder resin compositions that have been used in making such composite wood products include phenol formaldehyde resins, urea formaldehyde resins, melamine urea formaldehyde, and isocyanates resins. Isocyanate binders are commercially desirable because they have low water absorption, high adhesive and cohesive strength, flexibility in formulation, versatility with respect to cure temperature and rate, excellent structural properties, the ability to bond with lignocellulosic materials having high water contents, and no additional formaldehyde emissions from resin. The disadvantages associated with the use of isocyanates include difficulty in processing due to their high reactivity, too much adhesion to platens, lack of cold tack, high cost and the need for special storage.
[0006] It is known to treat lignocellulosic materials with polymeric diphenylmethane diisocyanate (polymeric MDI or PMDI) to improve the strength of the composite material. Typically, such treatment involves applying the isocyanate to the material and allowing the isocyanate to cure, either by application of heat and pressure or at room temperature. While it is possible to allow the polymeric MDI to cure under ambient conditions, residual isocyanate groups remain on the treated products for weeks or even months in some instances. It is also known, but generally less acceptable from an environmental standpoint, to utilize toluene diisocyanate for such purposes. Isocyanate prepolymers are among the preferred isocyanate materials that have been used in binder compositions to solve various processing problems, particularly adhesion to press platens and high reactivity.
[0007] In the past, various solvents have been added to binder resin with the aim of achieving a lower viscosity and better handling properties. After application, the solvent evaporates during the molding process, leaving the bound particles behind. One major disadvantage of prior art solvents is that they cause a reduction in the physical properties of the formed board including a reduction in the internal bond strength of the formed board.
[0008] Separately from the formulation of improved lignocellulosic composite materials, it is desirable to prevent insects from damaging the composite materials over time and during normal use. Those skilled in the art of insecticides have developed numerous insecticides that are capable of killing or intoxicating various insects once they are exposed to the insecticide.
[0009] While these insecticides have been very commercially successful in the agricultural applications, typical applications have encountered difficulty in applying them in lignocellulosic composite materials. Various methods have been employed to incorporate these insecticides into the wooden structures discussed above and any other wooden article. For example, various prior art methods dissolve an insecticide in a solvent, such as water, and spray the solution onto the wooden structure. The solvent then absorbs into the wood and prevents the insects from damaging the wooden structure. However, one drawback with spraying the solution on wood that is already formed is that over time, the insects will eat away at the wood and eventually get beyond the point where the solution has absorbed. At this point, the wooden structure is vulnerable to subsequent attacks by insects. Another drawback to this method is that any additional water added during formation of the composite material reduces the physical properties of the final composite material. During the pressing stage, steam pressure from any water present in the composite material tends to reduce the physical properties. Therefore, adding additional water would increase the steam pressure and further reduce the physical properties. Additionally, it is typical to dry the wood strands to lower moisture content at the beginning to minimize this effect, but this additional drying costs energy and time.
[0010] Other methods, especially used in the formation of plywood, include incorporating a powder insecticide directly into a glue or an adhesive. Plywood, or laminated veneer, is prepared by applying glue to an already formed layer of wood and compressing it together with another layer of wood. The glue, having the insecticide therein, is applied between the layers of the wood and is compressed to form the plywood. However, the insecticide is not present, i.e., dispersed, throughout the wood, since it is only located in the glue between the layers. Therefore, it is possible to have an initial infestation of insects eat through the glue layer exposing the unprotected wood underneath. Subsequent infestations of insects are then able to cause substantial damage because the insecticide has been removed. In this method, the plywood has not been made insect resistant, only the glue is insect resistant.
[0011] Still other methods have incorporated the insecticide by encapsulating the insecticide in a polyurethane. It is known that the dispersibility and dissolvability of certain insecticides, such as fipronil, is difficult to achieve in certain substances, such as water. Therefore, encapsulating the insecticide in polyurethane improves the dispersibility of the insecticide. However, the encapsulation restricts the direct contact of the insecticide with the insect and requires the insect, in addition to eating the wood, to eat through the polyurethane prior to reaching the insecticide. Therefore, encapsulating the insecticide is not desirable. Further, the additional steps required to encapsulate the insecticide increase the time and cost of production, which are commercially unacceptable.
[0012] Fungicides have also been used to treat lignocellulosic composite materials. Fungicides are substances possessing the power of killing or preventing the growth of fungus. Therefore, the fungicides reduce the likelihood that the composite material will decay as a result of fungus over time. However, the application of the fungicide has been limited in similar circumstances as the insecticides discussed above.
[0013] Accordingly, it would be advantageous to provide a lignocellulosic composite material that is insect and fungus resistant and that is capable of withstanding insect attacks over a longer period of time to prevent insect damage to the composite material. The related art methods that only apply the Insecticide to the surface of the wood or in the adhesive layers between the wood are subject to subsequent insect attacks after the insecticide layer has been breached. Therefore, it is desirable to produce a lignocellulosic composite material that has the insecticide present in a low dosage and dispersed throughout the composite material for preventing insect attacks.
[0014] The subject invention provides a lignocellulosic composite material formed from lignocellulosic particles and a binder resin. The lignocellulosic particles are used in an amount of from about 75 to 99.5 parts by dry weight based on 100 parts by weight of the composite material and the binder resin is used in an amount of from 0.5 to 25 parts by weight based on 100 parts by weight of the composite material. The binder resin comprises a polyisocyanate and at least one of an insecticide and a fungicide. The insecticide(s) and/or the fungicide(s) are dispersed throughout the polyisocyanate, which is then dispersed throughout the lignocellulosic particles. Since the insecticide(s) and/or the fungicide(s) are dispersed throughout the composite material, the composite material is insect resistant and/or fungus resistant to withstand subsequent insect attacks and prevent fungus growth and decay.
[0015] The binder resin more specifically includes the polyisocyanate, a polar solvent, and at least one of an insecticide and / or at least one of a fungicide that is/are dissolved in the polar solvent to form pesticidal solution. The polar solvent is capable of dissolving at least 10 grams of the insecticide(s) and or fungicide(s) per one liter of the polar solvent. The pesticidal solution is dispersed throughout the polyisocyanate to form the binder resin. Next, a lignocellulosic mixture is formed that comprises the lignocellulosic particles and the binder resin. The lignocellulosic composite material is formed by compressing the lignocellulosic mixture at an elevated temperature and under pressure.
[0016] The binder resin more preferably includes the polyisocyanate, a polar solvent, and at least one of an insecticide, preferably selected form the pyrazole insecticides, most preferably selected from the group of fipronil, ethiprole, acetoprole, and combinations thereof.
[0017] The subject invention provides a lignocellulosic composite material having at least one of the insecticides and/or at least one of the fungicides dispersed throughout the composite material. The resultant composite material is insect and/or fungus resistant.
[0018] The composite material is able to repel insect attacks and/or fungus decay throughout the life of the composite material. Since the insecticide(s) and/or fungicide(s) are dispersed throughout, an initial infestation of insects and/or fungi is not able to breach an insecticide/fungicide layer and any subsequent infestations of insects and/or fungi will suffer the same fate as that of the first. Therefore, the lignocellulosic composite material of the present invention enjoys a longer period of life because it is insect and/or fungi resistant.
DETAILED DESCRIPTION OF THE INVENTION
[0019] A lignocellulosic composite material and a method for preparing the lignocellulosic composite material are disclosed. The composite material includes lignocellulosic particles and a binder resin. Throughout the present specification and claims, the terms compression molded, compressed, or pressed are intended to refer to the same process whereby the material is formed by either compression molding the material in a mold or by using compression as between a pair of plates from a press. In both procedures, pressure and heat are used to form the material and to set the binder resin.
[0020] The lignocellulosic particles can be derived from a variety of sources. They can be derived from wood and from other products such as bagasse, straw, flax residue, nut shells, cereal grain hulls, and mixtures thereof. Non-lignocellulosic materials in flake, fibrous or other particulate form, such as glass fiber, mica, asbestos, rubber, plastics and the like, can be mixed with the lignocellulosic material. The lignocellulosic particles can come from the process of comminuting small logs, industrial wood residue, branches, or rough pulpwood into particles in the form of sawdust, chips, flakes, wafer, strands, medium density fibers (MDF), and the like. They can be prepared from various species of hardwoods and softwoods. The lignocellulosic particles may have a moisture content of from 1 to 15 weight percent. In a further preferred embodiment, the water content is from 3 to 12 weight percent, and most preferably from 4 to 10 weight percent. The water assists in the curing or setting of the binder resin, which is described further below. Even when the lignocellulosic particles are dried, they typically still have a moisture content of from 2 to 15 weight percent.
[0021] The lignocellulosic particles can be produced by various conventional techniques. For example, pulpwood grade logs can be converted into flakes in one operation with a conventional roundwood flaker. Alternatively, logs and logging residue can be cut into fingerlings on the order of about 0.5 to 3.5 inches long with a conventional apparatus, and the fingerlings flaked in a conventional ring type flaker. The logs are preferably debarked before flaking.
[0022] The dimensions of the lignocellulosic particles are not particularly critical. Flakes commonly have an average length of about 2 to 6 inches, and average width of about 0.25 to 3 inches, and an average thickness of about 0.005 to about 0.05 inches. Strands which are about 1.5 inches wide and 12 inches long can be used to make laminated strand lumber, while strands about 0.12 inches thick and 9.8 inches long can be used to make parallel strand lumber. The lignocellulosic particles can be further milled prior to use in the process of the invention, if such is desired to produce a size more suitable for producing the desired article. For example, hammer, wing beater, and toothed disk mills may be used.
[0023] In the subject invention, the lignocellulosic particles are present in an amount of from about 75 to 99.5 parts by dry weight based on 100 parts by weight of the composite material, preferably from about 80 to 99.5 parts by dry weight based on 100 parts by weight of the composite material, and most preferably 85 to 99.5 parts by dry weight based on 100 parts by weight of the composite material.
[0024] The binder resin includes a polyisocyanate and at least one of an insecticide and/or at least one of a fungicide. The binder resin is present in an amount of from 0.5 to 25 parts by weight based on 100 parts by weight of the composite material, whereby the remainder is the lignocellulosic particles. However, it is to be appreciated that other additives may be added, such as wax, flame retardant, and the like. In a preferred embodiment, the binder resin is present in an amount of from 0.5 to 20, and more preferably from 1 to 20 parts by weight based on 100 parts by weight of the composite material, and most preferably from 2 to 15 parts by weight based on 100 parts by weight of composite material.
[0025] The polyisocyanate that may be used In forming the binder resin includes aliphatic, alicyclic and aromatic polyisocyanates characterized by containing two or more isocyanate groups. Such polyisocyanates include the diisocyanates and higher functionality isocyanates, particularly the aromatic polyisocyanates. Mixtures of polyisocyanates which may be used include, crude mixtures of di- and higher functionality polyisocyanates produced by phosgenation of aniline-formaldehyde condensates or as prepared by the thermal decomposition of the corresponding carbamates dissolved in a suitable solvent, as described in U.S. Pat. No. 3,962,302 and U.S. Pat. No. 3,919,279, the disclosures of which are incorporated herein by reference, both known as crude diphenylmethane diisocyanate (MDI) or polymeric MDI (PMDI). The polyisocyanate may be an isocyanate-terminated prepolymer made by reacting, under standard conditions, an excess of a polyisocyanate with a polyol which, on a polyisocyanate to polyol basis, may range from about 20:1 to 2:1. The polyols include, for example, polyethylene glycol, polypropylene glycol, diethylene glycol monobutyl ether, ethylene glycol monoethyl ether, triethylene glycol, etc., as well as glycols or polyglycols partially esterified with carboxylic acids including polyester polyols and polyether polyols.
[0026] The polylsocyanates or isocyanate-terminated prepolymers may also be used in the form of an aqueous emulsion by mixing such materials with water in the presence of an emulsifying agent. The isocyanate compound may also be a modified isocyanate, such as, carbodiimides, allophanates, isocyanurates, and biurets.
[0027] Also illustrative of the di- or polyisocyanates which may be employed are, for example: toluene-2,4- and 2,6-diisocyanates or mixtures thereof; diphenylmethane-4,4′-diisocyanate and diphenylmethane-2,4′-diisocyanate or mixtures of the same, the mixtures preferably containing about 10 parts by weight 2,4′- or higher, making them liquid at room temperature; polymethylene polyphenyl isocyanates; naphthalene-1,5-diisocyanate; 3,3′-dimethyl diphenylmethane-4,4′-diisocyanate; triphenyl-methane triisocyanate; hexamethylene diisocyanate; 3,3′-ditolylene4,4-diisocyanate; butylene 1,4-diisocyanate; octylene-1,8-diisocyanate; 4-chloro-1,3-phenylene diisocyanate; 1,4-1,3-, and 1,2-cyclohexylene diisocyanates; and, in general, the polyisocyanates disclosed in U.S. Pat. No. 3,577,358, the disclosure of which is incorporated herein by reference. Preferred polyisocyanates include polymeric diphenylmethyl diisocyanate and monomeric diphenylmethane diisocyanate being at least one of diphenylmethane-4,4′-diisocyanate, diphenylmethane-2,4′-diisocyanate, and diphenylmethane-2,2′-diisocyanate. Most preferably, the polyisocyanate component is polymeric diphenylmethyl diisocyanate. One example of a preferred polyisocyanate is, but is not limited to, Lupranate® M20 S, commercially available from BASF Corporation.
[0028] The polyisocyanate is present in the binder resin in an amount of from about 60 to 99.99 parts by weight based on 100 parts by weight of the binder resin. In a preferred embodiment, the polyisocyanate is present in an amount of from about 80 to 99.9 parts by weight based on 100 parts by weight of the binder resin, and most preferably from about 90 to 99.9 parts by weight based on 100 parts by weight of the binder resin.
[0029] Preferably, the insecticide(s) and/or fungicide(s) are dissolved in a polar solvent to form a pesticidal solution. The pesticidal solution is then mixed with the polyisocyanate to form the binder resin with well-dispersed insecticide(s) and/or fungicide(s). This mixing process may occur right before applying the resin to the wood substrates, such as using in-line mixing techniques before feeding the resin mixture into the blending equipment. The polar solvent is capable of dissolving at least 10 grams of the insecticide(s) and/or fungicide(s) per one liter of the polar solvent.
[0030] In order to ensure that a sufficient amount of insecticide(s) and/or fungicide(s) is added without adding too much polar solvent, the dissolvability of the insecticide(s) and or fungicide(s) is important. It is desirable to only add a low dosage of the insecticide(s) and or fungicide(s) that is sufficient to repel insect and/or fungi attacks. Therefore, it is important to ensure the low dosage is distributed throughout. If the solvent is capable of dissolving only less than 10 grams, then in order to have enough of the insecticide(s) and or fungicide(s), more solvent would be needed. This creates the problem that the lignocellulosic composite material will not have sufficient physical properties, such as modulus of elasticity. When the lignocellulosic composite material is formed under elevated temperature, the solvent evaporates from the mixture. If too much solvent in added, the evaporating solvent creates a steam pressure Within the forming lignocellulosic composite material and it hinders the physical properties.
[0031] It has been determined that certain polar solvents are capable of dissolving at least 10 grams of the insecticide per liter of solvent. For example, it has also been determined that water is not a sufficient polar solvent for certain insecticides, such as fipronil, because it is capable of only dissolving 2.4 milligrams per liter of water. Generally, these polar solvents that are capable of dissolving at least 10 grams of the insecticide per liter are selected from at least one of an alcohol, a ketone, and an ester. More preferably, the polar solvent is selected from the group of octyl alcohol, isopropyl alcohol, methyl alcohol, acetone, carpryl alcohol, propylene carbonate, gamma-butyrolactone, 3-pentanone, 1-methyl-2-pyrrolidinone, and combinations thereof.
[0032] The insecticide(s) and/or fungicide(s) are present in an amount of from 0.001 to 10, preferably from 0.001 to 5, and most preferably from 0.001 to 2.5 parts by weight based on 100 parts by weight of the binder resin. The polar solvent is present in an amount of from 0.1 to 20 parts by weight based on 100 parts by weight of the binder resin. However, it is to be appreciated that the amount of the polar solvent depends upon the dissolvability of the insecticide in the polar solvent. Therefore, more of the polar solvent will be required if it can dissolve 10 grams of the insecticide(s) and/or fungicide(s) per liter than if the polar solvent can dissolve 600 grams per liter.
[0033] The insecticide is selected from at least one of the following:
[0034] Organophosphates: Acephate, Azinphos-methyl, Chlorpyrifos, Chlorfenvinphos, Diazinon, Dichlorvos, Dicrotophos, Dimethoate, Disulfoton, Ethion, Fenitrothion, Fenthion, Isoxathion, Malathion, Methamidophos, Methidathion, Methyl-Parathion, Mevinphos, Monocrotophos, Oxydemeton-methyl, Paraoxon, Parathion, Phenthoate, Phosalone, Phosmet, Phosphamidon, Phorate, Phoxim, Pirimiphos-methyl, Profehofos, Prothiofos, Sulprophos, Tetrachlorvinphos, Terbufos, Triazophos, Trichlorfon;
[0035] Carbamates: Alanycarb, Bendiocarb, Benfuracarb, Carbaryl, Carbofuran, Carbosulfan, Fenoxycarb, Furathiocarb, Indoxacarb, Methiocarb, Methomyl, Oxamyl, Pirimicarb, Propoxur, Thiodicarb, Triazamate;
[0036] Pyrethroids: Bifenthrin, Cyfluthrin, Cypermethrin, alpha-Cypermethrin, Deltamethrin, Esfenvalerate, Ethofenprox, Fenpropathrin, Fenvalerate, Oyhalothrin, Lambda-Cyhalothrin, Permethrin, Silafluofen, Tau-Fluvalinate, Tefluthrin, Tralomethrin, Zeta-Cypermethrin;
[0037] Arthropod growth regulators: a) chitin synthesis inhibitors: benzoylureas: Chlorfluazuron, Diflubenzuron, Flucycloxuron, Flufenoxuron, Hexaflumuron, Lufenuron, Novaluron, Teflubenzuron, Triflumuron; Buprofezin, Diofenolan, Hexythiazox, Etoxazole, Clofentazine; b) ecdysone antagonists: Halofenozide, Methoxyfenozide, Tebufenozide; c) juvenoids: Pyriproxyfen, Methoprene, Fenoxycarb; d) lipid biosynthesis inhibitors: Spirodiclofen;
[0038] Neonicotinbids: Flonicamid, Clothianidine, Dinotefuran, Imidacloprid, Thiamethoxam, Nitenpyram, Nithiazine, Acetamiprid, and Thiacloprid;
[0039] Various: Abamectin, Acequinocyl, Acetamiprid, Amitraz, Azadirachtin, Bifenazate, Cartap, Chlorfenapyr, Chlordimeform, Cyromazine, Diafenthiuron, Diofenolan, Emamectin, Endosulfan, pyrazoles such as Acetoprole, Ethiprole or Fipronil, Fenazaquin, Formetanate, Formetanate hydrochloride, amidinohydrazcones such as Hydramethyinon, Indoxacarb, semicarboazones such as (E+Z)-2-[2-(4-cyanophenyl)-1-(3-trifluoromethylphenyl)ethylidene]-N-(4-trifluoromethoxy-phenyl)hydrazine carboxamide, Pyridaben, Pyridalyl, Pymetrozine, Spinosad, Spiromesifen, Spirodoclofen, Sulfur, Tebufenpyrad, Thiocyclam, and the compound of formula (Γ)
[0000]
[0040] The insecticide preferably is selected from at least one of the following: pyrazole insecticides, pyrrole insecticides, pyrethroid insecticides, amidinohydrazone insecticides, semicarbazone insecticides, and neo-nicotinoid insecticides. Each of these insecticides attacks the insects in a different manner and is not intended to limit the subject invention. One preferred example of a pyrrole insecticide is chlorfenapyr. One preferred example of a pyrethroid insecticide, is alphacypermethrin. One preferred example of an amidinohydrazone insecticide is hydramethyinon. One preferred example of a semicarbazone insecticide, is (E+Z)-2-[2-(4-cyanophenyl)-1-(3-trifluoromethylphenyl)ethylidene]-N-(4-trifluoromethoxyphenyl)hydrazine carboxamide. One preferred example of a neo-nicotinoid insecticide is imidacloprid.
[0041] The pyrazole insecticide is typically available and used in at least one of a powder form and a granular form prior to being dissolved in the polar solvent. It is preferred that the pyrazole insecticide is an aryl pyrazole compound having the general formula of:
[0000]
[0000] wherein Z 1 may be an alkyl or an aryl group, Z 2 is an amine, an alkyl, or a hydrogen, Z 3 is a sulfoxide or haloalkyl, and Z 4 is CN or methyl. Further, the aryl pyrazole may open the aromatic pyrazole ring to form the insecticide.
[0042] More preferably, the pyrazole insecticide has the general formula of:
[0000]
[0000] wherein
[0043] R 1 is one of CN, C 1 -C 6 -alkoxy and C 1 -C 6 -alkyl, preferably CN or methoxy;
[0044] R 2 is S(O) n A, wherein A is C 1 -C 6 -haloalkyl and n is 0, 1, or 2, preferably S(O)CF 3 , S(O)CH 3 or S(O)CH 2 CH 3 ;
[0045] R 3 is one of H, amino, and C 1 -C 6 -alkyl, preferably NH 2 ;
[0046] R 4 is C 1 -C 6 -haloalkyl, preferably CF 3 ;
[0047] and R 5 and R 6 are halogen, preferably chlorine.
[0048] Preferably, the pyrazole insecticide may be selected from one of fipronil, ethiprole or acetoprole and combinations thereof.
[0049] Most preferably, the pyrazole insecticide is fipronil (5-amino-1-(2,6-dichloro-4-(trifluoromethyl)phenyl)-4-((trifluoromethyl)sulfinyl)-1H-pyrazole-3-carbonitrile) having the following structure:
[0000]
[0050] Fungicides are those selected from the group consisting of
acylalanines such as benalaxyl, metalaxyl, ofurace, oxadixyl, amine derivatives and morpholines such as aldimorph, dodine, dodemorph, fenpropimorph, fenpropidin, guazatne, iminoctadine, spiroxamin, tridemorph anilinopyrimidines such as pyrimethanil, mepanipyrim or cyrodinyl, antibiotcs such as cycloheximid, griseofulvin, kasugamycin, natamycin, polyoxin or streptomycin, azoles such as bitertanol, bromoconazole, cyproconazole, difenoconazole, dinitroconazole, epoxiconazole, fenbuconazole, fluquiconazole, flusilazole, hexaconazole, imazalil, metconazole, myclobutanil, penconazole, propiconazole, prochloraz, prothioconazole, tebuconazole, triadimefon, triadimenol, triflumizol, triticonazole, flutriafol, benzimidazoles such as benomyl, carbendazim, chlorfenazol, cypendazol, debacarb, fuberidazol, mecarbinzid, rabenzazole, thiabendazol, dicarboximides such as iprodion, myclozolin, procymidon, vinclozolin, dithiocarbamates such as ferbam, nabam, maneb, mancozeb, metam, metiram, propineb, polycarbamate, thiram, ziram, zineb, heterocyclic compounds such as anilazine, benomyl, boscalid, carbendazim, carboxin, oxycarboxin, cyazofamid, dazomet, dithianon, famoxadon, fenamidon, fenarimol, fuberidazole, flutolanil, furametpyr, isoprothiolane, mepronil, nuarimol, probenazole, proquinazid, pyrifenox, pyroquilon, quinoxyfen, silthiofam, thiabendazole, thifluzamid, thiophanate-methyl, tiadinil, tricyclazole, triforine, copper fungicides such as Bordeaux mixture, copper acetate, copper oxychloride, basic copper sulfate, nitrophenyl derivatives such as binapacryl, dinocap, dinobuton, nitrophthalisopropyl phenylpyrroles such as fenpiclonil or fludioxonil, sulfur other fungicides such as acibenzolar-S-methyl, benthiavalicarb, carpropamid, chlorothalonil, cyflufenamid, cymoxanil, dazomet, diclomezin, diclocymet, diethofencarb, edifenphos, ethaboxam, fenhexamid, fentin-acetate, fenoxanil, ferimzone, fluazinam, fosetyl, fosetyl-aluminum, iprovalicarb, hexachlorobenzene, metrafenon, pencycuron, propamocarb, phthalide, toloclofos-methyl, quintozene, zoxamid strobilurins such as azoxystrobin, dimoxystrobin, flucxastrobin, kresoxim-methyl, metominostrobin, orysastrobin, picoxystrobin, pyraclostrobin or trifloxystrobin, sulfenic acid derivatives such as captafol, captan, dichlofluanid, folpet, tolylfluanid cinnemamides and analogs such as dimethomorph, flumetover or flumorph.
[0068] Preferred are fungicides selected from the azoles, benzimidazoles, morpholines, dicarboxamides and/or strobilurines. The method of forming the lignocellulosic composite material includes the steps of dispersing at least one of the insecticide and the fungicide in the polyisocyanate to form the binder resin. The insecticide(s) and/or fungicide(s) are added in an amount of from 1 to 500 parts per million (PPM) based on dry weight of the lignocellulosic particles, preferably from 1 0 to 300, and most preferably from 20 to 250 parts per million based on dry weight of the lignocellulosic particles. The polyisocyanate is present in an amount of from 0.5 to 25 parts by weight based on 100 parts by dry weight of the lignocellulosic material.
[0069] After the binder resin is formed, the lignocellulosic mixture is formed by combining from about 75 to 99.5 parts by weight of the lignocellulosic particles based on 100 parts by weight of the lignocellulosic mixture with the binder resin in an amount of from 0.5 to 25 parts by weight based on 100 parts by weight of the lignocellulosic mixture. The lignocellulosic particles are resinated using the binder resin described above. The binder resin and the lignocellulosic particles are mixed or milled together during the formation of a resinated lignocellulosic mixture. Generally, the binder resin can be sprayed onto the particles while they are being agitated in suitable equipment. To maximize coverage of the particles, the binder resin is preferably applied by spraying droplets of the binder resin onto the particles as they are being tumbled in a rotary blender or similar apparatus. For example, the particles can be resinated in a rotary drum blender equipped with at least one spinning disk atomizer.
[0070] For testing on a lab scale, a simpler apparatus can suffice to resinate the particles. For example, a 5 gallon can is provided with baffles around the interior sides, and a lid with a hole large enough to receive the nozzle of a spray gun or other liquid delivery system, such as a pump sprayer. It is preferred that the binder resin be delivered as a spray. The particles to be resinated are placed in a small rotary blender. The blender is rotated to tumble the particles inside against the baffles, while the desired amount of binder resin is delivered with a spray device. After the desired amount of binder resin is delivered, the particles can be tumbled for a further time to effect the desired mixing of the particles with the binder resin.
[0071] The amount of binder resin to be mixed with the lignocellulosic particles in the resinating step is dependant upon several variables including, the binder resin used, the size, moisture content and type of particles used, the intended use of the product, and the desired properties of the product. The mixture produced during the resinating step is referred to in the art as a furnish. The resulting furnish, i.e., the mixture of flakes, binder resin, parting agent, and optionally, wax, wood preservatives and/or other additives, is formed into a single or multi-layered mat that is compressed into a particle board or flakeboard panel or another composite article of the desired shape and dimensions. The mat can be formed in any suitable manner. For example, the furnish can be deposited on a plate-like carriage carried on an endless belt or conveyor from one or more hoppers spaced above the belt. When a multi-layer mat is formed, a plurality of hoppers are used with each having a dispensing or forming head extending across the width of the carriage for successively depositing a separate layer of the furnish as the carriage is moved between the forming heads.
[0072] The lignocellulosic composite material may be formed of a single mat, or layer, having a thickness of from 0.1 inches to 2 feet with the insecticide and/or the fungicide dispersed throughout the layer, or formed of a plurality of mats, or layers, with each of the plurality of layers having a thickness of from 0.1 inches to 6 inches with the insecticide and/or the fungicide dispersed throughout each of the plurality of layers. The mat thickness will vary depending upon such factors as the size and shape of the wood flakes, the particular technique used in forming the mat, the desired thickness and density of the final product and the pressure used during the press cycle. The mat thickness usually is about 5 to 20 times the final thickness of the article. For example, for flakeboard or particle board panels of ½ to ¾ inch thickness and a final density of about 35 lbs/ft 3 , the mat usually will be about 0.1 to 6 inches thick.
[0073] Finally, the lignocellulosic composite material is formed by compressing the lignocellulosic mixture at an elevated temperature and under pressure. Press temperatures, pressures and times vary widely depending upon the shape, thickness and the desired density of the composite article, the size and type of wood flakes, the moisture content of the wood flakes, and the specific binder used. The press temperature can be from about 100° to 300° C. To minimize generation of internal steam and the reduction of the moisture content of the final product below a desired level, the press temperature preferably is less than about 250° C. and most preferably from about 180° to about 240° C. The pressure utilized is generally from about 100 to about 1000 pounds per square inch. Preferably the press time is from 50 to 350 seconds. The press time utilized should be of sufficient duration to at least substantially cure the binder resin and to provide a composite material of the desired shape, dimension and strength. For the manufacture of flakeboard or particle board panels, the press time depends primarily upon the panel thickness of the material produced. For example, the press time is generally from about 200 to about 300 seconds for a pressed article with a ½ inch thickness.
[0074] The following examples, illustrating the formation of the lignocellulosic composite material, according to the subject invention and illustrating certain properties of the lignocellulosic composite material, as presented herein, are intended to illustrate and not limit the invention.
EXAMPLES
[0075] The following examples describe the formation of a lignocellulosic composite material by adding and reacting the following parts.
[0000]
TABLE 1
Example 1
Example 2
Example 3
Example 4
Amount
Amount
Amount
Amount
[g]
Pbw
[g]
Pbw
[g]
Pbw
[g]
Pbw
Binder Resin
283.83
3.0
282.52
3.1
1182.44
4.8
1183.58
4.8
Polyisocyanate
282.42
—
282.24
—
1181.29
—
1181.29
—
Insecticide
1.41
—
0.28
—
1.15
—
2.29
—
Lignocellulosic
9076.38
97.0
9076.38
97.0
0.0
0.0
0.0
0.0
Particles A
Lignocellulosic
0.0
0.0
0.0
0.0
24566.56
95.2
24425.95
95.2
Particles B
Total
9360.21
100.0
9358.90
100.0
25749.0
100.0
25609.53
100.0
[0076] The polyisocyanate is LUPRANATE® M20SB, commercially available from BASF Corporation. The pyrazole insecticide is fipronil. The lignocellulosic particles A are a southern yellow pine mix having a moisture content of about 8.27%. The lignocellulosic particles B are Aspen particles having an average moisture content of about 6.76%.
[0077] In Examples 1 and 2, the lignocellulosic composite material was formed having a thickness of 0.437 inches with a density of about 39 lb/ft 3 . In Example 1, 1.41 grams of fipronil were dissolved in 5.03 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 150 PPM based on the dry weight of the lignocellulosic particles. In Example 2, 0.28 grams of fipronil were dissolved in 1.00 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 30 PPM based on the dry weight of the lignocellulosic particles. The polar solvent was 1-methyl-2-pyrrolidinone (NMP). NMP is capable of dissolving about 289 grams of fipronil per liter of NMP.
[0078] In Examples 3 and 4, the lignocellulosic composite material was formed having a thickness of 0.719 inches with a density of about 40 lb/ft 3 . In Example 3, 1.15 grams of fipronil were dissolved in 5 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 50 PPM based on the dry weight of the lignocellulosic particles. In Example 4, 2.29 grams of fipronil were dissolved in 10 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 100 PPM based on the dry weight of the lignocellulosic particles. The polar solvent in Examples 3 and 4 was 3-pentanone, which is capable of dissolving about 326 grams of fipronil per liter of 3-pentanone.
[0079] The insecticide solutions formed in each of the examples was then added to the polyisocyanate component to form the binder resin and the binder resin was then mixed with the lignocellulosic particles. The lignocellulosic particles were pressed under elevated temperature and pressure to form the composite materials. The composite materials were then tested to determine the insecticide potency based upon the number of days after treatment (DAT) with the results listed below as the mean percent knockdown or mortality at DAT.
[0000]
TABLE 2
Example 1
Example 2
Example 3
Example 4
Control
Eastern Subterranean Termite
1 DAT
51.1
7.7
0.0
4.9
1.1
2 DAT
75.0
44.0
16.1
46.2
1.1
3 DAT
89.8
82.4
74.1
79.2
1.1
4 DAT
95.5
98.9
93.9
89.4
1.7
5 DAT
96.6
100.0
90.9
95.8
1.7
6 DAT
97.7
—
96.0
97.7
1.7
[0080] The insecticidal potency of pyrazole insecticide in the lignocellulosic composite material was determined against workers of the eastern subterranean termite, Reticuliterme flavipes: The control was an ordinary, untreated oriented strand board. Petri dishes were used as containers for termite assay. Each Petri dish was set up with a thin layer of moistened sand. Two corners (triangle with 15×15×20 mm) of a composite material were placed directly onto the sand. Thirty termites were placed into the dishes, the lid replaced, covered with blotter paper, and then held in an incubator (25° C.). Data was collected at specified days after treatment listed above recording knocked down, or dead termites, and intoxicated termites.
[0081] In Examples 1-4, the mean percent mortality of termites approached 100 percent, whereas the Control only reached a mean percent mortality of 3.3 percent. It is to be appreciated that these results were observed only over a short period of time, whereas in practice, the composite material will be exposed for longer period of times. Therefore, the results for the treated composite material will provide a greater insecticide resistance over time relative to the Control.
[0082] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. | A lignocellulosic composite material and a method for preparing the lignocellulosic composite material are disclosed. The composite material is formed from lignocellulosic particles and a binder resin. The binder resin comprises a polyisocyanate, at least one of insecticide and/or at least one of a fungicide that are dispersed throughout the polyisocyanate. The insecticide and/or fungicide is also dispersed throughout the lignocellulosic particles. Since the insecticide and/or fungicide is dispersed throughout the composite material, the composite material is insect and/or fungi resistant and is able to withstand insect attacks and prevent fungus growth and decay. | 3 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to processing of porous materials. More specifically, the present invention relates to porous electrodes and to energy storage devices, such as electrochemical double layer capacitors, fabricated using porous electrodes.
BACKGROUND
[0002] Electrodes are widely used in many devices that store electrical energy, including primary (non-rechargeable) battery cells, secondary (rechargeable) battery cells, fuel cells, and capacitors. Important characteristics of electrical energy storage devices include energy density, power density, maximum charging rate, internal leakage current, equivalent series resistance (ESR), and durability, i.e., the ability to withstand multiple charge-discharge cycles. For a number of reasons, double layer capacitors also known as supercapacitors and ultracapacitors, are gaining popularity in many energy storage applications. The reasons include availability of double layer capacitors with high power densities (in both charge and discharge modes), and with energy densities approaching those of conventional rechargeable cells.
[0003] Double layer capacitors use electrodes immersed in an electrolyte (an electrolytic solution) as their energy storage element. Typically, a porous separator immersed in and impregnated with the electrolyte ensures that the electrodes do not come in contact with each other, preventing electronic current flow directly between the electrodes. At the same time, the porous separator allows ionic currents to flow between the electrodes in both directions. As discussed below, double layers of charges are formed at the interfaces between the solid electrodes and the electrolyte. Double layer capacitors owe their descriptive name to these layers.
[0004] When electric potential is applied between a pair of electrodes of a double layer capacitor, ions that exist within the electrolyte are attracted to the surfaces of the oppositely-charged electrodes, and migrate towards the electrodes. A layer of oppositely-charged ions is thus created and maintained near each electrode surface. Electrical energy is stored in the charge separation layers between these ionic layers and the charge layers of the corresponding electrode surfaces. In fact, the charge separation layers behave essentially as electrostatic capacitors. Electrostatic energy can also be stored in the double layer capacitors through orientation and alignment of molecules of the electrolytic solution under influence of the electric field induced by the potential.
[0005] In comparison to conventional capacitors, double layer capacitors have high capacitance in relation to their volume and weight. There are two main reasons for these volumetric and weight efficiencies. First, the charge separation layers are very narrow. Their widths are typically on the order of nanometers. Second, the electrodes can be made from a porous material, having very large effective surface area per unit volume. Because capacitance is directly proportional to the electrode area and inversely proportional to the widths of the charge separation layers, the combined effects of the large effective surface area and narrow charge separation layers result in capacitance that is very high in comparison to that of conventional capacitors of similar size and weight. High capacitance of double layer capacitors allows the capacitors to receive, store, and release large amounts of electrical energy.
[0006] Electrical energy storage capability of a capacitor is determined using a well-known formula, to wit:
E = C * V 2 2 . ( 1 )
In this formula, E represents the stored energy, C stands for the capacitance, and V is the voltage of the charged capacitor. Thus, the maximum energy (E m ) that can be stored in a capacitor is given by the following expression:
E m = C * V r 2 2 , ( 2 )
where V r stands for the rated voltage of the capacitor. It follows that a capacitor's energy storage capability depends on both (1) its capacitance, and (2) its rated voltage. Increasing these two parameters is therefore important to capacitor performance. Indeed, because the total energy storage capacity varies linearly with capacitance and as a second order of the voltage rating, increasing the voltage rating is the more important of the two objectives for improving capacitors.
[0007] Voltage ratings of double layer capacitors are generally limited by chemical reactions (reduction, oxidation) and breakdown that take place within the electrolytic solutions in presence of electric field induced between capacitor electrodes. Electrolytic solutions currently used in double layer capacitors are of two kinds. The first kind of electrolytic solutions includes organic solutions, such as propylene carbonate. Long lifetime prior art double layer capacitors made with organic electrolytes can boast voltage ratings approaching 2.5 volts.
[0008] Double layer capacitors may also be made with aqueous electrolytic solutions, for example, potassium hydroxide and sulfuric acid solutions. Double layer capacitor cells manufactured using aqueous electrolytes and activated carbon are typically rated at or below 1.2 volts in order to achieve a commercially acceptable number of charge-discharge cycles. Even small increases above 1.2 volts tend to reduce substantially the number of charge-discharge cycles that the capacitors can withstand without significant deterioration in performance.
[0009] The 2.5 volt rating is considerably below voltage rating theoretically achievable in organic electrolyte-based double layer capacitors. According to some calculations, double layer capacitors made with an organic electrolyte and activated carbon should perform reliably at voltages ranging to about 3.2-3.5 volts. Achieving this range, however, has been an elusive goal because of early decomposition and breakdown of the electrolyte. The problem results, at least in part, from presence of impurities within the activated carbon and within the electrolyte. Water is one of these impurities.
[0010] Trace amounts of water and other impurities can be found in most electrolytes, and they may affect capacitor reliability, durability, and voltage rating. Highly purified electrolytes, however, are commercially available at reasonable cost.
[0011] The active material of the electrode—activated carbon or another porous material, for example—almost invariably has some impurities, including water. Water may be present in the raw carbon, and it may be introduced or added during the electrode manufacturing process. In practice, purifying activated carbon has proven to be a much more difficult task than purifying electrolyte. Water molecules can attach to the carbon in several ways, including by means of VanderWaal's forces responsible for physical bonding, and chemical (covalent and hydrogen) bonding forces.
[0012] Whatever the nature of the bond between a water molecule and activated carbon, a high energy “excited site” is formed around it. Electrolyte interacts with the water molecules and decomposes more readily near such sites than elsewhere in the capacitor. The trapped water functions deleteriously at the capacitor's working potential, so that the maximum application voltage is affected by the water devolution voltage. This is believed to be a major contributing cause to the lower actual-versus-theoretical breakdown voltage of double layer capacitors.
[0013] It would be desirable to increase actual breakdown voltage of double layer capacitors. It would also be desirable to increase reliability and durability of double layer capacitors, as measured by the number of charge-discharge cycles that a capacitor can withstand without significant deterioration in its operating characteristics. Because capacitor breakdown voltage and durability are both compromised by interaction between electrolyte and water molecules trapped in the activated carbon, it would be desirable to reduce the interactions or eliminate the interactions altogether. More generally, it would be desirable to provide a method for preventing impurities attached to porous materials from interacting with surrounding gas or liquid in which the porous material is immersed.
SUMMARY
[0014] A need thus exists for methods for preventing or reducing exposure of high energy excited sites within porous materials to outside agents. Another need exists for porous materials with reduced exposure of water and other impurities trapped in the materials to outside agents. A further need exists for electrodes made from porous materials having reduced content of water molecules that can interact with surrounding gas or liquid in which the electrodes are immersed. Still another need exists for double layer capacitors and other electrical energy storage devices that employ electrodes made from these materials.
[0015] Various embodiments of the present invention are directed to methods, electrodes, electrode assemblies, and energy storage devices that satisfy one or more of these needs. An exemplary embodiment of the invention herein disclosed is a method for processing porous material. According to this method, the porous material is treated with a sealing coating capable of sealing impurities in micropores of the porous material. The porous material is then dried, so that the coating seals water molecules in the micropores. Treatment may involve, for example, immersing the porous material in the sealing coating, and then draining the sealing coating from the porous material before the material is dried. The coating may be such that it does not seal at least a majority of mesapores of the porous material as measured by surface area, while sealing at least a predetermined percentage of water molecules in the micropores of the material.
[0016] In other aspects of the invention, the porous material includes activated carbon in particulate form, fibril-forming binder, and conductive carbon. These ingredients may be blended, for example, dry-blended; and subjected to high-shear forces in order to fibrillize the material. The high-shear forces may be applied using non-lubricated techniques.
[0017] To make an electrode, the porous material processed as described above may be coated onto one or both sides of a current collector so that film or films of the material are formed on the current collector when the material is dried. To densify the films, the electrode may be calendered. The electrode may then be used in a double layer capacitor, for example, by providing a second electrode, interposing a porous separator between the two electrodes, and immersing the separator and the two electrodes in an electrolyte.
[0018] In another aspect, an electrode assembly is made by coating a porous separator with the porous material processed as described above, so that films of the material are formed on the separator. Current collectors may then be attached to the surfaces of the films that are not in contact with the separator. The resulting electrode assembly may be calendered to density the films. A double layer capacitor is obtained when the assembly is immersed in an electrolyte.
[0019] In one embodiment, a method for processing porous material comprises steps of: providing a porous material, at least some of the porous material comprising micropores, at least some of the micropores having impurities disposed therein; treating the porous material with a sealing coating to seal the impurities in micropores of the porous material; and drying the porous material. The treating step may comprise immersing the porous material in the sealing coating, the method further comprising: draining the sealing coating from the porous material before the drying step. The sealing coating may be such that it does not seal at least majority of mesapores of the porous material as measured by surface area. The sealing coating may be capable of sealing water molecules in micropores of the porous material. The step of providing the porous material may comprise providing activated carbon. The step of providing the porous material may comprise: providing a fibril-forming binder; providing conductive carbon; blending the activated carbon, the fibril-forming binder, and the conductive carbon, thereby obtaining blended active electrode material; and applying high-shear forces to the blended active electrode material to fibrillize the blended active electrode material. The step of providing the porous material further may comprise: providing a fibril-forming binder; providing conductive carbon; dry-blending the activated carbon, the fibril-forming binder, and the conductive carbon, thereby obtaining blended active electrode material; and applying a non-lubricated high-shear force technique to the blended active electrode material to dry fibrillize the blended active electrode material. The method may comprise processing porous material, wherein the step of providing activated carbon comprises providing the activated carbon in particulate form; providing a current collector; and coating the current collector with the fibrillized active electrode material before the step of drying, thereby obtaining the electrode. The step of coating the current collector may comprise coating both sides of the current collector with the fibrillized active electrode material so that first and second films of active electrode material are formed on both sides of the current collector. The method may comprise calendering the current collector with the films after the step of drying. The method may comprise: making first and second electrodes by providing a porous separator; disposing the separator between the first and second electrodes so that active electrode material is interposed between the separator and respective current collector of the electrodes; and immersing the electrodes and the separator in an electrolyte. The method may comprise providing processed porous material wherein the step of providing activated carbon comprises providing the activated carbon in particulate form; providing a porous separator; and coating the porous separator with the porous material before the step of drying; whereby the electrode assembly is obtained. The step of coating the porous separator may comprise coating both sides of the porous separator with the active electrode material so that a first film of active electrode material is formed on a first side of the porous separator and a second film of active electrode material is formed on a second side of the porous separator. The method may comprise attaching a first current collector to the first film so that the first film is disposed between the first current collector and the porous separator; and attaching a second current collector to the second film so that the second film is disposed between the second current collector and the porous separator. The method may further comprise calendering the electrode assembly. The method may comprise comprising: making the electrode assembly of claim; and immersing the electrode assembly in an electrolyte. The method for providing film of active electrode material may comprise providing processed porous material and calendering the processed porous material to obtain the film of active electrode material. The method may comprise providing processed porous material and calendering the processed porous material to obtain a first film of active electrode material and a second film of active electrode material; providing a porous separator; providing a first current collector and a second current collector; attaching the first film to the porous separator and to the first current collector so that the first film is disposed between the porous separator and the first current collector; attaching the second film to the porous separator and to the second current collector so that the second film is disposed between the porous separator and the second current collector, and the porous separator is disposed between the first and second films; and immersing the porous separator and the first and second films in an electrolyte.
[0020] In one embodiment, an electrochemical double layer capacitor comprises: a first and a second electrode material, wherein the active electrode material comprises a porous material and a sealing coating that seals water molecules in micropores of at least some of the porous material; a porous separator disposed between the first electrode material and the second electrode material; a first current collector and a second current collector, wherein the first electrode material is disposed between the porous separator and the first current collector, and the second electrode material is disposed between the porous separator and the second current collector; and an electrolyte, wherein the first electrode material, the second film electrode material and the porous separator are immersed in the electrolyte. The porous material may comprise activated carbon. The porous material may comprise dry fibrillized carbon particles and fibril-forming binder particles.
[0021] In one embodiment, an electrochemical double layer capacitor comprises: a first and a second fibrillized electrode material, wherein the fibrillized electrode material comprises a porous activated carbon and a sealing coating that seals water molecules in micropores of at least some of the activated carbon; a porous separator disposed between the first electrode material and the second electrode material; a first current collector and a second current collector, wherein the first electrode material is disposed between the porous separator and the first current collector, and the second electrode material is disposed between the porous separator and the second current collector; an electrolyte, wherein the first electrode material, the second film electrode material and the porous separator are immersed in the electrolyte; and a container, the container holding the electrolyte, the separator, and the first and second electrode material.
[0022] Active electrode material, such as fibrillized blend of activated carbon, polymer, and conductive carbon, can thus be pretreated by immersion in a sealing coating. After the active electrode material is dried the coating seals micropores of the activated carbon or another porous material, thus preventing exposure of water molecules or other impurities trapped in the micropores to outside agents. At the same time, the sealing coating does not seal most mesapores of the porous material, allowing exposure of the mesapores' surface area to the outside agents. The pretreated active electrode material is used for making electrodes or electrode assemblies of electrical energy storage devices. For example, the electrodes may be immersed in an electrolyte to construct electrochemical double layer capacitors. Pretreatment with the sealing coating reduces the number of water molecules interacting with the electrolyte, enhancing the breakdown voltage of the capacitors.
[0023] These and other features and aspects of the present invention will be better understood with reference to the following description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE FIGURES
[0024] FIG. 1 illustrates selected steps of a process for making an electrode wherein active electrode material is pretreated with a sealing coating;
[0025] FIG. 2 illustrates selected steps of a process for making an electrode assembly wherein paste of pretreated electrode material particles is deposited on a separator of a double layer capacitor;
[0026] FIG. 3 illustrates selected steps of another process for making an electrode with pretreated active electrode material;
[0027] FIG. 4 illustrates selected steps of a process for making an electrode film with pretreated active electrode material; and
[0028] FIG. 5 illustrates, in a high-level manner, cross-section of an electrode assembly of a double layer capacitor.
DETAILED DESCRIPTION
[0029] Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Same reference numerals may be used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, left, right, up, down, over, above, below, beneath, rear, and front may be used with respect to the accompanying drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner.
[0030] The words “embodiment” and “variant” refer to particular apparatus or process, and not necessarily to the same apparatus or process. Thus, “one embodiment” (or a similar expression) used in one place or context can refer to a particular apparatus or process; the same or a similar expression in a different place can refer to a different apparatus or process. The expression “alternative embodiment” and similar phrases are used to indicate one of a number of different possible embodiments. The number of potential embodiments is not necessarily limited to two or any other quantity.
[0031] The expression “active electrode material” and similar phrases signify material that enhances the function of the electrode beyond simply providing a contact or reactive area approximately the size of the visible external surface of the electrode. In a double layer capacitor electrode, for example, a film of active electrode material includes particles with high porosity, so that the surface area of the electrode exposed to an electrolyte (in which the electrode is immersed) is increased well beyond the area of the visible external surface; in effect, the surface area exposed to the electrolyte becomes a function of the volume of the film made from the active electrode material. The meaning of the word “film” is similar to the meaning of the words “layer” and “sheet”; “film” does not necessarily imply a particular thickness of the material. The references to “fibrillizable binder” and “fibril-forming binder” within this document are intended to convey the meaning of polymers, co-polymers, and similar ultra-high molecular weight substances capable of fibrillation. Such substances are often employed as binder for promoting cohesion in loosely-assembled particulate materials, i.e., active filler materials that perform some useful function in a particular application. When used to describe processing of porous materials, the words “pretreat,” “treat” and their inflectional morphemes refer to subjecting the porous material to contact with a sealing coating to seal impurities within micropores of the material. For example, the material may be immersed in the coating, mixed with the coating, sprayed with the coating, exposed to condensation of coating vapors, or otherwise brought in contact with the coating. Note that “treat” and “pretreat” have a different meaning when these words are used to describe processing of current collectors, as is explained in context. “Calender” and “nip” as used in this document mean a device adapted for pressing and compressing. Pressing may be, but is not necessarily, performed using rollers. When used as a verb, “calender” means processing in a press, which may, but need not, include rollers.
[0032] Other and further definitions and clarifications of definitions may be found throughout this document.
[0033] Referring more particularly to the drawings, FIG. 1 illustrates selected steps of a process 100 for fabricating an electrode of a double layer capacitor. Although the process steps are described serially, certain steps may also be performed in conjunction or in parallel, in a pipelined manner, or otherwise. There is no particular requirement that the steps be performed in the same order in which this description lists them, except where explicitly so indicated, otherwise made clear from the context, or inherently required. Not all illustrated steps are strictly necessary, while other optional steps may be added to the process 100 . A high level overview of the process 100 is provided immediately below; more detailed explanations of the steps of the process 100 and variants of the steps are provided following the overview.
[0034] At step 105 , fibrillized particles of active electrode material are provided. At step 110 , the fibrillized particles are dried to evaporate water molecules that may be present within the active electrode material. At step 115 , the particles are mixed with or immersed in a sealing coating. The sealing coating is capable of sealing water molecules (and possibly also other impurities) in micropores of the active electrode material. The coating may also perform as an adhesive promoting cohesion of the particles of the active electrode material and adhesion of the particles to a surface, for example, current collector or separator surface. In some embodiments, two coatings are used: one for sealing the micropores, the other for acting as an adhesive. The sealing coating is such that it does not seal at least a majority (as measured by surface area) of mesapores of the active electrode material. At step 120 , a current collector is provided. At step 125 , the treated active electrode material is mixed with one or more processing material or liquid as known to those skilled in the art to form a slurry like paste, which is then coated onto the current collector. As will be discussed below, the current collector can be coated on two sides. At step 130 , the paste is dried, resulting in an electrode sheet that includes (1) the current collector, and (2) one or two active electrode material layers. At step 135 , the electrode sheet is calendered to densify the active electrode material layers. At step 140 , the calendered sheet is formed into one or more electrodes/electrode assemblies for use in double layer capacitors.
[0035] We now turn to a more detailed description of the individual steps of the process 100 , beginning with the step 105 in which fibrillized active electrode material is provided.
[0036] According to one technique for obtaining the fibrillized active electrode material, particles of active electrode material are dry-blended or otherwise mixed together with a fibrillizable binder (e.g., a polymer) and a conduction promoter to form a dry powder material. Dry-blending may be carried out, for example, for 1 to 10 minutes in a V-blender equipped with a high intensity mixing bar, until a uniform dry mixture is formed. Those skilled in the art will identify, after perusal of this document, that blending time can vary based on batch size, materials, particle size, densities, as well as other properties, and yet remain within the scope of the present invention. The resulting dry powder material is dry fibrillized (fibrillated) using non-lubricated high-shear force techniques, such as jet milling, pin milling, hammer milling, or similar techniques known to a person skilled in the art. The shear forces that arise during the dry fibrillation process physically stretch the polymer particles, causing the polymer to form a network of fibers that bind the polymer to the conduction promoter and to the active electrode particles. The polymer acts as a matrix for holding the active electrode particles and the conduction promoter particles within the fibrillized material.
[0037] In some embodiments, the active electrode material and the conduction promoter used in this process are, respectively, activated carbon and conductive carbon or graphite. Suitable activated carbon materials are available from a variety of sources, including Nuchar® powders sold by Westvaco Corporation of Stamford, Conn.; and YP-17 activated carbon particles sold by Kuraray Chemical Co., LTD, Shin-hankyu Bldg. 9F Blvd. C-237, 1-12-39 Umeda, Kiata-ku, Osaka 530-8611, Japan.
[0038] The polymers used in electrode embodiments in accordance with the present invention include, without limitation, polytetraflouroethylene (PTFE or Teflon®), polypropylene, polyethylene, co-polymers, and various polymer blends.
[0039] The specific proportions of the activated carbon, conductive carbon, and polymer used in selected exemplary embodiments are as follows: 85-90 percent by weight of activated carbon, 5-8 percent by weight of PTFE, and 2-10 percent by weight of conductive carbon. Other exemplary embodiments contain 85-93 percent of activated carbon, 3-8 percent of PTFE, and 2-10 percent of conductive carbon. Yet other exemplary embodiments contain activated carbon and PTFE, and do not use conductive carbon.
[0040] It should be noted that the references to dry-blending, dry powders, other dry processes, and dry, materials used in the manufacture of the active electrode material films do not exclude the use of electrolyte in the double layer capacitors. As has already been mentioned, the electrodes and the separator are typically immersed in and impregnated with an electrolytic solution in order to make a double layer capacitor. Furthermore, even though additives, such as solvents, liquids, and the like, are not necessarily used in the manufacture of certain embodiments disclosed herein, a certain amount of impurity, for example, moisture, may be absorbed by the active electrode material from the surrounding environment. Those skilled in the art will understand, after perusal of this document that the dry particles used with embodiments and processes disclosed herein may also, prior to being provided by particle manufacturers as dry particles, have themselves been preprocessed with additives and, thus, contain one or more pre-process residues. For these reasons, one or more of the embodiments and processes disclosed herein may utilize a drying step prior to a final electrolyte impregnation step so as to remove or reduce the aforementioned preprocess residues and impurities. It is identified that even after one or more drying steps, trace amounts of the aforementioned pre-process residues and impurities may be present in the active electrode material and the electrode film made from the material.
[0041] The drying step 110 may involve air-drying the fibrillized particles. Alternatively, the particles are force-dried at an elevated temperature. For example, the particles may be subjected to a temperature between about 100 and 150 degrees Celsius. It has been identified that subjecting the active electrode material to the elevated temperature substantially reduces the presence of water molecules held by physical bonding forces (VanderWaal's forces) in mesapores and macropores of the material. At the same time, water molecules held by the physical binding forces in micropores may remain trapped because of the small size of the micropores and capillary effects. Note that for the purposes of this document, we roughly divide the pores according to their dimensions (diameters or longest dimensions) along the following lines:
Micropores—under about 2 nanometers; Mesapores—between about 2 and about 25 nanometers; and Macropores—over about 25 nanometers.
[0045] It has been identified that drying has a less pronounced effect on the water molecules held by chemical bonding forces within the active electrode material than on water molecules held by physical bonding forces. The probable reason for the diminished effect is that chemical bonding forces are generally stronger than VanderWaal's forces.
[0046] In some embodiments, the drying step 110 is performed prior to fibrillizing the active electrode particles.
[0047] At the step 115 , the fibrillized particles axe mixed with a sealing coating. The coating is “sealing” in the sense that it penetrates the micropores of the active electrode material and surrounds the water molecules (and possibly other impurities) within the micropores. The water molecules become sealed within the micropores. In some embodiments, more than 30 percent of water molecules in the micropores are sealed. In more specific embodiments, at least 50 percent of water molecules in the micropores are sealed. In yet more specific embodiments, at least 80 percent of water molecules in the micropores are sealed. When the active electrode material is subsequently immersed in an electrolyte, the sealed water molecules are not able to interact with the electrolyte, or the effect of such interaction is diminished. Consequently, the number of high energy excited sites is reduced. The other desirable (but not strictly necessary) property of the coating is that it can act as an adhesive.
[0048] One sealing coating adapted for use in methods described throughout this document is known by the trade name Electrodag® EB-012. It is available from Acheson Colloids Company, 1600 Washington Avenue, Port Huron, Mich. 48060; telephone number (810) 984-5581; www.achesonindustries.com. The Electrodag® EB-012 is a water-based dispersion of graphite in a thermoplastic binder.
[0049] Other coatings adapted for use in the described methods can be selected from the Adcote® line of solvent-based adhesives, available from Rohm and Haas Company, 100 Independence Mall West, Philadelphia, Pa. 19106-2399; telephone number 215-592-3000; facsimile number 215-592-3377; www.rohmhaas.com.
[0050] In one embodiment, the active electrode material particles are first immersed in a sealing coating. The sealing coating is then drained through a filter, and the particles are dried, allowing the micropores to be sealed. After treatment with the sealing coating, the active electrode particles are mixed with an adhesive coating. The resulting material may then as be mixed with one or more processing material or liquid to obtain a slurry-like paste.
[0051] The current collector provided in the step 120 may be made of a sheet of conductive material, such as metal sheet, foil, screen, or mesh. In one electrode embodiment, the current collector is a sheet of aluminum foil approximately 40 microns thick. In alternative embodiments, the thickness of the foil is between about 20 and about 100 microns. In other, more specific embodiments, the thickness of the aluminum foil is between about 30 and about 50 microns. In still other alternative embodiments, the current collector is relatively thick and is better described as a plate.
[0052] Conductive materials other than aluminum can also be used in the current collector. These materials include, for example, silver, copper, gold, platinum, palladium, steel, and tantalum, as well as various alloys of these metals. Non-metal materials are also potential candidates for use in the current collector.
[0053] In some embodiments, the current collector may be pretreated to enhance its adhesion properties. Treatment of the current collector may include mechanical roughing, chemical pitting, and/or use of a surface activation treatment, such as corona discharge, active plasma, ultraviolet, laser, or high frequency treatment methods known to a person skilled in the art.
[0054] In the step 125 , the paste made with the treated active electrode particles is applied uniformly to one or both sides of the current collector, so that one or two films of active electrode material are formed after the paste is dried in the following step. The advantage of applying the paste to both sides of the current collector is that the two films or layers of the active electrode material may be made at the same time, resulting in an electrode assembly that includes two electrodes sharing the current collector.
[0055] At the step 130 , the paste applied to the current collector may be allowed to air-dry, or it may be force-dried at an elevated temperature. Drying at elevated temperature has the advantage of shortening the drying time and, therefore, shortening the overall time for manufacturing electrodes. After the paste is dried, film (or films) of active electrode material is (are) formed on the current collector.
[0056] At the step 135 , the current collector and the film(s) are processed in a calender or another high-pressure nip. As a result of this step, the active electrode material of the films is compacted and densified under the pressure applied by the nip. Compaction in a nip generally does not significantly reduce porosity on a small scale level. Because compacting reduces the film's volume while keeping pore surface area relatively unchanged, the normalized effective surface area of the material is increased. The volumetric efficiency of the active electrode films is therefore also increased. Moreover, compacting tends to decrease the equivalent series resistance of the capacitors built with electrodes made from the resulting current collector-film product. Structural integrity of the films and the films adhesion to the current collector may also be improved as a result of calendering.
[0057] At the step 140 , the combination of the current collector and the one or two films is shaped for use as electrodes, for example, trimmed to predetermined dimensions.
[0058] FIG. 2 illustrates selected steps of a process 200 for fabricating an electrode assembly wherein the paste of pretreated electrode material particles is deposited on a separator of a double layer capacitor. Although the process steps are described serially, certain steps may also be performed in conjunction or in parallel, in a pipelined manner, or otherwise. There is no particular requirement that the steps be performed in the same order in which this description lists them, except where explicitly so indicated, otherwise made clear from the context, or inherently required. Not all illustrated steps are strictly necessary, while other optional steps can be added to the process 200 . A high level overview of the process 200 is provided immediately below; more detailed explanations of the steps of the process 200 and variants of the steps are provided following the overview.
[0059] At step 205 , fibrillized particles of active electrode material are provided. At step 210 , the fibrillized particles are dried to evaporate the water molecules within the active electrode material. At step 215 , the particles are mixed with a sealing coating after which a slurry-like paste composition is formed. The sealing coating is capable of scaling micropores in the active electrode material. The coating may also perform as an adhesive promoting cohesion of the particles of the active electrode material and adhesion of the particles to a surface, for example, current collector or separator surface. In some embodiments, two coatings are used: one for sealing micropores, the other for acting as an adhesive. At step 220 , a porous separator sheet is provided. At step 225 , the paste obtained in the step 215 is applied to both sides of the porous separator. Note that in alternative embodiments the paste is applied to only one side of the separator. At step 230 , the paste is dried, resulting in electrode films being formed on the separator. At step 235 , two current collectors are provided. At step 240 , the current collectors are attached to the surfaces of the active electrode material films that are opposite the surfaces of the films adjacent to the separator sheet. At step 245 , the combination of the separator sheet, active electrode material films, and current collectors is calendered. The resulting calendered product is formed into a shape appropriate for use in a double layer capacitor, at step 250 .
[0060] The steps 205 through 215 of the process 200 are similar or identical to the steps 105 through 115 of the process 100 of FIG. 1 .
[0061] The separator provided in the step 220 is made from a porous material that allows an electrolyte to pass through its pores or holes. At the same time, the separator material is capable of preventing direct electrical contact between the films of active electrode material disposed on each side of the separator. In various embodiments, the separator materials used include glass, polyethylene polyphenylene sulfide, rayon, polypropylene, polyetheretherketone, other polymers; as well as compositions, laminates, and overlays of these materials. Furthermore, sheets formed using woven and unwoven fibers of these and other substances can also be used in making the separators. Separators of various embodiments further include cellulose, paper, and cotton linter. In one particular embodiment, the separator is made from TF3045 paper available from Nippon Kodoshi Corporation of Japan.
[0062] In the step 225 , the paste made with the treated active electrode particles is applied uniformly to the sides of the separator, so that films of active electrode material are formed on the separator after the paste is dried in the following step.
[0063] At the step 230 , the paste applied to the separator may be allowed to air-dry, or it may be force-dried at an elevated temperature. After the paste is dried, the films of active electrode material are formed on the separator.
[0064] Each of the current collectors provided in the step 235 may be similar or identical to the current collector provided in the step 120 of the process 100 . For example, each current collector may be made of thin aluminum foil.
[0065] Turning next to the step 240 , the current collectors may be attached to the active electrode films using an adhesive. In certain alternative process embodiments, the current collectors are deposited on the films using high-energy metallization techniques, such as flame spraying, arc spraying, plasma spraying, and high velocity oxygen fuel (HVOF) thermal spraying. In other embodiments, the current collectors are applied onto the films by vapor deposition, for example, low-pressure or sub-atmospheric chemical vapor deposition (LPCVD or SACVD). In still other embodiments, the current collectors are simply brought into contact with the films before calendering performed in the step 245 , which laminates the current collectors to their respective films under high pressure, in addition to densifying the active electrode films. The step 245 is similar to the step 135 of the process 100 .
[0066] At the step 250 , the combination of the porous separator, films, and current collectors is shaped for use as electrodes, for example, trimmed to predetermined dimensions.
[0067] Films of active electrode material pretreated with a sealing coating may be made before they are attached to the current collectors (as in the process 100 ) or to the porous separator (as in the process 200 ). FIG. 3 illustrates selected steps of one such process 300 . Although the process steps are described serially, certain steps may also be performed in conjunction or in parallel, in a pipelined manner, or otherwise. There is no particular requirement that the steps be performed in the same order in which this description lists them, except where explicitly so indicated, otherwise made clear from the context, or inherently required. Not all illustrated steps are strictly necessary, while other optional steps can be added to the process 300 .
[0068] At step 305 , two films of active electrode material are provided. In some process embodiments, polymer powder, active electrode material powder (e.g., activated carbon), conduction promoter powder (e.g., conductive carbon or graphite), and possibly other powder materials are blended, for example, using a dry-blending process. The proportions of the materials, the specific materials used, and the blending operation may be similar or identical to those described in relation to the process 100 of FIG. 1 .
[0069] The dry powder material (that results from mixing and blending) is fibrillized (fibrillated) using non-lubricated high-shear techniques, such as jet milling, pin milling, hammer milling, or similar techniques known to a person skilled in the art. The fibrillized material is then fed into one or more high-pressure nips, such as roll mills, calenders, belt-presses, or flat plate presses, to press the material into films.
[0070] After the active electrode films are made, they are immersed in a sealing coating, for example, the Electrodag® EB-012 or Adcote® coating, at step 310 . At step 315 , the films treated with the sealing coating are dried, for example, air-dried or force dried at an elevated temperature. At step 320 , a current collector is provided. This step is similar to the step 120 of the process 100 . The active electrode films are attached to the current collector in step 325 . Attachment may be performed using a number of different techniques, including these:
[0000] 1. Using an adhesive layer between each film and the current collector, optionally followed by calendering.
[0000] 2. Using high-energy metallization techniques, such as flame spraying, arc spraying, plasma spraying, and HVOF thermal spraying.
[0000] 3. Using vapor deposition, for example, LPCVD and SACVD techniques.
[0071] At step 330 , the current collector and the films are processed in a calender or another high-pressure nip. At step 335 , the combination of the current collector and the one or two films is shaped for use as electrodes, for example, trimmed to predetermined dimensions.
[0072] Treatment of porous material with a sealing coating may be performed before the material is fibrillized. FIG. 4 illustrates selected steps of a process 400 for making film of fibrillized active electrode material wherein the porous material is treated with a sealant before the material is fibrillized. Although the process steps are described serially, certain steps may also be performed in conjunction or in parallel, in a pipelined manner, or otherwise. There is no particular requirement that the steps be performed in the same order in which this description lists them, except where explicitly so indicated, otherwise made clear from the context, or inherently required. Not all illustrated steps are strictly necessary, while other optional steps can be added to the process 400 .
[0073] At step 405 , activated carbon is provided. For example, carbon particles may be activated using thermal or chemical activation techniques that increase carbon porosity. At step 410 , the activated carbon particles are washed to remove solid impurities.
[0074] At step 415 , the carbon particles are force-dried at elevated temperature, or simply allowed to dry at room temperature. The step 415 may be similar to the step 110 of the process 100 described above.
[0075] At step 420 , the carbon particles are treated with a sealing coating. This step is similar to the step 115 of the process 100 . As has been described in relation to the process 100 , the coating is “sealing” in the sense that it penetrates the micropores of the active electrode material and surrounds the water molecules (and possibly other impurities) within the micropores. The water molecules become sealed within the micropores. At step 425 , the sealing coating with which the carbon particles have been treated is dried, for example, force-dried or allowed to dry at ambient temperature.
[0076] At step 430 , the activated carbon particles are mixed with fibrillizable binder and, optionally, with particles of a conduction promoting material, such as conductive carbon. The mixture is then blended. After blending, the resulting dry powder material is fibrillized using, for example non-lubricated high-shear force techniques, such as jet milling, pin milling, hammer milling, or similar techniques known to a person skilled in the art. This is done at step 435 . Mixing, blending, fibrillation, and specific materials and proportions used in the steps 430 and 435 may be similar or identical to those that have been described in relation to the step 105 of the process 100 .
[0077] At step 440 , film or films are formed from the fibrillized material. In some exemplary embodiments, the fibrillized material is fed into one or more high-pressure nips, such as roll mills, calenders, belt-presses, or flat plate presses, to press the material into films. In other exemplary embodiments, particles of the fibrillized material are mixed with an adhesive to form a slurry-like paste composition, which may be deposited on a current collector or porous separator, and allowed to dry, as has been described in relation to step 125 / 130 and 225 / 230 of the processes 100 and 200 , respectively. In yet other embodiments, treatment with sealant as described herein is performed on particles that are used form extruded type electrode films, as are known to those skilled in the extruded electrode arts.
[0078] The electrodes, electrode assemblies, and electrode films obtained through the processes 100 , 200 , 300 , and 400 may be used in double layer capacitors and other electrical energy storage devices. FIG. 5 illustrates, in a high level manner, cross-section of an electrode assembly 500 of a double layer capacitor. In the Figure, the components of the assembly 500 are arranged in the following order: (1) first current collector layer 505 , (2) first active electrode Elm 510 , (3) porous separator 520 , (4) second active electrode film 530 , and (5) second current collector 535 . A double layer capacitor using the electrode assembly 500 further includes an electrolyte and a container, for example, a sealed can, that holds the electrolyte. The assembly 500 is disposed within the container (can) and immersed in the electrolyte.
[0079] To understand better various steps of the processes 100 , 200 , 300 , and 400 , a person skilled in the art may also benefit from reading U.S. patent application Ser. No. 10/817,701, filed 2 Apr., 2004 and one or more provisional referenced therein. These commonly assigned patent documents are hereby incorporated by reference as if fully set forth herein, including all figures, tables, claims, and additional subject matter incorporated by reference therein.
[0080] Additional details for manufacturing double layer capacitors are described in various sources, including Farahimandi et al., U.S. Pat. No. 6,585,152, entitled METHOD OF MAKING A MULTI-ELECTRODE DOUBLE LAYER CAPACITOR HAVING SINGLE ELECTROLYTE SEAL AND ALUMINIUM-IMPREGNATED CARBON CLOTH ELECTRODES; and in Bendale et al. U.S. Pat. No. 6,631,074, entitled ELECTROCHEMICAL DOUBLE LAYER CAPACITOR HAVING CARBON POWDER ELECTRODES. These commonly-assigned patents are hereby incorporated by reference as if fully set forth herein, including all figures, tables, claims, and additional subject matter incorporated by reference therein.
[0081] The inventive active electrode films, electrodes, electrode assemblies, energy storage devices, and processes used in the course of their fabrication are described above in considerable detail for illustration purposes. Neither the specific embodiments of the invention as a whole, nor those of its features, limit the general principles underlying the invention. In particular, the invention is not limited to the specific materials and proportions of constituent materials used for fabricating the electrodes. The invention is also not limited to electrodes used in double layer capacitors, but extends to other electrode applications. The specific features described herein may be used in some embodiments, but not in others, without departure from the spirit and scope of the invention as set forth. Many additional modifications are intended in the foregoing disclosure, and it will be appreciated by those of ordinary skill in the art that, in some instances, some features of the invention will be employed in the absence of a corresponding use of other features. The illustrative examples therefore do not define the metes and bounds of the invention and the legal protection afforded the invention, which function is served by the claims and their equivalents. | Active electrode material, such as fibrillized blend of activated carbon, polymer, and conductive carbon, is pretreated by immersion in a sealing coating. After the active electrode material is dried, the coating seals micropores of the activated carbon or another porous material, thus preventing exposure of water molecules or other impurities trapped in the micropores to outside agents. At the same time, the sealing coating does not seal most mesapores of the porous material, allowing exposure of the mesapores' surface area to the outside agents. The pretreated active electrode material is used for making electrodes or electrode assemblies of electrical energy storage devices. For example, the electrodes may be immersed in an electrolyte to construct electrochemical double layer capacitors. Pretreatment with the sealing coating reduces the number of water molecules interacting with the electrolyte, enhancing the breakdown voltage of the capacitors. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a vacuum sampling vial and more particularly to a vacuum sampling vial capable of safe sample extraction in only a single step.
With the advance of quantitative laboratory measuring techniques to easily and accurately measure certain ionic species such as heavy metals (i.e., Pb, Fe, Cu) in ultra low ranges (0-25 ppb) the need to obtain water samples which are truly untainted has increased many fold.
To date, water sampling technologies for trace level water samples require a skilled operator to extract a sample because of the handling of hazardous materials used to stabilize water samples and the need to prevent exposure to contaminants introduced from unclean vessels or implements. The risk of sample contamination is so great for extreme low level measurements that sterilized sampling containers once opened to permit the sample to be placed in it can be contaminated by exposure to surrounding environmental conditions. Additionally, once the sample has been extracted and inoculated with a stabilizer such as concentrated nitric acid for copper samples, a product results which has personal and transportation hazards.
For example, to test for the presence of the element copper in water via the use of an ICP (Inductively Coupled Plasma) analyzer, the currently available sampling systems provide for a multi step extraction procedure before the ICP can perform its analysis. Steps involved are the filling of a copper free bottle with water, sample inoculation with copper free nitric acid, extraction of the sample from the sample container via copper free apparatus such as a pipetter and resealing of the sample container without contamination and for eventual environmentally safe disposal of the excess acidified sample. The entire procedure can take hours.
In our patent application Ser. No. 07/781,875 entitled "Vial With Powdered Reagent" filed on Oct. 24, 1991, we describe a method of manufacturing an evacuated vial containing a powdered reagent under conditions in which contamination is avoided so that the vial can be stored for an indefinite period of time. Once the frangible tip is broken and the vial is filled with a sample and taken to a laboratory for analysis. If it were desired to remove the sample, the sample will not leave the vial merely by unsealing the neck due to the narrow diameter of the opening so that destruction of the vial itself is required with the attendant risks of contamination. Hence, so that the use of such an evacuated vial either requires a more expensive procedure to avoid the contamination or the use of such a vial is limited to circumstances where contamination is not considered to be a problem.
In other words, evacuated sampling vials are not useful where high levels of purity and accuracy are required due to the inability to transfer the sample from the vial to the testing apparatus without risk of contamination.
A number of United States Patents teach sampling methods and apparatus for testing purposes.
U.S. Pat. No. 3,332,288 discloses a device for sampling molten metal using an elongated tube which is evacuated and has a weakened portion which breaks when thrust into the metal. The tube is made by glass blowing.
U.S. Pat. No. 3,626,762 shows a method and apparatus for filling a capillary tube with liquid in which a wedge device is employed to break the frangible tip of the tube.
U.S. Pat. No. 4,445,390 discloses a sampling tube and apparatus for use in detecting the presence of hydrogen in a molten specimen. A porous plug is employed within the tube through which the hydrogen passes.
U.S. Pat. No. 4,537,747 teaches a disposable sampling device in which an evacuated vial with a frangible tip is employed. The sample is then shaken out of the vial for testing.
None of the preceding patents teaches the present invention.
SUMMARY OF THE INVENTION
In this invention there is provided a sampling vial particularly useful where the need to avoid contamination is great and a method of manufacturing such a vial.
In a preferred embodiment of this invention the sampling vial is evacuated with a frangible tip at one end for receiving the sample. The other end of the vial is provided with an internal breaking tip which is readily punctured to permit the sample to be removed through the tip.
The method of manufacturing the vial according to a preferred embodiment involves cutting a preformed glass tube to a fixed length, forming a flat glass bottom at one end, heating a small circle in the glass bottom, pressing a tungsten plunger into the heated circle creating an internal breaking tip, and dipping the glass bottom with the internal breaking tip in a plasticized bath to form a seal. In an alternative embodiment, an ultra thin glass bottom is mounted on and sealed over the internal breaking tip. The other end of the vial is then formed into an external tapered tip in accordance with the method described in our patent application identified above.
It is thus a principal object of this invention to provide a sampling vial of unique design and manufacture for use in sampling liquids with minimum risk of contamination.
Other objects and advantages of this invention will hereinafter become obvious from the following description of preferred embodiments of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 4 are diagrammatic views of the steps involved in adding a bottom to a tube to form a vial incorporating the principles of this invention.
FIG. 4a is a diagrammatic view of an alternative embodiment.
FIG. 5 is a diagrammatic, schematized view of a glove box in which the close bottomed tubes are supplied with mixture, and sealed
FIGS. 6-10 are diagrammatic views of the steps involved in sealing the load filled vial under vacuum.
FIGS. 11 and 12 are diagrammatic views of the steps involved in preparing the frangible tip of the vial for use.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a hollow, preformed glass tube 10 cut to a fixed length is provided with a glass bottom by heating one end of tube 10 using a burner 12 and welding a glass blank 13 to the bottom of tube 10 as shown in FIG. 1.
As seen in FIG. 2, bottom 13 is heated in the center, typically, a 5 mm circle, to about 750 degrees F. A tungsten plunger 14 is pressed in and through glass bottom 13 to a prescribed depth (dependent on the width and vacuum pressure) creating an internal breaking tip 15 in the bottom of tube 10 as seen in FIG. 3. This operation must take no more than 0.5 seconds. Properly done, as will be seen later, a sample release mechanism has been created which is both sturdy enough to withstand the application of a vacuum and transportation of a filled vial yet frangible enough to be broken by a lab technician in a controlled manner.
Having now created an open ended tube 10 with internal release point 15, open ended tube 10 is heated to 800-1000 degrees F. for a period of 6 hours to clean it of potential contaminants.
Next the closed end with the internal break point 15 is dipped in a plasticized sealant bath 16 as seen in FIG. 4 forming a membrane over the closed bottom of tube 10. If desired, as an alternative, an ultra thin glass bottom 17 is attached as seen in FIG. 4a. This step is necessary to assure no contamination enters the sample during sample release. The choice of end seal will be dependent on sampling application.
Referring to FIG. 5, clean open at the top tubes 10 are then placed inside of a glove box 18 containing an inert gaseous medium such as nitrogen gas supplied by and maintained at an overpressure through a hose 19.
Mounted on glove box 18 is a sealed funnel herein referred to as retention vessel 20 containing a previously prepared highly purified mixture 22 of a stabilizing agent or reagent having an outlet tube 24 extending into glove box 18. Within glove box 18, tube 24 is provided with a stopcock 26, which, as is understood in the art, each rotation thereof would release a predetermined measured amount of mixture 22 into the open mouth of tube 10 directly underneath, the details of which are described in our earlier application identified above.
As is understood in the art, the worker would reach into glove box 18 using gloves (not shown) to fill a number of tubes, or as now hereinafter referred to as vials 10 with the measured amount of mixture 22 of the reagents, followed by closing off each vial 10 with a stopper 28. A vial 10 in position A would be moved to position B directly underneath tube 24, filled with mixture 22, then stoppered and moved to position C.
A number of vials 10 closed off with mixture 22 contained therein are removed from glove box 18 and handled in a manner to be described.
Referring to FIGS. 6-10, each vial 10 containing mixture 22 is placed upright with its bottom inserted for support in a hollow closely fitted base 32. Stopper 28 is removed and immediately replaced by a cap 34 which seals and grasps the top, and is attached to a vacuum hose 36 connected to a suction pump (not shown) or other source of vacuum to evacuate the interior of vial 10 leaving only nitrogen under less than atmospheric pressure.
As seen in FIG. 7, a flame nozzle 38 jets a flame to make contact with an intermediate portion of vial 10 while base 32 is rotated to cause vial 10 to spin so that it is heated uniformly around the circumference. After the glass is softened in the region heated, as seen in FIG. 8, cap 34 is pulled upwardly to stretch vial 10. Heat is controlled carefully to insure that the glass is softened only enough to permit the elongation. The softened portion under the influence of the vacuum is drawn inwardly to form a narrow waist 42.
In the next step, seen in FIG. 9, a flame nozzle 44 is employed to heat a very narrow portion of waist 42 until total collapse takes place sealing off the bottom portion 10a of vial terminating in a sealed tip 46. Cap 34 with the top portion of vial 10 is removed. The bottom portion, now referred to as vial 10a, containing the stabilizing agent 22 under vacuum is then removed from base 32 and may be otherwise prepared for use, i.e., labelling, scoring of the tip, etc.
The result of the preceding steps is a sealed vial or ampule 10a containing an inert gaseous medium such as nitrogen under a subatmospheric pressure and a stabilizing agent or reagent where required.
Referring to FIGS. 11 and 12, a plastic sampling hose 52, previously chemically rinsed to remove any contaminants, is applied over the external tip 46. The open end 54 of hose 52 is hermetically heat sealed closed, and is folded in half. If desired, a hose clamp 56 may be applied at the fold point and a ring 58 slipped over the folded hose.
Sealed vial 10a with the plastic sampling hose 52 attached is then placed under a rotating UV light source as is understood in the art to kill any bacterial contaminants and then packaged for shipment.
To use vial 10a to obtain a sample, vial hose 52 is straightened by removing clamp 56 and ring 58, the sealed tip 54 is snipped off, and the straight hose is inserted into the water to be sampled. Vial tip 46 is snapped by the operator using his fingers to squeeze hose 52. The vacuum applied during manufacture causes a sample to be drawn into vial 10a. The operator then folds vial hose 52 and reapplies the hose clamp and ring 58 for transportation back to the lab facility. The hose will act as a pressure compensator arising from temperature changes during transportation and storage. It is seen that the extraction of the sample occurs without the exposure to contaminants or personal hazard to the operator. Additionally, the operator need not be of special skill or education.
Once at the laboratory, the lab technician removes the hose clamp 56 and cuts the plastic hose 52 off to open it up. Holding vial 10a in the inverted position and directly over the ICP sample chamber or other testing device, the technician depresses the center of the membrane or penetrates the thin glass bottom 17 covering the flat bottom of the vial with a plastic rod. This causes the very unique internal release point 15 to break and permits the sample to flow freely into the ICP sample chamber.
The entire procedure of sample extraction and sample loading takes a minute without permitting contact to outside contaminates where current technologies can take hours of a skilled technician's time.
This unique sampling arrangement is applicable to a multitude of different elemental tests in water and may have application in the future for gaseous elements as well. It is understood that the vial can be used for extracting liquid samples only and not containing any stabilizing agent or reagent. This would be accomplished by using glove box 18 in FIG. 5 only to provide the inert atmosphere and not to insert the mixture.
It will be seen that the novel sampling vial and the attendant methods of manufacture and use afford many advantages over previous vial designs. It provides a sterilized container with indefinite shelf life and a one step procedure for sample extraction in which there is an easy and non contaminating method of removing the sample from the sampler into the laboratory analytical vessel thus eliminating any operator introduced contamination. Also, the use of this vial eliminates hazardous material classifications for both operator and transportation.
While only certain preferred embodiments of this invention have been described it is understood that many variations of this invention are possible without departing from the principles of this invention as defined in the claims which follow. | An evacuated vial for collecting a fluid sample and a method for manufacturing the vial comprising a cylindrical glass tube, one end of the tube formed into a frangible tip, a glass bottom closing off the other end of the tube, and a depression formed in the bottom forming an internal breaking tip extending into said tube. The bottom of the tube is sealed in a manner permitting convenient puncture thereof to break the tip when a sample is to be delivered. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains, in general, to tire-reinforcing bead wires, and in particular, to a tire-reinforcing bead wire coated with benzoic acid to increase rubber adhesion.
[0003] 2. Description of the Prior Art
[0004] Generally, bead wires is steel wires in a diameter of about 0.95 mm made of carbon steel containing 0.6-0.95% of carbon, and plated with 0.3-0.5 μm thick bronze layer. The bead wires are superior in strength, modulus, heat-resistance and fatigue-resistance to other inorganic and organic fibers, thus being applicable to reinforcing bead portions of tires (See FIG. 1).
[0005] As for such bead wires, surface oxidation should be avoided through the preparation process of the bead wires in order to obtain excellent adhesion to rubber. However, it is very difficult to regulate the surface oxidation below certain level. Also, the finished bead wires in which surface oxidation is avoided in the process of producing can be easily oxidized in accordance with aging due to heat, stress and moisture.
[0006] Therefore, researches for improving initial and aged adhesion and preventing surface oxidation have been carried out by tire cord producers. In particular, surface coating treatment of bead wires using adhesion enhancers has been mainly focused, but formal research results with respect to bead wires are scarcely found. Only some techniques for treatment of steel cord surface by adhesion enhancers have been reported. In this regard, Belgian Pat. No. 786,059 and German Pat. No. 2,227,013 disclose a method of coating the surface of the steel cord with a mineral oil solution of an organic acid and a long chain aliphatic amine salt, or with a mixture of the solution and very small amount of benzotriazole. The key point in such a method is uniform mixing of an oily ingredient and an organic acid contained in the solution. Due to this problem, the above method lacks reproducibility to form uniform solution in preparation, thus the above method is unsuitable for use in practical preparation processes.
[0007] In U.S. Pat. No. 4,283,460 by Goodyear Tire & Rubber Company, USA, disclosed are methods for increasing rubber adhesion and surface cleanness of steel tire cord by coating the steel cord with an alcohol solution of a benzotriazole-based compound, a cyclohexylamine borate-based compound or a mixture thereof. This method is advantageous in that the coating solution can be easily produced and thus the method shows good productivity and economic benefit being realized. However, benzotriazole initial and aged adhesion badly, though it improves surface clearness of the steel cord.
[0008] Despite much research to improve initial and aged-adhesion between rubber and steel cord or bead wire, only laboratory-level research, regardless of productivity and economic benefit, has been mainly performed. There is thus a need for methods for improvinf rubber adhesion by simpler process.
SUMMARY OF THE INVENTION
[0009] Leading to the present invention, the intensive and thorough research on bead wires, carried out by the present inventors aimed at avoiding the problems encountered in the prior art, resulted in the finding that, when benzoic acid is coated to the surface of a bead wire, adhesion between metal and rubber is increased.
[0010] Therefore, it is an object of the present invention to provide a tire-reinforcing bead wire, which is advantageous in light of prevention of surface oxidation on the bead wire and increased adhesion with rubber.
[0011] In accordance with an aspect of the present invention, there is provided a tire-reinforcing bead wire, coated with benzoic acid.
[0012] In accordance with another aspect of the present invention, there is provided a tire comprising such a bead wire used as a reinforcing material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 shows a tire structure schematically;
[0014] [0014]FIG. 2 a shows an XPS (X-ray photoelectron spectrometer) depth profile of the bead wire according to Example 3;
[0015] [0015]FIG. 2 b shows an XPS depth profile of the bead wire according to comparative Example 3;
[0016] [0016]FIG. 3 a shows only a Sn oxidation profile in the XPS depth profile of FIG. 2 a; and
[0017] [0017]FIG. 3 b shows only a Sn oxidation profile in the XPS depth profile of FIG. 2 b.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The inventor completed the present invention by finding that rubber adhesion of bead wires is improved when benzoic acid is coated on the bead wires.
[0019] Bbenzoic acid is represented by the following formula (1):
[0020] Benzoic acid exists as colorless crystalline fragments at room temperature and has a melting point of 121° C. and a boiling point of 250° C. (sublimated at around 100° C.). Benzoic acid is hardly dissolved in cold water but easily dissolved in hot water, alcohol, ether, etc.
[0021] By coating benzoic on the surface of bead wires, segregation problem during rubber mixing is prevented and adhesion of metal to rubber is directly increased at the same time.
[0022] The bead wires are coated by passing it through cotton ropes sufficiently soaked with benzoic acid and being dried, right after plating process such as bronze plating.
[0023] At this time, an additional coating apparatus is not needed. The cotton ropes through which the bead wires passed are easily soaked with benzoic acid solution by capillary phenomenon. Moreover, the bead wires which are passed through the cotton ropes can be naturally dried before being wound. Thus a separate post-treatment process is unnecessary.
[0024] The benzoic acid solution useful in the present invention is prepared by dissolving benzoic acid in a solvent such as alcohol, benzene, toluene, acetone, ether, water, etc in the concentration of 1-20 mol %, preferably 5-10 mol %. In consideration of the solubility of benzoic acid and solvent evaporation after coating, alcohol, particularly methanol, is preferred.
[0025] When the concentration of the solution is less than 1 mol %, the resultant bead wires cannot sufficiently improve rubber adhesion. To the contrary, when the concentration exceeds 20 mol %, rubber adhesion and coverage are decreased.
[0026] The benzoic acid-coated bead wires according to the present invention are about 5% higher in initial and aged adhesion with rubber than non-coated bead wires. As well, stable rubber coverage is maintained and surface oxidation is prevented.
[0027] Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLE 1
[0028] and
Comparative Example 1
[0029] 0.80-0.85% carbon-containing bead wire (A) (Hyosung Corporation, Korea) having a diameter of 0.95 mm plated with bronze comprising 88% Cu and 12% Sn, and 0.80-0.85% carbon-containing bead wire (B) (Hyosung Corporation, Korea) having a diameter of 0.95 mm plated with bronze comprising 97% Cu and 3% Sn were coated with methanol solutions of benzoic acid in the concentrations of 1, 5, 10, 20 and 30 mol % under atmosphere. Control specimen was left uncoated. Thereafter, initial adhesion to available tire rubber having the composition shown in the following Table 1 was determined according to ASTM D1871-84a. Bonded portions between the bead wire and the rubber were observed with the naked eye, while being rotated 360°, to determine rubber coverage. The results are given in Table 2, below.
EXAMPLE 2
[0030] and
Comparative Example 2
[0031] 0.80-0.85% carbon-containing bead wire (A) (Hyosung Corporation, Korea) having a diameter of 0.95 mm plated with bronze comprising 88% Cu and 12% Sn, and 0.80-0.85% carbon-containing bead wire (B) (Hyosung Corporation, Korea) having a diameter of 0.95 mm plated with bronze comprising 97% Cu and 3% Sn was coated with methanol solutions of benzoic acid in the concentrations of 1, 5, 10, 20 and 30 mol % under atmosphere. Control specimen was left uncoated. Thereafter, such bead wires were allowed to stand under a circumstance of 30° C./relative humidity 55% for one week. After one week, aged adhesion and rubber coverage was determined according to the same method in Example 1. The results are given in 5 the following Table 2.
TABLE 1 Composition of Tire Rubber Component Part by Weight Nutural Rubber 100 Peptizer 0.1 Resorcinol 3 Process Oil 10 Stearic Acid 2 Furance Black 55 Zinc Oxide 10 Hexamethylene Terramine 2 Antioxidant 0.75 Accelerator 1 Retarder 5 Sulfur 5
[0032] [0032] TABLE 2 Bead Wire A B A B Benz. 0% 30% 0% 30% 1% 5% 10% 20% 1% 5% 10% 20% Sol. Mol. Conc. Adhesion Com. 79 83 96 117 Ex. 83 87 87 85 116 122 119 117 (kg/inch 2 ) Ex.1 1 Coverage 82 83 90 87 85 90 88 85 93 95 95 90 (%) Adhesion Com. 72 79 109 112 Ex. 81 82 84 81 115 118 116 113 (kg/inch 2 ) Ex.2 2 Coverage 77 82 90 90 83 85 85 83 93 95 93 92
[0033] From the above Examples and Comparative examples, it can be seen that the bead wires coated with 1-20% benzoic acid solution are superior in both of adhesion and coverage than the non-coated wires. But, in the case of 30% benzoic acid-coated bead wires, excess benzoic acid is attached to the bead wires, and thus the coverage is unfavorably decreased (B type bead wire), even though the adhesion is improved.
EXAMPLE 3
[0034] and
Comparative Example 3
[0035] 0.80-0.85% carbon-containing bead wire (Hyosung Corporation, Korea) having a diameter of 0.95 mm, plated with bronze comprising 88% Cu and 12% Sn was coated with 5 mol % benzoic acid in methanol solution was coated under atmosphere. Control specimen was left uncoated. Then, such bead wires were allowed to stand under a circumstance of 30° C./relative humidity 55% for one week. After that, surface analysis was performed by X-ray photoelectron spectrometer. XPS depth profiles obtained from such analysis are shown in FIGS. 2 a and 2 b (FIG. 2 a: benzoic acid-coated; FIG. 2 b: benzoic acid-noncoated). FIGS. 3 a and 3 b show only Sn oxidation profiles (Sn: 484.5, 493.3 eV; SnO 2 : 486.8, 495.3 eV) (FIG. 3 a: benzoic acid-coated; FIG. 3 b: benzoic acid-noncoated) in the XPS depth profiles of FIGS. 2 a and 2 b.
[0036] Since Cu and Sn exist as oxides that are thermodynamically stable under atmosphere, an oxide film is naturally formed to the surface of the bead wire. However, as can be seen in FIGS. 2 a, 2 b, 3 a and 3 b, the non-coated bead wire is oxidized to its deep internal portion, compared to the bead wires coated with benzoic acid. The results show that a coating treatment using benzoic acid solution can restrain oxidation on the surface of the bead wire, in addition to improving rubber adhesion and coverage.
[0037] As described above, according to the present invention, the bead wires, which are advantageous in light of increased initial and aged adhesion of rubber, excellent rubber coverage and restrained surface oxidation, can be easily obtained.
[0038] The present invention has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be in the nature of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | Disclosed is a tire-reinforcing bead wire coated with benzoic acid, which is advantageous in terms of rubber adhesion. As well, the bead wire shows increased initial and aged adhesion of rubber, high rubber coverage, and suppression of surface oxidation. | 3 |
FIELD OF THE INVENTION
The present subject matter relates generally to spray arms for dishwasher appliances.
BACKGROUND OF THE INVENTION
Dishwasher appliances generally include a tub that defines a wash compartment. A rack assembly can be slidably mounted within the wash compartment and configured for receipt of articles for washing. In addition, dishwasher appliances can include spray arm assemblies for applying wash fluid to articles in the rack assembly.
Spray arm assemblies for dishwasher appliances generally include a housing that defines a cavity. The cavity can receive wash fluid during operation of the dishwasher appliance. The cavity directs such wash fluid to a plurality of orifices defined by the housing. The wash fluid exits the cavity through the orifices and can be directed towards articles within the rack assembly.
Each of the plurality of orifices can have any of a variety of outlet geometries or configurations. For example, a particular one of the plurality of orifices can have a pencil jet geometry or configuration. Conversely, another of the plurality of orifices can have a fan jet geometry or configuration. Various arrangements of outlet geometries can be selected to adjust the spray pattern of the spray arm assembly. For example, pencils jets direct a concentrated stream of wash fluid adapted, e.g., to removing food particles and stains from articles in the rack assembly during a wash cycle. On the other hand, fan jets direct a mist of wash fluid adapted, e.g., to rinsing wash fluid from articles in the rack assembly during a rinse cycle. Accordingly, a dishwasher designer can select outlet geometries in order to generate a particular spray pattern for the spray arm assembly. By carefully selecting the spray pattern, the designer can improve performance of the dishwasher appliance.
In certain dishwasher appliance, the spray arm assembly is molded from single piece of material. Accordingly, during the molding process, the outlet geometries of the plurality of orifices are determined by the mold used to construct the spray arm assembly. Thus, in the event of a design change involving the outlet geometries of the plurality of orifices, the entire mold is modified or replaced. For example, if the designer desires to change the direction of a pencil jet, the entire mold used to construct the spray arm assembly may require replacement or modification.
Replacing or modifying the entire mold can be a time intensive and expensive process. Accordingly, a spray arm assembly with features for more easily modifying an outlet geometry of an orifice would be useful. In particular, a spray arm assembly with features for modifying an outlet geometry of an orifice without requiring modification or remanufacture of the remainder of the spray arm assembly would be useful.
BRIEF DESCRIPTION OF THE INVENTION
A dishwasher appliance is provided with a spray arm assembly. The spray arm assembly defines an orifice for directing liquid out of the spray arm assembly. The orifice can selectively receive a nozzle with a particular outlet geometry. By selectively receiving the nozzle, a spray pattern of liquid exiting the orifice can be changed by replacing or modifying the nozzle without remanufacturing or replacing the spray arm assembly. Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In a first exemplary embodiment, a spray assembly for a dishwasher appliance is provided. The spray assembly includes a spray arm that defines a chamber configured for receipt of a wash fluid. The spray arm further defines a plurality of orifices. A first nozzle is inserted within one of the plurality of orifices. The first nozzle has a first outlet geometry. A second nozzle is inserted within another one of the plurality of orifices. The second nozzle has a second outlet geometry. The second outlet geometry is different from the first outlet geometry. The first and second nozzles are configured for directing wash fluid out of the chamber of the spray arm.
In a second exemplary embodiment, a dishwasher appliance is provided. The dishwasher appliance has a tub that defines a wash compartment. A rack assembly is received within the wash compartment. The rack assembly is configured for receipt of articles for washing. A spray assembly is configured for applying wash fluid to articles in the rack assembly. The spray assembly includes a spray arm that defines a chamber configured for receipt of a wash fluid. The spray arm further defines a plurality of orifices. A first nozzle is inserted within one of the plurality of orifices. The first nozzle has a first outlet geometry. A second nozzle is inserted within another one of the plurality of orifices. The second nozzle has a second outlet geometry. The second outlet geometry is different from the first outlet geometry. The first and second nozzles are configured for directing wash fluid out of the chamber of the spray arm.
In a third exemplary embodiment, an intermediary component for a spray arm is provided. The intermediary component includes a first nozzle. The first nozzle has a first outlet geometry. A second nozzle has a second outlet geometry. The second outlet geometry is different than the first outlet geometry. A web extends between and connects the first nozzle and the second nozzle.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
FIG. 1 provides a partial, cross-sectional side view of a dishwasher appliance according to an exemplary embodiment of the present subject matter.
FIG. 2 illustrates a top, perspective view of an exemplary embodiment of a spray arm assembly as may be used in the dishwasher appliance of FIG. 1 and, in particular, illustrates a first plurality of exemplary nozzles and a second plurality of exemplary nozzles of the spray arm assembly.
FIG. 3 illustrates an exploded, perspective view of the spray arm assembly of FIG. 2 .
FIG. 4 provides a bottom cross-section view of the spray arm assembly of FIG. 2 taken along line 4 - 4 of FIG. 2 .
FIG. 5 provides a side cross-section view of the spray arm assembly of FIG. 2 taken along line 5 - 5 of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
Reference now will be made in detail to exemplary embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
FIG. 1 is a side view of an exemplary domestic dishwasher system 100 shown in partial cut-away and is representative of a type of a dishwasher that may incorporate aspects of the present subject matter. It is contemplated, however, that the present subject matter may be practiced in other types of dishwashers and dishwasher systems beyond dishwasher system 100 described and illustrated herein. Accordingly, the following description is for illustrative purposes only, and the present subject matter is in no way limited to use in a particular type of dishwasher system, such as dishwasher system 100 .
Dishwasher 100 includes a cabinet 102 having a tub 104 therein that defines a wash compartment 106 . The tub 104 includes a front opening (not shown in FIG. 1 ) and a door 120 hinged at its bottom 122 for movement between a normally closed vertical position (shown in FIG. 1 ) wherein the wash compartment 106 is sealed shut for washing operation, and a horizontal open position (not shown) for loading and unloading of dishwasher contents.
Upper and lower guide rails 124 , 126 are mounted on tub side walls 128 and accommodate upper and lower roller-equipped racks 130 , 132 , respectively. Each of upper and lower racks 130 , 132 is fabricated from known materials into lattice structures including a plurality of elongate members 134 , and each rack 130 , 132 is adapted for movement between an extended loading position (not shown) in which the rack is substantially positioned outside the wash compartment 106 , and a retracted position (shown in FIG. 1 ) in which the rack is located inside wash compartment 106 . Conventionally, a silverware basket (not shown) is removably attached to the lower rack 132 for placement of silverware, utensils, and the like that are too small to be accommodated by upper and lower racks 130 , 132 .
A control input selector 136 is mounted at a convenient location on an outer face of the door 120 and is coupled to control circuitry and control mechanisms for operating a fluid circulation assembly (not shown) to circulate water and dishwasher fluid in the dishwasher tub 104 . The fluid circulation assembly is located in a machinery compartment 140 located below a bottom sump portion 142 of the tub 104 .
A lower spray assembly 144 is mounted within a lower region 146 of the wash compartment 106 and above tub sump portion 142 . A mid-level spray assembly 148 is located in an upper region of the wash compartment 106 and is located in close proximity to the upper rack 130 and at a sufficient height above lower rack 132 to accommodate larger items, such as a dish or platter. In a further exemplary embodiment, an upper spray assembly (not shown) may be located above the upper rack 130 at a sufficient height to accommodate taller items, such as a glass of a selected height.
Lower and mid-level spray assemblies 144 , 148 and the upper spray assembly are fed by the fluid circulation assembly and include an arrangement of discharge ports or nozzles for directing washing liquid onto dishes located in the upper and lower racks 130 , 132 , respectively. Lower and mid-level spray assemblies 144 , 148 may include spray arms such that the assemblies 144 , 148 rotate during application of washing liquid. For example, the arrangement of the discharge ports in the lower and mid-level spray assemblies 144 , 148 induces a rotational torque by virtue of the angle and force of the water exiting the discharge ports. The resultant rotation of the lower and mid-level spray assemblies 144 , 148 provides coverage of dishes and other articles with a washing spray. Thus, it should be appreciated that one or all of the spray arm assemblies may be rotatably mounted and configured to generate a swirling spray pattern within the wash compartment 106 when the fluid circulation assembly is activated.
FIG. 2 illustrates a perspective view of an exemplary embodiment of a spray arm assembly 200 that, e.g., may be used in dishwasher appliance 100 as lower, and/or mid-level spray assemblies 144 , 148 . Spray arm assembly 200 includes an upper housing 210 . Upper housing 210 is configured for directing washing fluid during operation of dishwasher appliance 100 ( FIG. 1 ) as described in greater detail below. Upper housing 210 may be constructed of metal, plastic, and/or any suitable material or combination of materials.
Upper housing 210 includes a first pair of arms 214 and a second pair of arms 216 . First and second pair of arms 214 , 216 are configured for rotation about an axis of rotation A, e.g., during operation of dishwasher appliance 100 . In FIG. 2 , first and second pairs of arms 214 , 216 extend away from axis of rotation A arcuately. However, it should be understood that spray arm assembly 200 is provided an example only and is not intended to be limiting. Thus, spray arm assembly 200 may have any suitable configuration. For example, first and second pairs of arms 214 , 216 may be substantially linear or have any other suitable shape. Similarly, spray arm assembly 200 may include only first or second pairs of arms 214 , 216 or may contain any suitable number of additional arms.
Upper housing 210 supports a first plurality of inserts or nozzles 230 on first pair of arms 214 and a second plurality of inserts or nozzles 240 on second pair of arms 216 . First and second pluralities of nozzles 230 , 240 direct liquid from within spray arm assembly 200 out of spray arm assembly 200 as discussed in greater detail below. First and second pluralities of nozzles 230 , 240 define various exit or outlet geometries. For example, first and second pluralities of nozzles 230 , 240 include nozzles with various pencil jet outlet geometries 250 and other nozzles with various fan jet outlet geometries 252 .
Pencil jet geometries 250 direct a substantially columnar jet of liquid out of upper housing 210 . Pencil jet geometries 250 may have varying circumferences in order to direct jets of liquid with various circumferences out of upper housing 210 . Also, pencil jet geometries 250 may be directed in various directions to provide particular spray patterns. Nozzles 230 , 240 with pencil jet geometries 250 may, e.g., be suitable for removing or urging food particles off of articles within dishwasher appliance 100 ( FIG. 1 ). Conversely, fan jet geometries 252 , e.g., direct a substantially conic or triangular jet of liquid out of upper housing 210 . Nozzles 230 , 240 with fan jet geometries 252 may, e.g., be suitable for rinsing or soaking articles within dishwasher appliance 100 .
Thus, for example, first and second pluralities of nozzles 230 and 240 may include a first pencil jet geometry 250 with a first diameter and a second pencil jet geometry 250 with a second diameter. As another example, first and second pluralities of nozzles 230 and 240 may include a first pencil jet geometry 250 that directs wash fluid in a first direction and a second pencil jet geometry 250 that directs wash fluid in a second direction. As a further example, first and second pluralities of nozzles 230 and 240 may include a pencil jet geometry 250 and a fan jet geometry 252 . However, it should be understood that first and second pluralities of nozzles 230 , 240 may have any other suitable outlet geometry or combination of geometries. Thus, the examples of outlet geometries disclosed herein are not intended to be limiting.
First and second pluralities of nozzles 230 , 240 may be constructed of any suitable material. For example, first and second pluralities of nozzles 230 , 240 may be constructed of a plastic. In addition, first and second pluralities of nozzles 230 , 240 may be constructed of a substantially rigid material, e.g., polyethylene, polypropylene, polystyrene, polyvinyl chloride, or any other suitable substantially rigid plastic or material. Alternatively, first and second pluralities of nozzles 230 , 240 may be constructed of a substantially elastic material, e.g., an elastomer or any other suitable substantially elastic material.
FIG. 3 illustrates an exploded view of spray arm assembly 200 . As may be seen in FIG. 3 , upper housing 210 defines a plurality of orifices 220 . Orifices 220 receive first and second pluralities of nozzles 230 , 240 as may be seen in FIG. 2 . Thus, first and second pluralities of nozzles 230 , 240 are inserted into orifices 220 . Orifices 220 are substantially uniformly distributed on first and second pairs of arms 214 , 216 . However, orifices 220 may be distributed in any suitable manner, e.g., non-uniformly.
In FIG. 3 , first and second pluralities of nozzles 230 , 240 both include a web or sheet 260 that connects the various nozzles of first and second pluralities of nozzles 230 , 240 . Thus, for example, sheet 260 extends between the nozzles of first plurality of nozzles 230 and couples or secures the nozzles together. However, it should be understood that in alternative exemplary embodiments, first and second pluralities of nozzles 230 , 240 need not include sheets 260 . For example, each nozzle of first and second pluralities of nozzles 230 , 240 may be independently inserted into a particular one of the orifices 220 . Thus, the nozzles of first and second pluralities of nozzles 230 , 240 need not be coupled or secured together. As may be seen in FIG. 4 , sheet 260 is disposed within upper housing 210 , e.g., within a chamber 212 ( FIG. 5 ), when spray arm assembly 200 is assembled.
First and second pluralities of nozzles 230 , 240 may be secured to upper housing 210 and within orifices 220 in a variety of ways. For example, first and second pluralities of nozzles 230 , 240 may be secured within orifices 220 , e.g., using heat staking, ultrasonic welding, co-molding, over-molding, and/or any other suitable method or combination of methods. Such methods may be used when first and second pluralities of nozzles 230 , 240 are substantially rigid.
Conversely, first and second pluralities of nozzles 230 , 240 may simply be inserted into orifices 220 and mechanically secured therein. For example, a complementary snap-fit or interference fit may be used to secure first and second pluralities of nozzles 230 , 240 within orifices 220 . By way of additional example, the first and second pluralities of nozzles 230 , 240 can deform during insertion through orifices 220 . After insertion and when first and second pluralities of nozzles 230 , 240 are properly positioned within orifices as shown in FIG. 2 , first and second pluralities of nozzles 230 , 240 may be held in place by portions of first and second pluralities of nozzles 230 , 240 with a diameter greater than a diameter of orifices 220 . Such methods may be used, for example, when first and second pluralities of nozzles 230 , 240 are substantially elastic.
A bottom housing 270 is shaped to fit upper housing 210 . Thus, bottom housing 270 mounts to upper housing 210 in order to form spray arm assembly 200 . Bottom housing 270 cooperates with upper housing 210 to direct wash fluid during operation of dishwasher appliance 100 as described in greater detail below. In FIG. 3 , bottom housing 270 does not define additional orifices 220 . However, in alternative exemplary embodiments, bottom housing 270 may define additional orifices that receive nozzles and direct wash fluid into wash chamber 106 . Bottom housing 270 may be constructed of metal, plastic, and/or any suitable material or combination of materials.
FIG. 4 provides a bottom cross-section view of spray arm assembly 200 taken along the line 4 - 4 of FIG. 2 . FIG. 5 provides a side cross-section view of spray arm assembly 200 taken along the line 5 - 5 of FIG. 2 . As shown in FIG. 5 , upper housing 210 and bottom housing 270 define a chamber 212 for receipt of wash fluid (e.g., water and/or detergent) during operation of dishwasher appliance 100 ( FIG. 1 ). Chamber 212 is in fluid communication with the fluid circulation assembly (not shown) described above.
First and second pluralities of nozzles 230 , 240 are disposed within orifices 220 ( FIG. 3 ). Thus, during operation of dishwasher appliance 100 , wash fluid flows through chamber 212 of spray arm assembly 200 and exits chamber 212 through first and second pluralities of nozzles 230 , 240 . As may be seen in FIG. 5 , wash fluid may be directed in various directions by nozzles 230 .
It should be understood that, by providing first and second pluralities of nozzles 230 , 240 that are received within orifices 220 , a spray pattern for liquid emitted from spray arm assembly 200 may be modified or customized. For example, nozzles with various outlet geometries may be inserted into any particular one of the orifices 220 . Thus, as will be understood by those skilled in the art, nozzles may be selected to customize and/or improve the spray pattern of spray arm assembly 200 , e.g., while still using a single model of upper housing 210 and/or bottom housing 270 .
In various exemplary embodiments, first plurality of nozzles 230 may be a first color (e.g., blue). Conversely, second plurality of nozzles 240 may be a second color (e.g., green). Thus, the first and second pluralities of nozzles 230 , 240 may be different colors. In particular, first and second pluralities of nozzles 230 , 240 may contain dyes or pigments for providing the first and second colors respectively.
Upper housing 210 may be a third color (e.g., red). Thus, upper housing 210 and first and second pluralities of nozzles 230 , 240 may each be a different color. However, it should be understood that upper housing 210 and first and second pluralities of nozzles 230 , 240 may be the same color or have any suitable combination of colors. Varying colors between upper housing 210 and first and second pluralities of nozzles 230 , 240 may, e.g., permit product differentiation or provide marketing advantages as well as provide ready identification of parts during assembly.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | A dishwasher appliance is provided with a spray arm assembly. The spray arm assembly defines an orifice for directing liquid out of the spray arm assembly. The orifice can selectively receive a nozzle with a particular outlet geometry. By selectively receiving the nozzle, a spray pattern of liquid exiting the orifice can be changed by replacing or modifying the nozzle without remanufacturing or replacing the spray arm assembly. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to a process and an apparatus for laminating layers of partially thermoplastic films by action of heat and pressure on the layers.
Laminating thermoplastic film under pressure with the action of temperature on other films or other layers, for example paper, creates a firm bond. Along with other uses, this process is used for the preparation of identity cards which have a core layer which can have security prints, personal data, further information and details, and, if appropriate, an image of the cardholder, with the core layer laminated between transparent films for the protection against unauthorized alterations.
As far as identification cards, such as check cards, identity cards or passport cards, are concerned, a multiplicity of security features, such as guilloche prints or watermarks make an imitation more difficult and thus contribute to its avoidance. Security features such as microfilm images, holograms and relief grid images can be used for this purpose as well. These security features are generally inserted in a window hole in the card core and protected by the outer transparent films.
From West German Offenlegungsschrift No. 2,308,876 a plasticized identity card is known, which comprises a thicker, transparent film, a printed special paper of high quality and as far as the securing technology is concerned, which shows differences in thickness resulting from watermarks and/or additionally incorporated security features, and of a thinner transparent film. The thicker transparent film acts as supporting film and confers to the identity card the necessary stability and rigidity as well as the desired thickness. The supporting film can alternatively represent the front or the rear of the plasticized identity card. The thinner transparent film acts as a covering film and may alternatively compose the rear or the front of the identity card.
A photograph in the form of a film transparency can additionally be plasticized in this identity card. In this case the exposed, developed and fixed film transparency is alternatively inserted between the supporting film and the special paper or between the special paper and the covering film and is plasticized together with the films. In addition a signature field of a special paper can be incorporated in the identification card and be plasticized with it. In another embodiment of the identity card, no additional special paper strip is introduced as signature field but an opening in either the supporting film or covering film is left in the covering film during the plastification process and acts as signature field.
During the plastification or lamination process, high pressures and temperatures are required, which endanger the inserted images or holograms. A slight melting of the gelatin layer may occur which could lead, in a photographic information carrier, to image distortions which can end in illegibility of the stored data and information. Holograms are even more sensitive to layer displacement. Layers with relief images are endangered even to a greater extent than are photographic layers during this lamination process. These relief images are produced by exposing and developing photolacquer layers, by embossing thermoplastic films or in an electrophotographic process, by electrostatically charging, exposing and developing a photoconductive, thermoplastic recording layer until a relief image is formed.
To avoid melting of the security features certain precautions have been taken, including eg. embossing the films at temperatures which are as high as possible and are higher than the laminating temperature, crosslinking substances such as aromatic azides being added, thermally or photochemically, to the photoconductive, thermoplastic recording layers. However, these measures are in general insufficient for the image stabilization during the lamination process.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a process and an apparatus for carrying the process out where pressure and temperature sensitive securing features such as grid images, microfilm images, holograms etc. can be laminated in a bond of films in such a way that the image remains stable, without any destruction of the information carried in the image.
The above and other objects are achieved in accordance with the present invention by the process of: aligning at least two thermoplastic layers; pressing the two thermoplastic layers together; and heating the external surfaces of the thermoplastic layers in a discontinuous manner across the surface, the discontinuous heating occurring at a selected window portion of the layers wherein the temperature at the window portion is at least 10° C. lower than the rest of the external surface of the layers.
The above and other objects are achieved through the use of a laminating apparatus which includes: first and second laminating plates; means for discontinuously heating the first and second laminating plates; and means for pressing the plates together with the thermoplastic layers to be laminated therebetween, with the discontinuous heating means heating the thermoplastic layers less at a window portion than elsewhere on the external surface of the layers.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and the attendant advantages thereof will be more clearly understood by reference to the following drawings wherein:
FIG. 1a is a plan view of an identity card with a laminated relief grid;
FIG. 1b is a sectional side view of the identity card in FIG. 1a;
FIG. 2 is a graph showing the theoretical and actual temperature distributions along the card during lamination in accordance with the present invention;
FIG. 3 is a side view, partially in section, of a pressing apparatus for laminating, including two plates and layers for lamination situated therebetween;
FIG. 4 is a side view, partially in section, of a modification of the FIG. 3 apparatus; and
FIG. 5 is an enlarged part-side cross-sectional view of a further embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The problem of laminating identity cards with images was solved by the process, mentioned above, in such a way that the laminating temperature acting on the layers, is lowered by 10° to 70° C. in the window area compared to the remaining areas of the layers. Additionally, the pressure in the window area may be lowered, compared to the laminating pressure on the remaining surface of the layers which are to be laminated.
According to the development of the process, the laminating temperature is increased in a narrow area around the window area, compared to the laminating temperature in the other areas outside the window area of the layers which are to be laminated.
For carrying out the process a pressing apparatus with two plates is used; each plate is heated and has an opening with an inserted plug, the temperature of which is lower than the temperature of the plate, and in this apparatus both plates are arranged in axial symmetry and the layers which are to be laminated can be inserted between them.
By this invention excellent laminations of the security features in the identity card can be obtained with no influence on their information content and without any destruction of the films in the window area of the identity card.
Referring now to the drawings wherein like reference characters designate like parts throughout the several views, the identity card 1 shown in FIGS. 1a and 1b comprises a card core 4 which has a window area 3 or a window hole, in which a security feature 2, for example, a relief grid image, a hologram or a microfilm image, is inserted. The card core 4 is protected on the front and on the rear by outer transparent films 5. The card core 4 is provided with personal data of the cardholder which may include the family and christian name of the cardholder and a reference number as shown in the plan view of FIG. 1a.
It is technically extremely difficult to produce a jump of some 10° C. in temperature over distances in the order of magnitude of 1 mm and to keep it up for a determined period. Two temperature profiles 6 and 7 extending along the line AB in FIG. 1a are represented in FIG. 2. The desired, theoretically obtainable, temperature profile 6 in the window area 3 is represented by an interrupted line and has a rectangular-shaped form in the area of the window. In actuality, the temperature profile 7 occurs because the changes in temperature are not discontinuous. It is desirable that the edges of the temperature graph be as vertical as possible when passing in the window area 3. To obtain this a pressing apparatus with two plates is used as shown in FIG. 3 in which the temperature and the pressure in the window area 3 of the layer which is to be laminated can be lowered in comparison to the temperature and pressure used for lamination in the other areas of the identity card.
The pressing apparatus comprises two plates 8 which have an axial symmetrical arrangement and between which the layers which are to be laminated are inserted. Each plate 8 is heated and has an opening with an inserted plug 9. The layers which are to be laminated to a bond 26 have two core layers 27', 27" which enclose a supporting layer 28. The card core, comprising both core layers and the supporting layer, is covered by an upper protection layer 29 and a lower protection layer 30. The core layers 27' and 27" include window openings 25' and 25", and the supporting layer 28, also has a window opening 25'" which is coincident with the window openings 25', 25".
The upper core layer 27' comprises a diagrammatically indicated relief grid in the window opening 25'. Before the process of lamination the card-bond 26 is inserted in such a way in the pressing apparatus that the plugs 9 of both plates 8 are brought to coincide with the window openings 25' and 25". The plugs 9 consist of a material of good thermal conductivity, such as copper or brass, and include a system of channels 10, one of which is diagrammatically indicated in the respective plug 9. Cooling liquid, compressed air or preferably carbon dioxide gas, is conducted through the channels 10. Thus, it is obtained that the temperature in plug 9 is from 10° to 70° C. lower than in the other areas of plate 8. The respective temperature reduction depends on the thermal conductivity of the plug material as well as the type and quantity of the cooling agent passing through the channels.
The plugs 9 can also be prepared of pressure resistant material of a low thermal conductivity having no cooling channels therein, and instead of this would be removable from the openings of the plates 8. To obtain a sufficient temperature reduction in the area of the openings, the plugs 9 are then removed from the openings of the plates 8 after a determined number of working hours in order to cool off.
The cooled plugs 9 are thermally insulated against the plates 8 by a temperature and pressure resistant filling layer 11. Polyfluoroethylene, such as ® Teflon, of a thickness of from 0.5 to 2 mm may be used for this filling layer. It would also be possible to provide an air gap between plug 9 and plate 8 to aid in the thermal insulation of the plug 9 although this may have the disadvantage that laminating material could flow into this air gap. In the embodiment shown in FIG. 3, the heating of the plates 8 result indirectly by the physical contact of the plate with heating elements in the form of resistance wires 12 which are connected to voltage sources 18. The resistance wires 12 are inserted together with a thermometer probe 13 in the plates 8 in order to measure and control the temperature of the plates. The resistance wires 12 are more closely packed around the plugs 9 than in the other areas of the plates 8. Thus the edge-steepness of the jump in temperature between plugs 9 and plates 8 is especially large, because the plugs 9 are intensively cooled and, in order to compensate the resulting heat loss to the coolant the plates 8 around the plugs 9 are heated to a larger extend than the other areas of plates 8 by the closer packing of the resistance wires 12. The plates 8 are insulated in a suitable manner against the supporting plates 15 of the pressing apparatus by insulating layers 14. A further embodiment of the pressing apparatus is shown in FIG. 4 and comprises plates 8 to which a laminar heating resistance layer 16 acting as heating element is connected in series. The heating resistance layer 16 faces the thermoplastic layers which are to be laminated and which are to be laminated and the resistance layers are also thermally insulated from the plates 8 by an insulating layer 14. Contacts 17 which are linked to a heating voltage source 31, are connected to the heating resistant layer 16. This heating voltage source can be a source which applies pulse-shaped voltages to the heating resistant layer. The rest of the structure of the pressing apparatus corresponds generally to the embodiment shown in FIG. 3 and will therefore not be described again.
To obtain the desired pressure reduction in the window openings 25',25" of the card bond 26, ech plug 9 in the window area is recessed a distance D from the surface of plate 8, as it can be seen in FIG. 5. The distance D is within the order of magnitude of 20 μm to 150 μm. This pressure-reduction contributes to the fact that the process of laminating the identity card takes place without compressing of the information on the prepared but pressure sensitive relief images.
In the embodiments of FIGS. 3 and 4 the contact surfaces of plate 8 can be textured as it is shown in FIG. 5. In this case, the surfaces of plate 8 comprise smooth areas 19,20,21,22,23,24. After the lamination process the given geometric arrangement of the smooth areas results in corresponding smooth surface areas on the outer thermoplastic films. The relief like texture on the contact surface of plate 8 can be arranged to form a reproducible geometric arrangement which results in corresponding matt areas on the outer thermoplastic film after the lamination process.
It is evident that each continued forming of matt and glossy card-areas in certain geometric arrangements, for example, in the form of heraldic figures, represent a security feature which can be easily controlled, especially if the structure causing the matting comprises structures which are difficult to imitate, for example relief grid structures. Additionally, the plates 8 can be roughened on their surface, so that the laminated cards, with the exception of the clear window area, have a matt surface without disturbing reflection.
With a pressing apparatus according to FIG. 3 in which the plugs 9 were recessed by 50 μm, a 125×90 mm-card of polyvinyl chloride films was lamintated from top to bottom with the following components: a transparent glass-clear film 29 having a thickness of 100 82 m- a matt-whitefilm 27', 140 μm thickness with a security print and an electrophotographically produced card-image--an intermediate layer 28, 80 to 100 μm thickness, as supporting layer of perforated paper--a matt-white film 27" with a thickness of 140 μm and with a security print--and a transparent, glass-clear film 30 with a thickness of 100 μm. The lamination process took place at a laminating temperature of 140° C. and under a laminating pressure of 15 bars (Kp/cm 2 ) for a period of 4 mn. The plug cooling was accomplished with carbon dioxide, which was introduced in the channels 10.
The card had window openings 25', 25" which were brought into congruence with the plugs 9, when being positioned. A grid image of embossed transparent polyvinyl chloride film having a thickness of 80 to 120 μm and a diameter of 1 cm was inserted in the window opening 25'. A disc having a diameter of 1 cm and comprising 60 μm to 160 μm thick transparent polyester film was sutuated in the window opening 25' on the side of the grid image. Intermediate layer 28 and film 27", representing the lower core-layer, contained in the window areas 25'" and 25" two or a single transparent film-inserts, preferably capable of lamination, with a thickness over all of 80 μm to 240 μm. The sum of the combined thicknesses of the inserts in the openings 25', 25" and 25'" is equal to the sum of the thickness of the layers 27',28 and 27". The plugs 9 had also a diameter of 1 cm, whereas the insulating layer 11 had a thickness of 1 mm. After lamnination the intact grid image extended in a circular area of approximately 9 mm diameter in the window openings 25" of the card bond 26. The specified higher values of the thickness-ranges of the inserts are top boundary values.
Although the invention has been described relative to specific embodiments thereof, it is not so limited and many modifications and variations thereof will be readily apparent to those skilled in the art in light of the above teachings. It is therefore, to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: | Disclosed is a method and apparatus to facilitate the method of discontinuously laminating at least two thermoplastic layers together. The layers are heated and pressed together over all but a selected window portion of the layers to facilitate lamination between the layers at all points except the selected window portions. Relief grid images can be embossed in the selected window portion or holograms or other difficult to forge inserts can be provided in these window areas prior to lamination. During lamination, the reduced or absence of heating in these window portions permits lamination of the card without destruction of the selected window portion insert. | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to a germicide and, more specifically, to a germicidal composition suitable for preventing growth of various germs such as yeasts and filamentous fungi in industrial water such as waste water from pulp mills or cooling water for heat exchangers.
In industrial water such as waste water from paper making steps in pulp-related industries and recirculating cooling water used in various mills, microorganisms such as germs, fungi and bacteria are apt to grow and to cause various problems.
For example, filamentous fungi and yeasts are apt to grow in industrial water used in paper or pulp mills and to form slime within water passages such as pipe walls having roughened surfaces and other portions such as chests and flow boxes through which the water is passed at a low flow rate. The accumulated slimes occasionally depart from their depositing surfaces to cause contamination of paper and pulp products. Other industrial products such as aqueous coating materials, polymer latex, bonding agents, metal machining oils, hides and skins also encounter similar problems. Further, accumulation of slimes also cause blockage of water passages and reduction of heat transfer efficiency.
To cope with these problems, there have been hitherto used organometallic compounds, chlorinated organic compounds, sulfur-containing organic compounds and quarternary ammonium compounds for the prevention of growth of germs in industrial water. These known germicides, however, have certain problems. That is, the known organometallic compounds and chlorinated organic compounds must be used in a large amount in order to obtain satisfactory germicidal effects. This causes environmental pollution. The known sulfur-containing organic compounds and quarternary ammonium compounds cause a problem of generation of unpleasant odor. Some of these compounds also cause a problem of foaming of the water to which they are added.
Japanese Examined Patent Publication (Tokkyo Kokoku) No. Sho-51-33,171 discloses a germicide containing an α-chlorobenzaldoxime acetate derivative of the general formula (I): ##STR3## wherein n is an integer of 0 to 2. Japanese Tokkyo Kokoku No. 43-16460 discloses a germicide containing 2-bromo-2-nitro 1,3-diacetyloxypropane of the formula (II): ##STR4## These germicides are effective only against limited kinds of germs and lack durability in germicidal effect.
SUMMARY OF THE INVENTION
The present invention has been made with the foregoing problems of the conventional germicides in view. There is provided in accordance with the present invention a germicidal composition comprising a derivative of α-chlorobenzaldoxime acetate of the formula (I): ##STR5## wherein n is an integer of 0 to 2, and 2-bromo-2-nitro-1,3-diacetyloxypropane of the formula (II): ##STR6##
It has been found that when an α-chlorobenzaldoxime acetate derivative of the formula (I) is used in conjunction with 2-bromo-2-nitro-1,3-diacetyloxypropane of the formula (II), a remarkably higher germicidal activity is obtainable than those obtained when they are used singly. Moreover, the germicide containing both of the ingredients of the formulas (I) and (II) exhibits its germicidal effect for a long period of time against a wide variety of germs including filamentous fungi and yeasts.
The present invention will now be described in detail below.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples of the compounds of the formula (I) include α-chlorobenzaldoxime acetate, α-chloro-4-chlorobenzaldoxime acetate and α-chloro-2,4-dichlorobenzaldoxime acetate. These compounds may be used singly or in combination of two or more.
The compounds of the formulas (I) and (II) are used in such a proportion that the weight ratio of the compound (I) to the compound (II) is 1:10 to 10:1, preferably 1:5 to 5:1.
The germicidal composition of the present invention may be suitably in the form of a solution, a dispersion or an emulsion. Thus, a suitable liquid medium, which may be aqueous or organic, may be used for dissolving, dispersing or emulsifying the two germicidal ingredients. An emulsifier such as a surfactant or a stabilizer may be also be used to stabilize the dispersion or emulsion. Examples of organic media include alcohols, ketones, ethers and hydrocarbons. If desired, the germicidal composition may be supported on a solid carrier.
Because of its high synergistic effect, a low concentration of the composition of the present invention can exhibit satisfactory germicidal activities. Thus, for example, when the composition is used for incorporation into industrial water of paper or pulp mills, a concentration of 0.01-100 ppm (calculated as a total weight of the compounds of the formulas (I) and (II)) is sufficient to obtain desired effect. For incorporation into industrial water for use in the field of aqueous coating materials, bonding starch or hides and skins, the concentration is generally 1-500 ppm.
The following examples will further illustrate the present invention. In the examples, "part" and "%" are by weight.
EXAMPLES 1-5
Germicides having the composition shown in Table 1 were prepared.
TABLE 1______________________________________ Example 1 2 3 4 5______________________________________α-Chlorobenzaldoxime 18 15 10 5 2acetate (parts)Compound of the Formula (II) (parts) 2 5 10 15 18Diethylene glycol monomethyl 77 77 77 77 77ether (parts)RAPISOL B-80* (parts) 3 3 3 3 3______________________________________ *Anionic surfactant, manufactured by Nihon Yushi K.K.
EXAMPLES 6-10
Germicides having the composition shown in Table 2 were prepared.
TABLE 2______________________________________ Example 6 7 8 9 10______________________________________α-Chloro-4-chlorobenzaldoxime 18 15 10 5 2acetate (parts)Compound of the Formula (II) (parts) 2 5 10 15 18Diethylene glycol monomethyl 77 77 77 77 77ether (parts)RAPISOL B-80 (parts) 3 3 3 3 3______________________________________
COMPARATIVE EXAMPLE 1
A germicide having the following composition was prepared:
______________________________________α-Chlorobenzaldoxime acetate 20 partsDiethylene glycol monomethyl ether 77 partsRAPISOL B-80 3 parts______________________________________
COMPARATIVE EXAMPLE 2
A germicide having the following composition was prepared:
______________________________________α-Chloro-4-chlorobenzaldoxime acetate 20 partsDiethylene glycol monomethyl ether 77 partsRAPISOL B-80 3 parts______________________________________
COMPARATIVE EXAMPLE 3
A germicide having the following composition was prepared:
______________________________________Compound of the Formula (II) 20 partsDiethylene glycol monomethyl ether 77 partsRAPISOL B-80 3 parts______________________________________
The above compositions were subjected to the following tests for evaluating their germicidal properties.
Activity Test
The following germs were used (Indicated in the brackets are abbreviations):
______________________________________Pseudomonas aeruginosa (P.a)Aerobactor aerogenes (A.a)Bacillus subtilis (B.s)Alcaligenes viscosus (A.v)Aspergillus niger (A.n)Geotrichum sp. (G.s)______________________________________
Each germ was suspended in an aqueous culture medium containing 0.1% peptone, 0.05% glucose, 0.01% potassium hydrogen phosphate and 0.005% magnesium sulfate. A predetermined amount of the suspension was sampled in test tubes to which a predetermined amount (5, 10, 20, 40 and 80 ppm) of the germicidal composition to be tested was mixed. The mixture was cultured with shaking at 32° C. for 24 hours. Thereafter, the degree of growth of the germ was measured by measurement of turbidity. The minimum concentration of the germicidal composition which perfectly prevented the growth of the germ was as shown in Table 3. Each germ was found to grow upon culturing in the absence of the germicide.
TABLE 3______________________________________Example P.a A.a B.s A.v A.n G.s______________________________________1 <10 <10 <10 <10 <10 <102 <5 <5 <5 <5 <5 <53 <5 <5 <5 <5 <5 <104 <5 <5 <5 <10 <5 <55 <10 <10 <5 <10 <10 <106 <20 <10 <10 <10 <10 <107 <5 <5 <5 <5 <5 <58 <5 <5 <5 <5 <5 <59 <10 <5 <5 <5 <5 <510 <10 <10 <10 <20 <10 <10Comp. 1 <40 <40 <20 <40 <40 <40Comp. 2 <40 <40 <20 <40 <40 <20Comp. 3 <40 <20 <20 <40 <40 <40______________________________________
From the results shown in Table 3, it will be appreciated that the germicidal compositions of the present invention can prevent any of the tested germs from growing and the germicidal effect is much better than those obtained when the germicidal ingredients are used by themselves.
Growth Preventing Test (1)
To a recirculating white liquor used in a paper making step of a paper mill was added each of the above germicidal compositions three times per day (2 hours in one time) so that the concentration of the germicide in the white liquor was maintained at 20 ppm. The test was carried out continuously for 7 days. Then the white liquor was sampled to measure the number of germ cells. Thus, the sampled white liquor was diluted with sterilized water and poured into a glass tray in a predetermined amount, to which a Waxman agar culture medium was poured. After gentle mixing, the mixture was allowed to be solidified with a flattened surface and placed in an incubator at 32° C. for 2 days for culturing. Then the colony was counted by a colony counter to give the results shown in Table 4. During the 7 days test, the number of occurrences of paper breakage in the paper making step was counted. The results are also shown in Table 4.
TABLE 4______________________________________Example Number of Cells Number of OccurrenceNo. (per 1 ml) of Paper Breakage______________________________________1 10.sup.2 or less 02 10.sup.2 or less 03 10.sup.2 or less 04 10.sup.2 or less 05 10.sup.2 or less 16 10.sup.2 or less 07 10.sup.2 or less 08 10.sup.2 or less 09 10.sup.2 or less 010 10.sup.2 or less 1Comp. 1 4.6 × 10.sup.4 5Comp. 2 3.8 × 10.sup.3 6Comp. 3 3.6 × 10.sup.5 6Control* over 10.sup.8 15______________________________________ *no germicide was used.
Growth Preventing Test (2)
To an aqueous paper coating liquid (pH 9.0) of a starch type was added a bouillon liquid medium and a previously rotted, paper coating liquid, to which was added each of the germicidal compositions to a concentration of 300 ppm. The resulting mixture was incubated at 32° C. for 5 days and the number of the living cells was counted. The results are shown in Table 5.
TABLE 5______________________________________Example Number of CellsNo. (per 1 ml)______________________________________1 8.6 × 10.sup.32 10.sup.2 or less3 10.sup.2 or less4 10.sup.2 or less5 2.4 × 10.sup.36 5.9 × 10.sup.37 10.sup.2 or less8 10.sup.2 or less9 10.sup.2 or less10 4.1 × 10.sup.3Comp. 1 1.5 × 10.sup.7Comp. 2 2.1 × 10.sup.5Comp. 3 1.8 × 10.sup.5Control* 3.8 × 10.sup.9______________________________________ *no germicide was used | A synergistic germicidal composition includes a derivative of α-chlorobenzaldoxime acetate of the general formula (I): ##STR1## wherein n is an integer of 0 to 2, and 2-bromo-2-nitro-1,3-diacetyloxypropane of the formula (II): ##STR2## | 0 |
PRIORITY CLAIM
[0001] The present application claims the priority of Canadian patent application, Serial No. 2,419,982, titled “Executing A Large Object Fetch Query Against A Database,” which was filed on Feb. 26, 2003, and which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates in general to database management systems, and in particular to a system and associated method for executing a large object fetch query against a database.
BACKGROUND OF THE INVENTION
[0003] With the advent of Web application servers, the use of large objects (LOBs) in database systems is increasing. In many cases, these LOBs are used to store session state: serialized Java objects or other structures known to applications accessing the database systems. Once requested, retrieval of the LOBs from database servers to the application in a performance efficient fashion is critical.
[0004] Typically, these LOB objects are relatively small (i.e., less than 10 K), but on occasion they can be quite large (i.e., greater than 100 K). To take into account future growth, database administrators typically define quite large sizes (i.e., greater than 1 GB) for LOB columns of the database. If the database administrator knew these objects would never have the possibility of becoming LOBs, the column could be defined as long varchar for bit data. It is assumed that defining columns as LOBs indicates the corresponding objects will occasionally have very large values (i.e. considered as LOBs). There currently exists two methods for retrieving LOBs from the database, with current architectures: by defining a locator, or by asking for the LOB value.
[0005] The locator approach can have an advantage that only a handle flow is returned from the database server to the application. The actual LOB value remains on the database server until the application is ready to fetch the LOB value or any part of the LOB value. A disadvantage to the locator approach, especially in the case where the LOBs are relatively small, can be that an additional network flow to the database server is required to retrieve each LOB. Therefore, by always specifying locators in response to the data request, system drivers are forcing a second trip to the database server to retrieve the value of every LOB, thus exacting a potential system performance penalty.
[0006] An alternative approach for LOB retrieval is that of fetching the LOB value up front. LOB value retrieval can be more appropriate for the case of small LOBs, but can consume a considerable amount of memory on the client for large LOBs, especially if the application was only interested in a small portion of the large LOB. One disadvantage of the LOB retrieval method is that by always specifying the value to be returned, the client of the application can be occasionally hit by a very large LOB, which can force a significant amount of memory to be used at the client for LOB buffering. Further, the application may not require the entire LOB, and as a result may cause inefficiencies in client memory allocation and utilization.
[0007] Consequently, with current architectures, the application (or for example a JDBC/ODBC driver) must make the decision up front to retrieve the LOB either by the locator or by value. This decision is typically made by the driver without assistance from the application; the driver usually selects the locator approach. The locator approach can be the recommended approach for JDBC implementers to use. In either case, the decision for retrieval type is made at the client with possible knowledge of a defined maximum length of the column (which is often quite large), but without knowledge of the actual length of the particular resident LOB value in the corresponding database field.
[0008] What is therefore needed is a system and associated method that enable the database management system to make a dynamic decision for sending either the LOB locator or the LOB value in the fetch response, depending upon the actual value of the LOB in comparison to the threshold value. The need for such system and method has heretofore remained unsatisfied.
SUMMARY OF THE INVENTION
[0009] The present invention satisfies this need, and presents a system, a computer program product, and an associated method (collectively referred to herein as “the system” or “the present system”) for executing a large object fetch query against a database.
[0010] A database management system DBMS (operating on a server) is adapted to receive a fetch query having a fetch request for fetching a LOB (large object). The DBMS processes each fetch request by accessing or retrieving LOB values from a database. The DBMS decides whether to return a LOB locator in place of returning a LOB value, or to return the LOB value by itself, depending upon a comparison between the specific LOB value being accessed or retrieved and a threshold value.
[0011] The threshold value is associated with the fetch query and is linked to the fetch request as a threshold parameter. The LOB value or the LOB locator is returned in a fetch answer corresponding to the processed fetch request. A fetch response containing each fetch answer is returned to a client by the DBMS as a result of the fetch query. During processing of each fetch request of the fetch query, LOB values (sizes) resident in the database and below the threshold value are retrieved and returned by the DBMS to the client as LOB values in the fetch answer corresponding to the fetch request. Otherwise, LOB values (sizes) resident in the database and above the threshold value are accessed but returned by the DBMS to the client in the fetch answer as LOB locators in the fetch request of the fetch response.
[0012] The use of the threshold parameter (with associated threshold value) provides a mechanism for returning LOB values to the client when the LOB value is considered relatively small, and sending the LOB locators when the LOB value is considered relatively large in comparison to the threshold value. Therefore, the use of the threshold parameter of the fetch query enables the database management system to make a dynamic decision (that is, a decision made on the fly) for sending either the LOB locator or the LOB value in the fetch response. The choice of including the LOB locator or LOB value in the fetch response depends upon the actual value of the LOB in comparison to the threshold value. For example, the LOB values lower than the threshold value are sent as LOB values in columns (i.e. the fetch answers) of the fetch response, while the LOB values larger than or equal to the threshold value are sent as LOB locators in place of the LOB values.
[0013] Distinct indicators are also included in the fetch response, placed in a fetch parameter. The fetch parameter is associated with the fetch response and is linked to the fetch answer, preferably one fetch parameter for each fetch answer. One of a pair of distinct indicator values is inserted in the fetch parameter for each fetch answer. This pair of distinct indicator values informs the receiving client (that is, the client receiving the fetch response) which form of access or retrieval was used for each requested LOB value being returned (via the fetch answers in the fetch response). As a result of the query received by the database management system (operating on the server), the fetch parameter uses these distinct indicator values to help inform the client of the form of access/retrieval present in the fetch response.
[0014] In an embodiment of the present invention, a method is provided for directing a database management system to execute a fetch query against a database used for storing LOB (Large Object) values and associated LOB locators. This fetch query is adapted to contain at least one LOB fetch request. This method includes the steps of:
[0015] receiving the fetch query,
[0016] accessing a selected LOB value stored in the database,
[0017] comparing the selected LOB value with the predefined threshold value, and
[0018] returning a fetch response having a LOB fetch answer corresponding to the LOB fetch request according to one of a pair of return operations.
[0019] The fetch query includes a threshold parameter associated with the LOB fetch request and the threshold parameter has a predefined threshold value. The selected LOB value corresponds to the LOB fetch request of the fetch query. The first return operation of the pair returns the selected LOB value in the LOB fetch answer if the compared LOB value is less than the predefined threshold value. A second return operation of the pair returns the LOB locator in the LOB fetch answer if the compared LOB value is greater than the threshold value.
[0020] In another embodiment of the present invention, a computer program product is provided that has a computer-readable medium tangibly embodying computer executable instructions for directing a database management system to execute a fetch query against a database used for storing LOB (Large Object) values and associated LOB locators. The fetch query is adapted to contain at least one LOB fetch request. The computer program product comprises: computer readable code for receiving the fetch query, computer readable code for accessing a selected LOB value stored in the database, computer readable code for comparing the selected LOB value with the predefined threshold value, and computer readable code for returning a fetch response having a LOB fetch answer corresponding to the LOB fetch request according to one of a pair of return operations.
[0021] As described earlier, the fetch query includes a threshold parameter associated with the LOB fetch request and the threshold parameter has a predefined threshold value. The selected LOB value corresponds to the LOB fetch request of the fetch query. The first return operation of the pair returns the selected LOB value in the LOB fetch answer if the compared LOB value is less than the predefined threshold value. A second return operation of the pair returns the LOB locator in the LOB fetch answer if the compared LOB value is greater than the threshold value.
[0022] In yet another embodiment of the present invention, there is provided an article comprising a computer-readable signal-bearing medium usable on a network. This article also comprises means in the medium for directing a database management system to execute a fetch query against a database used for storing LOB (Large Object) values and associated LOB locators. The fetch query is adapted to contain at least one LOB fetch request. This article comprises: means in the medium for receiving the fetch query, means in the medium for accessing a selected LOB value stored in the database, means in the medium for comparing the selected LOB value with the predefined threshold value, and means in the medium for returning a fetch response having a LOB fetch answer corresponding to the LOB fetch request according to one of a pair of return operations.
[0023] As described earlier, the fetch query includes a threshold parameter associated with the LOB fetch request and the threshold parameter has a predefined threshold value. The selected LOB value corresponds to the LOB fetch request of the fetch query. The first return operation of the pair returns the selected LOB value in the LOB fetch answer if the compared LOB value is less than the predefined threshold value. A second return operation of the pair returns the LOB locator in the LOB fetch answer if the compared LOB value is greater than the threshold value.
[0024] In still another embodiment of the present invention, a database management system is provided for executing a fetch query against a database used for storing LOB (Large Object) values and associated LOB locators. The fetch query is adapted to contain at least one LOB fetch request. The database management system comprises: means for receiving the fetch query, means for accessing a selected LOB value stored in the database, means for comparing the selected LOB value with the predefined threshold value, and means for returning a fetch response having a LOB fetch answer corresponding to the LOB fetch request according to one of a pair of return operations.
[0025] As described earlier, the fetch query includes a threshold parameter associated with the LOB fetch request and the threshold parameter has a predefined threshold value. The selected LOB value corresponds to the LOB fetch request of the fetch query. The first return operation of the pair returns the selected LOB value in the LOB fetch answer if the compared LOB value is less than the predefined threshold value. A second return operation of the pair returns the LOB locator in the LOB fetch answer if the compared LOB value is greater than the threshold value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items, and wherein:
[0027] [0027]FIG. 1 is a schematic illustration of an exemplary server database system in which a large object fetch system of the present invention can be used;
[0028] [0028]FIG. 2 is a diagram of an exemplary client database system of FIG. 1 in which a large object fetch system of the present invention can be used;
[0029] [0029]FIG. 3A is a diagram of a data structure of the database of FIG. 1;
[0030] [0030]FIG. 3B is a diagram of a response structure of the system of FIG. 1;
[0031] [0031]FIG. 4 is a block diagram illustrating a method of an operation of a database management system of FIG. 1;
[0032] [0032]FIG. 5 is a process flow chart illustrating the method of a server fetch operation of the database management system of FIG. 4; and
[0033] [0033]FIG. 6 is a process flow chart illustrating the method of a companion client fetch operation of the server fetch operation of FIG. 5.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] The following detailed description of the embodiments of the present invention does not limit the implementation of the invention to any particular computer programming language. The present invention may be implemented in any computer programming language provided that the OS (Operating System) provides the facilities that may support the requirements of the present invention. An embodiment is implemented in the C or C++ computer programming language (or other computer programming languages in conjunction with C/C++). Any limitations presented would be a result of a particular type of operating system or computer programming language and would not be a limitation of the present invention.
[0035] The embodiments of the present invention provide a method (as shown in FIGS. 4, 5, 6 ), a data processing system (FIGS. 1 and 2), and/or a computer program product (not depicted), and/or an article (not depicted) for dynamic processing of a fetch query in a server database system. The server database system is coupled to a database adapted to store LOB values. It will be appreciated by those skilled in the art, that the article can be a signal-bearing medium for transporting computer readable code to a data processing system over a network, in which the code can be used to implement the method.
[0036] It will also be appreciated, by those skilled in the art, that the computer program product comprises a computer readable medium having computer executable code for directing a data processing system to implement the method. The computer program product can also be called a computer-readable memory, in which the memory can be a CD, floppy disk or hard drive or any sort of memory device usable by a data processing system. It will also be appreciated by those skilled in the art, that a data processing system may be configured to operate the method. The method may be operated either by use of computer executable code residing in a medium or by use of dedicated hardware modules, also generally or generically known as mechanisms or means, which may operate in an equivalent manner to the code which is well known in the art.
[0037] [0037]FIG. 1 shows a server database system 100 comprising a server data processing system 102 having a memory 108 tangibly embodying a database management system (DBMS) 116 , a collection of tables 120 having data 122 , and a query 118 for instructing the DBMS 116 to interact with the tables 120 . It will be appreciated that the collection of tables 120 may be included collectively as a single database, and that the database may be stored in the memory 108 , or alternatively may be stored in memories of a plurality of distributed data processing systems (not depicted) which may be interconnected by a network (not depicted).
[0038] The DBMS 116 is a computerized information storage and retrieval system. For example, a relational database management system (RDBMS) is a type of the DBMS 116 that stores and retrieves the data 122 organized as tables 120 . Each of the tables 120 comprises rows 300 and columns 302 (see FIG. 3A) of data 122 . The database of the server database system 100 will typically have many tables 120 and each table 120 will typically have multiple rows 300 and multiple columns 302 .
[0039] The DBMS 116 can be designed to store data 122 having a variety of data types. For example, the DBMS 116 may have the capability of storing and retrieving data 122 having standard data types, such as integers and characters, as well as non-standard data types, including very large data objects (LOBs). It is noted that typical DBMSs 116 can represent text, voice, and image data as LOB types. Exemplary applications 217 (see FIG. 2), server database system 100 , and client database system 200 may involve multimedia applications for the World Wide Web; medical care applications (e.g., X-rays, MRI imaging, and EKG traces); and geographical, space, and exploration systems (e.g., maps, seismic data, and satellite images).
[0040] The memory 108 of the server database system 100 may include volatile and non-volatile memory such as but not limited to RAM (random Access memory) and/or ROM (read-only memory). Also embodied in the memory 108 is an operating system (not depicted) which may be a program that executes on the server data processing system 102 for running other computer executable programs (such as but not limited to the DBMS 116 ).
[0041] Operating systems perform basic tasks, such as recognizing input/output from input/output interface modules 110 (for example coupled to a keyboard and display screen), keeping track of files and directories on a disk in the memory 108 , and controlling other peripheral devices such as but not limited to disk drives and printers. The memory 108 is operationally coupled to a CPU (Central Processing Unit) 104 , and the input/output interface modules 110 via a bus 106 .
[0042] Operationally coupled to the input/output interface modules 110 are input/output devices (such as a mouse and display unit), and persistent memory units (such as a hard drive, floppy drive). A communication interface 112 is used by the server database system 100 to communicate with the Client Database System 200 .
[0043] [0043]FIG. 2 shows the client database system 200 in greater detail. Components 202 through to 212 of FIG. 2 are generally identical to the corresponding components 102 through to 112 of FIG. 1, as is known in the art. A database system client 216 (alternately referenced as client 216 ) is a computer executable program that is a companion program to the DBMS 116 program, as is known in the art. The client 216 coordinates the queries 118 and responses 119 of the applications 217 to and from the server database system 100 . It is possible that hardware components of the server database system 100 (components 102 - 112 ) may be the same physical hardware components of the client database system 200 (corresponding components 202 - 212 ), which for simplicity of discussion are depicted here as separate systems.
[0044] Accordingly, FIGS. 1 and 2 show an example client-server system made up of the server database system 100 and the client database system 200 , where the client applications 217 with the client 216 can reside on the client computer (not shown) and the server application (DBMS 116 ) can reside on the server computer (not shown). The client database system 200 and the server database system 100 are connected by the communication interface 212 , such as but not limited to a local area network (LAN).
[0045] In operation of the client-server system, the client 216 sends the request for data 122 (for example in the form of the database query 118 ) to the DBMS 116 . The DBMS 116 processes each of the queries 118 to retrieve data 122 from the tables 120 , and returns an answer set in the form of a response 119 . The retrieved data 122 can include LOB data (i.e., data having a LOB data type).
[0046] [0046]FIG. 3, which is comprised of FIGS. 3A and 3B, illustrates an exemplary data and response structure. In response to the query 118 from the application 217 , the client database system 200 contacts the server database system 100 . The response 119 to the query 118 may contain LOB data 122 . Returning the response 119 to the client database system 200 can involve returning the row 300 of data 122 having both standard and non-standard data types.
[0047] An exemplary row 300 may have columns 10 , 20 , and 30 , with columns 10 and 30 containing data 122 having standard data types (e.g., integers or characters). Column 20 could contain data having a non-standard data type (e.g., LOB data that consumes two megabytes of space in the tables 120 ). When the row 300 containing these three columns 302 is transmitted from the server database system 100 to the client database system 200 , the data 122 can be transmitted sequentially.
[0048] Therefore, the client database system 200 first receives the column 10 of data 122 having the standard database data type, receives the column 20 of data 122 having the non-standard data type, and then receives the column 30 of data 122 having the standard database data type. These columns 302 of data 122 can be stored in a temporary storage location of the memory 208 and then moved to the long-term storage of the memory 208 of the application 217 .
[0049] Referring to FIG. 3B, the response 119 has a data structure including an inline flag 50 and an inline LOB threshold value 60 , as further described below. These flag 50 and threshold value 60 are used as fetch parameters in the query 118 and the response 119 . The response 119 also has a header 40 . It is recognized that the query 118 has a similar format to the response 119 , including row 300 , columns 302 , the inline flag 50 , the inline LOB threshold value 60 , and the header 40 . The similarity in format of the query 118 and response 119 is typified by the database system client 216 being the computer executable program that is the companion program to the DBMS 116 program. Further, it is recognized that the queries 118 and the responses 119 can contain more than one row 300 , if desired.
[0050] [0050]FIG. 4 shows the computer readable memory 108 of FIG. 1. Stored in the memory 108 are operations S 310 of the DBMS 116 of FIG. 1. The operations S 310 process a series of requests or queries 118 (see FIG. 1) received from the client 216 of FIG. 2. Within the DBMS 116 there is contained a module 117 or unit of executable computer programmed instructions comprising the operations S 360 to S 370 for directing the CPU 104 to manage the table 120 . The CPU 104 manages the table 120 by creating and transmitting the response 119 as a base data object with the header 40 (see FIG. 3B). For example, operation S 360 receives the query 118 . Operation S 362 parses the query 118 .
[0051] Operation S 364 creates the data base object. Operation S 366 completes the columns 302 of the base data object 119 including the inline flag 50 and the inline LOB threshold value 60 . Operation S 368 returns the base data object in a return buffer (not shown) for transmission to the client database system 200 as the response 119 . Operation S 370 inquires if there is another query 118 present for processing by the DBMS 116 .
[0052] In the client-server environment as shown in FIGS. 1 and 2, each fetch query 118 is sent from the client database system 200 to the server database system 100 . The server database system 100 can respond to the fetch queries 118 using a predefined protocol, such as a distributed relational database architecture (DRDA) single-row fetch protocol or a DRDA limited block fetch protocol.
[0053] Those skilled in the art will recognize that the DRDA protocols discussed herein are not intended to limit the present invention. Indeed, those skilled in the art will recognize that other alternative protocols may be used without departing from the scope of the present invention. For example, the single-row fetch protocol returns each response 119 with either zero rows 300 or 1 row of an answer set (such as but not limited to containing columns 10 , 20 , 30 , flags 50 , and thresholds 60 ). For example, the limited block fetch protocol returns zero to N rows of the answer set for each query 118 .
[0054] Generally, the variable N is the number of rows that can fit into a query block, wherein the query block is the return buffer that contains the formatted rows 300 of the answer set. It is recognized that the client database system 200 and the server database system 100 may negotiate the return buffer size, and that the answer set rows 300 may be returned to the client database system 200 as a data object. It is also recognized that the server database system 100 can choose the fetch protocol, or the client database system 200 sent instructions associated with the query 118 to use a predefined fetch protocol, e.g., DRDA single row fetch protocol.
[0055] It will be appreciated that other operations can be included in the operations S 310 as is known in the art. Further, it will be appreciated that the instructions of the module 117 may be implemented in any computer programming language and translated into processor-readable instructions or code for execution by the CPU 104 of the server data processing system 102 . In an alternative embodiment, it may be appreciated that operations S 360 to S 370 may reside in another programmed module (not shown) which operates independently of the DBMS 116 . These operations correspond to client queries 118 , and a non-exhaustive list of these operations would comprise such as but not be limited to connecting to the tables 120 , compiling an SQL statement, fetching data 122 , inserting data 122 , updating data 122 , etc.
[0056] [0056]FIGS. 3B and 5 show the details of one of the operations S 310 that corresponds to the fetch query 118 . For this example, it is assumed that operation S 364 corresponds to a particular fetch query 118 to retrieve data 122 from the table 120 , where one or more columns 302 contains LOB data 122 . Prior to making the fetch query 118 to the server database system 100 , the client 216 presets the inline LOB flag 50 for querying a LOB value, and presets the inline LOB threshold value 60 to a value such as but not limited to 10,000 bytes.
[0057] This flag 50 and threshold value 60 alter the fetch processing of the DBMS 116 as further described below. Referring again to FIG. 5, as the server database system 100 is processing operation S 364 , the operation S 364 loops through each of the columns 302 in the answer set for each row 300 of the answer set represented in the response 119 . The server database system 100 retrieves the values of data 122 from the database tables 120 , and binds them out as quantities in the response 119 and through the communication interface 112 for delivery to the client database system 200 .
[0058] Operation S 402 represents the start of processing for each row 300 of the answer set. In operation S 404 , the large object fetch system determines whether the column 302 represents a LOB value. If the column 302 does not represent a LOB value, operation S 406 could perform a conventional bind out process. If the column 302 does represent a LOB value, the large object fetch system proceeds to operation S 408 . The large object fetch system determines in operation 408 whether the inline LOB flag 50 is set.
[0059] If the inline LOB flag 50 is not set for this LOB column 302 , traditional LOB bind out occurs at operation S 410 . If the inline LOB flag 50 is set for this LOB column 302 , the flag 50 is set as a fetch LOB request. Operation S 412 determines if the LOB size for this column 302 is less than or equal to the inline LOB threshold 60 specified for this column 302 . If the size is less than or equal to the inline LOB threshold 60 , a first binding operation S 416 is executed which places an inline LOB indicator in the flag 50 of the response 119 . This inline LOB indicator verifies the presence of the LOB value as a return quantity in the respective column 302 of the base data object. The large object fetch system then places the LOB data value inline in the response 119 being sent to the client database system 200 .
[0060] Alternatively, if operation S 412 indicates the LOB size is greater than the inline LOB threshold 60 , then a second binding operation S 414 is executed which places an inline LOB locator in the flag 50 , followed by the LOB locator as the return quantity for this LOB column. All processing continues with operation S 418 that loops over all columns 302 in the row 300 .
[0061] As is known in the art, the LOB locator provides only a handle flow returned from the server database system 100 to the application 217 of the client database system 200 . The actual LOB value remains on the server database system 100 until the application 217 is ready to fetch it in a subsequent query 118 . Two distinct indicators, the inline LOB indicator and the inline LOB locator indicator, return states of the flag 50 .
[0062] The flag 50 is used by the client 216 to determine, on a column by column basis, transmission of the LOB value or the LOB locator in the corresponding column 302 of the response 119 . This provision allows the client database system 200 to help interpret the data 122 being sent by the server database system 100 . With these two distinct indicator return states of the flag 50 , the delivery of the LOB data 122 by either the inline LOB value or the LOB locator can be transparent to the client application 217 after the client application 217 has enabled LOB inlining.
[0063] [0063]FIG. 6 details the companion client 216 operation of the corresponding operation S 364 as was detailed in FIG. 5. The client database system 200 processes the fetched values returned from the server database system 100 in the response 119 (see FIG. 3). As these values are processed, the client 216 loops through each of the columns 302 in the answer set of the response 119 . The client 216 retrieves the values of the data 122 from the communication interface 212 and binds them out to buffers provided by the user application 217 driving the query 118 .
[0064] Operation S 502 represents the start of processing for each row 302 of the response 119 . The client 216 determines in operation S 504 whether the column 302 represents a LOB value. If the column 302 does not represent a LOB value in operation S 504 , operation S 506 performs traditional bind out processing, as it is known in the art.
[0065] For the LOB value, operation S 508 determines whether the inline LOB indicator is present in the flag 50 . If true, the data 122 immediately following the inline LOB indicator is perceived by the client 216 as the inline LOB value, and this data 122 is bound out to the client application 217 in operation S 510 .
[0066] If the inline LOB indicator is not present in the flag 50 , operation S 512 checks for the inline LOB locator indicator in the flag 50 . If the inline LOB locator indicator is present, the data 122 following is perceived by the client 216 as the LOB locator and that data 122 is bound out to the client application 217 in operation S 514 . If neither of these distinct indicators were present in the respective column 302 of the response 119 , then operation S 516 would perform traditional LOB bind out as it is known in the art. The operation continues at block S 518 that loops over all columns 302 in the row 300 . The LOB indicator and the LOB locator are considered distinct return states of the flag 50 (i.e. fetch parameter).
[0067] Accordingly, in view of the above, the use of distinct indicators in the flags 50 of the response 119 provides a mechanism by which the server database system 100 can make a dynamic decision of sending either a LOB locator or the inline LOB value in the response 119 . This decision depends upon the specific value of the LOB in comparison to the threshold value 60 .
[0068] Consequently, the LOB values below the threshold 60 are sent as values in the columns 302 of the response 119 , while the LOB values above the threshold 60 are sent as locators. The flag 50 uses the distinct indicator values to help inform the client 216 of the form of retrieval present in the response 119 as a result of the query 118 . It is recognized that the flags 50 and/or the thresholds 60 may be stored/read in the header 40 (see FIG. 3A, 3B), in the columns 302 as inline values, or a combination thereof. Further, it is recognized that default threshold values 60 can be used for each LOB by the server database system 100 and/or a single threshold value 60 can be used for more than one column 302 for comparison against multiple LOB values requested in the query 118 .
[0069] In an alternative embodiment, there is provided a computer program product having a computer-readable medium tangibly embodying computer executable instructions for directing a data processing system to implement any method as previously described above. It will be appreciated that the computer program product may be a floppy disk, hard disk or other medium for long term storage of the computer executable instructions.
[0070] It will be appreciated that variations of some elements are possible to adapt the invention for specific conditions or functions. The concepts of the present invention can be further extended to a variety of other applications that are clearly within the scope of this invention. Having thus described the present invention with respect to preferred embodiments as implemented, it will be apparent to those skilled in the art that many modifications and enhancements are possible to the present invention without departing from the scope and spirit of the present invention. | A database server helps to streamline the retrieval of LOB values by deciding to send a locator in replacement of the LOB value, or the LOB value itself, depending upon the specific LOB value being retrieved. A threshold value is determined in a fetch query, and the LOB sizes below that threshold are sent as values in a corresponding fetch response, and the lengths above are sent as locators in the fetch response. Indicators are inserted in a fetch parameter of the response to inform the receiving client the form of retrieval that was used for each requested LOB value being returned. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to concrete dowel devices and, more particularly, to a plate and a sleeve concrete dowel device with break-away alignment tabs.
BACKGROUND
[0002] Concrete dowels are embedded into joints between adjacent slabs of concrete to prevent vertical displacement between the slabs to maintain a smooth pavement surface and increase the strength of the concrete in the region of the joint. While the dowels are provided to prevent excessive vertical displacement between the slabs, they are typically designed to allow a small amount of horizontal separation and lateral displacement between the slabs to relieve internal stress to accommodate drying shrinkage and thermal expansion and contraction of the slabs. This permits a normal amount of slab movement to prevent excessive cracking while still maintaining a smooth top surface of the pavement.
[0003] Traditionally, two foot lengths of rebar rods were used as the concrete dowels. But rod dowels tend to cause cracking in the concrete due to concentration of the stress on the relatively small surface area of the rods. Concrete dowels configured as larger bars and load plates were therefore developed to reduce cracking by increasing the surface area of the dowel. In comparison to rebar rods historically used as concrete dowels, larger dowel bars and plates provide a flat and significantly increased dowel surface area to improve the dowel's load transfer capability and reduce the tendency of cracking to form at the dowel location. U.S. Pat. No. 6,354,760 and U.S. patent application Ser. No. 11/109,781 describe examples and the benefits of this approach.
[0004] To assist in embedding the dowels within adjacent slabs of concrete while the concrete is being poured, dowel devices including dowel bars (or plates) and sleeves have been developed. U.S. Pat. No. 6,145,262 describes this approach. The sleeved dowel bar has the benefit of permitting the bar to slide within the sleeve to accommodate a small amount of horizontal separation between the slabs to relieve internal stress. To accommodate lateral displacement between the slabs the sleeve is a little bit wider than the bar, which allows the bar to move laterally within the sleeve after the concrete slabs have cured. But simply making the sleeve wider than the bar removes positive registration between the bar and sleeve making it difficult to determine when the bar has been properly centered within the sleeve. As a result, construction workers have to install the bars carefully to ensure the proper spacing on either side of the plate within the sleeve, which can be a lot to ask of construction workers in some setting. To solve this problem, the sleeve described in U.S. Pat. No. 6,145,262 contains fins along the side walls of the sleeve to help align the dowel bar within the sleeve.
[0005] However, providing dowel sleeves with elongated fins along the interior side walls is an expensive solution. Including the fins along the internal surfaces of the sleeve complicates the manufacturing process and can require multiple molds to create the sleeve. Although a structure containing the fins may be manufactured separately and inserted into to the sleeve after the sleeve has been molded, this significantly complicates the manufacturing process and increases the cost of the dowel. For example, manual assembly steps may be required to insert and secure the fins within the sleeve.
[0006] In addition, even when fins are included, it is still possible with prior sleeved dowel devices to install the bar on a slant deflecting the fins prior to pouring the concrete slabs, which can reduce or eliminate the effectiveness of the fins. A plate installed on an angle within the sleeve with the fins deflected before the concrete is poured reduces or eliminates the lateral play that the dowel was designed to allow. With this system, it can also be difficult for the construction workers in the field to see whether the fins have been deflected when the plate is inserted, leading to some portion of the plates being installed without proper alignment within the sleeves.
[0007] As a result, there is a persistent need for a lower cost and more reliable concrete dowel solution and, more particularly, a need for a concrete dowel device to ensure proper registration of the plates within the sleeves without requiring cumbersome manufacturing or assembly procedures.
SUMMARY OF THE INVENTION
[0008] The present invention meets the needs described above in a concrete dowel device including a sleeve and plate in which the sleeve includes break-away alignment tabs at the opening of the socket to ensure proper alignment of the plate within the sleeve during field installation. The tabs are positioned at the sleeve opening, rather than along the length of the socket, to avoid misalignment of the plate within the sleeve, simplify use and reduce the manufacturing costs of the product. The plate may have a tiered structure to enhance registration between the place and sleeve. Alternatively or additionally, the sleeve and plate may include additional alignment surfaces at the rear corners or along the rear side of the plate and sleeve. For example, slanted corners and/or a “V” shaped grove can be provided to assist in properly aligning the plate within the sleeve.
[0009] To facilitate manufacturing, the break-away alignment tabs may be formed as molded components of the sleeve, which are rotated and snapped into position after the sleeve has been molded. Alternatively, the break-away alignment tabs may be formed as part of an insert plate that is molded separately and attached to the flange of the sleeve after the sleeve has been molded. Both approaches allow the sleeve (without the insert plate) to be molded as a single part without the need to insert fins or another alignment structure along the side walls of the sleeve.
[0010] In view of the foregoing, it will be appreciated that the present invention provides an improved plate and a sleeve concrete dowel device with break-away alignment tabs. The specific structures and techniques for accomplishing the advantages described above will become apparent from the following detailed description of the embodiments and the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a top view of a plate and sleeve concrete dowel device with the plate positioned outside the sleeve.
[0012] FIG. 1B is a front view of the sleeve showing the break-away alignment tabs before insertion of the plate into the sleeve.
[0013] FIG. 2A is a top view of a plate and sleeve concrete dowel device with the plate inserted within the sleeve.
[0014] FIG. 2B is a front view of the sleeve showing the break-away alignment tabs with the plate inserted within the sleeve.
[0015] FIG. 3A is a plan view of the sleeve nailed to a concrete form before pouring of a first concrete slab over the sleeve.
[0016] FIG. 3B is a cross-section plan view of the sleeve nailed to a concrete form after the first concrete slab has been poured over the sleeve.
[0017] FIG. 3C is a cross-section plan view of the sleeve embedded within the first concrete slab after the first slab has set and the form has been removed.
[0018] FIG. 3D is a cross-section plan view of the sleeve embedded within the first concrete slab after the plate has been inserted into the sleeve.
[0019] FIG. 3E is a cross-section plan view of the dowel formed by the sleeve and plate embedded at the joint between the first and second concrete slabs.
[0020] FIG. 4A is a top view of a first alternative concrete dowel device with the plate located outside the sleeve.
[0021] FIG. 4B is a top view of the first alternative concrete dowel device with the plate inserted within the sleeve.
[0022] FIG. 4C is a top view illustrating a waste-free approach for stamping the plated for the first alternative concrete dowel device from sheet stock material.
[0023] FIG. 5 is a top view of a second alternative concrete dowel device with the plate located outside the sleeve.
[0024] FIG. 6 is a top view of a third alternative concrete dowel device with the plate located outside the sleeve.
[0025] FIG. 7 is a top view of a sleeve for the concrete dowel device with break-away alignment tabs formed as molded components rotated and snapped into position.
[0026] FIG. 8A is a top assembly view of an alternative sleeve design utilizing a plate insert for the break-away tabs.
[0027] FIG. 8B is a front assembly view of the alternative sleeve design utilizing the plate insert for the break-away tabs.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] The present invention may be embodied in a concrete dowel device, a method for constructing concrete structures using the concrete dowel devices, and concrete structures that include embedded concrete dowel devices. The innovative concrete dowel represents a significant improvement over the concrete dowel approaches shown in U.S. Pat. No. 6,354,760; U.S. Pat. No. 6,145,262; U.S. Pat. No. 4,733,515 and U.S. Pat. No. 8,454,265, which are incorporated by reference.
[0029] The concrete dowel device includes a sleeve and plate configured for use with a concrete form typically constructed with wooden boards. The dowels are embedded at the joints between adjacent concrete slabs to provide vertical support to keep the surface of the concrete level while allowing a small amount of horizontal and lateral movement to accommodate thermal expansion of the slabs while curing and during normal use, vibration, and other normal types of movement between adjacent concrete slabs. Providing for this type of relative movement between the slabs relieves stress to prevent or reduce cracking in the concrete during normal use while maintaining a smooth top surface of the pavement at the joints.
[0030] The concrete dowel accommodates a small amount of movement of the slabs away and towards each other transverse to the joint as well as lateral displacement between the slabs in the direction of the joint, while preventing substantial vertical movement to maintain a smooth, level surface at the joint between the concrete slabs. An improvement resides in the break-away tabs positioned at the opening of the sleeve to guide insertion of the plate into the sleeve during construction without inhibiting normal lateral movement between the slabs after they have cured. Additional guide structures, such as slanted corners ore a “V” groove in the sleeve and plate may provide additional guide structures to ensure proper registration of the plate within the sleeve.
[0031] The sleeve is designed to be nailed to a wooden form defining the edge of the first slab (one side of the joint between adjacent slabs) where a dowel is desired prior to pouring the first slab. The first slab is then poured with the sleeve held in place by the form, which embeds the sleeve within the first slab. Once the first slab has set sufficiently, the form is removed and the plate is inserted into the sleeve so that about half the plate extends into the sleeve and half extends into the area where the second concrete slab is to be poured. The second slab is then poured with the plate held in place by the sleeve. Once the second slab sets, the dowel formed by the sleeve and plate is embedded into the joint between the slabs, while the plate can slide a small amount within the sleeve to accommodate horizontal separation and lateral displacement between the slabs while maintaining the slabs in vertical alignment.
[0032] The present invention includes break-away alignment tabs positioned at opposing sides of the opening to the socket of the sleeve. The alignment tabs remain in place during slab construction to guide proper alignment of the plate with the sleeve. The tabs are configured to break away as forced by relative movement of the concrete slabs after the concrete has cured to allow a small amount of displacement between adjacent slabs. Various embodiments include additional alignment mechanism, such as angled corners and a “V” groove along the rear side of the sleeve, with corresponding guide surfaces in the plate, to facilitate proper registration between the sleeve and the plate.
[0033] Turning now to the figures, FIG. 1A is a top view of a plate 10 and sleeve 12 forming a concrete dowel device with the plate positioned outside the sleeve. The sleeve 12 includes a socket 13 configured to snugly receive the plate 10 and typically includes ridges, dimples or other internal surface features to ensure a snug interference fit between the plat and the socket. The sleeve 12 also includes a flange 14 at the opening of the socket 13 that includes two nail guides 16 a - b that typically support two pre-installed nails 18 a - b positioned ready for nailing into a wooden form.
[0034] FIG. 1B is a front view of the sleeve 12 showing the flange 14 defining a plate opening 20 flanked by two break-away alignment tabs 22 a - b before insertion of the plate into the sleeve. FIG. 2A is a top view of a plate and sleeve concrete dowel device with the plate 10 inserted within the sleeve 12 . FIG. 2B is a front view of the sleeve 12 showing the break-away alignment tabs 22 a - b with the plate inserted within the opening 20 of the sleeve, as guided by the alignment tabs to center the plate within the sleeve. The socket of the sleeve is a bit wider than the plate to accommodate some lateral movement of the plate within the sleeve after the concrete slabs have set, and the break-away alignment tabs are provided to facilitate proper centering of plate within the sleeve during construction of the concrete slabs. For example, the plate may be about eight inches wide and the socket in the range of about nine inches wide. The break-away alignment tabs are attached sufficient strongly to the flange to remain in place during construction, but are thinner than the rest of the sleeve, have thinner seams, are scored or interference fit in place to break away after the concrete has set to accommodate lateral movement between the concrete slabs joined by the dowel. The interference fit between the plate and the sleeve accommodates a bit of horizontal separation between the concrete slabs as wells as lateral displacement while maintaining smooth vertical alignment of the top surface of the slabs.
[0035] FIGS. 3A-E illustrate use of the dowel during construction of the concrete structure, such as a pavement. Many dowels are used in a typical pavement project and the figures depict a representative dowel. FIG. 3A is a plan view of the sleeve 12 nailed to a concrete form 30 before pouring of a first concrete slab over the sleeve. The nail 18 a is typically pre-installed allowing the construction worker to easily nail the sleeve to the form in the desired position with a few hammer strikes. As shown in FIG. 3B , once the dowel has been nailed in place on the form, the first slab 32 is poured, which embeds the sleeve 12 within the first slab 32 . Once the first slab has set, the form 30 is removed as shown in FIG. 3C . This exposes the socket opening of the sleeve at the edge of the first concrete slab. A construction worker then inserts the plate 10 into the sleeve 12 as shown in FIG. 3D . It is at this point when the alignment tabs assist the construction worker to properly align the plate 10 within the sleeve 12 to ensure that the dowel accommodates the desired amount of lateral movement. It will be appreciated that dowel will not function as designed if the plate is not aligned properly in the center of the sleeve and construction worker are prone to work hastily with variable levels of attention. The alignment tabs do a good job of squaring the plate within the sleeve when the plate is jammed into the sleeve, for example when a worker pushes or hits the plate with a board, hammer, hand or foot. The second slab 34 is then poured as shown in FIG. 3E leaving the dowel formed by the sleeve and plate embedded at the joint between the first and second slabs.
[0036] It will be appreciated that ensuring proper registration between the plate and sleeve is of primary importance when installing the dowels. Several alternatives may be utilized to further ensure proper registration and, once these techniques are understood, other variations will become apparent to those skilled in the art. FIGS. 4A-C show a first alternative designed to ensure proper registration, which includes a plate 40 that has a wider portion 42 designed to remain outside the sleeve and a narrower portion 44 designed to be fully inserted into the sleeve. When the plate is fully inserted into the sleeve, transition edges 46 a - b between the wider and narrower portions are designed to bottom out against the flange 14 providing a visual and physical indication of positive registration of the plate in the sleeve. Basically, this allows the construction worker to hand push, kick, or hit the plate with a board or hammer until the transition edges 46 a - b of the plate are flush against the flange 14 . A quick visual inspection will confirm that all of the plates are properly installed. As shown in FIG. 4C , the wider and narrower portions 42 , 44 can have the same depth so that the plates can be formed (typically stamped) from sheet stock without waste.
[0037] FIG. 5 illustrates a second alternative to ensure proper registration of the plate 50 within the sleeve 52 . This alternative includes beveled corners 54 a - b on the plate 50 configured to mate against beveled corners 56 a - b one the sleeve 52 . The beveled corners cause the plate 50 to square up as the plate 50 is forced into the sleeve 52 . FIG. 6 illustrates a variation on this theme, which utilizes mating “V” grooves 64 , 66 in the plate 60 and sleeve 62 , respectively, serving the same purpose. The various registration techniques may be employed individually or combined, as desired. For example, the “V” groove alternative shown in FIG. 6 also includes the two-tiered plate configuration shown in FIGS. 4A-C .
[0038] Ease and efficiency of manufacturing is another aspect of the present invention. The undercut nature of the alignment tabs over the side portions of the socket of the sleeve could prevent the sleeve from being molded as a single part due the undercut nature of the tabs preventing easy extraction of the sleeve from the mold. To alleviate this problem, the sleeve may be configured for injection molding as a single structure with the alignment tabs pointed away from the opening of the socket with a thin, flexible seam at the junction between the tab and sleeve body and small interference structures on the tabs or sleeve body. After molding, the tabs can then be rotated and snapped into position with an interference fit as shown in FIG. 7 . Small taps, grooves or ridges may be provided as interference structures to ensure a positive interference fit when the tabs are rotated and snapped into place.
[0039] Another alternative is shown in FIGS. 8A-B , in which the alignment tabs are formed as part of an insert plate 80 that is molded separately from the sleeve 12 . The insert plate 80 defines the plate opening 20 flanked by the break-away alignment tabs 22 a - b and fits within an inset area 82 in the flange 14 of the sleeve. The insert plate 80 can be secured within the inset area 82 using an interference fit, adhesive, heat seal or any other suitable attachment technique.
[0040] Although the terms “horizontal” and “vertical” have been used to describe use of the dowel in the context of a horizontal pavement, it will be appreciated that the dowel is well adapted for but not limited to the pavement application and can be used for any concrete joint of sufficient size regardless of its orientation. For example, the invention is equally applicable to joints in concrete walls, ceilings, abutments and other structures Those skilled in the art will appreciate that the foregoing describes preferred embodiments of the invention and that many adjustments and alterations will be apparent to those skilled in the art within the spirit and scope of the invention as defined by the appended claims. | A concrete dowel device including a sleeve and plate in which the sleeve includes break-away alignment tabs at the opening of the sleeve to ensure proper alignment of the plate within the sleeve during field installation. The tabs are positioned at the sleeve opening, rather than along the length of the socket, to avoid misalignment of the plate in the sleeve, simplify use and reduce manufacturing costs of the product. The sleeve and plate may include additional alignment surfaces on the plate, at the rear corners, or along the rear side of the plate and sleeve. To facilitate manufacturing, the break-away alignment tabs may be formed as molded components rotated and snapped into position. Alternatively, the break-away alignment tabs may be formed as part of an insert plate manufactured apart from and attached to the flange of the sleeve. | 4 |
BACKGROUND OF THE INVENTION
Current discharge requirements for treated wastewater from sewage treatment plants generally call for a degree of suspended solids removal unattainable by secondary treatment technology on a predictable and uniform basis. For example, the standards currently applicable in Ohio are 8 mg/L monthly B.O.D. (Biochemical Oxygen Demand) average and 12 mg/L B.O.D. maximum weekly average. Various types of tertiary treatment techniques and devices have been employed, such as slow sand filtration, rapid gravity sand filtration, spray irrigation and polishing lagoons. Prior art patents have disclosed various tertiary treatment equipment and methods, as for example those disclosed in U.S. Pat. No. 4,190,543, U.S. Pat. No. 3,925,205 and in U.S. Pat. No. 3,774,770.
In addition to the removal of these suspended solids it is desirable to remove other contaminants which also exist in the effluent from a secondary treatment. It has been recognized that in the treatment of wastewater a process can be used in which various contaminants are decomposed by microorganisms. More particularly, it is known that when organic substances are subjected to various conditions insofar as temperature and oxygen are concerned that certain desirable aerobic microorganisms are created which decompose certain organic substances and convert them into non-harmful materials such as carbon dioxide, water and the like. In this connection U.S. Pat. No. 4,045,344 discloses a method wherein a bundle of straight tubes or the like are used in what is called a "submerged packing process." In this method the packings are submerged in wastewater in a treating tank and the wastewater is circulated through the packings under aeration so that aerobic microorganisms are generated on the surface of the individual packings aerobic as films. These films decompose various organic substances coming into contact with the films. The patent describes the importance of maintaining turbulent flow through the entire length of the packings and states that turbulent flow is preferred for the propagation of the aerobic microorganisms (see column 4 lines 38-60).
In U.S. Pat. No. 4,190,543, incorporated by reference herein, there is disclosed a tertiary treatment method for removing suspended solids which has proven to be commercially successful. In this process wedge wire media panels are positioned within the treatment tank and are inclined with respect to the vertical axis of the sidewalls. In operation a biological mat is established on the media panels. Canadian Pat. No. 881,668 and U.S. Pat. No. 3,774,770 disclose waste treatment apparatus wherein wedge wire media panels are also utilized.
The principle objectives of the present biofiltration invention have been to provide a tertiary treatment apparatus which provides for a high degree of suspended solids removal and in addition a high degree of carbonaceous B.0.D. and ammonia nitrogen removal. It is a further objective of this invention to provide such a treatment facility wherein continuous operation can be obtained over a wide range of conditions and when cleaning is required sludge buildup may be easily removed from the system.
SUMMARY OF THE INVENTION
It has been found that excellent solids removal and carbonaceous B.O.D. and ammonia nitrogen removal can be achieved in the bio-filtration system of the present invention. The tank and much of the auxiliary equipment used is substantially identical to that shown in U.S. Pat. No. 4,190,543, incorporated by reference herein. Wedge wire panels are used for suspended solids removal. However, rather than utilizing wedge wire media panels in an inclined position as shown in the '543 patent, the panels are positioned in a more conventional, horizontal fashion. In addition, immediately below the horizontally mounted wedge wire media panels is positioned a tubular, fixed film media reactor. This provides a surface on which the aerobic microorganisms grow. These two in combination provide excellent solids removal and excellent carbonaceous and nitrogenous B.O.D. removal. While I do not wish to be bound by any particular theory it appears that this is due to the use of the horizontal wedge wire panel, which when used in combination with the fixed film media reactor creates a laminar flow throughout the entire fixed film media tubes. The wedge wire forces the flow to pass through all segments of the fixed film reactor, utilizing all the surface area with even loading conditions. This is in contrast to the teaching in U.S. Patent No. 4,045,344. As a result provides a much more efficient system is provided. The present invention therefore provides a tertiary treatment system which efficiently removes suspended solids and certain organic contaminants.
DETAILED DESCRIPTION OF THE INVENTION
Following is a description of the invention with reference to the accompanying diagramatic drawings, in which:
FIG. 1 is a cross-sectional view of a rectangular waste treatment tank;
FIG. 2 is a plan view of the tank taken on
line 2--2 of FIG. 1;
FIG. 3 is a section on line 3--3 of FIG. 2;
FIG. 4 is a section on line 4--4 of FIG. 2;
FIG. 5 is an isometric view of the fixed film media reactor;
FIG. 6 is a cross-sectional view of the fixed film media reactor and wedge wire media; and
FIG. 7 is a cross-sectional view of the wedge wire media.
Additional pertinent drawing details of the tank may be found in U.S. Pat. No. 4,190,543 which has already been incorporated by reference herein.
The waste treatment tank 2 of the present invention has external sidewalls 4, end walls 6 and a sloped bottom wall 8. All may be made of concrete or steel. An inlet 10 is provided in one end wall 6 for introducing the effluent to be treated while at the opposite end wall 6 an outlet 12 for the treated material is provided. Pre-aeration diffusers 14 of a conventional design are provided through which air is introduced into the waste material. FIG. 1 shows the direction of travel of the effluent into the tank 2, into the fixed film media reactor 16, through the wedge wire media panels 18 and then into an effluent trough 20 and then out through the outlet 12. Tests have demonstrated the uniformity of flow and evenness of loading throughout the system.
The wedge wire media panels 18 are of conventional design and are described in more detail in U.S. Pat. No 4,190,543. See also Canadian Pat. No. 881,668. As shown in FIGS. 1 and 2 they are horizontally disposed across most of the tank 2. Any type of suitable frame means and fastening means can be used, as for example, the wedge wire media frame 22 shown. In one application, wedge wire panels 18 made from polyethelene and having the dimensions of 12"×12 3/8"× 3/8" were used.
In the operation of prior art treatment systems with horizontally disposed wedge wire panels it has been noted that as effluent passes upwardly through the tank and through the wedge wire panels, a high pressure zone and a laminar flow zone are established.
Mounted below the wedge wire media panels 18 in the present system is a fixed film media reactor 16. An isometric view of such is shown in FIG. 5. The surfaces of the tubular-like fixed film reactor 16 provide surfaces for biota (aerobic microorganism) growth and attachments. This biota acts as a scavenger by feeding on the untreated carbonaceous B.O.D. and nitrogeneous B.O.D.
As shown in FIG. 5 the reactor 16 comprises tubes or channels 26. These are generally rectangular in cross-section or if desired they may be more circular in cross-section. In one application it has been determined that the passageways are about 5MM on each side and the length of the tubes 26 is about 300MM. The reactor is sized so as to have about 175 square feet of surface area for each cubic foot of media. The fixed film media is to provide a surface on which biota can grow. This area =175 sq.ft./cu.ft. or stated in another way 1 cubic foot of the fixed film media 16 provides 175 square feet of surface area.
The fixed film reactor media 16 is positioned immediately below the wedge wire media panels 18 by means of a media support frame 28. The fixed film reactor 16 is positioned and constructed such that the flow of effluent passes upwardly through it and then through the wedge wire media panels 18. The use of the wedge wire panels 18 establishes laminar flow throughout the fixed film media reactor 16.
From the following table the surface area required in the fixed film media reactor 16 may be calculated based on ammonia nitrogen (Nitrogeneous B.O.D.) reduction.
TABLE______________________________________ RECOMMENDED MAXIMUM LOADING RATE______________________________________SUMMER MONTHS WITH TEMPERATURE18 TO 22 DEGREES CELSIUS MEDIA REQUIRED PEREFFLUENT LIMITATION POUND NH32 mg/l up 4,000 sq. ft./lb. NH31.5 mg/l 5,000 sq. ft./lb. NH31 mg/l 7,000 sq. ft./lb. NH3WINTER MONTHSWITH TEMPERATURE TO 11 DEGREES CELSIUS4 mg/l up 5,500 sq. ft./lb. NH33 mg/l up 6,000 sq. ft./lb. NH32 mg/l up 10,000 sq. ft./lb. NH3EXAMPLEAssume:Design Flow 0.030 MGDPlant Effluent NH3 10 mg/lSummer NH3 Limit 2 mg/lWinter NH3 Limit 3 mg/lMEDIA (Fixed Film Reactor)REQUIRED FOR SUMMER TREATMENT0.03 MGD.sup.1 × 8.34 × (10.sup.-2 mg/l) × 4000 sq. ft.= 8,006sq. ft. media8006 sq. ft. divided by 175 sq. ft./cf = 45.75 cu. ft.fixed film mediaMEDIA (Fixed Film Reactor)REQUIRED FOR WINTER TREATMENT0.03 MGD × 8.34 × (10.sup.-3 mg/l) × 6000 sq. ft. =10,508sq. ft. media10,508 sq. ft. divided by 175 sq. ft./cf. = 60.05 cu. ft.media______________________________________ NOTE: All loading rates and removals are based on USEPA Technology Transfer Manual on Nitrification, Chapter 4. .sup.1 MGD = million gallons per day
As noted hereinbefore, the wedge wire media panel 18 extends the laminar flow conditions throughout the full length of the fixed film 16 reactor media. Although this is contrary to teachings in the field, it has been found that when the reactor is used in combination with the wedge wire panels 18, an extremely efficient system is provided.
No special sludge removal equipment is shown and any conventional means may be utilized. | Disclosed herein is a bio-filtration system that provides excellent solids removal and carbonaceous B.O.D. and ammonia nitrogen removal and which comprises in combination a tank, wedge wire panels disposed horizontally therein, a fixed film media reactor with vertical channels therein, and means for introducing effluent to be treated into said tank whereby said effluent flow upwardly through said fixed film media reactor and then through said wedge wire panels. | 2 |
This is a division of application Ser. No. 07/013,490 filed Feb. 11, 1987, now U.S. Pat. No. 4,823,136 issued Apr. 18, 1989.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an a small, light weight transmit-receive means for use in a phased-array active antenna system utilizing a multiplicity of individual transmit-receive cells, all mounted upon a common wafer of semiconductor material. Each transmit-receive cell comprises a plurality of redundant electronic devices that are selectively and permanently interconnectable by mitered mechanical switches.
2. Description of the Prior Art
Previous phased array active antenna systems for radar or electronic warfare applications utilized active FETs (field effect transistors), passive capacitors and phase shifting microstrip lines all manufactured on a multiplicity of individual monolithic chips. Each individual chip performed a separate functions such as; attenuation, digital and analog phase shift, power amplification, transmit/receive duplexing, and low-noise amplification. All of the individual chips were then mounted together on a cooled platen in a metallic assembly. This aggregation of individual chips constituted only one active element of a phased-array active antenna system. A complete phased-array active antenna system required hundreds of such complex elements all mounted to a common matrix of radio frequency signal carriers.
Today, there are radar and electronic warfare applications, where lightweight active antenna systems are necessary. A prior art assembly of monolithic chips bonded onto a heavy metal matrix of carriers weighed over 600 lbs. (272.73 kgm). When a high speed, advanced tactical aircraft, performs high velocity tactical maneuvers; such a heavy, phased array active antenna radar or electronic warfare system would be subjected to high inertial forces. Only a lightweight, phased array active antenna system would be able to successfully withstand the high velocity turns and extreme gravitational forces developed by an advanced tactical fighter.
A standard phased-array active antenna system comprises; a means to produce a radio frequency signal, a transmit-receive means or duplexer which is operable to transmit or receive radio frequency signals, and a logic device, operable to shape the output beam from an antenna means.
The transmit-receive means or duplexer comprises; an attenuation means, a multistage amplification means, a low-noise amplification means, and appropriate transmit-receive switches which operate as a signal isolation means when the transmit-receive means is in either a transmit or receipt mode. Heat dissipation of heat away from the amplification means of the duplexer requires the use of heat sinks integrated with the duplexer to maintain operational temperatures for the circuits. Direct current, electrical energy is provided from a power generation means to the transmit-receive means devices.
Historically, a variety of systems of decreasing weight and size have been designed to achieve a lightweight antenna phased-array system. The patent to Stockton et al., U.S. Pat. No. 4,490,721 taught a monolithic microwave circuit including an integral array antenna. The Stockton invention included radiating elements, a feed network, phasing network, active and passive semiconductor devices, logic interface, and a microprocessor all incorporated on a gallium arsenide substrate. However, even with the incorporation of these devices on one substrate the Stockton invention perpetuated the individual element approach. Also, the lack of electronic device redundancy resulted in a low yield of operable chips. The reliance on this individual chip approach did not appreciably reduce the weight of the final antenna array with its multiplicity of individual elements. A multiple device or electronic device redundancy concept in the transmit-receive means would produce a high yield transmit-receive means. If a multiplicity of transmit-receive means are mounted onto a common semiconductor wafer a greater yield of operable devices would be the result.
The size of the antenna unit cell is constrained in that it cannot be any larger than 0.6 λ O is the free space wavelength given by this equation: ##EQU1##
The problem to be solved, then, is the manufacture of an active phased-array antenna system incorporating lightweight, redundant array elements operable for use in broadband radar or electronic warfare devices on advanced tactical fighters.
SUMMARY OF THE INVENTION
In accordance with the above requirements, the present invention, a phased-array active antenna transmit-receive means utilizing arrayed transmit-receive cells all mounted upon a common semiconductor substrate resolves the problem of multiple microelectronic modules and their resultant combined weight. For frequencies equal to 12 GHz, 15 GHz or 18 GHz triple electronic device redundancy can be incorporated into a space of 0.6 λ O or approximately 0.5 in. (1.27 cm).
This transmit-receive means, operable for use in an active antenna phased array system would transmit or receive individually phase shifted radio frequency signals. This transmit-receive means would comprise a single wafer of semiconductor material. This wafer would be planar in configuration having a top and a bottom surface. A plurality of individual transmit-receive cells would be layered upon the top surface of this common wafer utilizing standard photolithographic techniques. These individual transmit-receive cells would comprise a multiplicity of redundant electronic devices. These redundant electronic devices would be selectively, permanently interconnectable to form transmit and receive circuits on the surface of the wafer.
A critical component of these redundant devices would be a mechanical switching means that would be operable to selectively, permanently interconnect the various selected electronic devices. This application teaches a mitered mechanical switch which is operable to selectively interconnect various; attenuation, amplification or phase shifting devices during the transmit-receive means fabrication and test. These mechanical mitered switches are operable to be closed at room temperatures using standard pressure sensitive techniques.
To input and output radio frequency signals onto the transmit-receive means requires a via fabrication technique using metal evaporation to produce stable, solid electrical connections. Further these same vias could be produced to supply direct current to the field effect transistors of the various signal amplification devices on the transmit-receive cell.
The disclosed transmit-receive means therefore comprises an array of individual transmit-receive cells. Each individual transmit-receive cell comprises all of the necessary electronic devices to transmit or receive a radio frequency signal in a physical area of approximately 0.395 inches (1.002 cm). Further, these devices are positioned upon the individual transmit-receive cell in a state of triple redundancy. Mitered mechanical switches, which are closed using pressure or vibration applied at room temperature permits the selection and permanent interconnection of individual operable electronic devices into transmit or receive circuits. Further the individual devices have redundant elements such as field effect transistors which increase the probability of working devices, and operational transmit-receive circuits, thereby increasing transmit-receive cell yield. All of the individual transmit-receive cells are layered upon a single wafer of semiconductor material such as galium arsenide, in an array configuration. Each transmit-receive cell would control the individual output signal emitted from an individual antenna means or amplify the received signal from that same antenna means or amplify the received signal from that same antenna means. An array of sixteen transmit-receive cells would be approximately 2.08 inches (5.28 cm) in diameter. An antenna system comprising one hundred of such transmit-receive means of sixteen cells each would be approximately 208 inches (528.32 cm) in diameter with an overall weight of approximately 60-80 lbs. (27.27-36.36 kg). Therefore, the use of this novel transmit-receive means would have a ten-fold reduction in weight for the conventional active antenna radar system.
The transmit-receive cells are fully functional at broadband and narrow band radio frequencies. In the narrow band of 9.8 to 10.2 GHz, the active antenna system would operate as a radar system. In the broadband range of 2.0 GHz to 20.0 GHz the active antenna system is fully functional in electronic countermeasures and radio frequency jamming. Either application would find a place on an advanced tactical aircraft or space based configuration because of weight and size restrictions.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference may be had to the preferred embodiment exemplary of the invention shown in the accompanying drawings in which:
FIG. 1 is a flowchart of the individual means necessary for a phased array active antenna system;
FIG. 2 is a flowchart of the individual means necessary for a transmit-receive means as used in a phased array active antenna system;
FIG. 3 is a plan view of sixteen transmit-receive cells on a single uncut wafer of semiconductor material, three inch (7.62 cm) format;
FIG. 3A is a plan view of sixteen transmit-receive cells in a single, uncut wafer of semiconductor material, four inch (10.16 cm) format;
FIG. 3B is an exploded view of the array of sixteen transmit-receive cells on a single uncut wafer of semiconductor material, four inch (10.16 cm) format with sealed lid;
FIG. 4 is a chart showing the relative positions of the individual, redundant electronic devices on a single transmit-receive cell;
FIG. 5 is a schematic representation of the individual, redundant electronic devices on a single transmit-receive cell;
FIG. 6 is a chart showing the relative positions of various groups of devices as they appear on the surface of an individual transmit-receive means;
FIG. 6A is a plan view of the devices located in the portion shown as A on FIG. 6;
FIG. 6B is a plan view of the devices located in the portion shown as B on FIG. 6;
FIG. 6C is a plan view of the devices located in the portion shown as C on FIG. 6;
FIG. 6D is a plan view of the devices located in the portion shown as D in FIG. 6;
FIG. 6E is a plan view of the devices located in the portion shown as E in FIG. 6;
FIG. 7 is a plan view of the attenuator;
FIG. 7A is a plan view of the digital phase shifter;
FIG. 7B is a plan view enlargement of the left side of the digital phase shifter;
FIG. 7C is a plan view enlargement of the right side of the digital phase shifter;
FIG. 7D is a plan view of the analog phase shifters;
FIG. 7E is a plan view of the transmit-receive switch;
FIG. 7F is a plan view of the first stage amplifier;
FIG. 7G is a plan view of the driver stage amplifier;
FIG. 7H is a plan view of the output stage amplifier;
FIG. 7I is a plan view of the low noise amplifier;
FIG. 8 is a cross sectional of the manner of making the direct current and radio frequency input/output vias within the common semiconductor wafer;
FIG. 8A is a cross sectional of the manner of making the input/output vias with thin-sputtered metalization layer and photo-resist layer;
FIG. 8B is a cross section manner of making the plated Au layer upon the thin-sputtered metalization layer;
FIG. 8C is a cross section manner of utilizing the shadow mask layer;
FIG. 8D is a cross section manner of making the evaporated metal interconnect layer;
FIG. 8E is a cross section manner of making the completed input/output via in conjunction with the radio frequency and direct current manifold layers;
FIG. 9 is a plan view of a mitered mechanical switch in the open position;
FIG. 9A is a plan view of the first layer of metalization of the mitered mechanical switch in FIG. 10;
FIG. 9B is a plan view of the second layer of metalization of the mitered mechanical switch in FIG. 10;
FIG. 9C is a plan view of the third layer of metalization of the mitered mechanical switch in FIG. 10;
FIG. 9D is a side elevational view, left of the mitered mechanical switch of FIG. 10;
FIG. 9E is a side elevational view, right of the mitered mechanical switch of FIG. 10;
FIG. 10 is an isometric of a straight through mechanical switch in the open position;
FIG. 10A is an isometric of a straight through mechanical switch in the closed position;
FIG. 11 is an exploded view of the phased array active antenna system, narrow band electronic countermeasures embodiment;
FIG. 11A is an enlargement of a portion of FIG. 11, phased array active antenna system, narrow band electronic countermeasures embodiment;
FIG. 12 is an exploded view of the phased array active antenna system, broad band radar embodiment;
FIG. 12A is an enlargement of a portion of FIG. 12, phased array active antenna system, broad and radar embodiment;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1, is a flowchart of the individual means required for an improved phased-array active antenna system utilizing a transmit-receive means comprising; arrayed transmit-receive cells on a single substrate of semiconductor material.
This improved phased array active antenna system 1, comprises a central processing means 2. As shown in FIG. 1, this central processing means 2 is operable to generate an RF input signal 3, into the transmit-receive means 6. The central processing means 2, also generates coded signals 4 to a logic control means 5. The logic control means 5, decodes signal 4 into specific voltages. The voltage inputs 6, are then directed to the transmit-receive means 7. These input voltages 6 from the logic control means 5 will control various phase shifting electronic devices on the transmit-receive means 7. A direct current power generation means 8 located in the system 1, but not on the transmit-receive means 7, generates electrical energy to supply various power amplification devices of the transmit-receive means 7. If the phased array active antenna system 1 is operated in a pulsed mode, a capacitative storage means 9, would be located within the system 1, but close to the transmit-receive means 7. The direct current power generation means 8, used in conjunction with the capacitative storage means 9 would provide a direct current energy signal 10 to the transmit-receive means 7 during active antenna system 1 operation. This pulsed, direct current energy signal 10 would supply electrical energy to various devices on the transmit-receive means 7. Heat would be generated by the various amplification devices on the transmit-receive means 7 during the transmission of a frequency signal 3. A heat dissipation means 11 would dissipate the heat away from the transmit-receive means 7. The transmit-receive means 7 during a radio frequency signal transmission would emit transmission signal 12. Transmission signal 12 would have a specific, predetermined phase shift and frequency. Transmission signal 12 would enter some signal isolation means 13 prior to entering the antenna means 14. Signal isolation means 13 would be operable to transmit or receive a radio frequency in one direction only, i.e., an output signal 12 would not be transmitted while a signal 12a was being received by the antenna means 14. The antenna means 14 would be operable to transmit a signal 12, or receive a signal 12a in a predetermined frequency range. The received signal 12a would enter the transmit-receive means 7, where after; amplification, attenuation and phase shifting signal 12a would be transmitted within the system 1 to the central processing means 2 for analysis.
FIG. 2 is a flowchart of the various means necessary for a transmit-receive means 7 as used in a phased array active antenna system 1. The central processing means 2 supplies a radio frequency signal 3 to the transmit-receive means 7. The central processing means 2 also supplies a coded logic control signal 4 to the logic control means 5. The logic control means decodes the signal 4 and produces input voltages 6 to the transmit-receive means 7. The logic control input voltage 6, and the radio frequency signal 3 from the central processing means 2, enter the transmit-receive means 7 through the attenuator means 15, and the various phase shifting devices (digital 20 and analog 25), respectively. The logic control voltages 6 set the phase shifting devices 20, 25 to a predetermined phase shift. The attenuator 15 receives the radio frequency signal 3 and reduces it. This reduced signal enters the digital phase shifter 20 where it can be phase shifted from its original phase either zero degrees or a full one hundred and eighty degrees. A digital phase shifter 20 used in conjunction with an analog phase shifting device 25 would produce a phase shift of a full three hundred and sixty degrees. An analog phase shifter 25 is capable of producing a radio frequency phase shift of between zero degrees through one hundred and eighty degrees. Transmit-receive switch 30 would be operable as a signal isolation means. The attenuated, phase shifted signal 3 would next pass through the transmit-receive switch 30. When this electrically actuated transmit-receive switch 30 is closed, the radio frequency signal 3 would enter into a multi-stage amplifier 35, 50, 60. This multi-stage amplifier 35, 50, 60 would boost the amplifier output signal 12 to a predetermined power level. A second transmit-receive switch 30a would finally receive this amplified signal 12 and if switch 30a was in the closed position it would direct the output signal 12 to the antenna means 14 for transmission to the environment outside the antenna system 1. A signal 12a received by the antenna means 14 would enter the second transmit-receive switch 30a. This signal isolation means 30a would serve to separate the output signal 12 and the received signal 12a. An open transmit-receive switch 30a would direct the received signal 12a into the low noise amplifier stage 60. This weak, received signal 12a would be amplified in this low noise amplification stage 60. The amplified signal 12a would then enter the first transmit-receive switch 30 where if open it would transmit signal 12a into the analog 25 and digital 20 phase shifting devices. After appropriate phase shifting the radio frequency signal 12a would enter into attenuation means 15. After the received signal 12a was attenuated it would exit the transmit-receive means 7 and enter into the central processing means 2 for analysis by the central processing means.
FIG. 3 is a plan view of sixteen individual transmit-receive cells 7 on a single wafer 16 of semiconductor material. The wafer 16 in FIG. 3 is L 1 or approximately 3 inches (7.62 cm) in diameter.
FIG. 3A is a plan view of sixteen individual transmit-receive cells 7 on a single wafer 17 of semiconductor material. The wafer 17 in FIG. 3A is L 2 or approximately 4 inches (10.16 cm) in diameter and is representative of the size of the transmit-receive means 7 array of the preferred embodiment.
FIG. 3B is an exploded view of an array of sixteen transmit-receive cells 7 all upon an uncut common wafer of semiconductor material. The dimension L 4 represents a spacing of approximately 0.1 inch (0.254 cm) between each individual transmit-receive cell. Dimension L 5 represents the approximate width of each transmit-receive cell 7 of 0.395 inches (1.00 cm). The overall length of the common wafer of semiconductor material 17, having a four-by-four array of transmit-receive cells would be approximately 2.08 inches (5.28 ). The multi-layer ceramic support means 19 upon which the single layer 17 of semiconductor material is mounted upon is shown in FIG. 3B. In the fabrication of the transmit-receive cell 7 array, a sealed lid 18 would enclose the surface of the transmit-receive cell 7 array.
FIG. 4 is a chart showing the relative positions of the individual, redundant electronic devices on the single transmit-receive cell 7. Specifically, upon this single cell 7 we have an attenuator 15, a digital phase shifter 20, analog phase shifters 25 and 25a, a first transmit-receive switch 30, a three stage amplification system 35, 40, 50, a low noise amplification system 60 for weak received radio frequency signals and a second transmit-receive switch 30a. Each stage, 35, 40 and 50, of the three stage amplification system is a triple redundant system. The first stage 35, comprises three distinct first stage amplifiers 35a, 35b, and 35c. The second stage or driver stage 40, comprises amplifiers 40a, 40b and 40c. Finally, the output stage amplifier system 50 comprises three output amplifiers 50a, 50b, 50c. Amplification systems 35, 40 and 50 would be used in the signal transmit circuit. Low noise amplifiers 60a, 60b, 60c, 60d, 60e, and 60f would be utilized for weak received radio frequency signals. Note: that only one amplifier in the first stage system 35 need be operational, only one amplifier of either the driver stage 40 or the output stage 50 and only two of the six low noise amplifiers 60a-60f must function to achieve a fully operative transmit-receive cell. Also only one of the two analog phase shifters 25, 25a must function for the transmit-receive cell 7 to operate.
FIG. 5 is a schematic representation of the individual, redundant electronic devices on a single transmit-receive cell 7. A signal 3 from the radio frequency manifold enters the transmit-receive cell 7 at via 21. This signal 3 enters the attenuator 15. The signal 3 is split and enters two legs formed by variable voltage resistors 22, or field effect transistors. Signal 3 is divided in one half and reflected through the field effect transistors 22. The reflected summed signal from the field effect transistors 22 is the result of the voltages applied to the field effect transistors 22. The reduced, reflected signal 3 then enters the digital phase shifter 20. The digital phase shifter which comprises a π network 23 and a coupled line segment 24 utilizes field effect transistors 26 to switch between the π network 23 and the coupled line segment 24. If the signal 3 passes through the π network the signal 3 will be phase shifted 180° from its input phase. If the signal 3 passes through the coupled line segment 24, the signal 3 will be phase shifted 0°. The signal 3 enters the analog phase shifter 25 or 25a through a mitered mechanical switch 27. This mitered mechanical switch 27 is used throughout the transmit-receive cell 7 to selectively interconnect various electronic devices. The analog phase shifters 25 or 25a are operable, utilizing continuously variable varactors having varactor diodes, to phase shift the signal 3 from the digital phase shifter 20 from 0° through 180°. The combination of the digital phase shifter 20 and one of the analog phase shifters 25 or 25a results in a potential RF signal phase shift of 0° through 360°. The phase shifted signal 3 now enters an electrically actuated transmit-receive switch 30. If this transmit-receive cell 7 is in the transmit mode this switch will be closed and connected to the transmit circuit and the signal 3 will enter a first stage gain control means 31. A gain control means such as a lossy equilizer or a lumped element resonator would be used to maintain the RF signal's 12 gain to a 50Ω system within each amplification stage 35, 40 and 50. The first stage gain control means 31 precedes first amplification stage 35. Three first stage amplifiers 35a, 35b and 36c are available for use. The first stage amplifiers 35a, 35b and 35c are all identical having input and output matching circuitry and a 600μ field effect transistor. These amplifiers are capable of producing one-quarter watt of power. Amplified signal 3 enters the driver stage gain control means 39, precedent to entering the driver stage amplifier system 40. This stage 40 comprises three independent, redundant amplifiers, 40a, 40b and 40c. Only one amplifier is required at this stage -- each amplifier has input and output matching circuitry and an equivalent 1200μ field effect transistor. The driver stage amplifiers are capable of producing one-half watt of power. Finally, twice amplified signal 12 enters output stage amplification system 50 with its three amplifiers 50a, 50b and 50c. Again, only one amplifier 50a, 50b or 50c need be operational. Each amplifier 50a, 50b or 50c has input and output matching circuitry and an equivalent 2400μ field effect transistor. Each output amplifier 50a, 50b or 50c is operable to produce one full watt of power. The signal 3 now exits the output stage 50 into a second transmit-receive switch 30a where if this switch is closed, signal 12 will exit the transmit-receive cell through antenna via 33 as transmitted signal 12. A received RF signal 12a enters the transmit-receive cell through the antenna via 33. This weak signal 12a encounters the second transmit-receive switch 30a. If the transmit-receive cell 7 is in the receive mode the electrically actuated transmit-receive cell 30a will be closed and will direct received signal 12a to the low noise amplification stage 60. Only two of the six low noise amplifiers 60a, 60b, 60c, 60d, 60e and 60f need be operational to boost the weak, received, RF signal 12a. The individual, identical low noise amplifiers 60a, 60b, 60c, 60d, 60e and 60f comprise; a feed back loop, input and output matching circuitry and a 600μ field effect transistor. After signal 12a is amplified it enters the first transmit-receive switch 30 where if the switch 30 is closed into the receive circuit signal 12a is directed into the analog phase shifter 25 or 25a, the digital phase shifter 20 and finally the attenuator 15. After the attenuator 15, the signal 12a enters the manifold via 21 for transmittal away from the transmit-receive cell 7 and to the central processing unit 2 for analysis.
FIG. 6 is a chart showing the relative positions of the various groups of devices as they actually, physically appear on the surface of the individual transmit-receive cell means. Subsequent FIGS. 6A, 6B, 6C, 6D and 6E detail the entire surface topography of the cell means.
FIG. 6A is a plan view of the upper left-hand corner of the transmit-receive cell 7. This FIG. 6A comprises driver stage amplifiers 40a and 40b, output amplifier 50a and low noise amplifiers 60a and 60b. Mitered mechanical switches 27 can be seen interconnecting the individual devices.
FIG. 6B is a plan view of the upper middle quadrant of transmit-receive cell 7. Driver stage amplifier 40c, output power amplifier 50b and low noise amplifiers 60c and 60d comprise this quadrant and output amplifier gain control means 90. Again, mechanical mitered switches 27 interconnect the various devices.
FIG. 6C is a plan view of the upper right-hand corner of the transmit-receive cell 7. Output amplifier 50c, low noise amplifiers 60e and 60f and the second transmit-receive switch 30a comprise the devices in this quadrant. The antenna via 33 is shown as a part of the second transmit-receive switch 30a.
FIG. 6D is a plan view of the lower left-hand corner and lower middle quadrant of the transmit-receive cell 7. First stage amplifiers 35a, 35b and 35c, transmit-receive switch 30, analog phase shifter 25 and first stage gain control means 31, and driver stage gain control means 39 comprise the devices in this quadrant.
FIG. 6E is a plan view of the lower right-hand corner of the transmit-receive cell 7. Analog phase shifter 25a, digital phase shifter 20, attenuator 15 and manifold via 21 comprise the devices in this quadrant.
FIG. 7 is a plan view of the attenuator 15. Eight field effect transistors 22, are utilized in two groupings of four each. Only one field effect transistor 22 of each group of four must be operable for the attenuator to perform during fabrication and test of the transmit-receive cell 7. Functioning field effect transistors operable in the specified range would be selected and interconnected into the attenuator 15 by straight-through mechanical switches 29. The Westinghouse patent, U.S. Pat. No. 3,681,134 to Nathanson et al., teaches a low capacitance configurable switch operable to serve as a straight-through mechanical switch.
FIG. 7A is a plan view of the digital phase shifter 20. The π network 23 of the digital phase shifter 20 is operable to phase shift the radio frequency signal 180° from its received phase. The coupled line segment 24 will pass the signal through the digital phase shifter 20 with a 0° phase shift. The field effect transistors 26, 26a occur in two groups of six each. Only one field effect transistor of group 26, 26a must be operable to serve as a field effect transistor switch between the π network 23 and the coupled line segment 24. Straight-through switches 29 allow the incorporation of the individual functional field effect transistors 26 or 26a during transmit-receive cell 7 fabrication and test. Line 34 is a microstrip direct current distribution line, operable to supply electrical energy to the field effect transistors of 26, 26a.
FIG. 7B is a plan view enlargement of the left side of the digital phase shifter 20. One-half of the π network 23 is shown as well as one-half of the coupled line segment 24. Six field effect transistors 26 offer multiple redundancy and a higher probability of a fully functional digital phase shifter 20, because only one must be operational among the six. Straight-through mechanical switches selectively incorporate each functional, field effect transistor 26. Microstrip line 34 is a direct current electrical energy distribution line supply power to the drain or sources of the selected field effect transistors 26.
FIG. 7C is a plan view enlargement of the right side of the digital phase shifter 20 direct current energy microstrip line 34 supplies electrical energy to the selected field effect transistor 26A. Only one field effect transistor 26A of the six need be operational for a fully functional digital phase shifter 20. One half of the π network 23 and one-half of the coupled line segment 24 is seen in this enlargement of the right side of the digital phase shifter 20. Straight-through mechanical switches 29 serve to interconnect the selected field effect transistor of the group 26A.
FIG. 7D is a plan view of the analog phase shifter 25, 25A. During transmit-receive cell 7 fabrication and test, mitered mechanical switches 27 allow a selection of either phase shifter 25 or 25A. Both phase shifters are identical and both 25 or 25A comprise a coupled line segment 36, spiral inductances 34, dual field effect transistors 26B and dual capacitors 37. Individual elements are interconnected to form the analog phase shifter 25 or 25A using straight-through switches 29. A radio frequency signal 3 received from the digital phase shifter 20 will be phase shifted either 0°, through the coupled line segment 36 or through 180° when passed through the varactor network of spiral inductances 34 and field effect transistors 26B.
FIG. 7E is a plan view of the transmit-receive switch 30, 30a. This electrically actuated switch 30, 30a comprises two legs each of the three field effect transistors 26c in parallel with spiral inductances 34a. Only one field effect transistor 26c of each group of three must be functional for an operational transmit-receive switch be functional for an operational transmit-receive switch 30, 30a. Again, straight-through switches 29 interconnect the selected field effect transistor 26c.
FIG. 7F is a plan view of a first stage amplifier 35a, 35b or 35c. Only one of these three amplifiers 35a, 35b or 35c must be operational during transmit-receive cell 7 fabrication and test. Each amplifier is identical to the other two, and comprise, microstrip inductances 41, interconnected to selected capacitors 37, tuning capacitors 37A and radio frequency bypass capacitors 37B. These elements are interconnected using straight-through mechanical switches and are operable as input and output matching circuitry. The "heart" of the first stage amplifier, 35a, 35b or 35c is a 600μ field effect transistor 38. This 600μ field effect transistor 38 is operable to produce an output signal of one-quarter watt of power.
FIG. 7G is a plan view of the driver stage amplifier 40, 40b and 40c. Only one of these three amplifiers 40a, 40b and 40c must be operational during transmit-receive cell 7 fabrication and test. Each amplifier is identical to the other two, and comprise, microstrip inductances 41, interconnected to selected capacitors 37, and tuning capacitors 37A to form input and output matching circuitry. The "heart" of the driver stage amplifier are two field effect transistors 38. Each field effect transistor has a value of 600μ and are connected utilizing Westinghouse patented "cluster matching" technique, U.S. Pat. No. 4,547,745, to Freitag et al., this combination of two field effect transistors 38 results in a combined value of 1200μ with a resultant output power level of one-half watt of power. Therefore the output radio frequency signal 12 issued from the selected driver stage amplifier will have an output power of one-half watt. Again, straight-through switches 29 interconnect the matching circuitry elements, as necessary. The term "μ" when referring to a field effect transistor 38 refers to the width of the channel of the field effect transistor 38 and its resultant power output capabilities.
FIG. 7H is a plan view of the output stage amplifier 50a, 50b and 50c. Again, only one of the output stage amplifiers 50a, 50b or 50c need be operational for the amplification of the radio frequency signal 3 to one full watt of power. Input and output matching circuitry comprising various capacitors 37, tuning capacitors 37a, and microstrip inductance lines 41 are interconnected as necessary by straight-through switches 29. Four field effect transistors 38, each having 600μ field effect transistors results in a total value of 2400μ. The output amplifier 50a, 50b, or 50c is equal to two one-half watt amplifiers in parallel. The radio frequency signal 12 will achieve one full watt of power from this output stage amplifier 50a, 50b and 50c.
FIG. 7I is a plan view of the low noise amplifiers 60a, 60b, 60c, 60d, 60e and 60f. The six low noise amplifiers 60a, 60b, 60c, 60d, 60e and 60f are operable to receive the weak radio frequency signal 12a from the environment outside of the active antenna system 1. Only two of the six low noise amplifiers are required to be operational for amplification of received signal 12a. The low noise amplifiers 60a, 60b, 60c, 60d and 60f 60f comprise input and output matching circuitry such as microstrip inductances 41, capacitors 37, tuning capacitors 37a and straight line switches 29. A blocking capacitor 37c functions as an integral part of a feedback loop 42. The received signal 12A will feedback into the 600μ field effect transistor 38a. This field effect transistor 38a is distinct from the previously described field effect transistors 38. The previous field effect transistors 38, had gate lengths of approximately 0.8μ. This gate length of 0.8μ is most applicable to field effect transistors in the power amplification mode. Field effect transistor 38a of the low noise amplifiers 50a, 60b, 60c, 60d, 60e and 60f have gate lengths of approximately 0.5μ. This gate length of 0.5μ provides less noise and higher gain for the received amplified signal 12a. In summary, the low noise amplifiers 60a, 60b, 60c, 60d, 60e and 60f are standard feedback amplifiers utilizing field effect transistors 38a, providing one-quarter watt of output power with increased signal gain and reduced noise.
FIG. 8 is a cross section of the manner of making the vias 21, 33 which bring signals from the bottom surface of the semiconductor wafer 17 to the top surface of that same semiconductor wafer 17. Via 21 is the manifold via which brings a radio frequency signal up through the semiconductor wafer 17 and across the microstrip upon the surface of the transmit-receive cell 7 into the attenuator 15. The antenna via 33 takes the radio frequency output signal 12 of approximately one watt from the second transmit-receive switch through the semiconductor wafer 17 and to the antenna means 14 for transmission outside of the active antenna system 1. A recommended fabrication method for these vias 21, 33 would produce solid electrical connections that could be repaired if improperly formed during transmit-receive cell fabrication. One method of via fabrication would utilize a metal evaporation technique. FIG. 8 shows a wafer of semiconductor material 17, i.e., gallium arsenide. The single wafer 17 would be thinned down to a thickness of approximately 100μ, as used in microwave circuitry. Wafer 17 would be mounted face down on wafer holder 45 using a soft wax 46 as an adhesive. Photoresist layer 47 is then applied to the waver 17. The photoresist 47 is then patterned to define the holes through which the vias 21, 33 would be etched. Vias 21, 33 formed through a gallium arsenide wafer 17 could be formed using wet chemical etching or reactive ion etching. Shown in cross section in FIG. 8 is a single field effect transistor 38, having a source 43 and drain 44.
Next, the photoresist mask 47 is removed and metal is sputtered over the bottom surface of wafer 17 forming a metalization layer 48 as shown in FIG. 8A, a cross section of the manner of making the via connections 21, 33. A second layer of photoresist 4a is patterned about via 21, 33.
FIG. 8B is a cross section manner of making demonstrating the removal of the second layer of photoresist 47a after a layer 51 of Au, or other similar highly conductive metal. When the second photoresist layer 47a is removed the thin-sputtered metal layer 48 is exposed. The removal of the second photoresist layer 47a can be performed by etching or ion-milling. The gallium arsenide wafer 17 is then lightly etched to clean the surface and insure its insulating properties. Gaps formed by the removed second layer of photoresist 47a are gaps 52, 52a and 52b.
FIG. 8C is a cross section method of making wherein the wafer 17 is demounted from wafer holder 45 and wax 46 is removed. The heat sink 53 for wafer 17 comprises a previously prepared wafer of aluminum nitride 53. This heat sink 53 should be of a semi-insulating material, having good thermal conductive properties and an expansion coefficient closely matched to the wafer 17, in this case, gallium arsenide. Close matching between wafer 17 and heat sink 53 will prevent cracking of the wafer 17 during thermal cycling. Solder 54 will serve to attach the aluminum nitride heat sink 53 to the gallium arsenide wafer 17.
FIG. 8D is a cross section manner of making wherein a metal shadow mask 55 is used to define the metal 57 evaporated through the orifice 56 in the mask 55. The first layer 58 and second layer 59 of the mask 55 are selectively etched to form orifice 56 which by its size defines the metal evaporation layer 57. Holes 52 and 52a are partially filled by evaporated metal 57. Gap 52b is not filled with evaporated metal 57 and remains open. Additional metal 57 may be evaporated into the area defined by orifice 56 is there is insufficient metalization during initial fabrication to make a good contact.
FIG. 8E is a cross section manner of making of the aluminum nitride layers 53, 53a and 53b. Heat sink layer 53 serves as a structural support and heat dissipation means for the gallium arsenide wafer 17. Layer 53a comprises a second layer of aluminum nitride and a laser drilled, metalized "T" contact 61. The planar top surface of "T" contact 61 contacts contact points 57a and 57b of metal evaporation contact 57. A third layer of aluminum nitride 53b comprises a Duroid, layer 62 of manifold material. During via 21, 33 operation a signal either radio frequency or direct current will enter the surface layer of the transmit-receive cell 7 devices through the metalization contact 57, from manifold 62, through "T" contact 61. This technique while not the exclusive method to manufacture vias 21, 33 will produce a high yield of successful contacts and facilitate re-metal evaporation of area 57 to increase or build up the contact.
FIG. 9 is a plan view of the mitered mechanical switch 27 which facilitates the interconnection of selected electronic devices on the surface of the transmit-receive cell 7. Mitered mechanical switch 27 comprises three layers of distinct metalization, layers 27a, 27b and 27c.
FIG. 9A is a plan view of first metalization layer 27a. First metalization layer 27a comprises three distinct portions; 27a1, a rectangular piece with a beveled left lower corner; 27a2 the left half portion of a bisected rectangle; and 27a3, the right half portion of a bisected rectangle.
FIG. 9B is a plan view of the second metalization layer 27b. Second metalization layer 27b comprises three distinct portions; 27b1, a rectangular piece substantially smaller than 27a1; 27b2 the left half portion of a bisected rectangle, also slightly smaller in size than 27a2; and 27b3 the right half portion of a bisected rectangle, again smaller in physical size than 27a3. During fabrication of the transmit-receive cell 7, metalization layer 27b will be layered upon layer 27a.
FIG. 9C is a plan view of the third metalization layer 27c. Third metalization layer 27c comprises three distinct portions; 27c1 a rectangular piece significantly smaller than 27b1; 27c2 the left half portion of a bisected rectangle, significantly smaller than 27b2; and a keystone shaped portion 27c3. This 27c3 keystone portion is significantly larger than 27b3. During fabrication of the mitered switches 27 on the transmit-receive cell 7, metalization layer 27c will be layered upon layer 27b.
FIG. 9D is a left side view of mitered switch 27 as shown in FIG. 9. An air gap or air path 28 can be seen formed between layers 27c3 and 27a1. When this air path or gap 28 exists the switch is open and no electrical or radio frequency energy will pass through mitered switch 27.
FIG. 9E is a right side view of mitered switch 27 as shown in FIG. 9. An air path or air gap 28 is found between metalization layers 27c3 and 27a. If this switch 27 is open this air path 28 will be open.
FIG. 9, in summary, is a plan view of mechanical mitered switch 27. During transmit-receive cell 7 fabrication and test various redundant electronic devices will be found operative or inoperative. Selected electronic devices may be permanently interconnected together forming transmit or receive circuits using the mechanical mitered switch 27. A switch 27 would be placed at the input and the output of each device. To close switch 27, to interconnect a specific device, portion 27c3 of metalization layer 27c must be actuated using pressure or vibration. Once layer 27c3 contacts layer 27a1 the switch will be closed forming a right angle switch. If a particular device is to be bypassed in the circuit, portion 27c3 must contact layer 27a2 -- only the lower "head" of the keystone 27c3 is contacted to 27a2 creating a straight-through electrical line connection between 27c3 and 27a2.
FIG. 10 is an isometric view of a low capacitance configurable or "straight-through" switch. Such a switch interconnects the various field effect transistors or capacitors within the individual electronic devices. This switch, which comprises two portions, 29a and 29b, is operable to be cold vibration welded into a closed position. FIG. 10 shows the low capacitance configurable switch in the open position. Portion 19a could be some type of gold alloy like AuTi. Portion 29a would have a width of L 6 or approximately, 0.005 inches (0.013 cm). Portion 29b would be layered of Au only, and having a width L 7 of approximately 1.5μ. The gap between portion 29a and portion 29b when the switch 29 is in the open position would be approximately 5μ or dimension L 8 . When in the open position, switch 29 will have portion 29a overhanding portion 29b by approximately 0.0025 inches (0.006 cm).
FIG. 10a is an isometric view of the low capacitance switch 29 in the closed position. When switch 29 is subjected to vibration at room temperature and permanent cold weld is formed between portion 29a and 29b. A portion of 29b of length L 9 or approximately 0.0025 inches (0.006 cm). This low capacitance configurable switch is taught by the U.S. Patent to Nathanson et al., assignee Westinghouse Electric Corporation, U.S. Pat. No. 3,671,134.
FIG. 11 is an exploded view of an active, phased array antenna system having electronic countermeasure applications, 1a. Logic control devices 5 rest upon the underside of sealed lid 18. Sealed lid 18 is operable to fully enclose the array of transmit-receive cells 7 all formed, uncut upon the single wafer of gallium arsenide 17. The logic control devices 5 feed their decoded voltages from the central processing unit 2 through lines 63 to strap 64. Strap 64 interconnects the voltages from the logic control devices 5 to the lines 65 between the individual transmit-receive cells 7. The wafer 17 comprising the array of transmit-receive cells 7 rests upon a multilayer aluminum nitride support layer 17. The multilayer support layer 19 comprises aluminum heat sink 53 and sublayers 53a and 53b. Input and output vias 21, 33 for the radio frequency signal or direct current energy are cut into the common wafer 17 for each individual transmit-receive cell 7. Electrical interconnection between the surface of wafer 17 and the underlying RF manifold 67 and direct current manifold 66 is achieved through the use of multistage metal evaporated vias 57, 61 and 62. Radio frequency signals 12 transmitted from this electronic countermeasure transmit-receive cell 7 would exit the RF manifold 67 by hardwire 68 which is connected to one horn of broadband antenna means 14a. A receive radio frequency signal, 12A would enter horn 14a and pass into the antenna via by hardwire 69. A broadband application would be in the range of 2 GHz to 20 GHz. A signal 12A in this range would be received by the horn antenna means 14a. Receipt of such a signal 12a would indicate that an enemy radar system was in the environment outside of the active antenna system 1A. The received signal 12A would pass up through the various support structures of system 1A into the RF manifold 67, up through via 57 by way of contacts 61 and 62. The input signal 12A would enter the surface of the transmit-receive cell 7 where the receive circuit would low noise amplify, attenuate, phase shift, analog or digitally dependent upon the logic control means 5 as directed by the central processing means 2. The received signal 12a would then pass into the manifold 11 and into the central processing means 2. During the transmission mode of an amplified radio frequency signal 12, heat is produced by the output stage amplifiers on the transmit-receive cell 7. This heat is effectively dissipated by the heat dissipation means 11. The active antenna ECM (electronic counter measures) system 1A can operate in the pulsed mode by the storage of electrical energy in the capacitative storage means 9. A transmitted signal 12 in this system will be transmitted, cross polarized from the enemy signal 12a thereby effectively jamming his radio frequency transmissions 12a.
FIG. 11A is a cross section enlargement of the ECM active antenna system 1A. Sealed lid 18 has logic control means 5 embedded upon it. Trap 64 carries the decoded voltages from the logic control means to the transmit-receive cell 7 which rests upon AlN layer 19. Upon the underside of AlN layer 19, a capacitative storage means 9 stores electrical energy for pulsed operation. Electrical connection 7 transmits this stored energy from storage means 9 to the individual transmit-receive cell 7. Heat dissipation means 11 with a multiplicity of orifices 71 dissipates heat buildup away from the transmit-receive cell 7. The antenna means 14a comprises dual horns which are operable to transmit signals polarized from the signals received. Received signals travel from one horn of antenna 14a in line 68. Transmitted signals pass through line 69 to the second horn of antenna 14A.
FIG. 12 is an exploded view of a radar application for the active antenna phased array system 1B. This narrow band application would broadcast in a range of approximately 9.8 GHz to 10.2 GHz. A patch antenna means 14B would transmit 12 or receive the reflected signal 12a. A sealed cover means 18 having a multiplicity of logic control means 5 embedded in its surface would fully enclose the gallium arsenide wafer 17 with its multiplicity of individual transmit-receive cells 7. Each transmit-receive cell is operable to, utilizing one logic control means 5 and one antenna means 14b transmit or receive a radio frequency signal of predetermined phase and frequency. Logic control signals, in the form of voltages are sent by common lines 63 through strap 64 to wafer surface lines 65. These logic control voltages direct the individual phase shifting devices on the transmit-receive cell 7. Each transmit-receive cell 7 has a multiplicity of electronic devices upon its surface, which are fully redundant and operable to be selectively, permanently interconnected to form distinct transmit or receive circuits. The wafer 17 is supported by a multilayer AlN support structure 19. This structure 19 further comprises 53, 53a and 53b. Vias 21, 33 formed of elements 57, 61 and 62 interconnect the surface of the wafer 17 and the embedded radio frequency 67 and direct current manifolds 66. Direct current energy is stored in capacitative storage means 9, and supplied to the cells 57 during pulsed signal transmission. Heat generated by the output amplifiers on the transmit-receive cell 7, is dissipated by heat dissipation means 11 through orifices 71. A transmitted signal 12 will pass from the RF manifold 67 by line 72 to antenna means 14b. The received, weak reflected signal 12a will pass on the same line 72 to the same RF manifold 67. Received signal 12a will be passed to the surface of the transmit-receive cell 7 by way of vias 21, 33 and to the central processor 2 for analysis.
FIG. 12A is a cross section enlargement of the radar, narrow band, active antenna system 1a. Sealed lid 18 has logic control means 5 embedded upon it. Strap 64 carries the decoded voltages from the logic control means to the transmit-receive cell 7 which rests upon AlN layer 19. Upon the underside of AlN layer 19, a capacitative storage means 9 stores electrical energy for pulsed operation. Electrical connection 70 transmits this stored energy from storage means 9 to the individual transmit-receive cell 7. Heat dissipation means 11 with a multiplicity of orifices 71 dissipates heat buildup away from the transmit-receive cell 7. The antenna means 14B comprises a patch antenna or flat circular disk, off center actuated which is operable to transmit signals or receive signals in the narrow band range. Received signals travel from the patch antenna 14B in line 72 to the cell 7. Transmitted signals pass through line 72 to the same patch antenna 14B and into the environment outside of the system 1B.
Numerous variations may be made in the above-described combination and different embodiments of this invention may be made without departing from the spirit thereof. Therefore, it is intended that all matter contained in the foregoing description and the accompanying drawings shall be interpreted as illustrative and not in the limiting sense. | An improved phased-array active antenna transmit-receive means utilizing a multiplicity of individual transmit-receive cells positioned in an array format upon a common wafer of semiconductor material. Each transmit-receiver cell, comprises a multiplicity of redundant, integrated circuit, electronic devices implanted upon the common semiconductor substrate. The transmit-receive cells utilize novel mitered mechanical switches to permanently interconnect individual electronic devices into either transmit or receive circuits during the fabrication and test of the transmit-receive cells. Radio frequency and direct current input and output vias formed from a novel metal evaporation technique connect the devices upon the surface of the common semiconductor wafer to underlying, insulated direct current distribution circuits and a radio frequency manifold. This array of improved phased-array active antenna transmit-receive means comprised of transmit-receive cells sharing common central processing means, logic control and heat dissipation means results in a significant reduction in the size and weight of the standard phased-array active antenna system. This significant reduction in antenna system size and weight is very important in broad band electronic countermeasure systems or narrow band phased array active antenna radar systems as used in advanced tactical fighters, or space applications. | 7 |
PRIOR PROVISIONAL APPLICATION
Applicant claims the benefit of the filing date of Provisional Application Ser. No. 60/061,491, filed Oct. 9, 1997.
This invention relates to an improved paper pulp refiner system, and method for the control of the position of the relatively rotating elements of a refiner.
BACKGROUND OF THE INVENTION
Cellulosic fibers such as paper pulp, bagasse, insulation or fiber board materials, cotton and the like, are commonly subjected to a refining operation which consists of mechanically rubbing the fiber between sets of relatively rotating bar and groove elements. In a disk-type refiner, for example, these elements commonly consist of plates having annularly arranged bar and groove patterns defining their working surfaces, with the bars and grooves extending generally radially of the axis of the rotating element, or more often at an angle to a radius to the center of the annular pattern, so that the stock can work its way from the center of the pattern to its outer periphery.
Disk-refiners are commonly manufactured in both single and twin disk types. In the former, the working surface of the rotor comprises an annular refiner plate, or a set of segmental refiner plates, for cooperative working action with a complementary working surface on the stator which also comprises an annular plate or a series of segmental plates forming an annulus. In a twin disk refiner, the rotor is provided with working surfaces on both sides which cooperate with a pair of opposed complementary working surfaces on the stator, with these working surfaces being of the same type of construction as with a single disk refiner.
Paper pulp refiners as described and including the plug or cone type, require the control of the position and spacing of the relatively rotating members, for the purpose of controlling refiner load and for controlling the quality of the refined paper fiber product, among other reasons. A plug type refiner is shown in Staege et al., U.S. Pat. No. 2,666,368, while a control arrangement for a dual inlet disk type refiner is shown in Hayward U.S. Pat. No. 3,506,199.
Traditionally, the control of refiners, resulting in the micrometer movement of one relatively moving refiner element with respect to another, has been accomplished by control systems which have electromechanical drives. While the control of the drives may be electrical or electronic such as shown in Hayward, in response to motor load, changing voltage or power factors, or pulp quality, the ultimate drive is by and through a gear reduction or high ratio mechanical positioning arrangement. In this connection, reference may be had to the Baxter U.S. Pat. No. 2,986,434 which shows a dual inlet radial disk type refiner and the reduction gearing through which the axial position of the stator and rotor elements may be accurately determined and maintained. For proper operation, not only is it necessary to control the relative position of the rotor members, it is also necessary to control the overall spacing between pairs of rotating and stationary refiner plates to compensate for plate wear and/or compensate for bearing wear or other parameters. As noted, such compensations have been made through mechanical or electro-mechanical gear or mechanical reduction type adjustments.
There has been no effective means by which the center of rotation of the rotating member can be shifted, adjusted or compensated in use except by making major set up changes in the alignment of the components. Accordingly, precise geometric control over and between the running relation of the rotary to the stationary member has never been fully available, during operation. Typically, while new refiners are manufactured to plus or minus 1 or 2 thousandths of an inch total run out or tolerance, most of these refiners actually run from 10 up to 20 or more thousandths of an inch out of alignment. Such non-alignment results in a reduction of pulp quality. Also, it is current practice in double disk refiners to allow the rotor to float and find its own position between non-rotating or stator elements. The success of such arrangements depends upon a maintenance of hydraulic balance but, from a practical point of view, such rotors tend to hunt back and forth between limit positions in which the rotor elements may come into actual contact with the stator refining elements.
SUMMARY OF THE INVENTION
This invention relates to a improved refiner system and a control system by which the precise location or position of the relatively rotating members may be determined, controlled and maintained during operation. This is accomplished in this invention by the use of magnetic bearings for supporting and positioning the rotor, and/or for positioning one or more of the stator components with respect to the rotor.
The arrangement permits the equalization of flow through a double refining system of a twin disk refiner by means of both axial and radial control. It features controllable electro-magnetic bearings to control the axial position, by means of an external control loop, of the rotor assembly and/or of the stator assembly thereby providing direct control of the position of these components and increased stability of refiner operation.
Radial electro-magnetic bearings maintain a uniformity in the gaps in the circumferential sense and provide a means by which optimal alignment of the components may be maintained, or concentricity in the case of conical elements. They also permit asymmetrical running conditions to be maintained if desired.
As an added benefit, the use of concurrent axial and radial magnetic bearings provides two new degrees of freedom to the conventional system in that they provide for axial rotor orientation and simultaneous angular orientation with respect to a stator plane.
Additionally, the invention provides a refiner system and method by which the refiner may be tailored or modified to process pulps of different consistencies or different degrees of refinement by reason of the universality of the control as provided by the use of a combination of axial and radial magnetic bearings. Accordingly, process equipment which requires precise geometry control is enhanced in capability. The increase in process control has the effect of minimizing fiber damage or enhancing fiber processing rate. The flow through a pair of gaps in a twin disk system may be fully equalized as to power, draw or the like. Increased accuracy in plate adjustment is possible and greater turn down ratios are
In a control system, the position of a rotor may be oriented with respect to one or more stator elements by using gap measuring techniques, as well known in the art, which the gap or gaps may be measured to provide a signal for controlling the rotor and/or one or more of the stators to maintain a desired gap or range of gaps. Also, on-line measurement of pulp quality may be employed as a control parameter.
From a mechanical and maintenance point of view, conventional bearing maintenance is eliminated. Magnetic bearings themselves are highly resistant to water contamination, which is always a threat and a problem with conventional mechanical bearings, and are resistant to small solids contamination that can quickly destroy a precision ball or roller bearing. Further in view of the substantial range of adjustments available, extremely close manufacturing and machining tolerances can be relaxed. Field adjustments and running adjustments may be maintained through appropriate software at the computer.
It is accordingly an important object of this invention to provide a paper pulp refiner which employs one or more magnetic bearings for position control. A single magnetic bearing may be used to provide a substantial improvement to the performance of the refiner.
Another object of the invention is to provide an apparatus and method by which a paper pulp refiner may be more accurately controlled and by which mechanical reduction in positioning elements commonly used for positioning control may be eliminated or simplified.
A still further object is the provision of a system, as outlined above, in which most or all of the conventional thrust and load carrying bearings and components may be eliminated and replaced with radial or axial thrust or combination magnetic bearings.
A further object of the invention is the provision of a refiner and method of operation in which the gap widths in a twin disk refiner or the like may be accurately maintained in an equalized condition of flow.
These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawing and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE of the drawing represents a diagrammatic view of a twin disk refiner and control system according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing which represents a preferred embodiment of the invention, a twin disk refiner is shown in diagrammatic form. This refiner may be made in accordance with the patent of Seiffert et al., U.S. Pat. No. 4,171,101, the disclosure of which is incorporated herein by reference. While a twin disk refiner is used to illustrate the principles of the invention, it is understood that the invention may be applied to a single disk refiner, or to a plug type Jordan refiner such as shown in Staege et al., U.S. Pat. No.2,666,368, or other conical type refiners.
The refiner 10 of FIG. 1 accordingly has a housing 12 and supports a central rotor 15 which carries on its radial surfaces a pair of oppositely facing refiner disk sets 16 and 17. These sets cooperate respectively with facing refiner disk sets 18 and 19 carried on the stator to define therebetween refiner gaps 20 and 21. A single inlet 25 may supply both of the refiner disk sets from a radially inner position, by providing a suitable passageway 26 through the rotor 15 or alternatively, separate inlets to the refiner may be provided as represented by the reference numerals 20 and 21 in patent '101. A common outlet 28 is formed to receive the refined pulp from the refiner gaps 20 and 21 and from the common chamber 29 defined by the housing 12.
The refiner disk set 18 is fixedly mounted on a wall of the housing 12 whereas the opposite non-rotating refiner disk set 19 is mounted on an axially positionable non-rotating housing member 30. The rotor 15 is connected to and driven by an input shaft 32 which, in turn, is driven by an electric drive motor 35. The drive motor 35 may be direct coupled to the shaft 32 or may be coupled through a flexible or universal coupling to permit the shaft 32 to be subjected to alignment and orientation to a certain degree separate from the shaft of the motor 35. Alternatively, the motor 35 may be belted to the shaft 32.
In the preferred embodiment a pair of radial type magnetic bearings 40 and 42 support the shaft 32 in the housing. The bearings 40 and 42 control the alignment of the plane of the rotor 15 and the rotor orbit.
A first axial magnetic bearing 44 includes an armature 45 joined with or mounted to the shaft 32 and receives the thrust of the shaft 32. The bearing 44 controls the axial position of the shaft and thereby controls the refining the width of the respective refining gaps 20 and 21. By this means, an equalized output condition can be maintained or, conversely, a controlled unequalized condition can be maintained in the refiner.
The refiner gap 21 and the gross spacing between the refiner disk sets 18 and 19 is controlled by regulating the axial position of the moveable stator housing member 30 by an additional axial thrust magnetic bearing 48 and its armature 49 which may be constructed the same as the bearing 44 and its armature 45. A gap pick up 50 may be used to measure and provide a signal of refiner gap.
The controllable magnetic bearings may be those as supplied by Revolve Technology, Inc., 300, 700-10th Avenue S.W., Calgary, Alberta, Canada T2R 0B3. Also, at least the radial bearing 42 and axial magnetic bearing 44 may be replaced by a single dual purpose magnetic bearing which provides for both radial and thrust control, such as shown in U.S. Pat. No. 5,514,924 or in U.S. Pat. No. 5,386,166. Further, it is understood that those persons skilled in the art have available control systems including a controller 60 by which the running clearances and gaps may be measured such as by the pick up 50, and the position of the rotor 15 including axial radial, and tilt or inclination, may be controlled by the controller 60 thereby suitably controlling the radial bearings 40, 42. Control systems for radial magnetic bearings are shown in U.S. Pat. Nos. 5,565,722, 5,530,306 and 5,347,190.
The axial bearing 44 may be employed in combination with the radial shaft supporting bearings 40, 42 to define and locate the relative axial position of the rotor 15 with respect to each of opposed stator members, while the second axial magnetic bearing 48 may be used to position the moveable housing member 30.
It will be therefore be seen that the usual complicated mechanical structure for supporting a refiner rotor and positioning the rotor through manual, remote or computer controlled motion reduction means has been eliminated. Similarly, the mechanical mechanism for moving or positioning one or more of the moveable refiner walls may be eliminated or simplified. Also, the system of this invention provides a wider range of operation and control since, for the first time in a refiner system, the radial running position or axial orientation of the drive shaft may be varied in use and during operation to optimize the refiner performance.
The benefits of this invention include improved pulp quality at lower cost, increased uniformity of treatment, reduced plate wear, wider operating flexibility and improved productivity.
While the method and form of apparatus herein described constitutes a preferred embodiment of this invention, it is to be understood that the invention is not limited to this precise method and form of apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims. | A rotary paper pulp refiner system and method includes a rotor having one or more refining elements mounted on a rotating shaft and complimentary non-rotating or stator elements defining with the rotating element a refining gap or gaps through which the paper stock material passes, and which the rotor is mounted for rotation on magnetic bearings that support the rotor shaft for rotation and define the axial and radial running position thereof. Optionally, a movable stator housing wall may also be controlled by a magnetic bearing. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to excavation tools for the mining industry, where fragmenting rock, coal and other minerals is accomplished by the use of drag bits. More particularly, the present invention relates to utilizing a double acting bit holder in lieu of known drag bit holders to improve the cutting action of the bit while providing a means for resharpening and maintaining the bit in a sharp condition during excavation use.
2. Description of the Prior Art
A large number of excavation machines used in the mining and construction industries are equipped with drag bits, and these machines include continuous miners, boring machines, road headers, saws, drills and trenchers. The cutting surfaces or heads of these machines may be equipped with a few to more than 100 individual drag bits, each of which is held in place by a bit holder or bit block. The types of bit holders will depend on the types of bits used, and the bits may be of a conical type, cutter type, or concave type. While there are different holders for different types of bits, each holder has a recess for the shank of the bit and some kind of mechanism to secure the bit to the holder.
The bit holders function to secure the replaceable drag bits securely to the cutting surface of the excavator, and the holders are simple devices with no moving parts that hold the bit secure in the proper cutting position. The cutting action of these drag cutters is a simple plowing motion that enables the bit to stay in contact with the material being cut. Nevertheless, the continuous plowing action produces a variety of small and large chips, and forms a zone of crushed material under the bit, and the materials under the crushed zone and the amount of small chips are indicative of inefficient and costly cutting that induces excessive bit wear and bit heating. The inefficient cutting motion is the first major disadvantage of conventional bit holders, and as the individual drag bits become worn out, they are replaced because there is no means for resharpening the bits during their cutting life. Therefore, as the bit becomes worn, the production rate falls off while the cutting forces, dust generation and damaging machine vibrations increase, and this process continues up to the end of the bits lives, where the bits may require up to five times the force and energy that would normally be required for new sharp bits.
Accordingly, the second major disadvantage of conventional bit holders is their inability to resharpen or keep the bit sharp over the course of its cutting life activity.
An exception to conventional bit holders with no moving parts are the pin mounted embodiments of U.S. Pat. No. 3,697,137 which allows rotation of the bit about a pin. However, these holders do not have a front sharpening position as defined by the front stop and thus cannot maintain or resharpen bits during cutting and they do not have the ability to provide an impact force to the bit in the direction of the cut to aid in the cutting process.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a bit holder characterized by more efficient cutting motion than conventional bit holders in order to substantially reduce or eliminate the crushed zone and the large number of small chips that are inefficiently and expensively produced as a result of expensive bit wear and bit heating using conventional bit holders.
Another object of the invention is to provide a bit holder having the capability to resharpen the bit and keep it sharp during the cutting life of the bit, in contrast to conventional bit holders.
A yet further object of the invention is to provide a double acting bit holder characterized by efficient cutting motion that lessens the crushed zone as well as the large number of small chips which normally accompany conventional bit holder action which causes excessive bit wear and bit heating, but no resharpening or maintenance of sharpening during the cutting life of the bit holder.
Another object of the invention is to provide a bit holder having the capacity to furnish an impact to assist chip formation ahead of the bit.
These and other objects of the invention will become more apparent by reference to the drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and form a part of the specification will illustrate preferred embodiments of the present invention, and together with the description, will serve to explain the principles of the invention. In the drawings:
FIG. 1 depicts a side view of a double acting bit holder;
FIG. 2 is an alternate embodiment of the double acting bit holder of the invention; and
FIG. 3 shows the bit positions with the double acting bit holder in the front position, mid-position and back position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In its essential characteristics, the double acting bit holder is a novel bit holder that automatically and continuously combines two separate functions. These two separate functions are a resharpening function and an improved cutting function which combines an indentation, an impact and a plowing motion. Further, the double acting bit holder may be designed for use with any type of drag cutter (point attack, cutter type and concave type) and can be mounted on any type of excavation machine.
Reference is now made to FIGS. 1 and 2, which show respectively, the double acting bit holder from a sectional side view and an alternate embodiment from a sectional side view.
In FIG. 1 and 2, there is depicted, a cutter head C on which a bit holder 10 is positioned. The double acting bit holder comprises a stationary base 11 with front stop 18 and back stop 19, a moveable part 12, and a coil spring 13 that fits into adjoining openings O disposed or bored in the stationary base and the movable part. The stationary base has an integral extension 14 having a hole through which a pin shaft 15 extends in order to pivotally connect the stationary base portion with the movable portion of the holder. The stationary base is rigidly attached to the cutter head section of the excavation machine by bolting or welding, and the movable part of the holder has a recess 17 which may be circular or rectangular, to hold shank portion S of bit B (which is not a part of the invention). In operation, the movable part of the holder carries the bit and rotates between front stop 18 and back stop 19 around the pin shaft to provide variable rotation that is limited between about 10° to about 30°. As the pin shaft holds the stationary and movable parts together while allowing the movable part to rotate, the spring or coil keeps the movable unit against the front stop 18 and returns it to this position. Arrows A show the distance to the full back impact position, while arrows D show the distance to the front sharpening position. In FIG. 1, the double acting bit holder is shown in the mid-position, and arrows E show the clearance angle between the bit in mid-position and the surface being cut.
FIG. 2 is an alternate embodiment of the double acting bit holder of the invention, where the reference numbers shown represent the same elements as those described in connection with FIG. 1. Spring 13 can be of any type (as shown by a coil spring in FIG. 1) and of any size that suits the bit and cutting conditions. Moreover, since different style bits use different shanks, the movable part that actually holds the bit will be different for each different bit type used. Also, all parts except the spring will be constructed of high quality steel which may be heat treated and case hardened. The spring can be of any type, including coil, leaf, torsional, disc or elastomer, and constructed of any suitable material.
While the cutting function and the resharpening function of the double acting bit holder of the invention will be described separately, it is emphasized that these two functions occur simultaneously, and that these two functions proceed continuously during normal excavation operations using the double acting bit holder of the invention.
CUTTING FUNCTION
In describing the cutting function, reference is made to FIG. 3 which depicts the various bit positions associated with installation of the bit in the double acting bit holder of the invention. The sequence of events that occurs during the cutting function combines an indenting motion (shown by arrow I) and a plowing motion (as shown by arrows P) a front position for sharpening and cutting (as shown by FP), a mid-position for cutting only (as shown by MP), and a back position for cutting only (as shown by BP) with impact.
In the front position (FP) of sharpening and cutting: the direction of cut is forward or reverse; the cutting action is shallow plowing; the depth of cut is shallow; and the clearance angle is zero or negative.
As to the mid-position (MP) of cutting only: the direction of cut is forward only; the cutting action is plowing and indention; the depth of cut is variable; and the clearance angle is variable positive.
In the back position (BP) of cutting only: the direction of cut is forward only; the cutting action is deep plowing; the depth of cut is maximum; and the clearance angle is maximum positive and an impact force is applied to the bit.
Before the bit enters the rock, the bit is in the forward position (FP), and is held in that position by the preset spring force. The bit's forward position is limited by the contact between the front portion of the movable and stationary parts. As the bit begins to cut into the material, the cutting force begins to rise, and when this cutting force is large enough, it overcomes the spring force and the bit is rotated backwards or clockwise, and this rotation effectively pushes or indents the tip of the bit deeper into the rock mass (RM). The indention and plowing action continues until conditions are favorable to form a chip ahead of the bit tip as shown in position MP (this may happen when the bit is partially backed or when it is fully backed). The back position is limited by the contact between the back portions of the movable part 12 and the back stop 19 of the stationary parts. In the full back position, the indenting action ceases, the plowing action dominates and an impact force is applied to the bit by back stop 19. Once a chip is formed, the bit swings rapidly back to the forward position by the action of the spring, whereupon the cycle repeats. While the total amount of angular motion is variable, it will normally be between about 10°-30°, and the amount of rotation may be controlled by varying the space between the movable and stationary parts.
Referring now to FIG. 2; if the moveable part 12 and the back stop 19 of the stationary part 11 strike each other with high velocity, then in addition to the plowing force, an impact force is generated and transmitted to bit B. This impact force helps to form a chip out ahead of the bit and can be a significant aid to the cutting process. If part 12 and part 19 do not strike each other with any significant velocity, then no impact force is created but the cutting process continues as described earlier.
It is important to note that the amount of spring force developed during cutting is a function of the size of the spring used, and is therefore adjustable. The force to move the movable part 12 off front stop 18 is also variable by changing the preload of the spring. The shape of the bit tip is also a variable and may be of a chisel, curved or conical shape and made of steel, tungsten carbide or any other suitable material.
In order to illustrate the principles of the operation of the double acting bit holder of the invention, a review of the traces of the cutting forces experienced by a conventional drag bit and a drag bit mounted in the double acting bit holder of the invention is useful. A conventional drag bit has a cutting force which varies constantly during cutting, and the large variation in force peaks indicate that chips of many different sizes are being produced. Also, there is greater or lesser continuous cutting between major force peaks, such that the conventional drag bit is in constant contact with the rock, and this is the primary cause of frictional heating of the bit and the large amounts of dust and fines that are produced.
On the other hand, the trace of the cutting force for the double acting bit show fewer, but higher force peaks, and each force peak represents the formation of a major chip. Since the large chips form at, or slightly below, the maximum depth of cut, the cutter tip generally does not contact the rock between major chips. This greatly reduces frictional heating and the generation of excessive fines and energy consumption. Therefore, the energy per unit volume used to fragment rock is significantly lower with the double-acting bit and therefore reflects its more efficient cutting action.
By controlling the depth of cut, the amount of rotation of the bit, and the speed of the cutter head, the size of the chips, and the frequency of chipping can be controlled. Further, the cutting action can be controlled from shallow rapid chipping to deep, slow chipping in order to suit the material being cut and the type of excavator being used.
SHARPENING FUNCTION
The second major function of the double acting bit holder is the sharpening action. For background understanding, it should be known that the normal method of resharpening a drag cutter is to grind the negative clearance angle into a positive clearance angle. The negative clearance angle becomes apparent as the rounding off of the leading edge of the bit occurs or by the development of a wear flat on the bit tip. As an example, a sharp bit is one that has a positive clearance angle as shown by arrows E in FIG. 1.
In order to maintain a sharp condition or to resharpen a worn bit, the double acting bit holder holds the bit in a special sharpening position as defined by the front stop 18. The special sharpening position is the full forward position that presents a zero, or slightly negative clearance angle (up to about -15°) to the material being cut, as is shown in position FP in FIG. 3. As the bit moves through the material, the dragging action of the bit itself serves to grind down the back clearance angle to remove any rounding or wear flats that occurred during normal cutting. The resharpening position will remain as long as the force on the cutter is less than the preset spring force. Generally however sharpening will normally occur at the shallow beginning and end of a crescent-shaped rotary cut, or it can be achieved by purposely taking shallow cuts or by abrading the bits against an artificial grinding surface. Also, in the case of machines that are able to reverse the direction of the cutter head, running the cutter head in reverse will also produce the resharpening effect.
The effectiveness of the resharpening process will depend on the material being cut (primarily its hardness and abrasiveness), the type and material of the bit, the magnitude of spring force, and the cutting technique employed. In most cases however, bit sharpening can be accomplished automatically and continuously during normal cutting operations.
The key features of the double acting bit holder of the invention are: the novel bit holder provides an indention action, a plowing action and an impact action automatically and continuously to produce larger, more energy-efficient cuttings while reducing the plowing scraping motion between major chips; the bit holder automatically holds the bit in a resharpening position during shallow cutting or in the reverse non-cutting direction; the bit holder has a movable portion that holds the bit and rotates around a pin shaft; and the bit holder comprises a spring that aids both in the chipping process and continuously restores the bit to the resharpening position. As a result of these key innovative features of the double acting bit holder of the invention, longer bit life is obtained, the bit is maintained in a sharp condition during the normal cutting process, the bit is resharpened without the necessity of removing it from the cutter head, the cutting process achieves a more energy-efficient fragmentation, there is a reduction in the amount of dust generated, and the ignition hazard from methane gas production is reduced.
While the foregoing description and illustration of the present invention have been particularly shown in detail with reference to preferred embodiments, it should be understood by those skilled in the art that the foregoing are exemplary only, and that equivalent changes may be employed without departing from the spirit and scope of the invention. The embodiments of the invention in which an exclusive property right or privilege are claimed as follows: | A double acting bit holder that permits bits held in it to be resharpened during cutting action to increase energy efficiency by reducing the amount of small chips produced. The holder consist of: a stationary base portion capable of being fixed to a cutter head of an excavation machine and having an integral extension therefrom with a bore hole therethrough to accommodate a pin shaft; a movable portion coextensive with the base having a pin shaft integrally extending therefrom that is insertable in the bore hole of the base member to permit the moveable portion to rotate about the axis of the pin shaft; a recess in the movable portion of the holder to accommodate a shank of a bit; and a biased spring disposed in adjoining openings in the base and moveable portions of the holder to permit the moveable portion to pivot around the pin shaft during cutting action of a bit fixed in a turret to allow front, mid and back positions of the bit during cutting to lessen creation of small chip amounts and resharpen the bit during excavation use. | 4 |
FIELD OF THE INVENTION
This invention relates to agronomy, in general, and golf course greens keeping, specifically. One of the most important elements of golf course management is the health of the putting greens. In attempting to maintain the most luxurious growth of grass, close attention is paid to watering and feeding of the greens. However, very little has been done in the area of temperature control, other than watering, even though it is well known that each species of greens grass has an optimum temperature range for best results. This invention provides a system by which the surface temperature of the grass may be changed from the ambient temperature without introducing other deleterious agents.
BACKGROUND OF THE INVENTION
Temperature control, or cooling, of the golf greens has conventionally been a by-product of watering. However, in the hotter climates or in the hotter parts of the summer, temperature control would require too much water for healthy growth of the grass. Too much water, particularly in high humidity conditions, may create a continuous wet environment more favorable to fungi, mildew, or other deleterious agents. Whereas watering during the heat of the day affects the subsoil which damages the root system of the grass. Therefore, watering, alone, can not be used to control temperature for a sustained period of time.
Large fans, located adjacent the greens, have been employed to control humidity and temperature by moving the air across the green. Any cooling effects are directly related to evaporation and in a high relative humidity environment there is little evaporation. In the situation where there is a low humidity heat, there is no water vapor to evaporate. This amounts to a hot dry wind which dries out the subsoil quicker than normal. In addition to the substantial breeze created by the fans, the noise produced is a distraction to the players.
The art of greens keeping lacks a system which can be used continuously in all high heat and high or low humidity conditions to control the temperature of the air directly above the green without deleterious side effects.
DESCRIPTION OF THE PRIOR ART
There are numerous devices for affecting the temperature of golf course greens. U.S. Pat. Nos. 5,596,836; 5,617,670; and 5,636,473 to Benson disclose an underground system for delivering treated air to the subsoil of a green. The operation of these devices depend on the specific preparation of the subsoil for their operation. This includes installation of a gravel bed under the green as part of the site preparation. The treated air is delivered underground and percolates upwardly through the gravel bed and the sod to achieve its desired result. U.S. Pat. No. 5,590,980 to Daniel discloses an underground system of conduits connected to a vacuum pump and reservoir to control the moisture content of the green through drainage. Yoshizaki, U.S. Pat. No. 5,306,317 uses an underground conduit system and a boiler for heating the soil for optimum growth. Rearden et al, U.S. Pat. No. 5,368,092, discloses a subsurface array of tubes for circulating a temperature controlling fluid and a temperature sensor for control of the device.
All of these devices attempt to influence the surface temperature of the green from subterranean application of the temperature altering agents. The intervening layers of earth and/or gravel would clearly act as a heat sink and detract from effectiveness of these agents on the upper surface of the grass.
SUMMARY OF THE INVENTION
A system for modifying the surface temperature and/or relative humidity of golf greens or other grass playing fields by applying temperature controlled air and/or a water mist through pop-up nozzles. The nozzles are controlled by a central control panel which activates the nozzles based on input from temperature sensitive probes in the greens.
Accordingly, it is an objective of the instant invention to teach the application of temperature controlling agents directly to the upper surface of the grass.
It is a further objective of the instant invention to teach the use of a temperature controlled air flow upon the surface of the grass which may be applied continuously without injury to the grass.
It is yet another objective of the instant invention to teach a system of providing temperature controlled air flow through an array of distribution lines which include the temperature and humidity modification of ambient air and delivery to the upper surface of the green. The system may be controlled by temperature sensitive probes inserted in the sod.
It is a still further objective of the invention to provide a particular nozzle construction for applying the temperature controlled air flow wherein the nozzle is displaced from an at-rest position within the sod to an activated position above the grass. The displacement of the nozzle may be accomplished by air flow.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic of the system of this invention;
FIG. 2 is a cross section of a nozzle of this invention in the activated position showing louvers for directing air flow; and
FIG. 3 is a cross section of a nozzle of this invention in the at-rest position showing the air activation mechanism.
DESCRIPTION OF THE INVENTION
The overall view of the system 10 , shown in FIG. 1, includes the features of a golf course. In this instance, a lake is a part of the golf course either as a source of irrigation water or an obstacle for the golfers or both. The deeper water in the lake has a naturally occurring, nearly constant, temperature which is below the ambient air temperature during the growing season. In the embodiment illustrated, the lake is the medium within which the radiator 3 is immersed. Of course, the radiator could be submerged in any fluid medium with a preselected temperature, such as a container of ice water or, in colder climates, a container of warm water. The fluid medium includes gases also, e.g. the radiator could be placed in a cavern or ice house. The temperature of the entrained air within the radiator coil is the result of the heat exchange through the radiator tubing. As shown, the radiator 3 is a rectilinear array of tubing but it can take any form, such as circular, to create a large surface area of tubing for increased heat exchange.
Atmospheric air is drawn into the inlet 1 of line 2 and passes through radiator 3 by the operation of the air pump 8 . Once the air has been temperature modified by the radiator, the remainder of the lines in the system are either buried or insulated or both.
The pump 8 may be reciprocal or rotary with an inlet line 4 carrying the temperature modified air through the system for distribution to the greens by line 11 . Inlet line 4 has an inlet valve 5 for controlling the inlet air flow. Another air inlet 6 is located on the air pump 8 for entraining air to operate the nozzles 20 through manifold 17 . Line 6 also has an on-off valve 7 for control of ambient air flow. A compressor (not shown) is operatively connected with the nozzles 20 to provide motive force for moving the nozzles from an at-rest position to an activated position. A supply line 29 for pressurized air connects the compressor and the nozzles. The compressor may or may not use preconditioned air.
The system may also be connected to the irrigation system 16 of the golf course. The irrigation system has a manifold 15 which connects with the nozzles 20 . The manifold is controlled by the control panel 9 and line 12 .
The system is operated through a control panel 9 which includes conventional air pressure gauges; air temperature gauges, both ambient and system; soil temperature gauges, both ambient and system; on/off control switches, both air alone and air and water; sensors, both temperature and humidity; a timer and a computer or CPU (none shown).
In a program mode, the sensor probes 14 which are placed in the soil of the greens give a reading of the temperature and humidity conditions existing on each green. In the program mode, air, only ; humidity, only; or both may be selected. If either or both of these conditions exceed a programmed preset limit, for any green, the CPU activates the system to produce temperature modified air flow, with or without humidity modification. The treatment may be a timed period or it may continue until the conditions fall within the preset limits.
As shown, in FIG. 1, there may be several probes 14 placed in each green. The CPU may activate the system based on the average of these readings or on the highest or on the lowest. The CPU may be programed to read only the temperature or humidity or the heat index based on both.
In a timed mode, the system may activate any combination of greens at a particular time for a particular period for temperature or humidity control or both.
As shown in FIG. 1, there is a golfer delay switch 18 located near the golf cart path 19 . This allows the treatment of the greens to be temporarily interrupted during play. The switch 18 includes a timer which may be fixed or adjustable. For example, in the fixed mode, the air and/or water treatment of the green would cease for a short period, such as 5 minutes, the switch is activated, then resume. When the cooler air, alone, is being delivered to the greens, the switch 18 may be deactivated.
The nozzle 20 shown in FIG. 2 in the activated position is extended upwardly out of the housing 21 and has open louvers 23 directing the temperature modified air parallel to the ground just above the grass. The louvers are pivotally mounted in the nozzle in such a way that the flow of conditioned air will open the passageway. The nozzle 20 has a bell shaped upper portion 26 carrying the louvers. The bell shaped portion continues into a tubular portion 24 which telescopes into a tubular housing extension in the at-rest position. The tubular portion 24 reciprocates through an annular collar 27 which acts as a guide for the movement. The collar 27 also forms the reaction surface for the return spring 28 . The other end of the return spring 28 is captured by the collar 38 at the lower end of the tubular portion 24 . The compressed return spring 28 expands to return the nozzle to the at-rest position when the system is inactive. The flange 25 surrounding the mouth of the housing is located at ground level and acts as a stop for the downward movement of the nozzle 20 . The lower tubular extremity of the housing 21 has a connection 22 for the conditioned air distribution line 11 .
In FIG. 3, the nozzle, in the at-rest position, is broken away to show the other working elements. The return spring 28 is extended and upper portion 26 of the nozzle is in contact with flange 25 . Since no air is circulating, the louvers 23 are closed. The nozzles 20 are activated by high pressure air supplied by line 29 into cylinder 30 . The high pressure air moves the piston 31 and piston rod 32 to raise the upper portion of the nozzle. The piston rod 32 has an attachment 32 ′ connected to a control arm 33 attached to the misting nozzle 34 .
The misting nozzle 34 is connected to water line 35 . Inside housing 21 there is an excess 36 of water line 35 to accommodate the movement of the misting nozzle. The pressure in this water line may be adjusted to give a fine spray for humidity control without flooding the green.
As shown in FIG. 1, some of the nozzles 13 around a green may not be connected to the irrigation system 16 .
In the program mode, the sensors 14 signal the control panel 9 that a green or greens is/are out of parameters of temperature or humidity or both, the control panel signals the air pump 8 and compressor to activate some or all of the nozzles 20 around the affected greens. Temperature adjusted air begins to flow and compressed air is delivered to raise each nozzle. If a humidity parameter is selected, the control panel signals the water system to supply water to each activated nozzle. This activated condition will continue either until the sensors show each green is within parameters or for a preselected period of time.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings. | A system for modifying the surface temperature and/or relative humidity of golf greens or other grass playing fields by applying temperature controlled air and/or a water mist through pop-up nozzles. The nozzles are controlled by a central control panel which activates the nozzles based on input from temperature sensitive probes in the greens. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a divisional application of co-pending U.S. application Ser. No. 12/093,871, filed May 15, 2008, which claims the priority of PCT International application No. PCT/EP2006/068517, filed Nov. 15, 2006, which designated the United States, and which claims the priority of German Patent Application, Serial No. 10 2005 054 845.8, filed Nov. 15, 2005.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an electrical device arrangement, in particular for an item of furniture, with a bus device and bus subscribers,
[0003] Such electrical arrangements are known in form of different electric-motor-driven drive configurations for adjusting items of furniture in the context of additional electrical loads, such as lamps, heaters, massagers, and the like. Because of the large variety in furniture design, these devices are configurable in many configurations. A large number of associated control units with power supplies, operating units and various connection designs is also available for the units to be connected.
[0004] Different standardizing measures are known, which not only reduce the variety of connection types, but also tend to add flexibility to the electric device arrangements, for example for upgrades and ease of assembly.
[0005] One such example is illustrated in DE 201 07 726 U1, which describes a device for controlling electrical devices of furniture in modular construction, wherein the modules can be plugged together and have data transmission lines and power supply lines. The data transmission lines form a bus system to which data processing devices are connected inside the individual modules. The modules also include control circuits for loads, and an operating unit can be connected to at least one module, or one module includes a remote control receiver.
[0006] There is a need to further simplify such arrangements and to add flexibility for connecting and controlling additional devices.
[0007] There is also a need to employ such electrical device arrangements also with items of furniture in areas subject to particular safety requirements, for example in nursing home and hospital settings.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the present invention to improve an electrical device arrangement, in particular for items of furniture, with a bus device and bus subscribers, and to improve over the state-of-the-art with respect to economy and safety.
[0009] The object is attained according to one aspect of the invention by an electrical device arrangement, in particular for an item of furniture, including a bus device and bus subscribers, wherein the bus device has a bus device having wirelessly configured control paths, and bus subscribers connected to the bus device, wherein at least one of the bus subscribers is an operating unit comprising a memory for storing control parameters and a control program and at least one of the bus subscriber is a controller of a furniture drive.
[0010] According to another aspect of the invention, a method for controlling such electrical device arrangement, in particular for an item of furniture, with a bus device and bus subscribers connected to the bus device, wherein at least one of the bus subscribers is an operating unit that is integrated in a mobile phone, and at least one of the bus subscribers is a controller of a furniture drive, includes the steps of operating an input unit of the mobile phone, and transmitting data wirelessly from the mobile phone over a control path of the bus device.
[0011] The invention is based on the concept that all bus subscribers connected via a bus device are, in addition to the bus lines, connected with an enable line, and that all adhere to the parameter choice from a bus subscriber functioning as a master, wherein the master stores the control parameters in addition to a sequence program. The bus subscribers can recognize each other, address each other fully automatically, and communicate with each other.
[0012] The electrical device arrangement of the invention, in particular for an item of furniture, with a bus device and bus subscribers is characterized in that the bus device has at least two control paths, two power paths and at least one enable path.
[0013] Implementing the additional enable path advantageously simplifies mutual identification of the bus subscribers. The enable path also provides or simplifies the possibility of so-called first fail-safety required with certain safety standards, allowing a large number of applications. The enable path has the additional advantage that the signals traveling on the enable path are only used the for network clearing or a sleep mode, thus allowing to reduce energy consumption when not in use.
[0014] In a first embodiment, the bus device includes at least one daisy-chain-path in form of a line. This advantageously simplifies even further the mutual identification of the bus subscribers. In addition, the enable path and the daisy-chain path can be combined into a single path. Several signals are hereby applied to the common path, wherein the common path has a first signal for the daisy-chain-linking and at least one additional signal in form of an enable signal. Advantageously, the form and/or the magnitude of the signals can be different. For example, a first signal for the daisy-chain-linking may be formed by an encoded signal, whereas the at least one enable signal is formed by at least one signal having a constant voltage, although the various voltage signals may have different amplitudes.
[0015] In a preferred embodiment, each subscriber includes at least one control unit, a basic control unit, a memory unit, and an output unit and/or an input unit. With this approach, all bus subscribers can be economically equipped with the same software. For example, this approach significantly simplifies synchronization of subscribers, or of drives configured as drives or as control units of the drives.
[0016] Advantageously, the basic control unit is particularly fault-tolerant, and advantageously has an easily comprehensible configuration.
[0017] Preferably, the basic control unit and/or the control unit is directly connected with the bus device. The basic control unit is used at startup or reset or upgrade for starting a program running in the control unit, wherein the program can be defined ahead of time in the memory unit or can advantageously be stored with changes permitted.
[0018] According to another embodiment, the bus subscriber forming an operating unit applies signals to the enable path, so that the enable path can affect the operating state of a selection of bus subscribers or of individual groups of bus subscribers.
[0019] To this end, a logical, encoded or periodic signal or a defined potential is applied to the enable line for enablement, which advantageously simplifies many interactions with the bus subscribers.
[0020] Advantageously, with the respective signal of the at least one enable path, the operating state of the corresponding bus subscriber can be switched between an active and a passive and/or optionally also an energy-saving operating state. This enhances the possible selection. Advantageously, the voltage supply of switching elements, for example relays, microprocessors or control units of the individual bus subscribers, can be ensured by using the respective signal of the at least one enable path. This enhances and/or satisfies the first fail-safe requirements.
[0021] Preferably, the bus device is implemented as a RS 485 interface with at least one additional enable path, representing a device of high quality and of a high standard, thereby advantageously ensuring interference-free data transmission. The RS 485 interface allows data to be transmitted in half-duplex, which preferably uses a master-slave configuration.
[0022] In an alternative embodiment, the bus device is implemented as a CAN-bus with at least one additional enable path.
[0023] According to another alternative embodiment, the control paths of the bus device are configured wireless, with the wireless connection implemented as a WLAN, DECT or Bluetooth device.
[0024] Alternatively, the enable path can be a component of the control paths of the bus device. This enhances potential applications of the invention.
[0025] According to another embodiment, an additional path with signals for mutual identification of the bus subscribers is arranged in addition to the enable path.
[0026] In another alternative embodiment, the bus subscribers form a daisy-chain-linking. Linking begins at a predetermined unit, for example the power supply unit, with the linking signal always being set at its output. Each bus subscriber compares the linking signal between its input and its output. If the signal is applied only to the input, then this bus subscriber confers with other bus subscribers, preferably with the master which can be implemented as an operating unit. The master now assigns an address to this bus subscriber which is stored on both devices. Finally, this bus subscriber sets the linking signal at its respective output, which is already queried from the input of another bus subscriber, allowing the other bus subscriber to communicate with the master and having an address assigned by the master.
[0027] In a preferred embodiment, each operating unit has a definite intelligence, whereas all other bus subscribers have preferably a standardized intelligence. Accordingly, all control parameters and the control programs and all required data are stored on a memory component of the operating units. The bus device is hence divided in commanding bus subscribers and executing bus subscribers. This has the advantage that all bus subscribers have the same programs, but that the operating units in addition include the program units required for controlling the bus device. This advantageously represents the least complexity when the control program is changed or during programming. The bus device can be later expanded by adding additional bus subscribers, without the need for a separate program.
[0028] According to another preferred embodiment, the electrical device arrangement can be controlled by data packets which are transmitted via the bus device, wherein the data packets include at least the address of a bus subscriber as an address byte, a command byte and a check byte. The data packets can have at least one data byte.
[0029] In a preferred embodiment, the address byte is structured in several parts. For example, the first four bits can contain information about addressing and additional bits information about the length of a data set. When using four bit information for assigning the address, up to 16 bus subscribers can be arranged on a bus device. A command byte which includes information for controlling a load or a bus subscriber follows. If needed, additional data bytes can be appended which include information, for example, for updates or for programming. The last byte is a check byte representing a checksum of the entire data set. In this way, data sets of variable length can be implemented; however, typical data sets consists of address byte, command byte and check byte. Because of the data sets are very short, data transfer is advantageously reduced to a minimum, resulting in a high degree of reliability and speed.
[0030] In a particular preferred embodiment, the bus subscriber which as an operating unit forms a master, has in its memory unit a program segment suitable for forming the control software of the master. By forming a master, additional operating units can advantageously be employed, for example on hospital beds, and operated by patients. In addition, the processor resources are then distributed in the device arrangement in a simple and comprehensible manner.
[0031] Preferably, the control units of all or of individual bus subscribers are not supplied with electric power or are not active when the electrical device arrangement is not in use. This advantageously reduces the energy consumption of the arrangement of the invention when not in use, because such device arrangements are most often not in use. In another embodiment, only portions of the individual bus subscribers are active, so that a power-saving sleep mode can be implemented, for example for battery operation.
[0032] A method for controlling such electrical device arrangement of the invention, in particular for an item of furniture, with a bus device and bus subscribers has the following method steps:
operating the input unit of a bus subscriber used as operating unit; classifying this bus subscriber by way of an enable path as a bus subscriber having a master function or as an additional bus subscriber; and controlling the particular bus subscriber addressed by the input unit.
[0036] Preferably, during startup, during a reset command or during upgrades, the basic control unit or the control unit of a corresponding bus subscriber exchanges data with the bus subscriber forming the master via the bus device for identification. This provides a device arrangement with a bus device which advantageously is flexible, both with respect to different bus subscribers and also with respect to different applications of items of furniture.
BRIEF DESCRIPTION OF THE DRAWING
[0037] Exemplary embodiments of the invention will now be described with reference to the schematic figures of the drawing.
[0038] FIG. 1 is a schematic block diagram of a first exemplary embodiment of the arrangement of the invention;
[0039] FIG. 2 is a schematic block diagram of an exemplary embodiment of a bus subscriber;
[0040] FIG. 3 is an exemplary embodiment of data packets; and
[0041] FIG. 4 is a schematic block diagram of a second exemplary embodiment of the arrangement of the invention.
[0042] Identical reference symbols in the Figures designate identical or similar components with identical or similar functionality.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] FIG. 1 shows a schematic block diagram of a first exemplary embodiment 10 of the arrangement of the invention.
[0044] The device arrangement 10 includes a bus device 11 configured as a RS 485 interface with a data path consisting of two control paths. The bus device 11 also includes at least two power supply paths which provide electric power from a supply unit 12 . The supply unit 12 is located at the beginning of the bus device 11 .
[0045] The bus device also includes an enable path.
[0046] Bus subscribers 13 . . . 18 are connected to the bus device 11 at any location, with connection to the data paths, the supply paths and the enable path. The supply unit 12 also forms a bus subscriber.
[0047] In the example illustrated in FIG. 1 the following bus subscribers 13 . . . 18 are shown: a PC unit 13 , a first operating unit 14 , a load 15 , a first control unit 16 , a second operating unit 17 , and a second control unit 18 .
[0048] The device arrangement 10 is only shown in exemplary form and can, for example, be an electrical device arrangement on a hospital bed, which is not illustrated.
[0049] The PC unit 13 is here a personal computer supplying data to the data paths of the bus device 11 , for example to initially store data in memory units of the bus subscribers for adapting the electrical devices, when the device arrangement 10 is started up or serviced. The data include, for example, tables about the stroke of the drives etc. The programs of individual or of all bus subscribers 13 . . . 18 can be changed, updated or exchanged by using the PC unit 13 or another portable programming device.
[0050] The first operating unit 14 is a manual switch used to control all functions of the electrical device arrangement 10 . The switch includes input and output functions which will be described below, as well as the control program for the device arrangement. The load 15 in this example is a lamp.
[0051] The first controller 16 is provided for a first drive 20 , which may be, for example, a dual drive for adjusting a slotted frame of the hospital bed. The controller also includes a power unit 41 which is connected with the first drive 20 . Its function will be described below.
[0052] A second operating unit 17 is a so-called manual patient switch with limited functionality, i.e., the patient in the hospital bed can only operate those functions of the electrical device arrangement 10 of the hospital bed permitted for that patient, for example the patient can adjust only the head section.
[0053] The system can be adapted to the respective patient by replugging the second operating unit or by reprogramming the second operating unit with the PC unit 13 . The device arrangement 10 can, of course, be advantageously and easily used also for other items of furniture by eliminating the second operating unit 17 .
[0054] The second controller 18 also includes a power unit 41 which is connected with second drives 21 which in the exemplary embodiment are separate drives for height adjustment of the bed, which will not described in detail.
[0055] The supply unit 12 is also a bus subscriber.
[0056] For example, the drives 20 , 21 can be synchronized via the bus device 11 .
[0057] Each bus subscriber 12 . . . 18 is provided with a process controller, as described in more detail below with reference to FIG. 2 .
[0058] FIG. 2 shows a schematic block diagram of an exemplary embodiment of a bus subscriber 13 . . . 18 .
[0059] The bus subscriber 13 . . . 18 includes the following: a control unit 30 , preferably a processor, a basic control unit 31 , a memory unit 32 , an output unit 33 with outputs 35 , and an input unit 34 with inputs 36 .
[0060] The control unit 30 is connected with the bus device 11 , i.e., with the data paths and power paths and with the enable path. In another embodiment, the basic control unit 31 is directly connected with the bus device 11 . The control unit 30 is furthermore connected with the basic control unit 31 , the memory unit 32 and the units for output 35 and input 34 .
[0061] If the bus subscriber is a controller of a drive 20 , 21 , then the output unit 33 is configured as a power unit 41 with an output 35 for connection to the respective drive 20 , 21 , which is not described in detail. The input unit 34 is used for receiving control signals from transducers of the drive 20 , 21 , for example for position measurement.
[0062] If the bus subscriber is an operating unit 14 , 17 , then the input unit 34 is connected with a keyboard. This keyboard can also be a touchscreen or the like. The output unit 33 is, for example, configured for connection to a display screen or indicator lights.
[0063] The memory unit 32 includes predefined data values, either individual or in table form, which can still be changed later by the PC unit 13 or automatically during operation. The defined data values are identity information and information about the capability and functionality of the respective bus subscriber.
[0064] With respect to the first operating unit 14 , the memory unit 32 includes the control program for the device arrangement 10 .
[0065] When the device arrangement 10 starts up, is serviced, reset, or started again, then the basic control unit 31 takes over the start of the program residing in the memory unit 32 of each bus subscriber 12 . . . 18 , and organizes updates/upgrades of the control software of the operating system of the respective bus subscriber 12 . . . 18 . The basic control unit 31 is also referred to as BIOS (Basic Input/Output System).
[0066] In another embodiment, each operating unit 14 , 17 includes a memory unit 32 and a control program for the device arrangement 10 .
[0067] The control unit 30 checks the data paths for a data set intended for the control unit 30 , i.e., the address of the bus subscriber in which the control unit 30 resides. After receipt of such data set (to be described later), the transmitted control command, for example “turn on lamp”, is executed. On the drives, the control unit 30 monitors the actual position of the drive and optionally returns data about the position to its control device, in this case the first operating unit 14 , via the data paths of the bus device 11 , wherein the control device compares the actual position with desired comparison values of the device arrangement and continues to operate the drive, or uses additional control commands to switch the drive off.
[0068] The respective bus subscriber 12 . . . 18 can only execute these control commands if the subscriber is enabled via the enable path. To this end, a signal is applied to the enable path, for example by pressing a key, which activates either all bus subscribers 12 . . . 18 or selectively only certain bus subscribers. This can be accomplished with a logical, encoded or periodic signal or with a switching signal or a certain potential. The signal can be monitored, so that, for example, wire breaks can be detected.
[0069] In a modification of this embodiment, several enable paths can be provided which can be assigned to different groups of bus subscribers 13 . . . 18 . The enable paths can be exclusively integrated in the bus device 10 or can be routed to the individual bus subscribers 13 . . . 18 over a dedicated path.
[0070] In another advantageous embodiment, the enable line ensures that voltage is supplied to switching devices, for example relays, microprocessors or control units 30 of the individual bus subscribers 13 . . . 18 . Another modification of this embodiment provides an operating unit which is located remote from the operating unit 14 , for example, mounted on the bed frame as a switching console with a switch which switches the signal of the enable line.
[0071] When a key is pressed on the first operating unit 14 , a data packet 50 is applied to the data paths of the bus device 11 , as illustrated in FIG. 3 . The first operating unit 14 can be defined as the unit that begins operation as the first subscriber on the bus device 10 , thereby forming the master.
[0072] The data packet 50 in this exemplary embodiment consists of bytes 51 - 1 to 51 - 18 : an address byte 52 with byte number 53 , a control byte 54 , data bytes 55 , and a check byte 56 .
[0073] Depending on the transmitted data packet, at least three bytes 52 and 53 , 54 and 56 are transmitted. In this exemplary embodiment, the address byte 52 consists of four bits, resulting in at most 16 bus subscribers. In a modification of the illustrated exemplary embodiment, each byte can consist of individual bits or several bytes, so that the bus device can be individually adapted.
[0074] The address byte 52 carries the address of the addressed bus subscriber, the byte number represents the number of the bytes 51 - 1 to 51 - 18 of the data packet 50 , the control byte 54 carries the encoded control command for the corresponding addressed bus subscriber, the data bytes 55 contain the data values to be transmitted, and the check byte 56 is used to check the data packet 50 and can be formed by a checksum, which will not be described in detail. It should be noted that in the exemplary embodiment, the length of the data bytes 55 is formed from the bytes 51 - 3 to 51 - 17 , having the exemplary indicated byte length of only 15 bytes. The length of the data byte depends on the quantity of the transmitted data as required, for example, during an update.
[0075] The startup and initialization of the device arrangement will now be described.
[0076] In the illustrated example, bus subscribers having the same properties are used, providing a high degree of flexibility. These have different addresses for identification. To obviate the need for placing encoding switches in the bus subscribers, a daisy-chain-path is employed.
[0077] Addresses are assigned at each key activation or setting of the enable path. This has the advantage that the entire system can be checked for complete functionality, and the addition or removal of subscribers is recognized automatically. Preferably, the bus device 11 consists of an RS485 interface with the additional enable path used for signaling, indicating that a master has seized the bus device 11 . This path can also be used for network release. The master can also include a power supply with a battery/rechargeable battery. The enable path can also be used to affect the operating states of a respective bus subscriber.
[0078] The bus device 11 furthermore has a daisy-chain-path.
[0079] The supply unit 12 is always arranged at the beginning of the bus device 11 and sets the daisy-chain-path to a predefined value.
[0080] Upon key activation, it is checked if the enable path has a certain signal or potential. If this is not detected, then the bus subscriber where the key was activated becomes the master. The enable path indicates if the master already exists. The bus subscriber then waits to be addressed with its bus address by the existing master. The bus subscriber then stores all addresses with the association of all bus subscribers.
[0081] If the bus subscriber is the master, then it sets the enable path to a certain signal, causing all bus subscribers to perform an initialization. The daisy-chain-path is set to a certain value.
[0082] All bus subscribers must be operational within a certain time, for example within 10 ms.
[0083] The bus subscriber which is connected immediately after the supply unit, has at its daisy-chain-input the defined data value of the supply unit 12 . This bus subscriber responds to the address and answers with its own identity and stores the address with which it was addressed. In the exceptional case where the master is that particular bus subscriber, then it assigns the address to itself and sends its identity to the bus device 11 and queries for the next bus subscriber. In this way, all bus subscribers are registered, and the master terminates initialization after receiving the last answer after a certain elapsed time interval of, for example, 10 ms, or if no answer is received, after a preset time interval.
[0084] The invention is not limited to the afore-described subject matter, but can be modified in various ways.
[0085] For example, in a second exemplary embodiment of the device arrangement 10 of the invention shown in FIG. 4 , an electric-motor-driven drive unit 40 can be implemented as a bus subscriber and include the controller 16 with the power unit 41 .
[0086] The bus device 11 can be configured, for example, as daisy-chain-linking. The bus device 11 can also be implemented as a CAN bus.
[0087] The enable path can provide so-called first fail-safety, by switching the enable path directly with a key on the master operating unit 14 . If no first fail-safety is required, then the enable path can be switched by a logic circuit or the processor of the master.
[0088] The enable path can switch a network release in the supply unit 12 , for example, as an additional bus subscriber. Alternatively, the enable path can also switch the bus subscribers between an operating mode and a non-operating mode to save energy.
[0089] Moreover, the enable path can affect the control unit 30 or the output 35 such as not to switch the output 35 in the absence of the enable signal, which may prevent an unintentional start up of, for example, a motor of a drive, or turn-on of a load 15 , 20 , 21 , 40 . In addition, the control unit 30 of each bus subscriber 13 . . . 18 can deactivate the output 35 after a preset time interval, after which data packets are no longer received.
[0090] The control units 31 of the bus subscribers, with the exception of the master, are supplied with energy only following key activation on the master.
[0091] It would also be feasible to implement the data paths of the bus device 11 in wireless form, configured for example as a Bluetooth or DECT network similar to a WLAN configuration. In this case, only two lines for supply or power paths to the bus subscribers are required, in particular to drive units and loads, such as lamps, etc. The operating units can then be powered by a battery or rechargeable battery. They can, for example, also be integrated in a mobile telephone.
[0092] If at least one bus subscriber 13 . . . 18 is powered by a rechargeable battery, then the signal from the enable line switches the corresponding bus subscriber 13 . . . 18 or at least the control unit 30 between an operating mode and a power-saving sleep mode.
[0093] A bus subscriber can also be a sensor.
[0094] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims: | An electrical device arrangement, in particular for an item of furniture, includes a bus device having wirelessly configured control paths, and bus subscribers connected to the bus device, wherein at least one of the bus subscribers is an operating unit comprising a memory for storing control parameters and a control program and at least one of the bus subscriber is a controller of a furniture drive. A method for controlling such an electrical device arrangement, in particular for an item of furniture, having a bus device and bus subscribers is also disclosed. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of pending application Ser. No. 332,534 filed Dec. 12, 1981, hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to aromatic amines and is more particularly concerned with a novel class of alkylated meta-phenylenediamines.
2. Description of the Prior Art
Aromatic amines and particularly aromatic diamines are well known types of compounds finding many applications in the chemical art. Typically, aromatic amines have found utility as starting materials and intermediates in the preparation of other products such as isocyanates, pharmaceuticals, various types of polymers, plastics, and the like. Some of the aromatic diamines find particular utility as curatives in various polymer systems.
Other known classes of aromatic diamines include, typically, the α,α'-bis(aminoaryl)xylenes disclosed in U.S. Pat. No. 3,424,795; the limited number of nuclear alkylated aromatic amines and diamines disclosed in U.S. Pat. Nos. 3,678,112; 3,678,113 and 3,862,233; the alkylated toluenediamines and alkylated 4,4'-diaminodiphenylmethanes disclosed in U.S. Pat. Nos. 3,428,610 and 4,218,543; certain meta- or para-isopropenylphenylbenzyl derivatives of aromatic mono- and diamines in German DS No. 17 686 97; and finally simple diamines such as the diaminodiphenylmethanes, toluenediamines, and the like.
I have now discovered a novel class of sterically hindered aromatic meta-phenylene diamines which are easily obtained from readily available starting materials. Further, the aromatic diamines in accordance with the present invention exhibit a wide range of amine basicity or reactivity depending on the extent of the steric hindrance which, in turn, depends on the extent of the substitution in the three possible positions ortho to the two amino groups on the aromatic ring.
Not only can the amine reactivity, i.e. amine basicity, be varied depending on the substitution noted above but other important molecular properties such as compound solubility and melting ranges can be influenced depending on the particular structure and/or isomer mixtures chosen.
The ability to influence amine basicity in the present diamines makes them particularly useful as chain extenders in polyurethane-polyurea polymers which application will be discussed in detail below as part of the present invention.
SUMMARY OF THE INVENTION
This invention comprises m-phenylenediamines (I) having (a) at least one, and not more than two, of the positions ortho to the amino groups substituted by a member selected from benzyl groups having the formulae: ##STR1## wherein R 1 is selected from the class consisting of hydrogen and lower alkyl, R 2 is lower alkyl, C n H 2n is alkylene having from 2 to 5 carbon atoms in the chain, R is an inert substituent, n is an integer from 0 to 5, m is an integer from 0 to 4; and (b) a member selected from the group consisting of hydrogen and lower alkyl attached to the nuclear carbon atoms ortho to the amino groups which do not carry one of said benzyl groups.
This invention also comprises m-phenylenediamines according to the above definition which are additionally substituted by hydrocarbyl on the nuclear carbon atom which is in the meta position with respect to the two amino groups.
Preferred m-phenylenediamines (II) in accordance with the present invention have (a) at least one, and not more than two, of the positions ortho to the amino groups substituted by a benzyl group having the formula ##STR2## wherein R 1 and R 2 are as defined above; and (b) a member selected from the group consisting of hydrogen and lower alkyl attached to the nuclear carbon atoms ortho to the amino groups which do not carry one of said benzyl groups.
This invention also comprises polyurethane-polyurea polymers prepared by reaction of an organic polyisocyanate, a polyol, and an extender wherein the improvement comprises employing as the extender a m-phenylenediamine according to (I) above.
The term "lower alkyl" means alkyl having from 1 to 8 carbon atoms, inclusive, such as methyl, ethyl, propyl, butyl, amyl, hexyl, heptyl, octyl, and isomeric forms thereof.
The preferred lower alkyl radicals have 1 to 4 carbon atoms and are as defined above.
The term "alkylene from 2 to 5 carbon atoms" means 1,2-ethylene, 1,3-propylene, 1,2-propylene, 1,4-butylene, 1,3-butylene, 1,2- and 2,3-butylene, 1,5-pentylene, 1,4-pentylene, 1,2-, 2,3-, 1,3- and 2,4-pentylene, and the like. Preferred alkylene is 1,2-ethylene.
The term "hydrocarbyl" means the monovalent radical obtained by removing one hydrogen atom from the parent hydrocarbon having from 1 to 18 carbon atoms. Illustrative of hydrocarbyl are alkyl such as methyl, ethyl, propyl, butyl, pentyl, hexyl, octyl, decyl, dodecyl, hexadecyl, octadecyl, and the like, including isomeric forms thereof; alkenyl such as vinyl, allyl, butenyl, pentenyl, hexenyl, octenyl, decenyl, undecenyl, tridecenyl, hexadecenyl, octadecenyl, and the like, including isomeric forms thereof; aralkyl such as benzyl, phenethyl, phenylpropyl, benzhydryl, naphthylmethyl, and the like; aryl such as phenyl, tolyl, xylyl, naphthyl, biphenylyl, and the like; cycloalkyl such as cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclo/o/ ctyl and the like including isomeric forms thereof; and cycloalkenyl such as cyclopentenyl, cyclohexenyl, cycloheptenyl, cyclo/o/ ctenyl, and the like, including isomeric forms thereof.
The hydrocarbyl groups can be substituted by one or a plurality of substituents provided the latter are not reactive with amine groups. Illustrative of such substituents are halo, i.e. chloro, bromo, fluoro and iodo; nitro; alkoxy from 1 to 8 carbon atoms, inclusive, such as methoxy, ethoxy, propoxy, butoxy, pentyloxy, hexyloxy, heptyloxy, octyloxy and the like, including isomeric forms thereof; alkylmercapto from 1 to 8 carbon atoms, inclusive, such as methylmercapto, ethylmercapto, propylmercapto, butylmercapto, pentylmercapto, hexylmercapto, heptylmercapto, octylmercapto, and the like, including isomeric forms thereof; and cyano.
A preferred class amongst the hydrocarbyl groups is the alkyl class defined above and a preferred species is methyl.
The term "inert substituent" means any radical which does not react with the amino groups and is inclusive of the hydrocarbyl groups which may or may not be substituted by inert groups as defined above.
The preferred inert substituents are halogen with chlorine most preferred.
The diamines in accordance with the present invention are useful for all the purposes set forth above for the prior art aromatic diamines but they find utility as curatives for polymer systems such as epoxy resin curatives and find particular utility as extenders in polyurethanes.
DETAILED DESCRIPTION OF THE INVENTION
Generally speaking, the aromatic diamines in accordance with the invention are crystalline solids. Depending upon the extent and type of substitution on the aromatic ring, the diamines can range from low to high melting solids, for example, having melting points from about 80° C. or lower, to a high of about 240° C. or higher with values intermediate therebetween. However, some diamines are liquids or oils even when in a pure state.
The aromatic diamines in accordance with the present invention are further characterized by having, for the most part, good solubility in common organic solvents such as ketones, alcohols, ethers, esters, chlorinated hydrocarbon solvents, dipolar aprotic solvents, and the like. Generally speaking, compound solubility can be increased by employing isomer mixtures of the diamines of formula (I).
In a surprising, and advantageous, feature of the aromatic diamines in accordance with the present invention, their reactivities as measured by their relative reactivities with phenyl isocyanate, can cover a relatively broad range depending on the type and extent of substitution on the aromatic diamine ring. In the test procedure, the subject diamine is reacted with a stoichiometric amount of phenyl isocyanate at a dilute reactant concentration level (for example about 6.8 weight percent) in a solvent (for example dimethylacetamide) at ambient room temperature (about 20° C.) under Argon and the disappearance of the isocyanate band (2250 cm -1 ) in the infrared is followed on aliquot samples.
Illustratively, 5-(α,α-dimethylbenzyl)-2,4-toluenediamine in accordance with the present invention is characterized by a reactivity approximately equal to MOCA or approximately 1/150 of 4,4'-methylenebis(aniline). 3,5-bis(α,α-dimethylbenzyl)-2,6-toluenediamine in accordance with the present invention is approximately 1/3 of MOCA in reactivity.
Therefore, the aromatic diamines in accordance with the present invention can provide a range of basic reactivities depending on the application in which they are being employed.
Illustrative, but not limiting, of the aromatic diamines in accordance with the present invention are 4-(α-methylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-methylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-ethylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-propylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-butylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-amylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-hexylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-heptylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-octylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-nonylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-decylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-octadecylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-isopropylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-isobutylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-2-ethylhexylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-isononylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-chlorobenzyl)-m-phenylenediamine, 4-(60 -methyl-p-bromobenzyl)-m-phenylenediamine, 4-(α-methyl-p-methoxybenzyl)-m-phenylenediamine, 4-(α-methyl-p-benzylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-phenethylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-phenylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-tolylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-allylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-cyclobutylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-cyclopentylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-cyclohexylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-cycloheptylbenzyl)-m-phenylenediamine, 4-(α-methyl-p-cyclooctylbenzyl)-m-phenylenediamine, 4-[α-methyl-p-(1-cyclopentenyl)benzyl]-m-phenylenediamine, 4-[α-methyl-p-(1-cyclohexenyl)benzyl]-m-phenylenediamine, and the like; 4-(α-ethylbenzyl)-m-phenylenediamine, 4-(α-propylbenzyl)-m-phenylenediamine, 4-(α-butylbenzyl)-m-phenylenediamine, 4-(α-amylbenzyl)-m-phenylenediamine, 4-(α-hexylbenzyl)-m-phenylenediamine, 4-(α-heptylbenzyl)-m-phenylenediamine, 4-(α-octylbenzyl)-m-phenylenediamine, 4-(α-ethyl-2,4-dimethylbenzyl)-m-phenylenediamine, 4-(α,α-dimethylbenzyl)-m-phenylenediamine, 4-(α,α-diethylbenzyl)-m-phenylenediamine, 4-(α-methyl-α-propylbenzyl)-m-phenylenediamine, 4-(1-benzocyclopentyl)-m-phenylenediamine, 4-(1-benzocyclohexyl)-m-phenylenediamine, 4-(1-benzocycloheptyl)-m-phenylenediamine, 4-(1-benzocyclooctyl)-m-phenylenediamine, 4-[1-(1-methylbenzocyclopentyl)]-m-phenylenediamine, 4-(α,α-dimethylbenzyl)-5-methyl-m-phenylenediamine, 4-(α,α-dimethylbenzyl)-5-ethyl-m-phenylenediamine, 4-(α,α-dimethylbenzyl)-5-methoxy-m-phenylenediamine, 4-(α,α-dimethylbenzyl)-5-allyl-m-phenylenediamine, and the like; 4,6-bis(α-methylbenzyl)-m-phenylenediamine, 4,6-bis(α-methyl-p-methylbenzyl)-m-phenylenediamine, 4,6-bis(α,α-dimethylbenzyl)-m-phenylenediamine, 4,6-bis(α,α-dimethylbenzyl)-5-methoxy-m-phenylenediamine, and the like; 5-(α-methylbenzyl)-2,4-toluenediamine, 5-(α-methyl-p-tolylbenzyl)-2,4-toluenediamine, 5-(α-methyl-p-ethylbenzyl)-2,4-toluenediamine, 5-(α-methyl-p-chlorobenzyl-2,4-toluenediamine, 4-(α-methylbenzyl)-6-ethyl-m-phenylenediamine, 4-(α-methylbenzyl)-6-butyl-m-phenylenediamine, 4-(α-methylbenzyl)-6-octyl-m-phenylenediamine, 5-(α,α-dimethylbenzyl)-2,4-toluenediamine, 5-(α,α-diethylbenzyl)-2,4-toluenediamine, 5-(α,α-dimethyl-p-tolylbenzyl)-2,4-toluenediamine, 5-(α-ethylbenzyl)-2,4-toluenediamine, 5-(α,α-dimethyl-p-chlorobenzyl)-2,4-toluenediamine, 5-(α,α-dimethyl-p-phenethylbenzyl)-2,4-toluenediamine, 5-(1-benzocyclopentyl)-2,4-toluenediamine, 5-(1-benzocyclohexyl)-2,4-toluenediamine, 5-(α,α-dimethylbenzyl)-6-methyl-2,4-toluenediamine, 5-(α,α-dimethylbenzyl)-6-ethyl-2,4-toluenediamine, 5-(α,α-dimethylbenzyl)-6-allyl-2,4-toluenediamine, 5-(α,α-dimethylbenzyl)-6-methoxy-2,4-toluenediamine, 3,5-bis(1-benzocyclopentyl)-2,4-toluenediamine, 3-(1-benzocyclopentyl)-2,4-toluenediamine, 3-(α-methylbenzyl)-2,4-toluenediamine, 3-(α,α-dimethylbenzyl)-2,4-toluenediamine, 3-(α,α-dimethyl-p-chlorobenzyl)-2,4-toluenediamine, 3-(α,α-dimethyl-4-methoxybenzyl)-2,4-toluenediamine, and the like; 3-(α-methylbenzyl)-2,6-toluenediamine, 3-(α,α-dimethylbenzyl)-2,6-toluenediamine, 3-(α,α-dimethylbenzyl)-4-methyl-2,6-toluenediamine, 3-(α,α-dimethylbenzyl)-4-ethyl-2,6-toluenediamine, 3-(α,α-dimethylbenzyl)-4-allyl-2,6-toluenediamine, 3-(α,α-dimethylbenzyl)-4-methoxy-2,6-toluenediamine, 3,5-bis(α,α-dimethylbenzyl)-2,6-toluenediamine, 3,5-bis(α,α-dimethylbenzyl)-4-methoxy-2,6-toluenediamine, 3-(α-methyl-α-ethylbenzyl)-2,6-toluenediamine, 3-(α-methyl-α-butylbenzyl)-2,6-toluenediamine, 3-(α,α-dimethyl-p-tolylbenzyl)-2,6-toluenediamine, 3-(α,α-dimethyl-p-chlorobenzyl)-2,6-toluenediamine, 3-(1-benzocyclopentyl)-2,6-toluenediamine, 3-(1-benzocyclohexyl)-2,6-toluenediamine, 3-(α,α-dimethylbenzyl)-5-methyl-2,6-toluenediamine, 4-(α,α-dimethylbenzyl)-2-ethyl-m-phenylenediamine, 4-(α,α-dimethylbenzyl)-2-butyl-m-phenylenediamine, 4-(α,α-dimethylbenzyl)-2-octyl-m-phenylenediamine, and the like.
Preferred amongst the aromatic diamines set forth above are those having either the 2,4-, or 2,6-toluene-diamine nucleus, and most preferred within each of those two groups are those having the α,α-dimethylbenzyl substituent group on said toluenediamine nucleus.
Particularly preferred are the diamine mixtures comprising (a) from about 70 to about 95 percent by weight of 5-(α,α-dimethylbenzyl)-2,4-toluenediamine and (b) the remaining 30 to 5 percent by weight being 3-(α,α-dimethylbenzyl)-2,6-toluenediamine based on the combined weights of (a) and (b).
The aromatic diamines (I) in accordance with the present invention are readily prepared by alkylating the appropriately substituted aromatic diamines (III) with an appropriate styrene compound (IVa) or precursor thereof (discussed in detail below) or an appropriate benzocycloalkene compound (IVb) according to the following schematic equation ##STR3## wherein X is hydrogen or hydrocarbyl, R, R 1 , m and n are defined as above, R 3 is hydrogen or lower alkyl, C n H 2n is alkylene having 1 to 4 carbon atoms similar to alkylene defined above but having the smaller carbon atoms range; and the alkylidene (R 3 CH═) and cycloalkylidene (C n H 2n CH═) of (IVa) and (IVb) become the R 2 and the C n H 2n respectively of the m-phenylenediamines (I) defined above.
Generally speaking, the alkylation is carried out conveniently by heating the reactants in the appropriate proportions in the presence of a catalyst until the desired compound (I) is formed. For typical reaction methods and conditions see the art cited supra, particularly DS No. 1768697, and see also U.S. Pat. No. 4,008,275 for typical catalysts.
Optionally, an inert organic solvent may be employed such as chlorobenzene, dichlorobenzene, nitrobenzene, and the like, and the resulting mixture or solution is brought into contact with the catalyst and the mixture stirred at the appropriate temperature.
Alternatively, and in a preferred embodiment, no organic solvent is employed but rather an excess of one reactant over the other is used. The reaction of (III) with (IVa) and (IVb) is an equilibrium process and by using an excess of one reactant the dual purpose of a solvent effect and the shifting of the reaction equilibrium toward higher conversions is achieved.
It will be readily understood by those skilled in the art that the choice of which reactant to use in excess to achieve the maximum yield of desired product (I) can readily be determined by trial and error by one skilled in the art.
Advantageously, the molar proportions of (IVa) or (IVb) to diamine (III) can fall within the ratios of about 20/1 to 1/20, preferably about 10/1 to 1/10. In a preferred mode of preparation, the (IVa) or (IVb) is used in a molar excess over (III) of about 10/1 to about 5/1.
Since compounds in accordance with the present invention can have two of the benzyl radicals arising from the double alkylation of the starting amine, such dialkylated products can be prepared in either a one-step reaction, wherein both alkylations take place in the one procedure, or, alternatively, in a two-step procedure wherein the first monoalkylated compound is formed and then alkylated in a second step to introduce the second benzyl radical.
Ordinarily, the alkylation is carried out at elevated temperatures, advantageously within a range of from about 40° C. to about 250° C.
The reaction mixture is preferably stirred with the catalyst component in any suitable reaction vessel, preferably, under an inert atmosphere such as nitrogen or argon at a temperature falling within the above range. Heating is continued until routine analytical procedures, carried out on an aliquot, indicate that reaction is substantially complete.
Illustrative of such analytical procedures are high pressure liquid chromatography (HPLC) to determine weight percent of components in the mixture, nuclear magnetic resonance (Nmr) and infrared spectroscopy, and the like.
Any convenient alkylation catalyst used for aromatic amine alkylation can be employed. Typically useful are the aqueous mineral acids, clays, acid clays, diatomaceous earths, zeolites, aromatic sulfonic acids and the salts formed between the starting diamines (III) and said aromatic sulfonic acids, and the like. For a discussion on such catalysts see U.S. Pat. No. 4,008,275 whose disclosure in respect thereof is hereby incorporated by reference.
A preferred group of catalysts for the preparation of the aromatic diamines (I) include the natural and synthetic zeolites and aromatic sulfonic acids and the salts formed between the starting diamines (III) and said aromatic sulfonic acids.
Generally speaking the catalyst is employed within a range of from about 5 weight percent to about 95 weight percent based on the combined weight of diamine and catalyst.
Illustrative of the diamines (III) which may be employed are m-phenylenediamine, 2,4-toluenediamine, 2,6-toluenediamine, 4-ethyl-m-phenylenediamine, 4-propyl-m-phenylenediamine, 4-butyl-m-phenylenediamine, 4-octyl-m-phenylenediamine, 5-methyl-m-phenylenediamine, 5-ethyl-m-phenylenediamine, 5-propyl-m-phenylenediamine, 5-butyl-m-phenylenediamine, 5-octyl-m-phenylenediamine, 5-methoxy-m-phenylenediamine, 5-allyl-m-phenylenediamine, 5-phenyl-m-phenylenediamine, 5-benzyl-m-phenylenediamine, 5-cyclohexyl-m-phenylenediamine, 2-ethyl-m-phenylenediamine, 2-butyl-m-phenylenediamine, 2-octyl-m-phenylenediamine, 6-methyl-2,4-toluenediamine, 6-ethyl-2,4-toluenediamine, 6-allyl-2,4-toluenediamine, 6-methoxy-2,4-toluenediamine, 6-phenyl-2,4-toluenediamine, 6-benzyl-2,4-toluenediamine, 6-cyclohexyl-2,4-toluenediamine, 4-methyl-2,6-toluenediamine, 4-ethyl-2,6-toluenediamine, 4-allyl-2,6-toluenediamine, 4-methoxy-2,6-toluenediamine, 4-phenyl-2,6-toluenediamine, 4-benzyl-2,6-toluenediamine, 4-cyclohexyl-2,6-toluenediamine, and the like.
Preferred starting diamines are the 2,4- and 2,6-toluenediamines. Particularly preferred are the mixtures comprising from about 60 to 85 percent by weight of 2,4-toluenediamine and 40 to 15 percent by weight being 2,6-toluenediamine.
Illustrative of the styrenes which can be employed in the preparation of the compounds of the invention are styrene itself, p-methylstyrene, p-ethylstyrene, p-propylstyrene, p-butylstyrene, p-amylstyrene, p-hexylstyrene, p-heptylstyrene, p-octylstyrene, p-nonylstyrene, p-decylstyrene, p-octadecylstyrene, p-isopropylstyrene, p-isobutylstyrene, p-2-ethylhexylstyrene, p-isononylstyrene, p-chlorostyrene, p-bromostyrene, p-methoxystyrene, p-benzylstyrene, p-phenethylstyrene, p-phenylstyrene, p-tolylstyrene, p-allylstyrene, p-cyclobutylstyrene, p-cyclopentylstyrene, p-cyclohexylstyrene, p-cycloheptylstyrene, p-cyclooctylstyrene, p-(1-cyclopentenyl)styrene, p-(1-cyclohexenyl)styrene, and the like; β-methylstyrene, β-ethylstyrene, β-propylstyrene, β-butylstyrene, β-pentylstyrene, β-hexylstyrene, β-heptylstyrene, β-methyl-2,4-dimethylstyrene, and the like; α-methylstyrene, α-ethyl-β-methylstyrene, α-methyl-β-ethylstyrene, indene, benzocyclohexene-1, benzocycloheptene-1, benzocyclooctene-1, 1-methyl-indene, α-methyl-p-chlorostyrene, α-methyl-p-bromostyrene, α-methyl-p-tolylstyrene, α-methyl-p-ethylstyrene, α-methyl-p-butylstyrene, α-methyl-p-benzylstyrene, α-methyl-p-allylstyrene, α-methyl-p-cyclopentylstyrene, and the like.
In addition to employing the styrenes per se in the preparation of aromatic diamines in accordance with the present invention it is possible to form said compounds in situ by introducing a precursor of any of said compounds which will generate the styrene under the conditions prevailing in the reaction mixture. For example, dimers, trimers, and higher oligomeric forms which will revert to the styrenes under the elevated temperatures and acid conditions of the above described preparation of (I) can be employed therein. Further, the various aryl substituted carbinols such as phenylisopropyl alcohol which on dehydration will provide the appropriate styrene compound can be employed to prepare the compounds of formula (I).
The starting aromatic diamines and styrenes are well known in the art as are the carbinols or oligomeric styrene materials.
As set forth above, the substituted aromatic amines of the invention find particular utility as extenders for the preparation of polyurethane polyureas. The polyurethane-polyurea polymers extended by the diamines having formula (I) can be formed as cellular, microcellular, or solid polyurethane-polyurea polymers using any of the prior art methods known to those skilled in the art; see Polyurethanes: Chemistry and Technology II, by J. H. Saunders and K. C. Frisch, 1964, Interscience Publishers, New York, N.Y., for teaching of the preparation of polyurethanes.
In a preferred embodiment of the present invention the polyurethane-polyurea polymers employing the diamines (I) as extenders are prepared as molded materials, particularly reaction injection molded polyurethane-polyureas; for typical lists of reactants and procedures which can be used in combination with the diamines (I) to produce the polyurethane-polyureas see U.S. Pat. No. 4,296,212 whose disclosure is incorporated by reference herein.
The following examples describe the manner and process of making and using the invention and set forth the best mode contemplated by the inventors of carrying out the invention but are not to be construed as limiting.
EXAMPLE 1
A 100 ml. reaction flask was equipped with a stirrer, thermometer, and reflux condenser. The flask was charged with 29.5 g. (0.25 mole) of α-methylstyrene, 6.48 g. (0.06 mole) of m-phenylene diamine, 7.24 g. (0.04 mole) of m-phenylene diamine dihydrochloride, and 20 ml. of water. The mixture was heated at reflux at 95°-100° C. for 24 hours.
The solution was allowed to cool and mixed with 140 ml. of 1.0N hydrochloric acid. The aqueous solution was washed in a separatory funnel 3× with 50 ml. portions each of methylene chloride in order to remove the excess α-methylstyrene. The resulting aqueous fraction was made slightly basic by the addition of the appropriate amount of 10N sodium hydroxide. An oil separated which was extracted with 2×40 ml. portions each of methylene chloride.
The combined methylene chloride fractions were washed with 3×50 ml. portions each of warm water to remove unreacted phenylene diamine. Concentration of the organic layer in vacuum resulted in a solid residue. Vacuum distillation of this residue provided a pale yellow distillate, b.p. 168°-176° C. (0.05 mm pressure of mercury; wt.=7.8 g. (62%) of 4-(α,α-dimethylbenzyl)-1,3-phenylene diamine having the following formula ##STR4## in accordance with the present invention.
The distillate solidified on standing at room temperature and was recrystallized from toluene to afford colorless crystals, m.p. 83°-83.5° C. Nuclear magnetic resonance (Nmr) confirmed the structure along with the following elemental analysis.
Calcd. for C 15 H 18 N 2 : C, 79.60%; H, 8.02%; N, 12.38%; Found: C, 79.63%; H, 8.10%; N, 12.42%.
High pressure liquid chromatography (HPLC) of the original solid residue product prior to vacuum distillation showed the presence of a small amount of a dibenzylated product which product was later prepared in a separate experiment described below.
EXAMPLE 2
A 250 ml. reaction flask equipped with a stirrer, thermometer, reflux condenser and gas outlet tube which was connected to a receiving flask cooled by a cold water bath was charged with 70.8 g. (0.6 mole) of α-methylstyrene, 10.8 g. (0.1 mole) of m-phenylene diamine, and 10 g. of Zeolite XZ-25 100-150 mesh untreated (supplied by W. R. Grace Chemical Co., Baltimore, Md. Under a slow stream of nitrogen and with rapid stirring, the flask contents were heated. Initially, a small amount of water (from the Zeolite) was co-distilled from the flask with some α-methylstyrene and was collected in the receiving flask. Following this, the nitrogen flow was stopped and the mixture was heated at about 165° C. for 24 hours.
The reaction mixture while still hot was filtered by pouring it through a heated Buchner funnel to remove the Zeolite. Upon cooling to room temperature, a crystalline precipitate separated from the filtrate. The precipitate was collected by suction filtration to provide 17.2 g. of a mixture of predominantly the dibenzylated product 4,6-bis(α,α-dimethylbenzyl)-1,3-phenylene diamine in accordance with ##STR5## the present invention and a minor amount of the monobenzylated diamine described in Example 1.
Pure dibenzylated product was obtained as colorless crystals by recrystallizing the crude crystalline material twice from toluene. Additional product was isolated by washing the Zeolite catalyst several times with methylene dichloride, combining the methylene dichloride washings with the first filtrate from the reaction mixture and removing the solvent and unreacted α-methylstyrene by distillation to provide a residue, and, finally, treatment with chloroform. Total yield of the isolated dibenzyl product was 58%; m.p. 236°-237° C.; insoluble in ethanol, acetone, ethylene glycol, soluble in methylene dichloride, diethylene glycol dimethyl ether (diglyme), and hot toluene; Nmr confirmed the structure along with the following elemental analysis.
Calcd. for C 24 H 28 N 2 : C, 83.67%; H, 8.19%; N, 8.13%; Found: C, 83.28%; H, 8.37%; N, 8.14%.
Thin layer chromatography (TLC) experiments as well as HPLC analysis on the residue above prior to treatment with chloroform indicated the presence of additional dibenzylated product, the monobenzylated compound of Example 1, unreacted phenylene diamine, a component believed to be polymeric α-methylstyrene and a trace of N-benzylated material.
EXAMPLE 3
A reaction flask equipped as set forth in Example 2 was charged with 2.26 g. (0.01 mole) of 4-(α,α-dimethylbenzyl)-1,3-phenylene diamine, 11.8 g. (0.1 mole) of α-methylstyrene, and 2.0 g. of Zeolite XZ-25.
Using the same procedure as set forth in Example 2, heating of the mixture was commenced. After 4 hours at 160°-165° C. the reaction mixture was analyzed by HPLC and TLC and shown to contain 4,6-bis(α,α-dimethylbenzyl)-1,3-phenylene diamine as the major component along with a minor amount of the starting 4-(α,α-dimethylbenzyl)-1,3-phenylene diamine plus a trace of m-phenylene diamine and a trace of poly α-methylstyrene.
The reaction mixture was treated according to the work-up procedure set forth in Example 2 to afford 2.1 g. (61%) of 4,6-bis(α,α-dimethylbenzyl)-1,3-phenylene diamine in accordance with the present invention.
EXAMPLE 4
A 250 ml. reaction flask equipped according to Example 2 was charged with 12.2 g. (0.1 mole) of 2,4-toluenediamine, 59 g. (0.5 mole) of α-methylstyrene, and 10 g. of Zeolite XZ-25.
Using the same procedure outlined in Example 2, the rapidly stirred mixture was heated for 20 hours at 160° C. HPLC analysis indicated that conversion of the 2,4-toluenediamine was at least 87%. The hot reaction mixture was filtered through a heated Buchner funnel. The collected Zeolite was washed 3× with 20 ml. portions each of methylene chloride. The filtrate and washings were combined and the solvent removed under vacuum leaving a residue. The residue was distilled under vacuum through a simple distillation head first at moderate vacuum to remove α-methylstyrene, i.e. b.p. 110° C. (23 mm. of mercury), then at higher vacuum to collect the following fractions: 1. b.p. 145°-165° C. (0.05 mm.), wt.=1.6 g. of unreacted 2,4-toluenediamine; 2. b.p. 165°-173° C. (0.05 mm.), wt.=19.0 g. of 5-(α,α-dimethylbenzyl)-2,4-diaminotoluene; 3. b.p. 173°-185° C. (0.05 mm., wt.= 2.8 g. of 5-(α,α-dimethylbenzyl)-2,4-diaminotoluene and two other components which were separated by TLC and believed to be N-alkylated-2,4-toluenediamine and polymerized α-methylstyrene; 4. residue, wt.=1.3 g. of a mixture of the same component comprising fraction 3.
The fraction 2 was fractionated through a 12 cm. Vigreux column under a vacuum of 0.07 mm. of mercury and using a heating bath temperature starting at about 230° C. and progressing up to about 250° C. to yield the following fractions: 2-1. b.p. up to 168° C., wt.=0.7 g.; 2-2. b.p. 168°-176° C., wt.=4.9 g.; 2-3. b.p. 176°-177° C., wt.=8.3 g. pale yellow oil; 2-4. b.p. 177°-172° C., wt.=2.0 g.; residue, wt.=1.0 g. light brown liquid. The major fraction which solidified was 5-(α,α-dimethylbenzyl)-2,4-toluenediamine ##STR6## in accordance with the present invention. The crystalline product was found to be very soluble in standard organic solvents including ethylene glycol. It still contained a trace of impurity. The impurity was removed by washing the crystals with low boiling (35°-60° C.) petroleum ether. The product was further recrystallized from a mixture of hot toluene and petroleum ether to provide colorless crystals; m.p. 90.0°-91.5° C. Total weight of product isolated from both fractions 2 and 2 was 19.7 g. (82%). Nmr confirmed the structure along with the following elemental analysis.
Calcd. for C 16 H 20 N 2 : C, 79.95%; H, 8.39%; N, 11.66%; Found: C, 79.80%; H, 8.45%; N, 11.62%.
EXAMPLE 5
The apparatus described in Example 4 was charged with 12.2 g. (0.1 mole) of 2,6-toluenediamine, 59 g. (0.5 mole) of α-methylstyrene, and 10 g. of Zeolite XZ-25.
The reaction mixture was heated in accordance with the procedure set forth in Example 4 at a temperature of about 160° C. After 8 hours the reaction appeared to have reached equilibrium as evidenced by the constancy of the product distribution determined from HPLC analysis of aliquots of the reaction mixture. However, heating was continued for a total of 20 hours so as to have equal reaction conditions with Example 4.
The hot reaction mixture was filtered through a heated Buchner funnel. The collected Zeolite was washed with 3×20 ml. portions of methylene dichloride and the washings concentrated under vacuum to leave a residue. The latter residue was combined with the filtrate obtained above which upon standing at room temperature had deposited a crystalline precipitate. After standing overnight the crystalline precipitate was collected by suction filtration to provide 18.6 g. of colorless crystals which were recrystallized from a combination of hot methanol and petroleum ether (b.p. 35°-60° C.) to provide large colorless prisms; m.p. 191°-192° C.; soluble in common organic solvents (i.e., acetone, ethanol, etc.) and soluble in ethylene glycol at 100° C. (at least to the extent of 3 to 5% by wt. in ethylene glycol). Nmr and the following elemental analysis confirmed the compound to be 3,5-bis(α,α-dimethylbenzyl)-2,6-toluenediamine in accordance with the present invention. ##STR7##
Calcd. for C 25 H 30 N 2 : C, 83.75%; H, 8.43%; N, 7.82%; Found: C, 83.86%; H, 8.61%; N, 7.18%.
The filtrate remaining after removal of the above dibenzylated product was distilled until the boiling point of the distillate reached 110° C. under 23 mm. of mercury pressure in order to remove α-methylstyrene. The residue was further distilled through a 5 cm. empty column under high vacuum (0.04 mm.) and the following fractions were collected: 1. b.p. 147°-158° C., wt.=0.7 g.; 2. b.p. 158°-162° C., wt.=0.5 g.; 3. b.p. 162°-164° C., wt.=3.5 g.; 4. b.p. 164°-170° C., wt.=1.6 g.; residue, wt.=1.0 g. Fraction 1 was essentially pure 2,6-toluenediamine. Fractions 2 to 4 were essentially pure 3-(α,α-dimethylbenzyl)-2,6-toluenediamine having the formula ##STR8## in accordance with the present invention.
Fractions 2 to 4 were recrystallized from a combination of hot carbon tetrachloride and petroleum ether (b.p. 35°-60° C.) to give colorless crystals, m.p. 113°-114° C. The structure of this product was confirmed by Nmr and the following elemental analysis.
Calcd. for C 16 H 20 N 2 : C, 79.95%; H, 8.39%; N, 11.66%; Found: C, 79.89%; H, 8.16%; N, 11.73%.
The product yields from this reaction were 23.3% of the monobenzylated material, 54.7% of the dibenzylated material and 6% of the starting 2,6-toluenediamine. A trace of an α-methylstyrene polymer was also obtained in the distillation residue.
Repetition of the above reaction but on a larger scale of starting materials and at 170° C. for 20 hours resulted in a 59% conversion of the starting diamine to form a 56.1% yield of the dibenzylated product and 36.5% yield of the monobenzylated product based on the converted diamine.
EXAMPLE 6
Using the apparatus and procedure described in previous examples, a reaction flask was charged with 36.6 g. (0.3 mole) of 2,4-toluenediamine, 15.3 g. (0.1 mole) of p-chloroisopropenyl benzene, and 10 g. of Zeolite XZ-25 (predried at 400° C. for 3 hours). The mixture was stirred and heated at 200° C. for 24 hours under nitrogen.
After filtration of the reaction mixture, and removal of solvent (methylene chloride) and excess diaminotoluene, the product mixture was distilled under high vacuum (0.07 to 0.05 mm. of mercury). The following six fractions were collected and analyzed by Nmr: 1. b.p. 50°-52° C., wt.=1.29 g. of p-chloroisopropenyl benzene; 2. b.p. 140°-175° C., wt.=1.1 g. of 2,4-toluenediamine plus an unknown; 3. b.p. 175°-192° C., wt.=2.0 g. of 5-(α,α-dimethyl-p-chlorobenzyl)-2,4-toluenediamine plus a small amount of unknown impurity; 4. b.p. 192°-200° C., and 5. b.p. 200°-204° C., both 4. and 5. together wt.=6.8 g. of crude 5-(α,α-dimethyl-p-chlorobenzyl)-2,4-toluenediamine; 6.) b.p. 204°-218° C., wt.=1.8 g. predominantly 5-(α,α-dimethyl-p-chlorobenzyl)-2,4-toluenediamine plus a small amount of unknown impurity; residue wt.=4.1 g. of tar.
Combined fractions 4 and 5 were further purified firstly by column chromatography by eluting the product from the column using a combination of petroleum ether and methylene chloride (75/25) and collecting it in column chromatography fractions 7, 8, and 9.
Secondly, the eluted product was distilled b.p. 194°-196° C. (0.05 mm.) to provide a light yellow glass, wt. 10.5 g. (38%). The hydrochloride salt of the product was prepared for further purification by dissolving the amine in ether and passing in dry hydrogen chloride gas until precipitation of hydrochloride ceases. The salt was isolated by filtration, recrystallized once from a mixture of methylene chloride and ether, and recrystallized once from a mixture of methanol and ether. A light yellow colored hydrochloride salt was obtained which was characterized by a double melting point, 184°-188° C. and 210°-214° C.
Upon neutralizing in aqueous solution of the hydrochloride, the free base was obtained which was extracted from the aqueous mixture using 100 ml. of methylene chloride solvent. The solvent was dried over magnesium sulfate and then taken to dryness. Thus there was obtained pure 5-(α,α-dimethyl-p-chlorobenzyl)-2,4-toluenediamine having the following structure in accordance with the present invention and whose structure ##STR9## was confirmed by Nmr and the following elemental analysis.
Calcd. for C 16 H 19 N 2 Cl: C, 69.93%; H, 6.97%; N, 10.20%; Cl, 12.90%. Found: C, 69.86%; H, 6.24%; N, 10.15%; Cl, 13.02%.
EXAMPLE 7
Using the same apparatus described in the previous examples except that the reaction flask was additionally equipped with an addition funnel, the following experiment was carried out.
The flask was charged with 61.0 g. (0.5 mole) of 2,4-toluenediamine, and 10.0 g. of Zeolite XZ-25 catalyst. The mixture was heated to 200° C. with rapid stirring under the positive flow of nitrogen. Over a 4 hour period under the above conditions, 4.17 g. (0.04 mole) of styrene was added slowly through the addition funnel to the reaction flask. Heating and stirring was continued for another 4 hour period after the styrene addition was completed. A small amount of styrene still remained refluxing at the end of the 8 hours.
The mixture was cooled to room temperature and treated with 50 ml. of methylene chloride. The catalyst was removed by filtration and to the filtrate was added 100 ml. of petroleum ether (b.p. 35°-60° C.) to precipitate the excess 2,4-toluenediamine which latter was also removed by filtration. The methylene chloride/petroleum ether filtrate was washed 3× with 100 ml. portions each of water. Solvent was stripped from the organic layer under vacuum leaving a residue which was distilled under 0.05 mm. pressure of mercury and the following fractions collected and identified by Nmr analysis: 1. b.p. 138°-165° C., wt.=0.3 g. of 2,4-toluenediamine; 2. b.p. 165°-170° C.; 3. b.p. 170°-180° C., combination of fraction 2 and 3 is 4.9 g. of light yellow oil; 4. b.p. 180°-183° C., wt.=0.70 g. of 5-(α-methylbenzyl)-2,4-toluenediamine; residue wt.=0.63 g.
The combination of fractions 2 and 3 was subjected to chromatographic separation on a 1"×12" column of silica gel. The following numbered fractions were the ones found to contain product after the solvent was removed and analyzed by Nmr with the eluting solvent noted in parenthesis.
Chromatographic column fraction 1 (petroleum ether), small amount of styrene; chromatographic column fraction 8 (petroleum ether/methylene chloride 85/15), 3-(α-methylbenzyl)-2,4-toluenediamine; chromatographic column fractions 9 to 15 inclusive (petroleum ether/methylene chloride 80/20), a mixture of 3-(α-methylbenzyl)-2,4-toluenediamine, along with the two N-benzylated side-products; chromatographic column fractions 17 to 24, inclusive (petroleum ether/methylene chloride 3/2), wt.=2.5 g. of pure 5-(α-methylbenzyl)-2,4-toluenediamine.
The latter product crystallized slowly and was eventually recrystallized from a combination of hot toluene and petroleum ether, m.p. 103°-103.5° C. pale yellow needles, total weight of this product was 3.1 g. (34%). Nmr and the following elemental analysis confirmed the following structure in accordance with the present invention ##STR10##
Calcd. for C 15 H 18 N 2 : C, 79.60%; H, 8.02%; N, 12.38%; Found: C, 79.59%; H, 7.97%; N, 12.30%.
The 3-(α-methylbenzyl)-2,4-toluenediamine obtained from chromatographic column fraction 8 remained an oil and was distilled again, b.p. 170°-174° C. (0.05 mm.) and formed a minor product with a yield of about 5%. The Nmr analysis confirmed the following structure in accordance with the present invention. ##STR11##
EXAMPLE 8
The apparatus described in Example 4 was charged with 12.2 g. (0.1 mole) of 2,4-toluenediamine, 58.0 g. (0.5 mole) of indene (practical grade >90% purity, supplied by Aldrich Chem. Co., Milwaukee, Wis.), and 10 g. of Zeolite XZ-25.
The mixture was stirred and heated under nitrogen according to the procedure set forth in Example 4, first at 160° C. for 16 hours but then temperature was increased to 185° C. and heating continued thereat for another 7 hours. During this heating moisture was distilled off from the catalyst.
On conclusion of the heating the reaction mixture was filtered hot through a heated Buchner funnel to remove catalyst. The filtrate was first distilled to remove the excess indene; b.p. 40° C. (0.05 mm. pressure of mercury), wt.=33.5 g. of indene. The residue was then fractionated through a 5 cm. hollow column under 0.05 mm. of pressure. The following fractions were collected: 1. b.p. 115°-130° C.; 2.) b.p. 130°-160° C.; combined wt. of 1 and 2=0.8 g. of 2,4-toluenediamine; 3. b.p. 160°-172° C.; 4. b.p. 172°-186° C., combined wt. of 3 and 4=3.7 g.; 5. b.p. 186°-200° C., wt.=10.4 g.; 6. b.p. 200°-204° C., wt.=1.2 g.; 7. b.p. 204°-240° C., wt.=9.0 g.; residue, wt.=12.2 g.
Fractions 3 and 4 were combined and chromatographed through a column of silica gel (1"×14"). The column was eluted first with 400 ml. of petroleum ether (b.p. 35°-60° C.) followed by mixtures of 400 ml. of petroleum ether/methylene chloride at 85/15 parts ratio and 400 ml. at 1/1 parts. Fractions were collected, evaporated, and analyzed by Nmr. The following numbered fractions were the ones yielding the significant eluted products; also shown are the solvent mixture parts ratios and product identity.
Chromatographic column fraction 1 (petroleum ether), wt.=1.8 g. unknown yellow oil; column fractions 9, 10 and 11 (petroleum ether/methylene chloride 85/15), wt.=1.1 g., 3-(1-indanyl-2,4-toluenediamine; column fractions 16 and 17 (petroleum ether/methylene chloride 1/1), wt.=0.65 g., 5-(1-indanyl)-2,4-toluenediamine.
Distillation fraction 7 was subjected to column chromatography following the same procedure described above and chromatographic column fractions 10 and 11 obtained by elution with 400 ml. of petroleum ether/methylene chloride 7/3 yielded after evaporation 3,5-bis(1-indanyl)-2,4-toluenediamine.
The 3-(1-indanyl)-2,4-toluenediamine obtained from chromatographic column fraction 10 of distillation fractions 3 and 4 above had crystallized and the material was recrystallized from hot methylene chloride and petroleum ether (50/50) to provide colorless crystals, m.p. 122.5°-124° C.; Nmr analysis and the following elemental analysis confirmed the following structure in accordance with the present invention. ##STR12##
Calcd. for C 17 H 18 N 2 : C, 80.63%; H, 7.61%; N, 11.76%; Found: C, 79.75%; H, 7.46%; N, 11.52%.
The 5-(1-indanyl)-2,4-toluenediamine obtained from chromatographic column fractions 16 and 17 of distillation fractions 3 and 4 remained an oil. It was distilled under 0.05 mm. pressure of mercury, b.p. 194°-196° C. and remained a very viscous oil. Nmr analysis confirmed the following structure in accordance with the present invention. ##STR13##
The 3,5-bis(1-indanyl)-2,4-toluenediamine obtained from chromatographic column fraction 10 of distillation fraction 7 above solidified on standing to form a glass, fusion at 93°-97° C. Nmr and the following elemental analysis confirmed the following structure in accordance with the present invention. ##STR14##
Calcd. for C 25 H 26 N 2 : C, 84.70%; H, 7.39%; N, 7.91%; Found: C, 84.68%; H, 7.39%; N, 7.86%.
The reaction was repeated using the same apparatus described above using 24.4 g. (0.2 mole) of 2,4-toluenediamine, 11.6 g. (0.1 mole) of indene (>90% purity described above), and 10 g. of the Zeolite catalyst. The mixture was refluxed at 200° C. for 7 hours. A small amount of indene was still refluxing which indicated incompleteness of reaction. However, after cooling, the mixture was diluted with methylene chloride and filtered to remove catalyst. An equal volume of petroleum ether (b.p. 35°-60° C.) was added to the solution causing the precipitation of 2,4-toluenediamine (12.4 g., 51% recovery dry isolated weight).
The mother liquor which still contained some toluenediamine was washed 4× with 50 ml. portions of water. The organic layer was separated and solvent removed under vacuum to yield 21.3 g. of residue. The residue was distilled under 0.05 mm. of mercury pressure through a 5 cm. hollow column and the following fractions collected and identified by Nmr and comparison to the products isolated above.
Forerun boiling up to 35° C., wt.=1.1 g. of unreacted indene; 1. b.p. 175°-184° C., wt.=0.98 g., mixture of the 3- and 5-(1-indanyl)-2,4-toluenediamine; 2. b.p. 184°-187° C.; 3. b.p. 187°-188° C.; 4. b.p. 188° C. constant, fractions 2 to 4, wt.=13.7 g. predominantly the 5-indanyl isomer with some of the 3-isomer; 5. b.p. 188°-196° C., wt.=2.0 g. pure 5-indanyl isomer; 6. b.p. 196°-225° C., wt.=0.98 g., 5-indanyl isomer plus a very small amount of the 3,5-bis(1-indanyl)-2,4-toluenediamine; residue wt.=1 g.
The overall product yield of 17.7 g. (74.4%) was comprised of the 5-(1-indanyl)-2,4-toluenediamine as the major product, with the 3-isomer as a minor component, and the bis compound in small amount.
EXAMPLE 9
Using the apparatus and procedure set forth in Example 4, a 12.2 g. sample (0.1 mole) of a mixture of 2,6- and 2,4-toluenediamine in the proportioned parts of 18.3/81.7 respectively was mixed with 59.0 g. (0.5 mole) of α-methylstyrene, and 10 g. of Zeolite XZ-25. The stirred mixture was heated at 160° C. under nitrogen and aliquots were withdrawn periodically and analyzed by HPLC. The following table of data sets forth the weight percent concentrations of the three following diamines all in accordance with the present invention and the two isomeric starting diamines (2,6-, and 2,4-toluenediamine) as measured at three different reaction intervals in the mixture. The three product diamines are 3,5-bis(α,α-dimethylbenzyl)-2,6-toluenediamine, 3-(α,α-dimethylbenzyl)-2,6-toluenediamine, and 5-(α,α-dimethylbenzyl)-2,4-toluenediamine, code named 1, 2 and 3 respectively.
______________________________________Reactiontime (hrs.) (1) (2) (3) 2,6- 2,4-______________________________________ 9 2.0% 14.3% 73.5% 1.9% 8.3%25 7.7% 9.4% 75.4% 0.4% 6.9%45 10.2% 8.9% 75.1% 0.4% 5.4%______________________________________
The reaction mixture was worked-up identically to the procedure set forth in Example 4. Distillation of the crude reaction product under high vacuum (described in Example 4) provided the following product distribution and overall yield of materials: 0.0104 mole of dibenzylated product (1), 0.0752 mole of the mixture of the monobenzylated products (2) and (3) to give an overall yield of 75.6%. HPLC analysis showed the weight percent distribution of (1), (2), and (3) in the isolated products based on their combined weights to be 10.5%, 10.1%, and 79.4% respectively.
EXAMPLE 10
A 250 ml 3-necked flask equipped with a magnetic stirrer, a thermometer, a reflux condenser (equipped with a nitrogen inlet tube), and a short path distillation head with condenser, receiver and a nitrogen outlet, was charged with a mixture of 9.76 g. (0.08 mole) of 2,4-toluenediamine and 2.44 g. (0.02 mole) of 2,6-toluenediamine, 59.1 g. (0.5 mole) of α-methylstyrene, 0.055 g. of hydroquinone, and 1.9 g. (0.01 mole) of p-toluene sulfonic acid monohydrate.
The system was flushed with nitrogen and then under a slow stream of nitrogen and during continual stirring the reaction mixture was heated rapidly to 160° C. Water of hydration from the sulfonic acid was released starting at about 120° C., carried from the reaction flask with the nitrogen stream, and collected in the receiver with a small amount of α-methylstyrene. When the water generation stopped, the nitrogen outlet was closed and the system maintained under a slight positive pressure of nitrogen by means of a gas bubbler.
Aliquot samples were withdrawn from the reaction mixture periodically (circa every hour) and analyzed by HPLC (column material was μ-Porasil and the elutant was a mixture of acetonitrile and 1,2-dichloroethane in a volume/volume ratio of 490/3000.
When conversion of the diaminotoluene reached about 75 percent, in about 3 hours, the weight percent concentrations of the starting amines and products was as follows:
______________________________________2,4-toluenediamine = 13.7%2,6-toluenediamine = 7.2%5-(α,α-dimethylbenzyl)-2,4-toluenediamine = 63.0%3-(α,α-dimethylbenzyl)-2,6-toluenediamine = 14.5%3,5-bis(α,α-dimethylbenzyl)-2,6-toluenediamine 1.6%______________________________________
The reaction was stopped at this point and cooled rapidly (within 0.5 hour) first by forced air and then by cold water bath to room temperature (circa 20° C.) during continuous stirring. As the reaction mixture cooled, p-toluene sulfonic acid crystallized out gradually as the salt of a toluenediamine.
After 2 hours at room temperature, 30 ml. of methylene chloride was added to the reaction mixture which was then stirred for 1 hour. The mixture was filtered and 2.83 g. (97% yield) of the 1:1 salt of p-toluene sulfonic acid and 2,4-toluenediamine was obtained. The sulfonic acid salt which was collected, was washed twice with 15 ml. portions of methylene chloride.
The filtrate and washings were combined and the small amount of residual acid in the solution was neutralized by bubbling a slow stream of anhydrous ammonia into the solution with stirring until the pH reached 8 to 9. The sulfonic acid precipitated as ammonium p-toluene sulfonate which was removed by filtration. Methylene chloride and ammonia were removed from the mixture by rotary evaporation under aspiratory vacuum (circa 20-30 mm of mercury pressure) at a temperature of up to about 40° C.
The excess α-methylstyrene was distilled at a head temperature of 70° to 80° C. under a pressure of about 23 mm of mercury and the residue was distilled under 0.03 mm of mercury and the following fractions were collected and identified by NMR:#1. b.p. 80°-155° C., wt.=3.1 g. of colorless distillate which crystallized at room temperature and contained 0.3 g. dimer of α-methylstyrene and 2.8 g. of a mixture of 2,4-toluenediamine, 2,6-toluenediamine, 5-(α,α-dimethylbenzyl)-2,4-toluenediamine, and 3-(α,α-dimethylbenzyl)-2,6-toluenediamine in the molar percent proportions of 54.9%, 23.1%, 17.8%, and 4.2% respectively; #2. b.p. 155°-175° C., wt.=15.0 g. yellow glass which was a mixture of 5-(α,α-dimethylbenzyl)-2,4-toluenediamine, 3-(α,α-dimethylbenzyl)-2,6-toluenediamine, and 3,5-bis(α,α-dimethylbenzyl)-2,6-toluenediamine in the molar proportions of 81.2%, 17.9%, and 0.9% respectively, and 0.1 g. of oligomers of α-methylstyrene as well as a trace of some N-alkylated side-products; #3. b.p. 175°-182° C., wt.=1.1 g. of orange colored distillate which was a mixture of 0.7 g. of 3,5-bis(α,α-dimethylbenzyl)-2,6-toluenediamine and 0.4 g. of oligomers of α-methylstyrene. A residue of 0.3 g. of black tar remained in the stillpot.
Fraction #2 was essentially a pure mixture of three alkylated phenylenediamines in accordance with the present invention. The completely pure crystalline mixture of the three products is obtained from the glass by recrystallization from toluene and petroleum ether. The total yield of alkylated products based on converted toluene diamine starting material was 87%.
EXAMPLE 11
The following two molded polyurethane-polyurea polymers A and B were prepared by a hand-mix technique. Polymer A was in accordance with the present invention while Polymer B was prepared in accordance with the prior art.
The molded polymers were prepared by reacting the ingredients in the proportions of parts by weight set forth in Table I, as an A component with a B component. Both components were mixed at high speed at room temperature (about 20° C.) in quart tubs using a drill press motor equipped with a Conn 3" blade. The ingredients were mixed for about 5 to 6 seconds and then immediately poured into a metal mold measuring 77/8"×77/8"×1/4" at 150° F. which mold was coated with a mold release agent (XMR-136 supplied by Chem-Trend Inc., Howell, Mich. 48843). The demold time was about 2 minutes for A and about 4 minutes for B. Both samples were post-cured for 1 hour at 250° F. and then subjected to the test procedures set forth in Table I.
The sample A in accordance with the present invention exhibited good physical and thermal properties. These properties, even if allowance is made for a density difference, are for the most part significantly better than those of the prior art sample B, particularly in regard to thermal stability.
TABLE I______________________________________ Sample A B______________________________________Ingredients (pts. by wt.)A Component: 57.9 (0.4008 eq.) 78.44 (0.5432 eq.)Polyisocyanate 1.sup.1B Component:E 2105.sup.2 100 (0.1 eq.) 100 (0.1 eq.)5-(α,α-dimethylbenzyl)- 35 (0.2892 eq.) --2,4-toluenediamineEthylene glycol -- 13.25 (0.4274 eq.)Dibutyl tin dilaurate 0.125 0.125NCO/OH Index 1.03 1.03[A]/[B] Ratio 0.429 0.693Catalyst (total wt. %) 0.064% 0.065%% Hard segment 40.7% 40.3%Properties:Density (g./cc) 1.078 0.914Shore D hardness 55 35Tensile str. (psi) 2720 1440Elongation at break (%) 198 292Flexural modulus (psi) 32,809 6201Flexural strength (psi) 1954 434Heat sag, inches.sup.3 0.085 0.32at 250° F./1 hr.______________________________________ Footnotes to Table I .sup.1 The polyisocyanate is a liquefied methylenebis(phenyl isocyanate) containing uretoneimine group, I.E. = 144.4. .sup.2 E 2105 is Thanol E 2105 ethyleneoxide capped polypropyleneoxy glycol, 45% ethylene oxide content by wt., 2000 M.W.; supplied by Texaco Chem. Corp., Bellaire, Texas. .sup.3 Heat sag is determined in accordance with Test CTZ006AA of the Chevrolet Div. of General Motors Corp., Flint, Mich. It is the amount, in inches, that a 1 inch wide sample with a 4 inch long unsupported length droops under its own weight when h eld at one end in a horizontal positio under the specified conditions of time and temperature. | Novel meta phenylenediamines are provided having one or two particular benzyl radicals as substituents along with other optional substituents on the aromatic diamine ring and optionally substituents on the benzyl aromatic ring.
The diamines are sterically hindered and thereby have lower amine reactivity as compared with the unsubstituted diamines.
The diamines are useful as curing agents for epoxy resins and find particular utility as extenders in the formation of novel polyurethane-polyurea polymers. | 2 |
RELATED APPLICATIONS
This application is a division of U.S. application Ser. No. 08/381,515, filed Feb. 1, 1995, now U.S. Pat. No. 5,793,032, which is a continuation of U.S. application Ser. No. 08/294,845, filed Aug. 29, 1994, now abandoned. This application is a continuation-in-part of U.S. application Ser. No. 08/637,011, filed Apr. 24, 1996, now U.S. Pat. No. 5,610,387. This application is also a continuation-in-part of U.S. application Ser. No. 08/068,025, filed May 28, 1993, now U.S. Pat. No. 5,514,861 and of U.S. application Ser. No. 07/884,734, filed May 15, 1992, now abandoned. This application is also a continuation-in-part of U.S. application Ser. No. 08/246,382, filed May 20, 1994, now U.S. Pat. No. 5,410,140, which is a continuation of U.S. application Ser. No. 08/073,995, filed Jun. 9, 1993, now abandoned, which is a continuation of U.S. application Ser. No. 07/787,458, filed Nov. 4, 1991, now abandoned. This application is related to U.S. application Ser. No. 08/068,024, filed May 28, 1993, now U.S. Pat. No. 5,416,310 and U.S. application Ser. No. 08/068,025, filed May 28, 1993, now U.S. Pat. No. 5,514,861.
BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates to portable optical scanners for reading indicia of varying light reflectivity, and in particular to such scanners which are adapted to be worn on the person. The invention further relates to optical scanning systems in which the optical module for generating and emitting the light beam is physically separate and apart from the detector module. The invention also relates to a laser pointer, adapted to be worn on a finger of a user.
2. Description of the Related Art
Various optical readers and optical scanning systems have been developed heretofore for reading indicia such as bar code symbols appearing on the label or on the surface of an article. The symbol itself is a coded pattern of indicia comprised of, for example, a series of bars of various widths spaced apart from one another to bound spaces of various widths, the bars and spaces having different light reflecting characteristics. The readers in scanning systems electro-optically transform the graphic indicia into electrical signals, which are decoded into alphanumeric characters that are intended to be descriptive of the article or some characteristic thereof. Such characteristics are typically represented in digital form and utilized as an input to a data processing system for applications in point-of-sale processing, inventory control and the like. Scanning systems of this general type have been disclosed, for example, in U.S. Pat. Nos. 4,251,798; 4,369,361; 4,387,297; 4,409,470; 4,760,248; 4,896,026, all of which have been assigned to the same assignee as the instant application. As disclosed in the above patents, one embodiment of such scanning Systems includes, inter alia, a hand held, portable laser scanning device supported by a user, which is configured to allow the user to aim the scanning head of the device, and more particularly, a light beam, at a targeted symbol to be read.
Such prior art hand held devices generally incorporate a light-receiving module which receives the light that has been reflected from the bar code symbol an determines, from the reflected pattern, the sequences of bars and spaces within the symbol. The unit may also incorporate decoding circuitry to decode the received information and to recover the underlying data (for example the alphanumeric data) which the bar code symbol represents.
It may in some circumstances be disadvantageous for the light generating and emitting module to be housed within the same unit as the light-receiving module and the decoding circuitry. In the first place, locating everything within the main housing requires that the bar code to be read is positioned so that most or at least a substantial proportion of the reflected light returns to the unit along the same path as the emitted light. It might not always be convenient for a user to position the bar code reading and/or the bar code so that the light is reflected back along the same path in that way. Secondly, locating everything within the same unit means that the unit has to be physically rather large and relatively heavy. Users may not find it easy to operate for long periods.
In the field of laser pointers, it is known to provide small hand held units which users can use at conferences, seminars or the like for pointing purposes. The visible spot of the laser beam, when shone onto a screen, indicates to the audience the point of interest, and enables the lecturer to dispense with the traditional physical pointer. Although modern laser pointers are relatively small and compact, they nevertheless still have to be grasped in the hand of the lecturer, which naturally restricts the lecturer's user of that particular hand. Typically, the laser pointer has to be put down every time the lecturer wishes to do something else, such as to turn over a page in his or her notes, or to operate and overhead projector.
It is a general object of the present invention at least to alleviate some of these problems of the prior art.
It is a further object to provide a portable optical scanning system with improved ergonomics, and which will be easier for a user to operate for long periods.
It is a further object of the present invention to reduce the weight of a portable optical scanning system adapted to be held in the hand of a user, or mounted to the user's body.
It is yet a further object to provide a laser pointer which permits the lecturer greater freedom to use his or her hands without continually having to put down and to pick up the pointer.
It is yet a further object to provide an easy to operate and convenient to use laser pointer.
It is yet a further object to provide a laser pointer which can optionally be used as part of a portable scanning system.
Additional objects, advantages and novel features of the present invention will become apparent to those skilled in the art from this disclosure, including the following detail description, as well as by practice of the invention. While the invention is described below with reference to preferred embodiments, it should be understood that the invention is not limited thereto. Those of ordinary skill in the art having access to the teachings herein will recognize additional applications, modifications and embodiments in other fields which are within the scope of the invention as disclosed and claimed herein and with respect to which the invention could be of significant utility.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is provided an optical system for reading indicia of different light reflectivity comprising:
an optical module having a light emitter for generating and emitting a light beam for illuminating an indicia to be read; and
a first peripheral module, housed separate and apart from said optical module, having a light detector for detecting the reflection of light from said indicia and producing electrical signals responsive to the light received.
The system may, but need not, be a scanning system in which the light beam scans the indicia to be read. Alternatively, the light beam may be merely illuminating; in that case the light detector may preferably be a CCD detector.
In a preferred embodiment, the optical module incorporates or forms part of a ring which is desirably worn on an index finger of the user. To scan the indicia, the user points his or her index finger in the relevant direction. In some embodiments, an automatic scanning mechanism may be incorporated within the module, so that the emitted beam automatically scans back and forth across the indicia (either in a two-dimensional scan or in a one-dimensional scan) even when the module is held stationary. In other embodiments, however, no automatic scanning mechanism is provided, and the emitted light beam emerges in a fixed direction from the module. In those embodiments, the user scans the beam across the indicia to be read by manually moving the module, typically by moving his or her arm back and forth or by a twisting movement of the wrist.
Switching means may be provided for actuating the optical module. Preferably, these may comprise a switch or button, attached to or forming part of the ring or part of a housing secured to the ring, whereby the user can operate the device merely by pressing the button with his or her thumb. This is particularly convenient when the module is arranged to be worn on the index finger. Alternatively, a pull-cord may be provided which is secured to a second ring, arranged to be worn on a finger of the user's hand adjacent to the finger which is wearing the optical module. By a suitable movement of the fingers, for example by flexing the second finger, the cord is pulled thereby operating the device.
It will of course be understood that there are many other possibilities for actuating the device, including switch mechanisms which operate under voice control, and mechanisms which determine when the user's hand is being moved in a scanning motion.
The first peripheral module which has a light detector for detecting the reflection of light from the indicia, may be either fixedly mounted to a stationary support or alternatively worn by the user. In a preferred embodiment, the first peripheral module takes the form of a wrist watch (or includes a wrist watch), and is worn on the same hand which wears the optical module. In that way, it is relatively easy to ensure that the detector or detectors face in the right direction to receive the reflected light. Alternatively, however, the first peripheral module could be worn on the other arm, or could be secured elsewhere on the user's person, for example on a belt.
The first peripheral module may incorporate radio frequency communication means, enabling the module to communicate with either a fixed base unit or, in some embodiments, a second peripheral module. In one preferred arrangement, the second peripheral module may be worn on the user's other arm. The second peripheral module may also incorporate radio frequency communication means, allowing communication between the second module and the first module, and (preferably at a different frequency) between the second module and a fixed base unit.
The optical module, the first peripheral module and the second peripheral module are all preferably operated by means of portable batteries, desirably relatively compact batteries which can be located within the respective housings.
In further embodiments, the optical module may be adapted to be held in the hand of a user and may be either gun-shaped or pen-shaped. The optical module could also be mounted to a stationary support.
According to a second aspect of the present invention there is provided a system for reading indicia having parts of different light reflectivity, comprising:
a light emitter for generating a light beam which illuminates the indicia and for producing reflected light of variable intensity reflected from said indicia; said light emitter having a housing adapted to be worn on a single finger of a user in a position such that the light beam is directed in a natural pointing direction of said finger; and
an optical detector for detecting said reflected light and producing an electrical signal indicative of the reflected light intensity; said detector having a housing adapted to be worn by the user in a position spaced apart from the light emitter.
The light emitter preferably generates a beam which scans the indicia.
A stand or container may be provided to receive the first and/or second peripheral modules when they are not in use. In the preferred form, this may comprise a box (akin to a jewellery box) having recesses for receiving the first peripheral unit in the form of a watch, and a second peripheral unit in the form of a ring. The stand/container may include electrical contacts, which are arranged to abut corresponding contacts on the first and/or peripheral modules, thereby allowing a battery of either or both of the modules to be recharged when the system is not in use. The box may have a lid, and may be lockable, to provide security.
Where the first peripheral module includes a data store, readout data contacts may be provided on the stand whereby the data may be downloaded to a computer automatically or on demand.
According to a third aspect of the present invention there is provided a light pointer module comprising:
a ring adapted to be worn on a single finger of a user;
a housing attached to the ring; and
a light emitting means within the housing arranged to generate and emit a light beam, whereby by pointing the finger the user may direct the light beam.
The laser pointer may desirably incorporate a is trigger mechanism such as the button mechanism or cord mechanism described above.
To enhance the visible effect of the light beam, the light emitting means preferably comprise a visible laser diode (VLD), whose output passes through a collimating optical system. Electronic control means may be provided which maintain the laser output at a predetermined level.
A battery is preferably provided within the housing.
It is within the scope of the present invention for the laser pointer just described to be used in conjunction with the optical scanning system described above.
According to a fourth aspect of the present invention there is provided a light pointer module comprising: a light pointer module comprising:
a portable housing;
a light emitter within the housing arranged to generate a light beam, whereby by pointing the module a user may direct the light beam;
a scanning element for selectively scanning the light beam;
a user-actuable switch in a first position of which the module emits a steady beam and in a second position of which the scanning element is actuated so that the module emits a scanning beam.
According to a fifth aspect of the present invention there is provided an optical system adapted to be worn on the body of a user, the system comprising an optical system adapted to be worn on the body of a user, the system comprising;
an optical module having a light emitter for generating and emitting a light beam; and
a band secured to the module and adapted to be worn around a part of the user's body, the band incorporating a battery for powering the module.
The invention may be carried into practice in a number of ways, and several specific embodiments will now be described, by way of example, with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b depict a portable optical scan system in accordance with a first embodiment of the present invention;
FIG. 2 illustrates schematically the ring unit and the wrist unit shown in FIGS. 1a and 1b;
FIG. 3 depicts a portable optical scan system in accordance with a second embodiment of the present invention;
FIG. 4 depicts a laser pointer in accordance with a third embodiment of the present invention;
FIGS. 5 and 6 illustrate the triggering mechanism which may be used with the laser pointer of FIG. 4, or with either of the portable optical scan systems of FIG. 1 or 3;
FIG. 7 illustrates a hand-held laser pointer/laser scanner of another embodiment;
FIG. 8 shows schematically yet a further embodiment in which a band for securing a pointer or scanner to the user's body comprises a flexible battery;
FIG. 9 represents a practical embodiment of the device shown in FIG. 8; and
FIG. 10 shows a storage box for use with the portable optical scan system of FIG. 1A.
FIGS. 11a and 11b are schematic representations of laser beam scanning patterns as is known in the prior art;
FIGS. 11c, 11d and 11e are schematic representations of laser beam pulsing patterns according to the present invention;
FIGS. 12a is the timing diagram of one embodiment of a laser beam pulsing pattern corresponding to FIG. 11c; and
FIGS. 12b and 12c are timing diagram of other embodiments of the laser beam pulsing pattern.
FIG. 13 depicts a pen scale module and computer with wireless communication links.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1a shows a portable optical scan system in accordance with a first embodiment of the present invention. An optical scan module 1 is detachably mounted on a single finger of a user 3 using a ring-shaped mounting. The detachable mounting may be of any number of conventional types suitably adapted for its ease of use for the desired application. For example, a ball and flexible socket mounting, or a slide mounting could be used. Other mountings with movable restraining members might also be used.
In additional to the optical scan module 1, the user 3 wears a first peripheral module 7, on the wrist, and a second peripheral module 9 on the other arm. As will be clear from the Figure, the scan module 1 emits a scanning laser beam 10 which the user directs towards a bar code symbol 13 to be read. The bar code symbol may be printed on or otherwise attached to on article 11, details of which the user 3 wishes to obtain for example for inventory or for sale purposes. The scanning beam 10 is reflected from the bar code symbol 13, and the reflected light 12 is detected by the first peripheral module 7.
FIG. 1b illustrates a variant of the embodiment of FIG. 1a in which the reflected light 12 returning from the barcode symbol 13 is detected by a peripheral module 7' which is secured to the user's clothing. In the variant shown, the peripheral module comprises a detector which is clipped on to the breast pocket of the user's shirt or shift. Other arrangements (not shown) could of course be envisaged, in which the peripheral module 7' is secured to or forms part of other articles of clothing.
FIG. 2 illustrates schematically the internal features of the scan module 1 and the first peripheral module 7. The module 1 incorporates a device for generating and scanning the light beam 10, desirably a visible laser diode (VLD) 1a, having a driver 1b. Scanning of the beam 10 is achieved by means of a scan element 1c, and a scan element driver 1d. Power is provided by means of a small battery 1e.
The first peripheral module 7 comprises a photodetector 7e and receiver circuitry 7d which are together arranged to detect the returning light beam 12. The output from the receiver circuitry is passed to a decoder 7a which is arranged to reconstitute the alphanumeric information which the bar code symbol 13 represents. The first peripheral module may also include a keyboard and/or display 7c along with other possible features 7g such as for example a time display so that the module 7 doubles as an ordinary watch when it is not in use as part of the optical scan system. A radio frequency (RF) or other wireless transmitter 7b, along with a battery pack 7f or other power supply completes the unit.
In use, the decoded information emanating from the decoder 7a is passed by wireless link from the radio 7b to the second peripheral module 9 which is located on the other arm or wrist of the user. The radio transmitter 7b could be a transceiver which is also capable of receiving signals from the second peripheral module 9 or from a separate base station 15.
The second peripheral module 9 incorporates a radio receiver 9a and a radio transmitter 9b for communicating with the first module 7 and/or with the base unit 15. Typically, the respective transmission frequencies will be different. The second peripheral module 9 further includes digitizing and processing circuits 9c which convert the transmitted analog signal to a digital signal and decode the signal in a conventional manner. An indicator light, beeper or audio transducer 9d signals the user when the decoding has been satisfactorily accomplished. Such notice could also or alternatively be provided by information displayed on a display unit 9e. A memory storage device 9h is also preferably included for temporary storage of the decoded data. A keypad 9f and/or touch screen may be used for inputting data to the system. A battery 9j is provided to supply power to the secondary peripheral module. Alternatively, or in addition, power may be supplied via an external lead 17 from a separate power supply 19 which is secured to the body of the user, for example on a belt 21.
Depending upon the preference of the user, the second peripheral module could be worn on the right arm, or wrist, like a watch (and in fact, may function as a watch) and the optical scan module 1 and the first peripheral module on the left. In an alternative embodiment (not shown) the second peripheral module 9 could be dispensed with, with all the features of that unit instead being incorporated within the first peripheral module 7. This would of course be expected to make the first peripheral module rather larger than is shown in the drawing.
It will be noted that in the arrangement shown in FIGS. 1a and 1b, there is no cable or other physical connection between the optical scan module 1 and either of the first or second peripheral modules. This improves the wearability of the system, and the likely user acceptance. It is also rather safer, since the lack of wires means that there is less to get caught as the user moves around, perhaps undertaking a variety of different tasks while wearing the devices shown. In a variation of the embodiment described above, the scan element 1c and the scan element driver 1d may be omitted from the optical scan module 1, so that the beam 10 is essentially a fixed beam. With such an arrangement, the user would then physically move his or her hand or arm, thereby manually scanning the beam 10 across the bar code symbol 13. Such an arrangement has the advantage that the module 1 can be reduced in size and in weight, not only by elimination of the mechanical and electronic scanning features, but also because the battery 1e may substantially be reduced in size. A suitable module for use with this variation is illustrated in FIGS. 5 and 6, which will be described in more detail below.
A second embodiment of the second invention is shown schematically in FIG. 3. In this embodiment, the light 12 which is reflected from the bar code symbol 13 is detected by a separate detector unit 70 which comprises a fixed bank of photodetectors 72 which look down on the surface of the article 11 so as to detect the reflected light. The detector unit could be mounted to a stand 74 which is positioned adjacent a conveyor 76 along which the item 11 is passing. Alternatively, the detector unit 70 could be mounted in or secured to a cash register, could be mounted to the ceiling, or may be suspended from the ceiling by a cable similar to a hanging lamp, or could be mounted within a tunnel which surrounds or at least partially surrounds the conveyor.
In this embodiment, the optical scan module 1 is preferably the same as the scan module illustrated in FIGS. 1 and 2, with or without the scan element 1c and the scan element driver 1d. If these are not provided within the module, the user has to manually scan the beam 10 across the bar code symbol 13 to be read. As a further alternative (not shown) a hand held pointer or hand held scanner could instead be used, but in each case the detectors are fixedly mounted over the scanned surface.
In those cases in which the optical scan module 1 does not incorporate a beam scanning mechanism, the module 1 effectively becomes a ring-mounted laser pointer. Such a pointer may, as previously described, be used for scanning applications merely by scanning the beam manually across the indicia to be detected, and providing separate detectors elsewhere, either fixedly mounted or secured to the body of the user, which detect the reflected beam. However, a laser pointer of this type is not necessarily restricted to scanning applications, and as may be seen from FIG. 4 the laser pointer could instead be used at lectures, seminars, meetings and so on, or indeed at any type of public presentation.
Reference should now be made to FIGS. 5 and 6 which illustrate certain preferred features of the laser pointer. The embodiment shown in FIGS. 5 and 6 is equally applicable both to the application of FIG. 4 and the application of FIGS. 1a,1b and 2.
The laser pointer 1 comprises a ring or shank portion 102, adapted to be worn on the finger of the user, to which is secured an upper housing portion 100. Within the housing is a battery 103 which provides power to a visible laser diode (VLD) or other light source 108. The VLD is mounted to a metal holder/heat sink 106. Light generated from the VLD passes through an optical system 110 comprising a plurality of lenses, out through an exit window 112 The optical system preferably provides that the beam 10 is collimated or at least quasi-collimated. Electronic circuitry 113 is provided which maintains the laser output at a predetermined level, and also acts as a trigger mechanism.
A trigger button 104 is provided on one side of the ring 102, where is can be actuated by the user's thumb. In this way, the user can easily switch the laser beam on and off.
Another alternative and/or additional switching mechanism may be provided by means of a separate ring 116 which is attached to the user's middle finger and which is secured to the ring 102 by means of a cord 114. As is shown in FIG. 6, the user may operate the device by flexing the middle finger, and so pulling on the cord. This could be done either by bending the middle finger with respect to the index finger, or by pulling the middle finger away from the index finger.
A device of this sort is both easy and convenient for a lecturer to wear, and it also allows free use of the hand at all times. Because the ring is preferably mounted to the index or forefinger, pointing accuracy is likely to be increased.
An alternative and/or additional switching mechanism may be provided by the use of a limited range proximity sensor. Reference is made to U.S. Pat. No. 5,280,162 which is hereby incorporated by reference, as describing "object sensing" or proximity sensing technology in a bar code reader. By appropriate setting of threshold signals in the circuits of such a system, the sensor may be made to trigger by a movement of the thumb, or by a more distant object embodiment of a "self triggering" mode which will be described in connection with FIGS. 11 and 12 in more detail. Another embodiment utilizes a very small range proximity sensor, so that the unit will not be triggered by a distant target, but only the user's thumb. In that embodiment, there is a very limited range proximity embodiment which provides a limited range proximity. The proximity sensor is located on the front or side surface of the ring 102. When the user wishes to turn the unit on, a slight movement of the thumb closer to the index finger will switch the unit on, thus avoiding the effort required for the thumb to press a trigger switch.
FIG. 7 illustrates, schematically, a hand-held laser pointer 200 which is capable either of providing a fixed laser beam, for pointing purposes, or a scanning laser beam. Whereas a fixed laser beam generates a point or dot, that can be aimed at a screen, a scanning beam generates a line or a circle. This especially convenient if the user wishes to underline or to circle a sentence or a figure that is being pointed to.
The pointer shown in FIG. 7 incorporates a hand-held body 202, having a manually actuable multi-positioned switch 204. Inside the body 202 there is a short wavelength VLD (visible laser diode) 206 which directs a beam onto a small, micro-machined mirror 208. This deflects the beam out of a window 210 in the housing, thereby providing a pointing beam 212. A scanning element 214 is provided for selectively oscillating the mirror 208, thereby causing the beam 212 to be scanned.
In a first position of the switch 204, the laser diode 206 is switched off, and no beam is produced. In a second position, the laser diode is switched on and is reflected from the stationary mirror 208, thereby providing a fixed pointing beam 212. In a third position of the switch, the scanning element 214 is actuated, causing the beam 212 to be scanned, thereby generating a visible line on the surface that is being pointed to. In the preferred embodiment, the scanning is in one dimension so that the resultant line on the screen is straight. In an alternative embodiment, however, the scanning element 214 could cause the beam 212 to be scanned in two directions, thereby forming any desired type of Lissajous pattern, such as a circle, on the screen. More complex scanning arrangements could also be envisaged, so that for example the image projected onto the screen is a square or other desired figure.
If the trigger 204 is a multi-position trigger, the device could provide a projected straight line in one position of the trigger, and a projected circle in another position. Different positions of the trigger could also provide different lengths of line and/or different sizes of circle or other images that are being projected.
Scanning of the beam 212 of course reduces the visibility of the image with respect to the visibility of the dot generated by a fixed beam. To compensate, the laser output power is increased according to the position of the trigger 204.
Instead of being hand-held, the device shown in FIG. 7 may be built into a ring, and in particular it may be built into any one of the rings that have previously been described. Naturally, in such a case, the trigger 204 will be replaced with an appropriate trigger or switch on the ring itself. For example, if the arrangement of FIG. 7 is built into the ring shown in FIG. 6, the trigger 204 is merely replaced by the trigger button 104 (FIG. 5) or the cord 114 (FIG. 6). It will of course be appreciated that, where appropriate, the button and/or cord may be multi-position. Alternatively (not shown) there may be several separate switches, one of which for example produces a fixed beam and another of which produces a scanning beam.
Batteries for wearable devices of the types which have already been described typically occupy a significant proportion of the device's volume, and additionally contribute to its weight. Where substantial power is required, such as for example the devices illustrated in FIGS. 1 to 3, a separate battery pack 19 is often the most convenient way to provide the power that is needed. However, in a variation of the embodiments previously described, power may instead or in addition be provided by a thin flexible battery which forms part of the band that wraps around the arm, wrist or finger of the user. Specifically, in FIG. 1A the wrist band 306 could be such a battery, as could be the arm bands 302,304. In FIG. 5, the ring 102 could be a battery.
Preferably, the battery is of the lithium polymer rechargeable type, which is simply cut into the appropriate shape. Such batteries may provide sufficient power, on their own, for operation of some devices; in other cases, they may be used as an auxiliary battery, thereby reducing the size of the additional cells that may be necessary.
FIG. 8 illustrates the concept in schematic form. A flexible battery strip 404, preferably a lithium polymer battery, is formed into a ring shape and is attached to a scanner and/laser pointer 402. Depending upon the size of the device, the band 404 may fit around a finger, a wrist or an arm of the user.
FIG. 9 illustrates a practical embodiment in more detail. A flexible battery strip 408 is attached to two circularly-shaped snap springs 418,420. One snap spring 418 is attached to the positive battery terminal, and the other 420 to the negative battery terminal. At one end of the spring 418 there is a contact portion 410, while at the opposite end of the other spring 420 there is a similar contact portion 412. These fit into corresponding grooves 414,416 in the lower surface of the scanner/laser pointer 406, thereby providing the necessary electrical power.
The exact shape and configuration of the battery and the contacts is not of course critical. In the embodiment shown in FIG. 9, the springs 418,420 could be in the form of thin, sprung wires. Alternatively, they could take the form of flat leaf springs, which extend out of the plane of the diagram. In the first case, the scanner/laser pointer 406 is provided with sockets 414,416 in the form of blind bores which receive the contact portions 410,412. Alternatively, where the springs take the form of leaf springs, the contact portions 410,412 may simply be slid into appropriate grooves 414,416 in a direction perpendicular to the plane of the figure. In either case, the snap springs 418,412 are preferably incorporated within the plastic protective jacket of the battery during the manufacturing process.
To make it easier to put the device on and to take it off, an alternative embodiment (not shown) provides for one end of the battery to be hinged to the underside of the scanner/laser pointer. The other end is secured by an easily-releasible clasp. To put the device on, or to take it off, the user merely releases the clasp and hinges the battery away from the underside of the scanner/laser pointer.
FIG. 10 shows a storage box 500 which is suitable for use with the system shown in FIG. 1A. The box comprises a base portion 502 and a lockable hinged lid portion 504. Within the base portion 502 there is a first recess 506 for storing the watch 7 (FIG. 1A) and a second recess 508 for storing the ring 1 (also FIG. 1A). In addition to providing convenient and secure storage, the box 500 incorporates a battery charger (not shown) to recharge any battery that may be incorporated within the watch 7 and/or the ring 1. To that end, when the watch is placed within the recess 506, its rear surface comes into contact with electrodes 510. Likewise, when the ring is placed in the recess 508, with the band portion pushed down into a slot 512, it comes into contact with further electrodes (not shown). Power is provided to these electrodes via a mains supply which is plugged into a socket 514 on the outside of the box. The electrodes become live, thereby recharging the batteries (for example overnight) when the lid 504 is closed, thereby closing a microswitch 520.
In some embodiments, the watch 7 of FIG. 1A may be used to store data, and may accordingly have a memory chip inside it. When the watch is placed in the recess 506, an electrical contact on its rear surface abuts a corresponding contact 522 at the base of the recess. The data within the watch may then automatically be downloaded, or downloaded on request, via a data socket 516 to an external computer (not shown).
Self Triggering Mode
Another key feature of the present invention is to implement a variety of adaptable "self triggering" or "object sensing" modes of operation that eliminate the need for a manual trigger switch, and also optimize the turning on of the scanning and bar code reading operation for different ergonomic implementations--fixed mount, hand-held (including hand-supported), ring or finger-mounted, body mounted, etc., all of which may require different "turn on" conditions for the user applications envisioned. Reference is first made to U.S. Pat. No. 5,280,162 of the present assignee for background information describing a scanning system operable in a "sleep" mode including object sensing, and a "scanning" mode after sensing an object in the scanning field.
Another prior art design uses an infrared LED which is blinking at a high frequency. A photo detector is connected to analog circuitry that responds to signals at the frequency at which the LED is blinking. When an object with a bar code is placed in front of the scanner, some infrared light is reflected back to the detector. The circuit responds to this by sending a "Trigger" signal to the decoder, which initiates scanning.
Such prior art systems have several drawbacks. The signal detector circuitry adds costs and complexity to the scanner. The LED also consumes power, which is a drawback in battery powered applications. The sensing range varies depending on the size and color of the object being sensed, and it is subject to false triggering which can cause accidental reading and wastes power.
In other prior art self-triggering designs, the laser is turned on for one scan and off for three scans. If during the scan with the laser turned on something resembling a bar code is detected somewhere in the scan field, the laser stays on until either a symbol is decoded or a predetermined time has elapsed. The scanner then resumes blinking the laser.
This is an improvement over the other prior art design since it adds no additional circuitry to the scanner. It is less likely to false trigger because it only turns on when real bar codes or at least things that look like bar codes are detected, and its range inherently matches the range of the scanner, regardless of the size of color of the item being scanned.
However, the blinking laser is visually annoying to some users. Sensing can be sluggish because it can take as much as three scan periods to detect an object (it cannot sense symbols when the laser is off). Accidental reads are still possible because it can sense a symbol anywhere along a wide scan line. Power is still consumed by the laser when it is turned on, and by the decoder which performs a control and monitoring function, and which therefore must be kept turned on to control the blinking and sensing.
Still another prior art design has the laser turned on all the time. Such design is usually not commercially useful since it would too rapidly use up the laser's limited life. It would also heat up the laser and the interior of the scanner housing which would further shorten the laser's life. It would also use a substantial amount of power. Except for the decoder, the laser uses more power than any other component of a hand-held scanning system.
The blinking laser mode is only practical with a very long lived motor, as it requires the motors to run continuously. These motors will not wear out and use so little power that they do not heat up the interior of the scanner.
It has been determined from experimental measurements that blinking the laser on for one out of four scans keeps it cool enough that its lifetime will be satisfactorily long, assuming adequate heat sinking and minimum heat generation by other circuitry.
The present invention provides a way to have the laser turned on only 25% of the time by turning it on every scan, but only for 25% of the scan period. In scanners that run typically at thirty-six scans per second, each scan takes 27.7 milliseconds, so if the laser is turned on for only 6.9 milliseconds in each scan, it will be on 25% of the time. The laser will then have the same lifetime as it would in a scanner that turns the laser on for one out of four scans. The figure 25% is chosen as an example in our discussion, but may be any appropriate percentage for the particular application envisioned.
Turning to the Figures, FIGS. 11a and 11b are schematic representations of laser beam scanning patterns as is known in the prior art. FIG. 11b is similar to that in U.S. Pat. No. 4,933,538, wherein t 2 is a later time than t 1 . FIGS. 11c, 11d and 11e are schematic representations of laser beam pulsing patterns according to the present invention. In the preferred embodiment, FIG. 11c, the laser should be turned on in the middle of the scan time so the scanner user will see a short scan line that occurs every scan, instead of a long line every fourth scan. The short line will not appear to blink because thirty-six scans a second is above the frequency at which the human eye can perceive the flickering of a light. Flickering is quite visible with existing bar code readers that blink only nine times per second.
Some care should be taken to assure that the laser is turned on in the center of the scan in both scanning directions. If the blinking is controlled by a microprocessor, preferably the same one that is used for decoding, this is easily accomplished, as follows.
If a scan motor such as described in U.S. Pat. Nos. 5,212,627 and 5,367,151 that runs at its own natural frequency is used, the blinking must be synchronized to the motor because the motor frequency varies a little bit from one motor to another. These patents are hereby incorporated by reference to illustrate a preferred scan motor design for use with the present invention. This can be done using the start of scan (S.O.S.) signal that is provided by the motor drive circuitry. The S.O.S. signal is derived from a feedback signal generated by the motor, so it is always synchronized with the motor. The S.O.S. signal is high when the motor is traveling in one direction and low when it is traveling in the other. High to Low or Low to High transitions occur when the motor changes direction at the end of each scan. The laser turn-on can be controlled as set forth in the timing diagram of FIGS. 12a, 12b, and 12c. FIG. 12a is the timing diagram of the embodiment of a laser beam pulsing pattern corresponding to FIG. 11c; and FIGS. 12b and 12c are timing diagrams of alternative embodiments of the laser beam pulsing pattern. There are two types of timing errors that occur with the start of scan signal that should be taken into account when the S.O.S. signals are used to synchronize the laser blinking with the motor. The start of scan is not always symmetrical. Sometimes, for example, a motor might take twenty-seven milliseconds to scan left to right and twenty-eight milliseconds to scan right to left. In addition, the S.O.S. transitions typically do not correspond exactly with the time that the motor reverses direction. The S.O.S. transitions are typically delayed by about one or two milliseconds, depending on the sensing circuitry used.
These variations can be corrected for by the microprocessor that controls the blinking as follows. When power is first applied to the scanner software in the decoder will measure the scan time in each direction using the start of scan signal. For each direction, the decoder then calculates the value equal to three eighths of the measured scan time. The software routine then subtracts from this value the number of milliseconds by which the start of scan signal lags behind the actual turn around moment of the motor (typically 1-2 milliseconds). The signal lag number must be determined from both the design of the particular type of motor and drive circuit being used. The signal lag will be approximately the same for all units of a given design.
When a start of scan transition occurs, the decoder waits the amount of time calculated above for the particular scan direction that is beginning. It then enables or turns on the laser for 25% of the measured scan time. This process is repeated every time the start of scan signal transitions, indicating the start of a new scan. Additional corrections for such things as slow response of the laser control circuitry can be made as necessary.
When all of the above is properly implemented, a scan line that is shorter than the full scan line will be visible that is centered with respect to the full scan line. This short line will be illuminated in both left to right and right to left scans. Although the laser is on for only 25% of the scan time, the visible scan line will be longer than 25% of the total scan line because the beam moves fastest in the center of the field. Experiments show that, in a typical scanning system with a resonant motor, the short scan line will be about 33% as wide as the full scan line, even though the laser is only on 25% of the time.
As described above, the present invention provides an optical scanner for reading bar code symbols on a target at a distance from the unit, including scanning means for generating a laser beam directed toward a target producing a pulsed relatively short image line on the target plane during a first time period and a substantially continuous wide angled laser beam that sweeps an entire symbol during a second time period for reading the symbol, and detection means for receiving reflected light from such symbol to produce electrical signals corresponding to data represented by such symbol. The first and second time periods cyclically repeat during normal operational use.
This system is used to sense symbols as follows. When power is applied to the scanner it begins blinking the laser as described above. The user aims the visible shortened scan line at the symbol to be scanned, or if the scanner is stand mounted, positions the symbol under the visible shortened scan line.
When the scan line crosses a symbol or part of a symbol, the scanner can try to decode the symbol. If it fails, the laser can be turned on for the full scan time for the next few seconds or until a decode has occurred, at which time the short scan line returns. Multiple decodes of the same symbol can be prevented by programming the decoder not to decode the same symbol again until it is out of view for a while (typically 0.5 to 1 second).
This self triggering means has the following advantages. It does not appear to flicker because it blinks above the flicker perception frequency. It reduces the possibility of accidental triggering because it will only sense an object that looks like a bar code and only when it is centered in the scan field. It adds nothing to the circuit complexity and provides easier aiming than an invisible Infra-Red Sensor. It is usable for hand-held, fixed mounted or wearable scanners. It is faster responding than blinking the laser one out of four scans because it can sense a symbol every scan, as opposed to every fourth scan.
Additional refinements can be used to further reduce power consumption. If necessary, the laser can be turned on for 25% of a scan time every other scan or even every third or fourth scan. This may result in visible flicker, but it might be acceptable in battery powered applications. In addition, the laser can be modulated at a high frequency during the sensing period. This can reduce its power consumption by half during its "On" Time.
With these measures, the scanner (excluding decoder) can operate in its sensing mode at an average current of less than ten ma. This assumes that one of the commercially available visible laser diodes that operate at around thirty ma is used. If it is blinked on for 25% of every fourth scan its average current draw will be 1.875 ma. If it is modulated at 50% duty cycle during its "On" Time, its average is 0.937 ma. Resonant motors we make today operate at 0.5 ma. With care analog circuitry including amplifiers, digitizer, motor control, and laser regulator have been built that use less than 8 ma for a total of 9.43 ma (all at 3 to 5 volts).
Sometimes it is desirable to have a triggerless scanner that has no on-board decoder. Ideally, it should be compatible with existing decoders that are made for hand-held scanners. Presently, a decoder has software that controls the laser blinking if this is to be done. This makes it impossible to connect triggerless or to use Intellistands with decoders. This problem can be avoided if an inexpensive microprocessor is used to control laser blinking and symbol sensing in a decoderless scanner.
There are small microprocessors available that can perform the blinking control as described above. The same microprocessor that blinks the laser can monitor the output of the digitizer during the time the laser is blinked on. If it detects a sufficient number of elements being digitized to indicate that a symbol might be present, it can generate a simulated trigger pull signal that will
With these measures, the scanner (excluding decoder) can operate in its sensing mode at an average current of less than ten ma. This assumes that one of the commercially available visible laser diodes that operate at around thirty ma is used. If it is blinked on for 25% of every fourth scan its average current draw will be 1.875 ma. If it is modulated at 50% duty cycle during its "On" Time, its average is 0.937 ma. Resonant motors we make today operate at 0.5 ma. With care analog circuitry including amplifiers, digitizer, motor control, and laser regulator have been built that use less than 8 ma for a total of 9.43 ma (all at 3 to 5 volts).
Sometimes it is desirable to have a triggerless scanner that has no on-board decoder. Ideally, it should be compatible with existing decoders that are made for hand-held scanners. Presently, a decoder has software that controls the laser blinking if this is to be done. This makes it impossible to connect triggerless or to use Intellistands with decoders. This problem can be avoided if an inexpensive microprocessor is used to control laser blinking and symbol sensing in a decoderless scanner.
There are small microprocessors available that can perform the blinking control as described above. The same microprocessor that blinks the laser can monitor the output of the digitizer during the time the laser is blinked on. If it detects a sufficient number of elements being digitized to indicate that a symbol might be present, it can generate a simulated trigger pull signal that will signal the remote decoder that a symbol is present, just as if someone pulled a trigger. When the symbol is removed, the "trigger" will be automatically released.
The example of a 25% is used as an appropriate blink duty cycle. Higher duty cycles can of course be used if long lived lasers are used or lifetime requirements are modest. Scanners that never operate in hot environments can also operate at higher duty cycles. Lower duty cycles can be used to reduce power consumption or if the scanner is to operate in a hot environment.
The duty cycle can be user selectable by programming the reader, or by scanning special bar codes. This makes it easy to match the scanner to the environment.
Although the present invention has been described with respect to reading bar codes, including stacked, or two dimensional bar codes such as Code 49, PDF 417 and similar symbologies, it is conceivable that the method of the present invention may also find application for use with various machine vision or optical character recognition applications in which information is derived from other types of indicia such as characters or from the surface characteristics of the article being scanned.
In all of the various embodiments, the elements of the scanner may be assembled into a very compact package that allows the entire scanner to be fabricated as a single printed circuit board or integral module. Such a module can interchangeably be used as the laser scanning element for a variety of different types of data acquisition systems. For example, the module may be alternately used in a ring, hand-held or body-mounted scanner, a table top scanner attached to a flexible arm or mounting extending over the surface of the table or attached to the underside of the table top, or mounted as a subcomponent or subassembly of a more sophisticated data acquisition system. Control or data lines associated with such components may be connected to an electrical connector mounted on the edge or external surface of the module to enable the module to be electrically connected to a mating connector associated with other elements of data acquisition system.
An individual module may have specific scanning or decoding characteristics associated with it, e.g. operability at a certain working distance, or operability with a specific symbology or printing density. The characteristics may also be defined through software or by the manual setting of control switches associated with the module. The user may also adapt the data acquisition system to scan different types of articles or the system may be adapted for different applications by interchanging modules on the data acquisition system through the use of a simple electrical connector.
The scanning module described above may also be implemented within a self-contained data acquisition system including one or more such components as keyboard, display, printer, data storage, application software, and data bases. Such a system may also include a communications interface to permit the data acquisition system to communicate with other components of a local area network or with the telephone exchange network, either through a modem or an ISDN interface, or by low power radio broadcast from the portable terminal to a portable or stationary receiver or base station.
In the FIG. 13 system, a pen computer has a pen module 302 which includes a scanning unit 312 for generating a light beam which scans the targeted symbol 306 by physically moving the pen 302 across the target symbol 306. The scanning unit 312 also includes a photodetector 310 which detects the reflection of light from the symbol and generates an electrical signal representing the scanned symbol 306. The electrical signal is transformed into a radio frequency, infrared, acoustic or other modulated wireless communication signal and transmitted by transmitter 312 to a computer module receiver 314. The received signal may be processed and/or stored in a computer module 300. The module 300 may also include a touch screen display 308 for inputting data to the system and/or displaying the data representing the symbol.
It will be understood that each of the features described above, or two or more together, may find a useful application in other types of scanners and bar code readers differing from the types described above.
While the invention has been illustrated and described as embodied in it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptions should and are intended to be comprehended within the meaning and range of equivalence of the following claims. | A housing, held or worn by a user, contains a light emitter for emitting a light beam that is manually moved by the user relative to a target in a pointing mode of operation. An actuator is operative for actuating a scanning element to automatically move the light beam relative to the target in a scanning mode of operation. The actuator may be a switch or proximity sensor to switch between the modes. | 6 |
CROSS-REFERENCE TO A RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional application Ser. No. 61/122,063, filed Dec. 12, 2008, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a dry powder fibrin sealant.
BACKGROUND OF THE INVENTION
[0003] WO97/44015 describes a dry powder fibrin sealant based on micro-particles of fibrinogen and thrombin. This has been demonstrated to be an easy-to-use, stable and efficacious topical haemostat. The product can be used immediately, without reconstitution. On contact with aqueous fluid such as blood, the exposed active thrombin immediately converts the exposed fibrinogen into insoluble fibrin polymers.
SUMMARY OF THE INVENTION
[0004] The novel fibrin sealant is a blend of spray-dried fibrinogen and thrombin, each of which has been individually co-spray dried with an excipient. A number of excipients have been used in the fibrin sealant formulation to stabilise the active ingredients fibrinogen and thrombin and the physical stability evaluated. In addition, the fibrin sealant formulation has been exposed to electron beam/gamma irradiation or heat sterilisation in order to terminally sterilize the product. The results of the evaluation indicate that trehalose is the most effective excipient in terms of protein protection during stability storage and electron beam exposure. The superior stabilization afforded by the trehalose-based formulations may be attributed to the higher glass transition temperature of trehalose compared to other excipients such as sucrose.
[0005] The influence of different parameters on the efficacy of the product was determined in pig liver biopsy models and pig liver resection models. The efficacy of the fibrin sealant powder to stop severely bleeding injuries, with blood loss of >10 ml/min, was enhanced by the opportunity to apply pressure directly after administration of the product. Fibrin sealant powders with a fibrinogen content of at least 4% w/w and a thrombin content of at least 139 IU/g were shown to be effective in stopping severe bleeding. The optimum fibrinogen and thrombin content was ˜7.5% w/w and ˜400 IU/g, respectively. Fibrinogen and thrombin from 3 different suppliers all performed equally well, demonstrating the robustness of the product. Terminal sterilization of the product using electron beam or gamma irradiation of up to 15 or 25 kGy had no effect on the efficacy of the product and is considered to reduce the risk of bacterial contamination before use. In summary, the invention provides a fibrin sealant product that demonstrates high efficacy at low fibrinogen levels in severely bleeding wounds and can be terminally sterilized using standard irradiation methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a plot of the particle size distribution of spray-dried thrombin:trehalose according to the invention.
[0007] FIG. 2 is a plot of the particle size distribution of spray-dried fibrinogen:trehalose according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0008] Respective fibrinogen-containing and thrombin-containing soluble microparticles can be formulated together, in stable, dry form. This formulation can be subsequently activated, as desired, to give a fibrin sealant that is useful in wound therapy and surgical repair. It can meet the primary objectives of achieving good flow properties, enhanced, effective delivery to the active site, and dissolution only at the site, not in the delivery system.
[0009] The content of fibrinogen in the microparticles containing it may be about 0.1 to 50% w/w, preferably about 0.5 to 20 w/w. The content of thrombin in the microparticles containing it may be about 10 to 20,000 IU/g, preferably about 25 to 1,000 IU/g.
[0010] Microparticles comprising fibrinogen or thrombin may be prepared by the procedures described in WO92/18164, WO96/09814 and WO96/18388. These spray-drying and associated particle manipulation processes enable the production of soluble protein microcapsules with defined size distribution, e.g. of up to 50 μm in diameter. For example, as described in those documents, the microparticles may be produced reproducibly, e.g. with 90% or more (by volume) up to 30 μm, e.g. 10 to 20 μm, in size.
[0011] Microparticles of the invention are preferably prepared by spray-drying. Typically, a 2-fluid nozzle is used which utilises compressed air during the atomisation process; this results in the production of hollow microparticles. The maximum particle size (X50) of microparticles that can be manufactured using this atomisation system on the Niro Mobile Minor spray dryer is ˜30 μm. Preferred X50 values for the micoparticles of the invention are between 5 and 50 microns, most preferably between 10 and 20 microns.
[0012] Microparticles of the invention may be prepared by spray-drying a solution of the active component with trehalose alone. An alternative procedure comprises co-spray-drying, in which fibrinogen or thrombin and another wall-forming material are formulated and spray-dried, to give microparticles in which the active component is incorporated in the wall of the particle. The product is preferably amorphous or in the form of a glass, as measured by a suitable technique such as FTIR or DSC., with a glass transition temperature of at least 50 Celsius, most preferably at least 80 Celsius.
[0013] The fibrinogen or thrombin may be full-length or any active fragment thereof. Fragments are known; see Caller et al, J. Clin. Invest. 89:546-555 (1992). Fibrinogen raw material may be a frozen solution, although, lyophilised powder which requires reconstitution prior to spray-drying may be used.
[0014] Suitable other proteins may be naturally occurring or recombinant. They may act as “wall-forming materials”, as described in WO92/18164, where various examples are given. A preferred material is HSA (human serum albumin). For example, fibrinogen is spray-dried alone or in the presence of varying amounts of excipients such as HSA (e.g. fibrinogen: HSA ratios of 1:1, 1:3, 3:1) and trehalose. Other suitable substitutes for HSA include surfactants, such as Tween 20, Tween 80, Poloxamer 407 or Poloxamer 188.
[0015] Calcium ion, e.g. as calcium chloride, may be incorporated in the thrombin feedstock. Alternatively, calcium chloride may be added to the microcapsules after processing.
[0016] Microparticles of the invention may be sterilised, if necessary or desired. Sterile processing, electron beam irradiation, y-irradiation and ethylene oxide are examples of suitable techniques.
[0017] Although the components of the microcapsules in a fibrin sealant of the invention are preferably water-soluble, and the microparticles are preferably obtained by spray-drying a suitable solution, the microparticles that are obtainable may be free-flowing, discrete and substantially anhydrous, with a residual moisture content preferably no greater than 5% w/w, most preferably no greater than 3% w/w. This means that the compounds of fibrin sealant in accordance with this invention are not activated until they are wetted, e.g. by coming into contact with liquid at a wound site. The active components may therefore be delivered as a dry mixture, although separate application of the different microparticles is also envisaged.
[0018] A dry powder fibrin sealant product may be of particular value where application to a large surface area is required. This includes surgery and repair of traumatic injuries to various organs such as the liver and spleen. A further advantageous application is in skin grafting for burns patients, and specifically where skin epidermal sheets are cultured in vitro and then transferred to the wound site. The use of fibrin sealant in the latter indication may be particularly effective in patients with extensive burns, providing a biocompatible anchorage for skin grafts. It may also be suitable in the treatment of topical ulcers.
[0019] The following Examples illustrate the invention.
Example 1
[0020] Spray-dried fibrinogen microparticles were prepared by dissolving 73.8 g human fibrinogen in 1650 mL water containing 275.1 g trehalose dihydrate. The resultant solution was spray-dried on a Niro Mobile Minor spray dryer using the following operating parameters:
[0000]
Inlet temperature:
160° C.
Atomisation type:
2 - Fluid Nozzle
Liquid insert:
0.5 mm
Atomisation pressure:
0.5 bar
Feed rate:
18 g/minute
[0021] The spray-dried powder had a particle size (X50, geometric diameter) of 18.4 μm and a fibrinogen content of 152 mg/g. The moisture content (Karl-Fischer) was 2%.
[0022] Spray-dried thrombin microparticles were prepared by dissolving 751,230 IU human thrombin in 1653 mL water containing 11.5 g calcium chloride dihydrate and 507.3 g trehalose dihydrate. The resultant solution was spray-dried on a Niro Mobile Minor spray dryer using the following operating parameters:
[0000]
Inlet temperature:
160° C.
Atomisation type:
2 - Fluid Nozzle
Liquid insert:
0.5 mm
Atomisation pressure:
0.5 bar
Feed rate:
18 g/minute
[0023] The spray-dried powder had a particle size (X50, geometric diameter) of 12.5 μm and a thrombin content of 977 IU/g. The moisture content (Karl-Fischer) was 3%.
[0024] The two spray-dried powders were blended in a 1:1% w/w ratio using a drum mixer at 18 rpm for 15 minutes. The resultant blend had a particle size of 15.5 μm, and a fibrinogen content of 69.1 mg/g.
[0025] The respective particle size distributions are shown in FIGS. 1 and 2 .
[0000] FIG. 1 shows the cumulative distribution as follows:
[0000]
x 0 /μm
Q 3 /%
1.80
6.71
2.20
8.45
2.60
10.02
3.00
11.48
3.60
13.58
4.40
16.36
5.20
19.25
6.20
23.15
7.40
28.33
8.60
33.97
10.00
40.87
12.00
50.65
15.00
64.07
18.00
75.17
21.00
83.61
25.00
91.27
30.00
96.53
36.00
99.11
42.00
99.85
50.00
100.00
60.00
100.00
72.00
100.00
86.00
100.00
102.00
100.00
122.00
100.00
146.00
100.00
174.00
100.00
206.00
100.00
246.00
100.00
294.00
100.00
350.00
100.00
[0000]
Evaluation:
WINDOX 5.1.2.0, HRLD
Product: Fibrocaps
Revalidation:
Density: 1.00 g/cm 3 , shape factor: 1.00
Reference measurement:
Disp. Meth: Set up for Fibrocaps R/M
08-20 11:42:05
C opt = 1.56%
Contamination: 0.00%
[0000] Trigger condition: Fibrocaps User parameters: Time base: 200.00 ms Batch Number: PV Thrombin Start: c.opt >= 0.2% Formulation: EM/08/126 Valid: always Name: aks Stop: 2.000 s c.opt <= 0.2% or Run Number: Run 1 10000 s real time FIG. 2 shows the cumulative distribution as follows:
[0000]
x 0 /μm
Q 3 /%
1.80
2.68
2.20
3.58
2.60
4.53
3.00
5.52
3.60
7.06
4.40
9.19
5.20
11.39
6.20
14.20
7.40
17.63
8.60
21.10
10.00
25.15
12.00
30.88
15.00
39.17
18.00
46.85
21.00
53.70
25.00
61.53
30.00
69.48
36.00
76.91
42.00
82.47
50.00
87.80
60.00
92.11
72.00
95.07
86.00
96.87
102.00
97.94
122.00
98.72
146.00
99.34
174.00
99.81
206.00
100.00
246.00
100.00
294.00
100.00
350.00
100.00
[0000]
Evaluation:
WINDOX 5.1.2.0, HRLD
Product: Fibrocaps
Revalidation:
Density: 1.00 g/cm 3 , shape factor: 1.00
Reference measurement:
Disp. Meth: Set up for Fibrocaps R/M
08-29 13:35:41
C opt = 7.30%
Contamination: 0.00%
[0000]
Trigger condition: Fibrocaps
User parameters:
Time base: 200.00 ms
P1: SD Fibrinogen: trehalose clinical
Start: c.opt >= 0.2%
P2: EM/08/129
Valid: always
P3: TR
Stop: 2.000 s c.opt <= 0.2% or
P4: run 1
10000 s real time
Example 2
[0026] Four batches of microparticles were produced, using the following formulations and a Mini spray dryer,
200 mg/ml trehalose-200 units/ml thrombin 200 mg/ml sucrose-200 units/ml thrombin-1% HSA w-v 200 mg/ml trehalose-40 mg/fibrinogen 200 mg/ml sucrose-40 mg/ml fibrinogen.
[0031] The spray-drying parameters were selected so as to produce particles in the region of 10 μm.
Thrombin Formulation:
[0032]
[0000]
Inlet temperature:
130° C.
Outlet temperature:
−80° C.
Atomisation Airflow:
5/-min
Drying Airflow:
5/-sec
Feed Rate:
5.0 g-min
Fibrinogen Formulation:
[0033]
[0000]
Inlet temperature:
130° C.
Outlet temperature:
−83° C.
Atomisation Airflow:
15/-min
Drying Airflow:
5/-sec
Feed Rate:
3.0 g-min
[0034] Each of the microcapsules batches was aliquoted into clear 10 ml glass vials both as separate components and as excipient-matched blends. A stability study at 4° C. was conducted over four weeks. Four timepoints were selected; initial, 1 week, 2 weeks and 4 weeks, and the following assays were employed to compare the effect of the different excipients on the stability and bioactivity retention.
[0035] Fibrinogen Analysis used a polyconal antibody to human fibrinogen as a capture antibody and a second peroxidise-labelled antibody to human fibrinogen is used for detection in a chromogenic assay.
[0036] Thrombin Analysis was based on a commercial substrate which is sensitive to thrombin and gives a colour change which can be measured. The initial rate of change in absorbance is proportional to thrombin concentration.
[0037] Particle Size was measured using a LS230 Laser Sizer in conjunction with Medium Chain Trigylceride oil to determine the particle size of the spray dried material.
[0038] Thermogravimetric Analysis was carried out to assess moisture content.
[0039] Flow time was the time taken for a microcapsule blend to pass through a funnel of a pre-determined size was used as a comparative measure of flowability between batches.
[0040] Angle of Repose indicates the flowability of a powder and was measured by the calculation of the angle created upon the flow of a powder through a funnel and subsequent accumulation on a flat surface.
[0041] Packed and tap density were measured using the Jolting Volume Meter and the values used in Carrs Compressibility Index (% CCI).
[0042] Clot Strength utilises the formulation of a clot from a blend in a plastic syringe. A bead is suspended in the syringe prior to clot formation and the weight required to pull the bead through the clot is recorded.
[0043] Adhesive Strength: blends are applied to a piece of rat skin via a 10 ml glass pipette fitted with a compressed air supply. The weight required to separate two pieces of the tissue bonded together by a blend is used as a measurement of adhesive strength. (This assay is based on a Gottlob skin test method-Gesting and Lerner: Autologous fibrinogen for tissue adhesion haemostatis (1983)).
[0044] Additional assays were performed at the four week timepoint; SDS PAGE to assess the effects of spray-drying on the structural integrity of the bioactives and a BCA assay for total protein determination. Scanning electron micrographs (SEM) were also obtained for each of the individual formulations.
[0045] Results demonstrated no significant changes over the stability period for either formulation, but the data do suggest a greater retention of activity generated for the trehalose formulation when compared with the sucrose formulation. The clot strength values also indicate an increased activity retention with the trehalose formulation. The addition of HSA to the trehalose-thrombin formulation showed no significant differences in bioactivity retention compared to the trehalose-thrombin formulation. The flow properties were retained over the stability period which is reflected in the consistent adhesive strength values.
[0046] SDS PAGE data demonstrated the retention of structural integrity post-spray-drying.
[0047] Scanning electron micrographs revealed similar morphology for all formulations.
[0048] Dry heat viral inactivation step was conducted for 72 hours at 80° C.
[0049] The individual fibrinogen and thrombin components were assessed using ELISA and chromogenic assays respectively and the blends were analysed using the clot strength assay. The results are documented in Table 1.
[0000] TABLE 1 Dry Heat Sterilisation Bioactivity - Clot Concentration per 100 mg Strength Sample spray-dried Product (g) Trehalose - Thrombin 101.6 units (97%) * microcapsules Trehalose - Fibrinogen 14.17 mg (103%) * microcapsules Trehalose - Active blend * 64.8 g Sucrose - Thrombin 93.8 units (89%) * microcapsules Sucrose - Fibrinogen 11.04 mg (80.5) * microcapsules Sucrose - Active blend * 62.7 g
Theoretical thrombin concentration=105 units-100 mg spray-dried product
Theoretical fibrinogen concentration=13.7 mg-100 mg spray-dried product
% Retention is shown in brackets
Expected clot strength=˜70 g
[0050] The bioanalytical results indicate the excipient trehalose allows a greater retention of the active during the dry heat step.
[0051] Gamma-irradiation employed 25 KG at a rate of 8 KG-hour. Samples were exposed to these irradiation conditions both as separate components and as a blend.
[0052] The components were assessed using ELISA and chromogenic assays respectively and the blends examined via the clot strength assay. The results are documented in Table 2.
[0000] TABLE 2 Gamma Irradiation Sterilisation Bioactivity - Clot Concentration per 100 mg Strength Sample spray-dried Product (g) Trehalose - Thrombin 71 units (71%) * microcapsules Trehalose - Fibrinogen 10.3 mg (73%) * microcapsules Trehalose - Active blend * 59.5 g Sucrose - Thrombin 71 units (71%) microcapsules Sucrose - Fibrinogen 7.7 mg (55.5 * microcapsules Sucrose - Active blend * 36.9 g
% Retention is shown in brackets.
[0053] The conditions investigated in the terminal sterilisation study (72 hours at 80° C.) suggest that trehalose offers a higher level of protection to the protein, as reflected by the activity retention. This observation may also suggest a trehalose formulation may be capable of room temperature storage. Gamma irradiation of the sucrose formulation resulted in a 50% drop in fibrinogen activity. The trehalose formulation was found to have a significantly higher fibrinogen activity retention (70%) as measured by the ELISA and clot strength assays. | The invention provides a composition comprising a mixture of first microparticles that comprise fibrinogen and trehalose, and second microparticles that comprise thrombin and trehalose. The invention further provides methods for treating wounds by administering the novel microparticle composition. | 0 |
BACKGROUND OF THE INVENTION
Complex electronic, electro-mechanical, and mechanical devices are generally tested using automated test systems. The tests may include validation tests which run through the various operations of a device under test (DUT) and records whether each operation was performed properly. The tests may also include environmental tests which expose the DUT to various combinations of temperature, pressure, and humidity. The results of operations are recorded as the environment changes. Other tests, such as production tests, may be completed. Generally, both the DUT and the systems providing the environmental and other constraints on the DUT are controlled electronically. In the last decade or so, computerized programs which are capable of controlling a variety of automated tests, referred to in the art as “test executive” programs, have been developed.
Test executive programs in the prior art include internal test executive programs developed by Agilent Technologies and TESTSTAND software developed by National Instruments Corporation, which is described as a ready-to-run test executive program for organizing, controlling and executing automated prototype, validation, or production test systems. The prior art Agilent Technologies test systems were DOS-based systems that do not use a graphical user interface (GUI), which limited the ability of the program to interact with other programs. The TESTSTAND software, while using a GUI, also is essentially a stand-alone program that does not interact with other separate systems.
Tests usually are defined by a set of rules or specifications to which the DUT is compared. The rules and specifications generally comprise various inputs defined by electrical and mechanical parameters applied to the DUT, such as voltage, current, specified manipulations of controls and device parts, as well as environmental parameters under which the test is conducted, such as temperature, humidity, pressure, and the time period over which a parameter is applied. Each test will include many combinations of the parameters applied to each element of the DUT, and often will be repeated many times. Each combination of parameters will define a measurement that results in one or more datapoints, which are recorded and compared to numerical or Boolean limits defining the specifications. Thus, as devices become more complex, electronic test programs have become very long and complex, often requiring several days, or even a week or more to complete a test.
The DUTs are often tested by or used in conjunction with other electronic instruments. For example, manufacturing process controllers and environmental test profile controllers are often used to perform tests on a DUT. These electronic instruments perform other functions as well as testing and thus are not fully replaceable by a test executive system. In prior art test executive systems, it was necessary to reconfigure the interface between such systems and the DUT each time it was desired to test the DUT. After the test, the original configuration had to be restored. Tests could be performed much quicker and more effectively if such reconfigurations were eliminated. Moreover, it would be useful if those used to operating such other systems did not have to adjust to or learn an entirely new system when it was necessary to test the DUT.
SUMMARY OF THE INVENTION
The above and other problems are solved and an advance in the art is made by an externally controllable electronic test program in accordance with this invention. The electronic test program of this invention provides an interface that communicates with an external system, such as separate software programs. The interface allows the external system to control the executive test program through the interface.
The present invention comprises both a computer apparatus and software product and methods executed by a processing unit. One skilled in the art will recognize that the instructions for the processes or methods of this invention may be stored in a memory as software instructions, may be fixed hardware, or stored as firmware.
The invention provides an electronic test system for testing a device under test (DUT) that is separate and distinct from the electronic test system, the test system comprising: a memory for storing an electronic test and an interface for communicating with an external system distinct from the test system and separate and distinct from the DUT and operating said test system with the external system; a display for displaying a graphical user interface (GUI) for operating the electronic test system and the results of the test; an electronic processor communicating with the memory for executing the test and with the display for displaying the results; and an input device for operating the GUI. Preferably, the interface comprises a software object. Preferably, the interface comprises an ActiveX COM interface. Preferably, the external system is a computer remote from the memory and processor. Alternatively, the external system is a software program stored in the memory, such as a software database system. Preferably, the GUI includes a drop-down menu for selecting one of a plurality of the interfaces. Preferably, the GUI comprises a GUI associated with the external system.
The invention also provides a product that provides a test executive program for controlling tests on a device under test (DUT) separate and distinct from the test executive system, the product comprising: instructions for directing a processing unit to: perform an electronic test on the DUT; provide interface software for communicating with an external system that is distinct from the test executive program; communicate with the external system and operate said test system responsive to the communication; and a media readable by the processing unit that stores the instructions. Preferably, the instructions further comprise: instructions for directing the processing unit to: display a list of different software interfaces for communicating with an external system that is distinct from the test executive program; receive a selection of one of the different software interfaces on the list; and load the selected interface into a memory. Preferably, the instructions further comprise instructions for directing the processing unit to execute the selected one of the plurality of interfaces. Preferably, the instructions further comprise instructions for directing the processing unit to remove the selected interface from the memory. Preferably, the instructions comprise an ActiveX COM interface.
The invention further provides a method of operating an electronic test system for testing a device under test (DUT) that is separate and distinct from the electronic test system, the method comprising: storing an electronic test and a software interface for communicating with an external system distinct from the test system and separate and distinct from the DUT and for operating said test system in response to said communication; displaying a graphical user interface (GUI) for operating the electronic test system; executing the test to produce test results; storing the test results; executing the software interface; receiving a communication from the external system; and, responsive to the communication, operating the test system. Preferably, the external system comprises an external software program and the act of receiving comprises executing the software program. Preferably, the act of displaying comprises displaying a GUI associated with the external software program. Preferably, the act of executing comprises executing a software object. Preferably, the act of storing comprises: displaying a list of a plurality of different software interfaces; receiving a selection of one of the plurality of software interfaces; and loading the selected software interface into a memory.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of this invention are described in the Detailed Description below and the following drawings:
FIG. 1 illustrates a block diagram of hardware components that execute an electronic test program in accordance with this invention;
FIG. 2 illustrates a block diagram showing a hierarchical structure of a test executive program in accordance with this invention;
FIG. 3 illustrates a view of a graphical user interface (GUI) of an electronic executive test program;
FIG. 4 illustrates a view of a GUI having menus for plug-in selection in accordance with a preferred embodiment of this invention;
FIG. 5 illustrates a flow diagram for an application that provides plug-in selection in accordance with the preferred embodiment of this invention;
FIG. 6 illustrates a flow diagram for an application for adding a plug-in to the plug-ins available in accordance with a preferred embodiment of this invention;
FIG. 7 illustrates a flow diagram of an application for removing a plug-in from the available plug-ins in accordance with a preferred embodiment of this invention; and
FIG. 8 illustrates a block diagram of software components of a test executive program in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to an electronic test executive program. FIG. 1 illustrates an electronic test system 100 that executes a test executive program in accordance with this invention. In the preferred embodiment, the test system comprises a computer system 100 that includes memory 101 , microprocessor 102 , input device 104 , output device 106 , and software including interface 140 . Memory 101 connects to microprocessor 102 via path 110 . Memory 101 may comprise a hard drive, a tape drive, a non-volatile memory such as a Read Only Memory (ROM) or a volatile memory such as a Random Access Memory (RAM) or other conventional memories or combinations of the above. Input device 104 connects to microprocessor 102 via path 112 . Input device 104 may be a keyboard, mouse, joystick, or any other device and software driver that allows a user to input data. Interface 140 is a key element of the invention, and will be described in more detail below. Interface 140 communicates with microprocessor 102 via path 138 and with systems 141 , 142 and 145 that are external to electronic test system 100 . Interface 140 preferably comprises software resident in a RAM portion of memory 101 when it is active. Here, “external” means outside the test executive system 800 ( FIG. 8 ). It does not necessarily mean in a separate computer, but may be a distinct software system residing in computer 100 , which software is separate and distinct from the software of test executive system 800 . External systems 141 and 143 may be hardware systems, software systems, or combinations thereof. Typically, external systems 141 and 143 are software programs, such as Microsoft Excel™. External Controller 145 may be a remote computer system, a manufacturing process controller, or other such system. Interface 140 communicates with external system 141 via path 142 , external system 143 via path 144 , and external controller 145 via path 146 .
In this disclosure, “separate” means located in a separate physical housing, and “distinct” means independently operable.
In a preferred embodiment, the test executive program of this invention is stored as instructions in memory 101 . Those skilled in the art will recognize that the instructions may either be stored as computer software and/or firmware that is readable and executable by microprocessor 102 . The results for a test performed by the test executive program are displayed on output device 106 . Output device 106 is a display and associated drivers that allow an application to display images to a user. Those skilled in the art will recognize that the display may be a conventional cathode ray monitor or Liquid Crystal Display (LCD). The actual display used does not matter for purposes of this invention.
Microprocessor 102 executes the test executive program of this invention. Microprocessor 102 communicates with a Device Under Test (DUT) 108 via path 116 . Processor 102 controls test equipment 117 via electrical line 118 . Signals received via paths 116 and 118 by microprocessor 102 may be saved in memory 101 .
One skilled in the art will recognize that this invention may be implemented by any electronic device having the same general configuration outline as in FIG. 1 . These electronic devices include, but are not limited to, a computer system, logic circuits embedded in hardware, and an electronic analyzer.
Sometimes the test system must work with other electronic devices. For example, the test executive program of this invention is often used with manufacturing process controllers, and environmental test profile controllers. Since the electronic test executive program is often only one of many functions that such an electronic instrument controls, the electronic test executive program according to the invention has an interface that allows another electronic system to control the test executive program.
FIG. 8 illustrates a block diagram of a test executive program 800 that provides an interface to other electronic systems in accordance with this invention. In test executive program 800 , test software 810 includes executable tests 812 and test systems control software 815 . Test software 810 is all of the instructions needed for test executive program 800 to operate. They include tests, test procedures, and test system drivers. In other words, test software 810 is the code components that a test developer provides to test a specific product. There will generally be a number of different test software systems in a complete test system, as indicated by the stack 811 . Each test software system 811 represents a software system for testing a different product or set of products. Tests 812 are the instruction for performing the individual tests. The heart of the test executive system are interfaces 817 which are preferably COM interfaces to the test software 810 and the external controls. Interface 817 includes instructions for applications that allow test software 810 to receive commands from other systems. Plug-ins 831 - 833 are instructions for interfacing with other systems 141 , 143 , and 149 , such as a database or an equipment calibration verification system. Each system 141 , 143 , 149 that test executive program 800 interfaces with has an associated plug-in 831 - 833 . Interface 820 also has generalized interface instructions 820 for allowing another system to control test executive program 800 . As discussed below, preferably, interface instructions 820 include an ActiveX COM 825 interface for allowing direct control. ActiveX COM interfaces are well-known in the art, and will not be discussed in detail herein. Any external program or system 145 that can communicate via an ActiveX COM interface can control the test executive system 800 .
To better understand this invention, a hierarchical structure of a test executive program is described in FIG. 2 . Block diagram 200 illustrates a hierarchical, multi-level structure of a test executive program.
First level 201 corresponds to a product model which is a file that a test developer creates to test a family of specific device model numbers. This file contains test procedures and inputs. Second level 202 is a group of procedures. A procedure is an ordered list, sequence, or script of tests to be run on a device. Several procedures may exist, which is represented in FIG. 2 by the stack of procedures 202 . The next level is a test level 203 that includes tests 1−N to be run in each procedure 202 . Each test 205 in turn includes a plurality of measurements 207 to be taken during a test 203 . For example, test 205 includes measurements 206 . Each measurement 1−N includes one or more datapoints 214 . For example, measurement 206 includes data points 210 - 212 .
Each procedure 202 is defined by a written program or a code used to build a structure of software objects. In one embodiment, the software objects are component object models, or COM, objects. COM is a language independent component architecture, not a programming language. COM is meant to be a general purpose, object-oriented structure to encapsulate commonly used functions and services.
COM and other object-oriented programming structures are well-known in the art. The exemplary software according to the invention was written in the Visual Basic™ programming language, but other programming languages may also be used. To connect with this body of art, we shall define various terms used herein within the context of that art. The term “test software” herein means the code components provided by a test developer to test a specific product. The term “manufacturing system” means the electronic test system manufacturing processes. The term “graphical user interface” means an input device that allows the user to manipulate and execute the invention by pointing and clicking on icons displayed on the invention. The term “input device” means a keyboard, knobs, spin controls, mouses, joy sticks, touch pads, roller balls, or other conventional input devices. The term “string” means a data structure composed of characters, usually in human-readable text.
The term “component object model (COM)” means component architecture independent and platform independent computer language that is meant to be a general purpose, object-oriented means to encapsulate commonly used functions and services. The COM defines the name, return type and parameters of the interface's methods. The term “objects” is a specific instance of a set of functions or methods collected into interfaces and each object has data associated with it. “Methods” are the action that a message carries out, the code which gets executed when the message is sent to a particular object. All communications to objects are done via “messages”. “Messages” define the interface to the object. “Classes” define what it is to be an object. Creating an object from a class means to have created an instance of the class. The instances of the class are the actual objects. “Classes” are the blueprint of an object. “Objects” are unique individual instances of a particular class. The term “interfaces” means a defined collection of properties and methods that can be implemented by a class. The interface is essentially a table of pointers to the functions that make up the interface. “Pointers” are an indirect reference to data or code, analogous to an address. Each interface under COM is numerically unique. A class can be derived from one or more other classes; this is known as “inheritance”.
COM supports interface inheritance, meaning the interface may be derived from another interface, inheriting the base interface's binary signature. The combination of the name and parameter of a method is usually called its signature. “Delegation” means the derived object creating or instantiating an instance of the base object. The derived object contains code for new behaviors and methods that are over-ridden, and serves as a pass-through for those method calls that are unchanged. The term “plug-in” means a program of data that improves or furthers the operation of the invention. The invention plug-ins are code components that allow the invention to be interfaced to other systems, such as a database or equipment calibration verification system. The term “computer platform” means a software operating system and/or open hardware such as Windows™ NT™ application. The term “dynamic link library (DLL)” means an executable code module for computer platforms that can be loaded on demand and linked at run time and then unloaded when the code is no longer needed. Test software and plug-in codes are contained in DLL files, so they can be developed and delivered independently.
Returning to FIG. 2 , a test 203 is a group of measurements 207 in a procedure 202 that share a common testing algorithm or the same test software code. Some examples of tests 203 include, but are not limited to, an amplitude accuracy test, a test of harmonic distortion. Test executive program 200 repeatedly calls a test for each measurement and datapoint.
A measurement such as 206 is a configuration or a set up of a test. Each measurement 206 within a test 203 can have different setup or configuration parameters. Tests 203 are parameter driven. Parameters are inputs at a measurement level. Measurements 207 are elements such as range in volts, frequency in kilohertz, or a harmonic (an integer number).
Each procedure 202 uses measurements 207 as data to be passed from procedure 202 to a test 203 . A measurement 207 is also a phase of execution. During a measurement phase of execution of a test 203 , a measurement 207 is started but data is not collected. Therefore, multiple DUTs 108 may be configured and tested concurrently.
Datapoints 210 - 212 are a subset of a measurement. These datapoints 210 - 212 include additional parameters that select a result when one measurement generates multiple results. For example, a measurement may have minimum and maximum datapoints for a spectrum analyzer sweep or different datapoints for each channel of a device. For each datapoint 210 - 212 , a value result is determined. The value result is then compared to specification results. Specification results may include numerical limits, string match, and/or Boolean pass/fail results. There may be three different types of numerical limits including marginal limits, line limits, and customer limits. Each limit has an upper value and a lower value.
User interaction of computer system 100 ( FIG. 1 ) executing a test executive program are handled through a Graphical User Interface (GUI). FIG. 3 illustrates a GUI 300 as displayed by output device 106 in accordance with a test executive program of this invention. GUI 300 includes buttons 301 that are used to control a test. For convenience of the user, buttons 301 have indicia that indicate the function served by a button. For example, buttons 301 appear as tape recorder buttons in accordance with a preferred embodiment of this invention. In the preferred embodiment, these buttons include abort button 302 , restart test button 303 , restart measurement button 304 , pause button 305 , run button 306 , skip measurement button 307 , and skip test button 308 . One skilled in the art will recognize that, while tape recorder symbols are used in this embodiment, any number of different indicia may be used to identify buttons 301 .
Area 314 on the right side of GUI 300 in the preferred embodiment is a display of test results. In the preferred embodiment, area 314 includes a series of rows 315 and columns 316 displaying results of individual tests. Column 317 indicates the time that a test is executed. Column 318 displays a status of the test. Column 319 also displays a name of a test. For example, one test is an amplitude frequency. Column 320 indicates a type of measurement being taken during a test. For example, range=5 Vp; frequency=1 kHz. Column 321 displays the channel or datapoint under test, for example, ch=1 or ch=2. Column 322 displays a value or result of the test for a channel or datapoint. Column 323 displays a specification, such as +0.2. Column 324 displays a parameter such as 1 kHz.
Buttons 325 facilitate the sorting of displayed tests to allow a user to view desired tests. In the preferred embodiment, buttons 325 include an all button, a marginal pass button, and a fail button. However, one skilled in the art will recognize that any number of additional ways to view the data may be added. Area 330 displays a progress bar that represents the progress of a procedure being executed.
In the preferred embodiment, area 309 illustrates a test tree 313 that represents the tests being performed in a procedure area 309 and includes a hierarchy of tests, measurements, and datapoints. Test tree 313 includes icons that indicate a status of a test. The icons indicate pass, fail, marginal, and not-yet tested. In a preferred embodiment, a “smiley face” indicates a pass, a “surprised face” indicates a marginal pass, and a “frowning face” indicates a fail. The icon for the procedure indicates the status of the entire procedure, while icons for each test represent the status of an individual test. The icon for the procedure is determined by a Boolean AND operation in which fail has priority. Thus, if one test fails, the procedure fails.
GUI 300 also includes a menu bar 350 . Menu 350 displays a list of menu options for controlling the test executive program. Menu 350 includes file menu 351 , model menu 352 , DUT menu 353 , setting menu 354 , plug-in menu 355 and help menu 356 . File menu 351 includes a list of options for opening and closing files for use with the test executive program. Model menu 352 displays a list of model families that may be tests. DUT menu 353 displays a screen for entry of a DUT model, serial number, options and other information for identifying a DUT. Settings menu 354 displays a menu for viewing and changing executive settings. When highlighted, plug-in menu 355 displays drop-down menu 400 ( FIG. 4 ). Help menu 356 displays a list of help functions available in the test executive program.
GUI 300 also includes a user interface 360 for a system, such as 141 , that is connected to the test executive system via a plug-in interface 140 . In the embodiment shown, system 141 is a Microsoft Excel database. As is known in the art, interface 360 is preferably a window that can be maximized by clicking on button 366 , minimized by clicking on button 365 , or closed by clicking on button 367 . As is known in the art, it can be located where desired on display 106 by clicking and dragging. The data displayed in area 315 is also displayed in area 364 in Microsoft Excel format. Similarly, the test executive system can be viewed and/or controlled via a host of other systems which may comprise software, hardware, firmware, or combinations thereof.
FIG. 4 illustrates a screen displayed to a user in response to plug-in menu 355 being selected by a user. One skilled in the art will recognize that the selection of plug-in menu 355 may be made by “clicking” on plug-in menu 355 , typing a “p” in with a keyboard, or any other method that may be used. When plug-in menu 355 is selected, menu 400 is displayed. In a preferred embodiment, menu 400 is a drop down menu that is displayed directly under the plug-in menu 355 icon. Menu 400 includes a list 403 - 406 of plug-ins available for use. One skilled in the art will recognize that, although shown as plug-in #1 through plug-in #3, each plug-in in list 403 - 406 may have a name that indicates the type of plug-in or system the plug-in serves. Clicking on a box 411 associated with a plug-in displays the user interface 360 for that plug-in. In the embodiment shown, plug-in #2 is enabled. The user interface may be closed by clicking on box 411 a second time, or by clicking on close button 367 on the interface.
Menu 400 may also include add option 401 . A user selects add option 401 to add a plug-in to the plug-ins in list 403 - 406 . A menu displaying available plug-ins is then displayed. The user then selects a plug-in to add. Menu 400 may also include remove option 402 . When remove option 402 is selected, the plug-ins available for use are displayed in a menu and the user selects one of the plug-ins to remove from the plug-ins available.
FIG. 5 illustrates a process 500 for display menu 400 of plug-ins available and receiving a selection of a plug-in to execute. Process 500 begins in act 510 when the processor receives a request for the plug-ins available to be displayed. In act 520 , process 500 determines the plug-ins available for use. Act 520 may be executed by reading a file storing file names of executable files for plug-ins. In act 530 , the plug-ins determined to be available for use are displayed. In a preferred embodiment, the display is list 403 - 406 displayed in menu 400 . In act 540 , the processing unit receives a selection of a plug-in to execute from the user. In act 550 , process 500 ends by executing the plug-in selected in act 540 .
FIG. 6 illustrates a process 600 for adding a plug-in to the list 403 - 406 of plug-ins available for use. Process 600 begins in act 610 when the processing unit receives a request to add a new plug-in. In the preferred exemplary embodiment, the request is received by receiving a mouse “click” on the add option 401 in menu 400 . In response to receiving a request to add a plug-in, the processing unit displays a request for the folder or directory in which the plug-in to add is stored in act 620 . In a preferred exemplary embodiment, this display is a dialog box that has a hierarchical view of the folders or directories stored in a specified memory in a first area and a second area showing files in a highlighted directory or folder. In 630 , the processing unit receives a directory or folder to search. The processing unit searches the input directory or folder for an executable file of a plug-in at 640 . The plug-ins available for selection are then displayed at 650 . The executable files of plug-ins found are shown in the second area of the dialog box in the preferred exemplary embodiment.
At 660 , the processing unit receives a selection of one of the displayed plug-ins to add to list 403 - 406 . In a preferred exemplary embodiment, the plug-in may be received as a double mouse “click” on the name of the plug-in executable file, or any other method those skilled in the art desire. At 670 , process 600 ends with the processing unit storing the file name and location of the selected plug-in in a file storing the names of available plug-ins.
FIG. 7 illustrates process 700 which a processing unit executes in response to receiving a request to remove a plug-in from the list of available plug-ins. Process 700 begins at 710 with the processing unit receiving a request to remove a plug-in from the list of available plug-ins. In the preferred exemplary embodiment, the request to remove an item is received by a double mouse “click” on remove option 402 displayed in menu 400 . At 720 , the processing unit determines the list 403 - 406 of plug-ins available for use. This may be done by reading a file storing a list of location and file names of executable files of plug-ins available for use.
At 730 , the processing unit displays the plug-ins available for use. This may be done in a dialog box showing the names of all plug-ins available for use. The user then inputs a selection of a plug-in to remove which the processing unit receives at 740 . At 750 , process 700 ends with the processing unit removing the selected plug-in from list 403 - 406 . This may be completed by removing the name of the executable file of the plug-in from the file containing the list of plug-ins available.
Returning to FIG. 8 , each plug-in 831 - 833 preferably comprises a DLL file. Each time a user selects a plug-in, the corresponding DLL is loaded. Multiple DLLs can run at the same time, and thus multiple systems can be connected to the system at the same time. The data objects that are shared by test software 810 and 811 , plug-ins 831 - 833 , and test interfaces 817 are defined in a DLL file that contains mostly class definitions for data objects and test interfaces. That is, these objects contain the pure virtual base classes that define interfaces 817 . Actual test software and plug-in classes are derived from these base classes, preferably by using Visual Basic's IMPLEMENTS keyword.
The system according to the invention makes the test executive system according to the invention extremely flexible. It permits the user to utilize a user interface that he or she is familiar with to operate the test system. It permits a wide variety of hardware or software systems to be used to control the test systems, and thus minimizes the reconfiguration of manufacturing and or test systems to be able to use the system. All this is done in a transparent way with a basic GUI that is intuitive and user friendly. The invention takes the test executive system out of the category of specialized niche products and into the mainstream of computer software that enables it to be used by nearly anyone experienced in the use of computers.
The above is a description of a preferred exemplary embodiment of an externally controllable test executive program. It is understood that, now that it has been described in detail how an exemplary externally controllable test executive system is designed, those skilled in the art can design alternative test executive programs that provide external controllability and plug-ins as set forth in the below claims either literally or through the Doctrine of Equivalents. | Disclosed is a product that provides a test executive program for controlling tests on a device under test that is separate and distinct from the test executive system. The product may be embodied in a media storing instructions that direct a processing unit to 1) perform an electronic test on the device under test, 2) provide an interface for communicating with an external system that is distinct from the test executive program, and for permitting the test system to be operated by the external system, 3) communicate with the external system, and 4) in response to signals generated by the external system, operate the test system. Other test executive methods and apparatus are also disclosed. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to pen shaped syringes comprising a proximal part containing a dose setting and driving mechanism, a piston rod having a non-circular cross section and carrying along one side a cogging engaged by a carrier unidirectonally transmitting axial movements from the driving mechanism to the piston rod, a piston rod guide positioned to maintain the piston rod in a rotational position in the syringe ensuring the engagement between the carrier of the drive mechanism and the cogging of the piston rod, the piston rod guide having a non-circular opening conforming to the cross section of the piston rod, and through which opening the piston rod passes, and a distal part containing a tubular reservoir for medicine, which reservoir at its distal end is closed by a pierceable rubber membrane, and at its proximal end is closed by a piston actuated by the piston rod of the proximal part.
DESCRIPTION OF RELATED ART
Such syringes are used by patients which have to frequently inject themselves. The reservoir contains medicine sufficient for several injections, and when the reservoir is empty, the proximal and the distal part of the syringe may be unscrewed and the reservoir renewed, whereafter the parts are screwed together again.
However, this screwing movement may be difficult to perform especially to patients suffering from diseases reducing their tactile motor function, and this way it may be difficult for these patients to administer the medicine which could just mitigate these symptoms.
SUMMARY OF THE INVENTION
Therefore, it is the object of the invention to provide a pen syringe wherein the medicine reservoir could easily be changed without performing many turns of screwing.
This is obtained by a syringe of the above mentioned kind, which syringe according to the invention is characterized in, that the proximal and the distal part have interlocking bayonet coupling means, and that the bayonet coupling means on the distal part is provided with means engaging the piston guide to rotate this guide and consequently the piston rod during at least part of the rotational movement of the bayonet lock.
When a reservoir is emptied the piston rod is protruding from the proximal part, and the engagement between the piston rod and the drive mechanism has the effect that the piston rod may not immediately be pushed back into the proximal part to be ready for actuating the piston of a new full reservoir. Therefore, a coupling is normally provided to release the engagement between drive mechanism and piston rod when the pen is unscrewed. This coupling is normally operated to reestablish the engagement when the parts are screwed together again, the operation being performed by the reservoir pressing a coupling member when the distal part is screwed onto the proximal part. This arrangement has the disadvantage that the coupling is performed before the parts are screwed totally home, and consequently, if the piston rod is pushed back by the piston of the new reservoir, the movement of the piston rod will be locked and will press the piston into the reservoir during the last part of the screwing. By the pen syringe according to the invention the coupling is performed by rotating the piston rod out of and into is engagement with the drive mechanism, and as this rotation is Performed without any concomitant axial movement the above mentioned disadvantage is avoided.
According to the invention, the bayonet coupling may comprise a stud protruding from a plane distal end surface of the proximal part, this stud being provided with a flange having an outer diameter corresponding to the inner diameter of the tubular distal part and leaving a space between the flange and the end surface, the flange being cut away preferably at diametrically opposite positions, and locking protrusions on the inner surface at the proximal end of the distal part, which protrusions correspond to the cuts of the flange and extend in the axial direction from the proximal end of the distal part to a position a distance away from this proximal end, which distance corresponds to the distance between the flange and the end surface.
According to the invention, the piston guide may be mounted at the distal end of the stud rotatably journaled in this stud and having a disc with a diameter corresponding to the diameter of the flange and with cuts at least corresponding to the cuts of the flange, the flange and the disc being provided with engaging stop means limiting the rotational movement of the piston guide, and the inner surface of the distal part may be provided with a protrusion engaging a cut in the piston guide disc, which protrusion lies at a distance from the proximal end of the distal part corresponding to the length of the stud.
The bayonet lock may be provided by the flange being provided with a set of cuts comprising a first cut forming a slot through the flange and a pair of cuts at a position principally diametrically opposite the first cut, but provided on both sides of a piece of the flange left at the position exactly diametrically opposite the first cut. This arrangement allows a 180° turning to lock the bayonet lock, as the protrusion passed through the first cut will abut the rear side of the left piece of the flange, and protrusions corresponding to the pair of cuts will abut the rear side of the flange on both sides of the first cut.
The distal part of the syringe may be manufactured as an integral disposable part containing the reservoir and a pawl mechanism for engagement with the cogging of the piston rod, and the cut in the piston guide disc engaged by a protrusion on the inner side of the distal part of the syringe may extend over an arch of 90°. As the pawl mechanism, which forms a retraction detent for the piston rod during the use of the syringe, is a part exposed to heavy wear it is appropriate to make this part disposable, so that it is changed each time a new reservoir is mounted.
By making the cut in the piston drive disc span 90°, the piston rod is maintained unrotated during the first 90° of the turning of the distal part, and this part of the turning may be used to bring the pawl mechanism in this distal part into engagement with the cogging of the piston rod. When the disc engaging protrusion of the distal part reaches the end of the arched cut in the disk, this disc and consequently the piston rod are rotated during the last 90° of the turning of the distal part and may this way come into engagement with the drive mechanism in the proximal part of the syringe.
The piston rod may appropriately have a square cross section and be provided with coggings along two opposite sides and be smooth along the other two opposite sides.
In the following the invention is described with reference to the drawing wherein
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the distal end of a proximal part of a pen syringe with a bayonet coupling according to the invention, the piston guide being in an initial rotational position,
FIG. 2 shows the same part of the syringe as FIG. 1 with the piston guide drawn away from the bayonet coupling, the piston rod guide being in the initial rotational position,
FIG. 3 shows the same part of the syringe as FIG. 2 with the piston guide drawn away from the bayonet coupling, the piston rod guide being in a final rotational position,
FIG. 4 shows a sectional view of a distal part of the syringe, this distal part comprising a reservoir and a bayonet coupling part for engagement with the mating bayonet coupling part on the distal end of the proximal part of the syringe,
FIG. 5 shows in an enlarged scale the coupling part at the proximal end of the distal part of the syringe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the distal end of the proximal part of a pen shaped syringe, which proximal part comprises not shown elements for setting a dose which is injected by advancing a carrier 1 having teeth for engagement with the coggings 2 along two opposite sides of a piston rod 3 having a square cross section, the other pair of opposite sides 4 being smooth. The teeth of the coggings have a steep leading edge and a ramp shaped rear edge to ensure a unidirectional advancing of the piston rod when the carrier 1 is reciprocated during consecutive injections.
The part shown in FIG. 1 is terminated by a plane end surface 5 carrying a bayonet coupling part comprising a tubular stud 6 with a flange 7. A piston rod guiding disc 8 is rotatably mounted to the stud 6 at the outer end of the flange. As illustrated in FIG. 2, wherein the disc is shown drawn away from the flange, this mounting is obtained by the disc 8 being provided with a tubular projection 12 on the side facing the flange, which projection is terminated by a snap lock hook 13 gripping behind an inner shoulder when the projection 12 is inserted in a central bore 9 through the stud.
The piston rod 3 passes through an opening in the disc 8, which opening conforms to the cross section of the piston rod 3 to keep this piston rod in a rotary position defined by the rotary position of the disc 8. In the initial position shown in FIGS. 1 and 2, the piston rod is maintained in a rotational position causing the teeth of the carrier 1 to rest on the smooth sides of the piston rod 8 the carrier being unrotatable in the proximal part of the syringe. In this position the piston rod may be pushed back into the proximal part, as its smooth sides may slide between the jaws of the carrier 1.
The piston rod 3 having a substantially square cross section has along two of its edges recesses 34 corresponding to protrusions 35 on the wall of the opening in the disk 8, the protrusions 35 projecting into this opening. Near the distal end of the piston rod the recesses 34 are interrupted by protrusions 36 provided by the pisron rod having its full square cross section. As due to the protrusions 35 the protrusion 36 cannot pass through the opening in the disc 8 a stop is provided for the movement of the piston rod into the proximal part.
The flange 7 is at its periphery provided with a recess 10 in the axial direction of the stud, and at a position diametrically opposite the recess 10 cuts in the flange make the remaining part of the flange appear as a projection 11 diametrically opposite the recess 10. Further, a protrusion 14 on the end surface of the flange projects into a 90° arched recess along the periphery of the disc 8.
The stud 6 and the flange 7 with its recess 10 and its projection 11 form one half of a bayonet coupling, the other half being provided at a proximal end of a distal part of the syringe as shown in FIG. 4 and in further details in FIG. 5.
FIG. 4 shows a sectional view of the distal part comprising a housing containing a cylinder ampoule 16. At its distal end the housing 15 is provided with a threaded member 17 receiving a hub 18 with a hypodermic needle 19 communicating with the internal space of the ampoule which is at its proximal end closed by a piston 20 which may be forced into the ampoule to press out its content through the needle 19. The proximal end of the housing has on its inner wall a coupling protrusion 21, a coupling recess 22, and a disc drive protrusion 23, which protrusions are designed for cooperation with the bayonet coupling part of the proximal part of the syringe.
When the distal part of the syringe is mounted on the proximal part which is in the position shown in FIGS. 1 and 2, the coupling protrusion 21 is passed into the recess 10 in the flange 7, and the projection 11 of the flange is passed into the coupling recess 22 formed between two internal protrusion 26 and 27 at the proximal end of the tubular housing 15. The disc 8 is provided with a 90° arched cut allowing the protrusion to pass the disc which else covers the end surface of the flange 7. During this operation the piston rod is pushed back into the proximal part until the projections 36 in the recess 34 in the piston rod 3 abut the projections 35 in the opening of the disc 8 and prevent a further movement of the piston rod 3. The end of the piston rod projecting from the proximal part will then be pressed into the space between the withdrawal detent pawl jaws 24, and these jaws to will slide along the smooth sides of the piston rod which is moved into the distal part towards a piston foot 25. When the proximal edge of the distal part abuts the end surface 5 of the proximal part of the syringe, the distal part is turned clockwise relatively to the proximal part. By this rotation the protrusion 21 will pass into the clearance between the surface 5 and the flange 7, and the flange will be adopted in the clearance between the protrusions 21 and 23 and behind the protrusions 26 and 27.
During the first 90° of the relative rotation the protrusion 23 will follow an arched 90° cut 28 in the disc 8, and consequently the piston rod will maintain its rotational position, i.e. the distal part will be rotated relatively to the piston rod. When the distal part is rotated 90°, the jaws 24 of the retraction detent will come into engagement with the cogging of the piston rod 3. Further, the disc drive protrusion 23 will abut the terminal surface 29 of the cut 28, and a continued rotation will be transmitted to the disc 8 and consequently to the piston rod, i.e. the piston rod 3 will now be rotated with respect to the proximal part of the syringe but not with respect to the distal part. By further clockwise turning of the distal part in relation to the proximal part, the jaws 24 will remain in engagement with the coggings of the piston rod, and a 90° further rotation will bring the carrier 1 into engagement with these coggings. The protrusion 21 will then be lodged behind the protrusion 11, and the protrusions 26 and 27 will be lodged at respective sides of the recess 10. Further relative rotation of the proximal and distal parts is obstructed partly by the protrusion 14 on the end surface of the flange abutting the terminal surface 30 of the arched recess 31 of the disc and partly by the protrusion 21 being adopted between two ridges 32 provided on the cylindric surface of the stud 6.
When the reservoir is empty, the parts may be dismounted by turning the distal part 180° anticlockwise in relation to the proximal part.
In the distal part some openings and cuts only serving moulding purposes are seen.
An external protrusion 33 at the proximal end of the distal part may be provided to engage a recess in a not shown housing of the proximal part to ensure that the two parts are placed in the correct mutual rotational position to be coupled together. More similar protrusions may be provided to form a pattern ensuring that a certain distal part may only be used in connection with a certain proximal part. The distal part is shown as a housing containing a cylinder ampoule, but it may also be an integral part.
In a not shown embodiment the withdrawal detent jaws may be placed in the proximal part. Then only a 90° relative rotation of the distal part with respect is to the proximal part is necessary to make the teeth of the carrier as well as the teeth of the withdrawal detent engage the coggings of the piston rod. When only a 90° relative rotation is needed, the bayonet coupling may be made more simple with only recesses in the flange and only protrusions on the inner wall of the distal part. | A pen-shaped syringe comprises a first part containing a dose setting and driving mechanism from which a piston rod is advanced by a carrier to actuate a piston of a reservoir in a second part. The first and second parts are coupled together by a bayonet coupling, wherein the bayonet coupling element of the second part has members for rotating a piston rod guide mounted on the bayonet coupling element of the first part. The piston rod determines the rotational position of the piston rod which rotational position again determines the engagement between the carrier and the piston rod. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This applications claims the benefit of U.S. Provisional Patent Application Ser. No. ______ filed Feb. 6, 2009, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] In a competitive real estate market, photographs of a home viewed online are often the first impressions a potential buyer gets when viewing numerous properties for sale on real estate listing-based websites. However, many pictures of vacant homes look very similar with neutral walls and sometimes unidentifiable rooms. Therefore, motivated sellers want the pictures of the property they are selling to be instantly recognizable by potential buyers online and be remembered because of their warm and inviting appearance.
[0003] Traditionally, properties for sale have been physically staged by actually decorating the home with furnishings and other home décor to improve the perceptions and impressions of potential buyers when they view the home. However, the staging process is often expensive, time-consuming, and/or labor intensive.
SUMMARY OF THE INVENTION
[0004] Therefore, it is an object of the present invention to provide a cost-effective real estate marketing solution for a fraction of the cost of traditional staging by virtually staging the property by adding images of real furnishings to the actual photographs of the property, thus transforming the photographs into attractive, attention-getting pictures that drive buyer traffic to the home for sale.
[0005] To attain the above object, according to an aspect of the invention, there is provided a system for virtually staging property to market real estate including a computing device communicably linked to a computer network, a database accessible by the computing device containing a plurality of images of household items, software executing on the computing device for receiving a digital photograph of a room of the property from a user via the computer network, retrieving at least one of the plurality of images from the database, digitally editing the retrieved image into the received digital photograph, and transmitting the edited digital photograph to the user via the computer network.
[0006] Preferably, the system further includes software executing on the computing device for operating and maintaining a website accessible by the user via the computer network, and the user uploads the digital photograph of the room to the computer via the website.
[0007] The computer network preferably includes the Internet, and the user preferably includes a seller offering at least one property for sale or lease.
[0008] Preferably, the images of household items in the database include images of furnishings and household décor.
[0009] The system preferably further includes software executing on the computing device for permitting access to the database to the user, and enabling the user to selectively edit the received digital photograph using at least one image from the database.
[0010] Preferably, the system further includes software executing on the computing device for permitting access to the database to the user, and enabling the user to download at least one image from the database.
[0011] The system preferably further includes software executing on the computing device for facilitating a payment from the user for the edited digital photograph.
[0012] In another aspect of the present invention, there is provided a method for marketing a property including obtaining a digital photograph of a room of the property to be staged, digitally editing the photograph to add at least one image of a household item, and presenting the edited photograph to potential buyers.
[0013] Preferably, the edited photograph is presented to potential buyers on an information flyer.
[0014] The edited photograph is preferably presented to potential buyers on an online listing service.
[0015] These and other exemplary features and advantages of the present invention will become clear from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing and other exemplary purposes, aspects and advantages will be better understood from the following detailed description of an exemplary embodiment of the invention with reference to the drawings, in which:
[0017] FIG. 1 shows a schematic of an exemplary embodiment of the present invention.
[0018] FIG. 2 shows an exemplary photograph of a dining room before being virtually staged.
[0019] FIG. 3 shows the photograph of FIG. 2 after being virtually staged.
[0020] FIG. 4 shows an exemplary photograph of a living room before being virtually staged.
[0021] FIG. 5 shows the photograph of FIG. 4 after being virtually staged.
[0022] FIG. 6 shows an exemplary photograph of a bedroom before being virtually staged.
[0023] FIG. 7 shows the photograph of FIG. 6 after being virtually staged.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring now to the drawings, and more particularly to FIGS. 1-7 , there are shown exemplary embodiments of the system according to the present invention.
[0025] FIG. 1 shows a schematic of an exemplary embodiment of the virtual staging system 10 of the present invention. Initially, the seller 12 provides photographs 16 , 18 of various rooms of the home for sale to the virtual staging entity 14 to be virtually staged.
[0026] Preferably, digital photographs 16 are electronically transmitted from the seller 12 to the virtual staging entity 14 over a computer network 20 , such as the Internet. The digital photographs 16 provided to the virtual staging entity 14 may be in any suitable format such as, for example, Joint Photographic Experts Group (JPEG), Tagged Image File Format (TIFF), or Encapsulated PostScript (EPS).
[0027] The digital photographs 16 are preferably uploaded to the virtual staging entity 14 via a dedicated website operated by the virtual staging entity 14 . However, it should be understood that the transmission of the digital photographs 16 may be accomplished through other known electronic means, such as electronic mail service or other file transfer protocol (FTP) procedures. It should also be understood that one or more physical data storage devices, such as optical discs or a flash memory data storage devices, containing the digital photographs 16 may be physically provided to the virtual staging entity 14 , such as by hand, mail or delivery service.
[0028] Physical photographs 18 of the home for sale may be scanned and converted into a suitable digital format 22 using appropriate scanning equipment and software. The seller 12 may scan and convert 22 the physical photographs 18 prior to providing the digital photographs 16 to the virtual staging entity 14 . However, the seller 12 may alternately provide the physical photographs to the virtual staging entity 14 for subsequent scanning and converting 22 by the virtual staging entity 14 .
[0029] The photographs 16 , 18 may be shot by anyone affiliated with or hired by a party of interest in the sale of the home, for example, the seller 12 , the agent, or the virtual staging entity 14 . Preferably, the photographs 16 , 18 include pictures of the living room, dining room, kitchen, master bedroom and master bathroom. However, the seller 12 may provide photographs of any room, and as many rooms, of the property for sale that they may wish to have virtually staged by the virtual staging entity 14 .
[0030] Preferably, the property is vacant when photographed in order to expedite and facilitate the virtual staging process. However, it should be understood that the photographs may be edited to remove existing furnishings that appear in the photographs, if necessary. Additionally, the photographs 16 , 18 are preferably taken in proper lighting levels, avoid under/over-exposure, and utilize natural or ambient light to further facilitate the virtual staging process.
[0031] Upon receipt of suitable digital photographs 24 , the virtual staging entity 14 uses editing software to virtually stage 26 the rooms by overlaying images of furniture, decorations and other pieces on to the received digital photographs 16 . Suitable furnishings and décor are selectively added to the photographs depending on the type of room and stylistic notions of the virtual staging entity 14 . In this manner, a photograph of a vacant room can be transformed into a picture of an attractive well-appointed room that would be pleasing to potential buyers of the home. FIGS. 2-7 show exemplary before and after illustrations of staged photographs.
[0032] The images added to the photographs are pulled from a furnishings image library 28 . The library 28 comprises an electronic database containing an inventory of digital images of a wide selection and variety of furniture, decorations and other pieces organized by style, size and viewing angle. It is to be understood that the database may be organized in any manner desired by the virtual staging entity 14 .
[0033] Once the photographs have been virtually staged 26 , they are returned to the seller 12 for use in marketing materials. Preferably, the staged digital photographs 30 are electronically transmitted to the seller 12 over the computer network 20 . For example, the transmission may be accomplished through a dedicated website, electronic mail service, or file transfer protocol (FTP) procedure. However, it should be understood that physical copies of the staged photographs 32 or one or more physical data storage devices, such as optical discs or flash memory data storage devices, containing the staged digital photographs 30 may be physically provided to seller 12 , such as by hand, mail or delivery service.
[0034] The seller 12 may then utilize the staged photographs 30 , 32 in the marketing materials for the home for sale. For example, the staged photographs 30 , 32 may be used in informational flyers and online listings. In the event the staged photographs 30 are used as part of the property's online real estate listings, the staged photographs 30 may positively differentiate the property from other listings. In this manner, the staged photographs 30 may increase traffic both on the website and in the actual home and, therefore, increase the selling opportunities for the seller 12 of the home.
[0035] Printed enlargements of the staged photographs 30 , 32 may also be physically posted at the property that was virtually staged in the photographs. Posting such staged photographs 30 , 32 would be particularly helpful when the property for sale is vacant, in order to help potential buyers better visualize what a particular room could look like when decorated while actually visiting the property.
[0036] Preferably, the furnishings image library 28 is created by photographing the furniture, decoration and pieces to be used in virtual staging process from many different angles. The images are then suitably cataloged in a database for rapid location and retrieval when needed during the virtual staging process. Preferably, the library 28 is continuously updated and expanded to account for prevailing stylistic trends and to simply increase the options available to the virtual staging entity 14 . In this manner, a large library may be created to suit a wide range of tastes and styles, and give the virtual staging entity 14 a broad range of décor options when virtually staging the photographs of the property.
[0037] The virtual staging entity 14 may also provide access to the furnishings image library 28 directly to the seller 12 . In this manner, the seller 12 may virtually stage their digital photographs 16 themselves. Preferably, the seller 12 would upload a digital photograph to a dedicated website operated by the virtual staging entity 14 that permits the seller 12 to access the furnishings image library 28 and virtually stage the photograph according to the seller's preferences and selections. Alternately, the virtual staging entity 14 may permit the seller 12 to download images from the furnishings image library 28 to their personal computer to stage the photographs themselves.
[0038] Preferably, the system 10 includes a web-based application, such as a dedicated website, wherein the entire transaction between the virtual staging entity 14 and seller 12 is completed electronically. The system 10 would comprise software executing on a computer operated by the virtual staging entity 14 for hosting and maintaining the web-based application and making it accessible to the seller 12 over the Internet. The computer may be any computing device, alone or in combination, such as a personal computer, web server, mainframe, or any other computing device that is communicably linked to a computer network 20 , such as the Internet. The communications link to the computer network 20 may take the form of any of the currently available means for connecting to the Internet.
[0039] The seller 12 may access the web-based application maintained by the virtual staging entity 14 over the Internet using any currently available web-browsing technology. Such browsing technology may include web-browsing software executing on any Internet-capable computing device, such as a personal computer or a handheld device. It is understood that there are many means for accessing the Internet known to those of skill in the art.
[0040] The virtual staging process of the present invention may also be implemented as a cohesive system or method of doing business in which the virtual staging entity 14 is solicited and financially compensated for creating and providing staged photographs of a property by the seller 12 .
[0041] An exemplary application of the virtual staging process of the present invention would be to market furnishings to customers. In particular, furniture manufacturers and retailers could enable a potential customer to visualize how the products they sell would actually look in the customer's home by virtually staging a photograph of a room in the customer's home with the manufacturer's or retailer's products.
[0042] For example, a manufacturer or retailer may build a furnishing image library 28 containing images of the products they offer for sale. An image of a retailer's couch may then be retrieved from the library 28 and virtually added 26 to a photograph of a potential customer's living room. The virtual staging process may be accomplished online at the manufacturer's or retailer's website. Alternately, the virtual staging process may be provided directly by retailer or manufacturer or at a self-service kiosk at retail locations.
[0043] While the invention has been described with respect to the sale of homes, it should be understood that the invention can be practiced and applied to any real property transaction. For example, the invention can be applied to rental markets to allow landlords and lessors to virtually stage photographs of rental properties to better market the property to potential tenants. The invention can also be utilized to offer virtual staging of commercial properties, such as offices, conference centers, or warehouses, and retail properties, such as retail stores and malls, to show potential buyers or tenants how a property could appear or be utilized.
[0044] While the invention has been described in terms of several exemplary embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.
[0045] Further, it is noted that, Applicant's intent is to encompass equivalents of all claim elements, even if amended later during prosecution. | A system for virtually staging property to market real estate including a computing device communicably linked to a computer network, a database accessible by the computing device containing a plurality of images of household items, and software executing on the computing device for receiving a digital photograph of a room of the property from a user via the computer network, retrieving at least one of the plurality of images from the database, digitally editing the retrieved image into the received digital photograph, and transmitting the edited digital photograph to the user via the computer network. | 6 |
CLAIM OF PRIORITY UNDER 35 U.S.C. §120
The present application for patent is a Continuation of patent application Ser. No. 10/029,711 entitled “Efficient Multi-Cast Broadcasting for Packet Data Systems” filed Dec. 19, 2001, now U.S. Pat. No. 6,856,604 pending, and assigned to the assignee hereof and hereby expressly incorporated by reference herein.
BACKGROUND
1. Field
The present invention relates generally to communications, and more specifically, to transmitting multi-cast broadcasts in wireless communication systems.
2. Background
The field of wireless communications has many applications including, e.g., cordless telephones, paging, wireless local loops, personal digital assistants (PDAs), Internet telephony, and satellite communication systems. A particularly important application is cellular telephone systems for mobile subscribers. As used herein, the term “cellular” system encompasses both cellular and personal communications services (PCS) frequencies. Various over-the-air interfaces have been developed for such cellular telephone systems including, e.g., frequency division multiple access (FDMA), time division multiple access (TDMA), and code division multiple access (CDMA). In connection therewith, various domestic and international standards have been established including, e.g., Advanced Mobile Phone Service (AMPS), Global System for Mobile (GSM), and Interim Standard 95 (IS-95). IS-95 and its derivatives, IS-95A, IS-95B, ANSI J-STD-008 (often referred to collectively herein as IS-95), and proposed high-data-rate systems are promulgated by the Telecommunication Industry Association (TIA) and other well known standards bodies.
Cellular telephone systems configured in accordance with the use of the IS-95 standard employ CDMA signal processing techniques to provide highly efficient and robust cellular telephone service. Exemplary cellular telephone systems configured substantially in accordance with the use of the IS-95 standard are described in U.S. Pat. Nos. 5,103,459 and 4,901,307, which are assigned to the assignee of the present invention and incorporated by reference herein. An exemplary system utilizing CDMA techniques is the cdma2000 ITU-R Radio Transmission Technology (RTT) Candidate Submission (referred to herein as cdma2000), issued by the TIA. The standard for cdma2000 is given in the draft versions of IS-2000 and has been approved by the TIA and 3GPP2. Another CDMA standard is the W-CDMA standard, as embodied in 3rd Generation Partnership Project “3GPP”, Document Nos. 3G TS 25.211, 3G TS 25.212, 3G TS 25.213, and 3G TS 25.214.
The telecommunication standards cited above are examples of some of the various communications systems that can be implemented to transmit voice and/or data. Within these systems, multiple users must share limited system resources. One such limitation is the availability of channels to support multiple users. For example, in a CDMA-type system, each user within the range of a base station is assigned one or more channels to conduct communications with the base station. If there were not enough channels, then a new user that is entering the range of the base station would be blocked from accessing the services of that base station.
In certain situations, it is desirable to transmit the same data to several users. This is particularly desirable for applications that incur a large load on the wireless network, such as video streaming. However, cellular base stations are presently configured to transmit the data on separate channels to each user, regardless of the similarity of the data to each user. Hence, it could be said that the base station is wasting channel resources every time the base station makes multiple transmissions with the same data content. There is a present need in the art for a method and apparatus for transmitting identical or similar data to multiple users without using multiple channels.
SUMMARY
The methods and apparatus presented herein address the above needs. In one aspect, an apparatus is presented for multi-cast transmissions that minimize channel resources, the apparatus comprising: a memory element; and a processing element for executing a set of instructions stored in the memory element, the set of instructions for: generating an identifier for a group of subscribers, wherein the identifier is for accessing a multi-cast service; using channel quality information for at least one subscriber to determine the timing of the multi-cast service to the group of subscribers; and transmitting the identifier and the multi-cast service on at least one channel, wherein the multi-cast service is transmitted in accordance with the timing determined by the channel quality information.
In another aspect, another apparatus is presented for generating an identifier for a group of subscribers, wherein the identifier is for accessing a multi-cast service; for using channel quality information for at least one subscriber to determine the transmission format of the multi-cast service to the group of subscribers; and for transmitting the identifier and the multi-cast service on at least one channel, wherein the multi-cast service is transmitted in accordance with the transmission format determined by the channel quality information.
In anther aspect, a method is presented for determining the channel quality information for a plurality of subscribers; for identifying the subscriber with the worst channel conditions; for scrambling a multi-cast service using a scrambling code known to the plurality of subscribers; and for transmitting the scrambled multi-cast service to the plurality of subscribers, wherein the scrambled multi-cast service is transmitted in accordance with a transmission format that is optimal for the subscriber with the worst channel conditions.
In another aspect, a method is presented for generating an identifier for a group of subscribers, wherein the identifier is for accessing a multi-cast service; for identifying the subscriber with the worst channel quality by analyzing a plurality of channel quality feedback indicators from a group of subscribers; for selecting a timing and a transmission format of the multi-cast service so that the multi-cast service will be received by the subscriber with the worst channel conditions; and for transmitting the identifier on a first channel and the multi-cast service on a second channel in accordance with the timing and the transmission format as determined by the subscriber with the worst channel quality.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a wireless communication network.
FIG. 2 is a flowchart of an embodiment for selecting the timing of a multi-cast transmission.
FIG. 3 is a flowchart of an embodiment for selecting the transmission format of a multi-cast transmission.
DETAILED DESCRIPTION
As illustrated in FIG. 1 , a wireless communication network 10 generally includes a plurality of mobile stations (also called subscriber units or user equipment or remote stations) 12 a - 12 d , a plurality of base stations (also called base station transceivers (BTSs) or Node B). 14 a - 14 c , a base station controller (BSC) (also called radio network controller or packet control function 16 ), a mobile switching center (MSC) or switch 18 , a packet data serving node (PDSN) or internetworking function (IWF) 20 , a public switched telephone network (PSTN) 22 (typically a telephone company), and an Internet Protocol (IP) network 24 (typically the Internet). For purposes of simplicity, four mobile stations 12 a - 12 d , three base stations 14 a - 14 c , one BSC 16 , one MSC 18 , and one PDSN 20 are shown. It would be understood by those skilled in the art that there could be any number of mobile stations 12 , base stations 14 , BSCs 16 , MSCs 18 , and PDSNs 20 .
In one embodiment the wireless communication network 10 is a packet data services network. The mobile stations 12 a - 12 d may be any of a number of different types of wireless communication device such as a portable phone, a cellular telephone that is connected to a laptop computer running IP-based, Web-browser applications, a cellular telephone with associated hands-free car kits, a personal data assistant (PDA) running IP-based, Web-browser applications, a wireless communication module incorporated into a portable computer, or a fixed location communication module such as might be found in a wireless local loop or meter reading system. In the most general embodiment, mobile stations may be any type of communication unit. The mobile stations 12 a - 12 d may advantageously be configured to perform one or more wireless packet data protocols such as described in, for example, the EIA/TIA/IS-707 standard.
In one embodiment the IP network 24 is coupled to the PDSN 20 , the PDSN 20 is coupled to the MSC 18 , the MSC is coupled to the BSC 16 and the PSTN 22 , and the BSC 16 is coupled to the base stations 14 a - 14 c via wirelines configured for transmission of voice and/or data packets in accordance with any of several known protocols including, e.g., E1, T1, Asynchronous Transfer Mode (ATM), IP, PPP, Frame Relay, HDSL, ADSL, or xDSL. In an alternate embodiment, the BSC 16 is coupled directly to the PDSN 20 , and the MSC 18 is not coupled to the PDSN 20 .
During typical operation of the wireless communication network 10 , the base stations 14 a - 14 c receive and demodulate sets of reverse signals from various mobile stations 12 a - 12 d engaged in telephone calls, Web browsing, or other data communications. Each reverse signal received by a given base station 14 a - 14 c is processed within that base station 14 a - 14 c . Each base station 14 a - 14 c may communicate with a plurality of mobile stations 12 a - 12 d by modulating and transmitting sets of forward signals to the mobile stations 12 a - 12 d . For example, as shown in FIG. 1 , the base station 14 a communicates with first and second mobile stations 12 a , 12 b simultaneously, and the base station 14 c communicates with third and fourth mobile stations 12 c , 12 d simultaneously.
BSC 16 provides call resource allocation and mobility management functionality including the orchestration of soft handoffs of a call for a particular mobile station 12 a - 12 d from one base station 14 a - 14 c to another base station 14 a - 14 c . For example, a mobile station 12 c is communicating with two base stations 14 b , 14 c simultaneously. Eventually, when the mobile station 12 c moves far enough away from one of the base stations 14 c , the call will be handed off to the other base station 14 b.
If the transmission is a conventional telephone call, the BSC 16 will route the received data to the MSC 18 , which provides additional routing services for interface with the PSTN 22 . If the transmission is a packet-based transmission such as a data call destined for the IP network 24 , the MSC 18 will route the data packets to the PDSN 20 , which will send the packets to the IP network 24 . Alternatively, the BSC 16 will route the packets directly to the PDSN 20 , which sends the packets to the IP network 24 .
In some communication systems, packets carrying data traffic are divided into subpackets, which occupy slots of a transmission channel. For illustrative ease only, the nomenclature of a cdma2000 system is used herein. Such use is not intended to limit the implementation of the embodiments herein to cdma2000 systems. Embodiments can be implemented in other systems, such as, e.g., WCDMA, without affecting the scope of the embodiments described herein.
The forward link from the base station to a remote station operating within the range of the base station can comprise a plurality of channels. Some of the channels of the forward link can include, but are not limited to a pilot channel, synchronization channel, paging channel, quick paging channel, broadcast channel, power control channel, assignment channel, control channel, dedicated control channel, medium access control (MAC) channel, fundamental channel, supplemental channel, supplemental code channel, and packet data channel. The reverse link from a remote station to a base station also comprises a plurality of channels. Each channel carries different types of information to the target destination. Typically, voice traffic is carried on fundamental channels, and data traffic is carried on supplemental channels or packet data channels. Supplemental channels are usually dedicated channels, while packet data channels usually carry signals that are designated for different parties in a time and code-multiplexed manner. Alternatively, packet data channels are also described as shared supplemental channels. For the purposes of describing the embodiments herein, the supplemental channels and the packet data channels are generically referred to as data traffic channels.
Voice traffic and data traffic are typically encoded, modulated, and spread before transmission on either the forward or reverse links. The encoding, modulation, and spreading can be implemented in a variety of formats. In a CDMA system, the transmission format ultimately depends upon the type of channel over which the voice traffic and data traffic are being transmitted and the condition of the channel, which can be described in terms of fading and interference.
Packet data systems traditionally transmit data to remote stations, from one to ten stations at a time. Data transmission occurs from a base station on a shared data traffic channel, which is accompanied by control information. The control information can comprise parameters of the data transmission, such as modulation, coding, and power, which are adjusted by the base station using channel quality feedback (CQF) information about the remote station. CQF information is used to maximize the system throughput, minimize channel usage, and maximize the likelihood that a data transmission will reach the remote station with a reasonable quality. The CQF can be explicit through a transmission from the remote station or the CQF can be derived by the base station through transmission power levels. The base station transmits the control information in order to aid the remote station in decoding the associated data transmission.
One piece of control information that is transmitted to the remote station is a medium access control identifier (MAC_ID). MAC_IDs are assigned to remote stations in accordance with a unique International Mobile Station Identify (IMSI) when the remote stations enter the communication system. Hence, the channel that is dedicated to the remote station can be identified by the MAC_ID that is assigned to the remote station.
Some packet data systems offer services such as multi-cast and broadcast. In a multi-cast, the same transmissions are sent to a group of remote stations. In a broadcast, the same transmissions are sent to all remote stations in the range of the base station. For example, a video broadcast would require the system to transmit the video stream to all users subscribed to the video streaming channel. However, as mentioned above, packet data systems are configured to transmit data to only one remote station at a time. Hence, multi-cast and broadcast in current packet data systems requires an independent transmission of the same data to each remote station. If N remote stations were present in the system and the system needed to broadcast the same message to all of the remote stations, then the system would transmit the same information N times, each transmission tailored to the needs of each remote station.
The same information is sent independently to each remote station because a transmission to each remote station would propagate through different channel conditions. The condition of each channel will vary in accordance to distance to the base station, fading, and interference from other channels. In order to ensure delivery of the information within a desired quality level, such as a frame error rate (FER) of less than 1%, the various transmission parameters can be adjusted. As a simplistic example, if the channel conditions were bad, then the base station would transmit information to a remote station using a format where data symbols are repeated often in the packet. Hence, the receiving party could soft-combine any corrupted data symbols to attain the original information. However, if the channel conditions are good, then the base station could transmit information to a remote station using a format that does not repeat data symbols, since the receiving party is likely to receive the uncorrupted data symbols. Hence, although the same information is being carried to the remote stations, the transmission formats of the data packets to each remote station can be different.
An example of the different transmission parameters at different rates that can be used by a communication network is shown in Table 1.
TABLE 1
Forward Link Modulation Parameters
Data Rate
Number of
Bits per
(kbps)
Slots
Packet
Code Rate
Modulation
38.4
16
1024
1/5
QPSK
76.8
8
1024
1/5
QPSK
153.6
4
1024
1/5
QPSK
307.2
2
1024
1/5
QPSK
614.4
1
1024
1/3
QPSK
307.2
4
2048
1/3
QPSK
614.4
2
2048
1/3
QPSK
1228.8
1
2048
2/3
QPSK
921.6
2
3072
1/3
8-PSK
1843.2
1
3072
2/3
8-PSK
1228.8
2
4096
1/3
16-QAM
2457.6
1
4096
2/3
16-QAM
It should be noted that Table 1 is merely an illustrative example of just some of the transmission parameters that can be different for a transmission to one subscriber versus a transmission to other subscribers. Other parameters, such as symbol repetition and transmission duration over multiple frames, are not shown.
The present embodiments are directed towards eliminating the waste of channel resources resulting from the multiplicity of identical broadcasts to multiple recipients. In one embodiment, the base station generates a special MAC_ID value that identifies a group of remote stations, rather than a single remote station. For each multi-cast service available, a corresponding special MAC_ID value is also generated. For example, MAC_ID 00203 could be reserved for the video streaming of a television channel. Remote stations wishing to receive the television channel via the communications system would subscribe to this service, and watch for MAC_ID 00203 in the control signaling information.
Since the MAC_ID identifies only one channel that will be demodulated and decoded by all the subscribing remote stations, embodiments for enabling each remote station in the subscription group to demodulate and decode the channel are also described herein. FIG. 2 is a flowchart for selecting the timing of a multi-cast to M subscribers. At step 200 , a scheduling element in a base station determines the channel quality feedback indicators from M subscribers to a multi-cast service. The scheduling element can comprise a memory element and a processing element that is configured to execute the method steps described herein. In one embodiment, measurements of channel interference (C/I) of the forward link common pilot signal serves as channel quality feedback indicators. At step 210 , the scheduling element selects an optimal time for transmitting the multi-cast on a channel marked by a special MAC_ID. The optimal time is selected by determining when the subscriber in the worst location has good channel conditions or the transmission delay of the data becomes too large. For example, the channel conditions could be unfavorable for a subscriber who is traveling at extremely high speeds near the base station. The high speed could cause random, but short-lived, deep fades. Such short-lived, deep fades would be an unfavorable channel condition that would decrease the data throughput of the system. At step 220 , the base station encodes the multi-cast data in a manner that would allow reception at an acceptable quality level by the subscriber with the worst channel conditions. The base station then scrambles the encoded multi-cast data as necessary with a scrambling code that is known by all subscribers, and transmits it at the selected time on the channel specified by the MAC_ID. At step 230 , the base station transmits using the modulation scheme and power level that allow the subscriber with the worst channel conditions to receive the broadcast at an acceptable quality level. An additional refinement to the embodiment is the use of a scrambling code that is common for all subscribers, or common to a select group of subscribers who have paid for extra services.
In one alternative embodiment, rather than using the C/I as the channel quality feedback indicator, the scheduling element determines when the worst location subscriber has good channel conditions by transmitting test data packets to the worst location subscriber until acknowledgement signals arrive from the worst location subscriber. Once acknowledgement signals indicating the successful demodulation and decoding of the test data packet arrives, the scheduling element can commence the multi-cast.
In another alternative embodiment, the scheduling element transmits test data packets to all subscribers and waits for acknowledgement signals from a predetermined percentage of the subscribers. The percentage could be anywhere from a simple majority of the subscribers to 100% of the subscribers. The actual percentage value can be chosen by the serving system. In a system wherein acknowledgement signals are scheduled to arrive at predetermined times, this embodiment can be adjusted so that the multi-cast occurs when at least one designated subscriber has transmitted an acknowledgment signal. The at least one designated subscriber can be chosen so as to maximize the probable receipt of the multi-cast by the majority of the subscribers.
It should be noted that it is unlikely for a subscriber in a good location to not successfully receive the test data packets or the multi-cast. If a base station does not receive an acknowledgment signal from this subscriber, it is more probable that the base station lost the reverse link acknowledgment signal rather than an unsuccessful receipt of the forward link signal by the subscriber. Hence, it is more important to concentrate on acknowledgment signals from the subscribers with poor channels rather than subscribers with favorable channels.
FIG. 3 is a flowchart for selecting the transmission format of a multi-cast to M subscribers. At step 300 , a scheduling element in a base station determines the channel quality feedback indicators from M subscribers to a multi-cast service. Based upon the channel quality feedback indicators, the scheduling element determines the time sensitivity of data and the transmission formats of the data. At step 310 , the scheduling element selects a transmission format that will allow the subscriber with the worst channel conditions to recover the original data. At step 320 , the base station transmits the multi-cast in the transmission format selected by the scheduling element, wherein the multi-cast is transmitted using a single MAC_ID. It should be noted that the other subscribers would not have difficulties decoding the multi-cast using the selected transmission format since all other subscribers had better channel conditions. As an alternative to using the single MAC_ID, the multi-cast is scrambled by a scrambling code known only to the subscribers.
In addition to the steps described above, the scheduling element could also send re-transmissions in the format designated by the subscriber with the worst channel conditions. Re-transmissions are redundant transmissions of the information, which have already been transmitted. Through the process of “soft-combining” at the receiver, symbols that have been corrupted during the transmission of one packet can be combined with symbols that have been corrupted during the transmission of another packet. Hence, the “good” symbol bits from the separate transmissions can be used together to recover the original data information.
As mentioned before, it is possible to have multiple special MAC_IDs for each possible multi-cast service. It is envisioned that the embodiments described above can allow a service provider to offer multiple multi-cast services, such as news, weather, sports, stock quotes, etc., without sacrificing channel resources that could be otherwise used for voice traffic and dedicated data traffic.
Those of skill in the art would understand that information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.
Those of skill would further appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | Methods and apparatus are presented for efficient broadcasting in wireless packet data systems. A single MAC_ID is used for broadcasting to a group of subscribers. By using the channel quality information of the group of subscribers, a base station determines the identity of the subscriber with the worst channel conditions. The timing and the transmission format of the multi-cast are then tailored so that the subscriber with the worst channel conditions is capable of recovering the transmission. If the timing and the transmission format is chosen in relation to subscriber with the worst channel conditions, it is probable that other subscribers will be able to recover the transmission as well. Hence, only a single MAC_ID need to be used to make a single broadcast, rather than sending multiple transmissions to multiple subscribers. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
The present Divisional application claims priority from U.S. application Ser. No. 11/474,787, filed Jun. 26, 2006 now U.S. Pat. No. 7,581,411, which claims priority from U.S. Provisional Patent Application Ser. No. 60/798,696 filed May 8, 2006.
FIELD OF THE INVENTION
The present invention is directed to the reliquefaction of boiloff vapors from liquefied natural gas (LNG) storage tanks. Such storage tanks are used on large ocean-going vessels for transport of LNG, and are in widespread use on land in many applications.
BACKGROUND ART
This invention is particularly applicable to shipboard re-liquefaction of boil-off natural gas from LNG carriers, where simplicity, weight, energy consumption, cost, and maintenance must strike an economic balance.
Such systems have typically incorporated a refrigeration cycle, composed of a working fluid such as nitrogen gas in mufti-stage compression and one or two turboexpanders which may drive compressors; and the boiloff gas is typically compressed in two stages. Such prior art is shown in existing patents: WO 98/43029 A1 (Oct. 1, 1998), WO 2005/057761 A1 (May 26, 2005), WO 2005/071333 A1 Aug. 4, 2005, each issued to Rummelhoff; and U.S. Pat. No. 6,449,983 B2 (Sep. 17, 2002) and U.S. Pat. No. 6,530,241 B2 (Mar. 11, 2003), each issued to Pozivil; and has also been prominently displayed in publications and web sites. The designs in the prior art include turboexpansion of the refrigerant gas through wide pressure and temperature ranges, considered essential for process efficiency under the selected overall plant design, leading to compression of the refrigerant gas in multistage compressors of increased weight and complexity. None of these patents (and other published material) has openly considered the viability of a single stage of refrigerant compression, though shipboard liquefaction of boiloff gas has been a topic of serious investigation. Hence, the advantages of single-stage compression of a refrigerant gas in a main compressor have not been obvious to practitioners with skill in the specific technology.
Since these installations are considered primarily (but not exclusively) aboard ship, size and weight, and the number of pieces of equipment, especially machinery, take on great importance. Additionally, requirements for unbroken on-stream time may necessitate full duplication of all rotating equipment, effectively doubling the savings which accrue from a reduction in component machinery and complexity.
In view of the compound requirements for achieving efficient reliquefaction and reducing the number of components, including their weights and complexity, it would be advantageous to develop a process which achieves both ends.
It has been determined that under certain design configurations, a refrigeration cycle requiring a main single-stage compressor for the refrigerant, can have high thermodynamic efficiency (low specific power); and have the aforementioned benefits of reductions in component rotating equipment.
The current invention breaks the state-of-the-art barrier to an efficient refrigeration cycle based on a low compression ratio for the refrigerant gas, and enables employment of a single-stage main compressor for the refrigerant gas. The current system offers attractive alternatives to other proposed and constructed systems.
This invention achieves the objectives of net capital cost and overall weight reduction by reducing the compression of nitrogen in a main compressor to one centrifugal stage, saving a large investment over a main compressor of multiple stages and its coolers. Further compression may take place in compressors which are shaft-connected to turboexpanders.
Another aspect of this invention is that the refrigeration cycle is so designed as to efficiently achieve boiloff gas condensation while utilizing only one turboexpander, while maintaining a low compression ratio on the single-stage refrigerant compressor.
This invention relates to a process and equipment configuration to liquefy natural gas boiloff, wherein gas machinery for the refrigeration cycle is composed of a single-stage main compressor and one or two turboexpanders, which may drive compressors.
Additional improvements may include, all or individually, a single-stage boiloff gas compressor; an inserted heat exchanger to enable compression of the boiloff gas from an ambient temperature condition; and throttling a small refrigerant sidestream at low temperature in order cover the complete cooling range, while maintaining a low compression ratio on the single-stage main cycle compressor without an increase in energy consumption. This is especially effective when the condensed boiloff gas is brought to a subcooled condition.
OBJECT OF THE INVENTION
The object of this invention is to provide equipment and process for reliquefaction of LNG boiloff gas which is thermodynamically efficient, in an installation which has a lower capital cost, smaller size (volume, footprint), lower weight, and less need for maintenance than systems utilizing the prior art.
SUMMARY OF THE INVENTION
Reliquefaction systems for liquefaction of LNG boiloff gas can be composed of a circulating working fluid, such as nitrogen in a closed cycle, which includes compression and machine expansion; as well as compression of the LNG boiloff gas. Such systems are machinery-intensive, i.e. the machinery size, weight, cost, and potential maintenance constitute major factors in the practicality and economy of the installation. This invention directly addresses machinery-intensive systems by means of a reduction in machinery components, i.e. stages of compression, while maintaining, and even improving, the energy requirements for reliquefaction.
The signal feature of the invention incorporates a single-stage main compressor for the circulating refrigerant fluid (nitrogen). Since each stage of compression in a main compressor requires an aftercooler (intercooler, if followed by another stage of compression), a reduction in stages of compression also reduces the heat exchanger requirements for cooling the compressed gas. Of course, savings are multiplied, if an installation must have a spare compressor.
Additionally, features can be incorporated in the invention which improve the thermodynamic efficiency (reduction in power consumption) of the reliquefaction process. These features include:
1. The cold boiloff gas emerging from the storage tank is warmed to approximately ambient temperature before it is compressed. Compression of cold gas has a thermodynamic penalty and leads to higher energy consumption. 2. A small refrigerant stream is liquefied, reduced in pressure, and introduced into the cold end of the main heat exchanger in order to achieve final cooling or subcooling of the reliquefied boiloff gas, as a means of reducing the overall compression ratio required for compression of the refrigerant.
The invention allows choices for employment of one or two stages of boiloff gas compression; one or two refrigerant turboexpanders; how the turboexpander(s) is loaded, i.e. by compressors, electric generators, mechanical load, and/or dissipative brakes; whether a combination of compressors is in series or parallel; if there are two turboexpanders, whether they operate in series or in parallel; and whether a turboexpander-driven compressor operates over the same pressure range as the main compressor, or a different pressure range.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures show multiple versions of the invention as examples of many alternative arrangements. These configurations are not exhaustive; but serve as a sampling of many possible arrangements which can accompany the externally-driven single-stage compression of the refrigerant gas as the chief element of the process invention.
FIG. 1 depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and a single turboexpander. Turboexpander shaft output could drive an electric generator, a mechanical load, or a dissipative brake.
FIG. 2 depicts a version of the invention which includes a single stage of boiloff gas compression, which compresses boiloff gas as it emerges cold from the cargo tank; and a single turboexpander. Turboexpander shaft output could drive an electric generator, a mechanical load, or a dissipative brake.
FIG. 3 depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and two turboexpanders. Turboexpanders shaft output could drive electric generators, mechanical loads, or dissipative brakes. The turboexpanders are shown in a series arrangement. The turboexpanders could also be in a parallel arrangement, operating across the same pressure ratio, instead of dividing the pressure ratio between them.
FIG. 4 depicts a version of the invention which includes a single stage of boiloff gas compression which compresses boiloff gas as it emerges cold from the cargo tank; and two turboexpanders. Turboexpanders shaft outputs could drive electric generators, mechanical loads, or dissipative brakes. The turboexpanders are shown in a series arrangement. The turboexpanders could also be in a parallel arrangement, operating across the same pressure ratio, instead of dividing the pressure ratio between them.
FIG. 5 (which is quantified in the Example) depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and a single turboexpander. Turboexpander shaft output drives a compressor, which further elevates the top operating pressure of the closed refrigeration cycle.
FIG. 6 depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and two turboexpander. Turboexpanders shaft outputs drive compressors, which further elevate the top operating pressure of the closed refrigeration cycle. The turboexpanders could also be in a parallel arrangement, operating across the same pressure ratio, instead of dividing the pressure ratio between them. The compressors are shown in a series arrangement. However, they may also be arranged in a parallel arrangement, each operating over the same suction and discharge pressures; or the compressors may operate over the same pressure range as the main refrigeration compressor.
DETAILED DESCRIPTION OF THE INVENTION
The drawings show the arrangement of equipment for effecting this process and its modifications.
( FIGS. 1 & 2 ) A refrigerant cycle gas 14 , such as nitrogen, is compressed in a single-stage compressor 2 . Through an arrangement of heat exchangers 6 and one turboexpander 8 , refrigeration is delivered to the compressed natural gas boiloff from the cargo of a liquefied natural gas carrier ship, or other liquefied natural gas storage container.
The compressed nitrogen 3 is cooled in an aftercooler 4 against cooling water or ambient air, and is partially cooled in a heat exchanger 6 against low-pressure returning streams. A first part of the partially-cooled compressed nitrogen 7 is withdrawn from the heat exchanger and is work-expanded in a turboexpander 8 . The exhaust stream 9 from the turboexpander re-enters the heat exchanger 6 and flows countercurrent to the feed streams and exits as stream 14 which returns to the suction side to the aforementioned single-stage nitrogen compressor.
The second divided stream 10 is further cooled in the heat exchanger 6 . It is removed and passed through a throttle valve 11 and stream 12 exits the throttle valve at the same or nearly the same pressure as the turboexpander exhaust pressure of the first divided stream. The valve-throttled stream 12 also re-enters the heat exchanger 6 and flows countercurrent to the feed streams. Stream 12 may be combined with stream 9 at junction point 13 and also returns to the suction side to the aforementioned single-stage nitrogen compressor. Power recovery from the turboexpander 8 may be by mechanical shaft connection to the single-stage nitrogen compressor or by means of an electric generator. In some cases, power recovery may not be practiced.
In FIG. 1 , natural gas boiloff 21 is warmed in a heat exchanger 22 and then compressed in either a single stage compressor, or in two stages with intercooling. The compressed boiloff gas 25 is cooled in an aftercooler 26 against cooling water or ambient air, and the cooled, compressed boiloff gas 27 is then cooled in the above-mentioned heat exchanger 22 by refrigeration derived from warming the aforementioned natural gas boiloff. The cooled, compressed boiloff natural gas 28 undergoes further cooling in heat exchange against the refrigerant in heat exchanger 6 . This stream 28 is further de-superheated and then partially or fully condensed. The condensate may be further subcooled. The condensate 29 is returned to the cargo tank of the vessel. The condensate 29 may be flashed to lower pressure with recycle or venting of vapor prior return of the liquid to the cargo tank of the vessel.
Alternatively ( FIG. 2 ), the cold natural gas boiloff 23 enters the boiloff gas compressor 24 at the temperature it leaves the cargo tank piping, and the stream 25 which exits a one- or two-stage boiloff gas compressor directly enters the heat exchanger 6 for further cooling. Compressed boiloff natural gas undergoes further cooling in heat exchanger 6 against the refrigerant, where the boiloff gas is further de-superheated and then partially or fully condensed. The condensate may be further subcooled prior to cargo tank return. The condensate 29 may be flashed to lower pressure with recycle or venting of vapor prior return of the liquid to the cargo tank of the vessel.
FIGS. 3 and 4 show arrangements similar to FIGS. 1 and 2 , but incorporating two turboexpanders in the refrigeration circuit. The turboexpanders operate over different temperature ranges, which may partially overlap. These systems consume less energy than single turboexpander systems, at the cost of an additional machine and related complexity.
FIGS. 5 and 6 show arrangements similar to FIG. 1 and FIG. 3 , respectively, with the exception that the turboexpanders drive compressors. The refrigeration cycle then includes the effects of further compression by these means. The processes represented in FIGS. 2 and 4 could also be modified to include turboexpander-driven compressors as part of the process cycle.
There are a large number of combinations of how turboexpander-driven compressors are employed in a refrigeration cycle. The common element in each of the figures is the single-stage centrifugal main refrigeration compressor.
EXAMPLE
kgmoles/hr=kilogram moles per hour (flow)
° C.=degrees Celsius (temperature)
bar=bar (absolute pressure)
composition %=molar percentages
FIG. 5 shows a process for the reliquefaction of boiloff gas 21 evolved from the cargo tanks of an ocean-going LNG transport vessel, where the boiloff gas evolution rate is 395.9 kgmoles/hr, reaching the deck at a temperature of −130° C. and a pressure of 1.060 bar. The boiloff gas composition is 91.46% methane; 8.53% nitrogen; and 0.01% ethane. The boiloff gas is warmed in heat exchanger 22 and stream 23 exits at 41° C. and 1.03 bar. Stream 23 enters boiloff gas compressor 24 and is compressed to 2.3 bar and 122° C. Stream 25 is cooled in aftercooler 26 to 43° C. and 2.2 bar. Typically, cooling water is the cooling medium in indirect heat transfer with the boiloff gas for this aftercooler and other aftercoolers in the process. The cooled, compressed gas 27 enters heat exchanger 22 in indirect heat transfer with stream 21 , and exits as stream 28 at −126.7° C. and 2.17 bar. Stream 27 enters heat exchanger 6 for further cooling, condensation, and subcooling. Stream 29 exits heat exchanger 6 at −169.2° C. and 2.02 bar. It then can be re-injected into the storage tank.
The refrigeration cycle working fluid in this case is nitrogen. A nitrogen stream 3 at 8.73 bar and 43.12° C. is compressed in a single-stage compressor 2 to 16.64 bar and 123.1° C. at a flow rate of 6875 kgmoles/hr. This stream is cooled in aftercooler 4 to 43° C. and 16.50 bar. Stream 41 is further compressed in turboexpander-driven compressor 81 to 18.99 bar and 59.53° C. Stream 42 cooled in aftercooler 82 to 43.0° C. and 18.89 bar, and stream 5 enters heat exchanger 6 , where it is cooled to −142.0° C. A division of nitrogen flow occurs here. Stream 7 is routed to turboexpander 8 at a flow of 6825 kgmoles/hr. The balance of the flow of 50 kgmoles/hr remains in heat exchanger 6 and is cooled to −163.0° C. and 18.49 bar and exits as stream 10 .
Stream 10 is valve-throttled to 9.00 bar which produces a two-phase mixture 12 at a temperature of −171.0° C., which enters the cold end of heat exchanger 6 and is vaporized and warmed as it further removes heat from the boiloff gas stream.
Stream 7 undergoes a work-producing turboexpansion which is utilized to drive compressor 81 . The discharged stream 9 is at −167.7° C. and 8.99 bar. This stream enters heat exchanger 6 at a point where the returning cold stream is at that temperature. The returning streams may be combined as they are warmed to 42.19° C. and 8.73 bar leaving the heat exchanger as stream 14 , transferring their refrigerative value to the incoming streams.
Stream 14 enters the suction side of the single-stage compressor 2 as part of the closed refrigeration cycle.
While particular embodiments of this invention have been described, it will be understood, of course, that the invention is not limited thereto, since many obvious modifications can be made; and it is intended to include with this invention any such modifications as will fall within the scope of the invention as defined by the appended claims. | A design for equipment and process for reliquefaction of LNG boiloff gas, primarily for shipboard installation, has high thermodynamic efficiency and lower capital cost, smaller size (volume, footprint), lower weight, and less need for maintenance than systems utilizing the prior art. The main refrigerant gas compressor is reduced to a single stage turbocompressor. Optional elements include: compression of boiloff gas at ambient temperature; compression of boiloff gas in one or two stages; turboexpansion of refrigerant gas incorporating one or two turboexpanders; turboexpander energy recovery by mechanical loading, compressor drive, or electric generator; refrigerant sidestream for cooling at the lowest temperatures. | 5 |
FIELD OF THE INVENTION
This invention relates to air valves for the intake manifolds of internal combustion engines, and, more particularly, to a lightweight, two-piece air valve which is easy to service, adaptable for use with different fuel injection systems and which smoothly transmits a flow of air or an air-fuel mixture therethrough into the intake manifold.
BACKGROUND OF THE INVENTION
Intake manifolds for internal combustion engines generally comprise a manifold body formed with a plenum having an inlet and a hollow interior. A number of air passages or runners are formed in the manifold body each having an inlet at the plenum interior and an outlet connected to one of the cylinders of the engine. In many designs, a mixture of fuel and air, or air only, is directed into the interior of the plenum through a throttle valve mounted to the manifold body. The throttle valve controls the volume of air, or air-fuel mixture, entering the plenum for distribution to each of the runners.
Conventional throttle valves generally comprise a one-piece valve body having a base which is bolted to the intake manifold and a number of throughbores each mounting a throttle blade. The throttle blades are pivotally mounted within a respective throughbore by a shaft which is rotatable in response to pivoting of a throttle arm. The throttle blades are selectively movable between a fully open position and a fully closed position relative to their associated throughbores to control the flow of air and/or an air-fuel mixture therethrough and into the plenum interior of the manifold.
A number of problems inherent in the design of many throttle valves limit their effectiveness and versatility. One-piece throttle valves tend to be relatively heavy thus adding to the overall weight of the engine and reducing performance. Such valves are often difficult to service because access to the throttle blades, throttle arms, shafts and associated bearings is restricted in many of the current engine designs. If the throttle valve must be removed from the manifold to perform a service operation, a problem is presented of obtaining an effective seal with the manifold after the repairs are completed. This sealing problem can also occur if the throttle valve must be removed to accommodate different size air cleaners or supercharger bonnets, and/or different manifold bolt patterns or mounting flange configurations.
In addition to the foregoing limitations of conventional throttle valves, it has been recognized as discussed in U.S. patent application Ser. No. 08/319,294, filed Oct. 6, 1994 and entitled "Air Intake Manifold," that engine performance can suffer in the event turbulent flow is developed within the interior of the manifold. An inability to create a substantially laminar flow of air and/or an air-fuel mixture within the runners of the manifold can result in a loss of torque, decreased fuel efficiency and increased hydrocarbon emissions. Throttle valves of the type described above contribute to the creation of turbulence within the plenum interior of the manifold, and thus play a role in degrading engine performance and reducing torque output.
SUMMARY OF THE INVENTION
It is therefore among the objectives of this invention to provide a throttle or air valve for the intake manifold of an internal combustion engine which is easy to repair and/or replace, which is readily adaptable for use with different fuel supply systems, which reduces turbulence within the associated intake manifold and which is lightweight in construction.
These objectives are accomplished in a throttle or air valve, particularly intended for use with air intake manifolds of the type employed with fuel injected, internal combustion engines, comprising a valve base adapted to be mounted to the plenum of the air intake manifold and a separate valve body sealingly engageable with a seat formed in the valve base. The valve body is formed with a number of inlet bores, each of which carry a rotatable throttle blade, and these inlet bores align with discharge bores in the valve base each having an outlet edge or lip formed with a substantially 90° radius.
One aspect of this invention is predicated upon the concept of providing an air valve designed to transfer a flow of air into the plenum interior of an air intake manifold with minimum turbulence and a comparatively smooth, more laminar flow. It has been found that engine performance and torque output are adversely affected by disruption of the flow of air and/or an air-fuel mixture through the interior of the plenum and within the runners of intake manifolds. Such turbulence reduces the efficiency with which air and/or air-fuel mixture is transmitted into the cylinders of the engine to which the manifold is mounted, thus reducing engine performance and lowering torque output for a given speed of operation of the engine. This problem is reduced with the air valve of this invention by the construction of both the valve body and valve base. Preferably, the inlet bores of the valve body each form an inner wall having a radiused lip at the inlet end, a substantially vertical portion at the outlet end and an intermediate portion which angles radially inwardly from the radiused lip to the vertical portion at the outlet end. Air, or an air-fuel mixture, entering the valve body is smoothly transferred within each inlet bore thereof into an aligning discharge bore in the valve base. Each discharge bore, in turn, is formed with a substantially 90° radius at the outlet end thereof which substantially eliminates vortices in the air flow after it exits the air valve, and assists in smoothly fanning out the air flow into the larger area of the interior of the plenum of the manifold. As a result, the stream of air entering the plenum interior from the air valve is more smoothly directed into each of the runners of the manifold in a more laminar flow with less turbulence. In turn, a more laminar air flow is achieved within each of the runners which aids in maintaining velocity of the air flow therethrough at low engine speeds, and also permits more air flow to pass through the runners at high engine speeds.
In addition to the improved air flow characteristics provided by the air valve of this invention, a number of advantages are obtained by its two-piece construction. As noted above, the air valve is formed with a valve base mounted to the plenum of an air intake manifold and a valve body mounted within a seat formed in the valve base. With this construction, the valve body may be readily removed from the valve base without disturbing its position on the manifold allowing repairs to be made on the throttle blades, shafts, bearings, throttle arms and other parts carried by the valve body. Additionally, one valve body may be exchanged for a valve body of another type or configuration to accommodate different sized air cleaners, supercharger bonnets or other engine alterations. Regardless, the valve base remains in place on the manifold thus maintaining the seal therebetween. Further, because the valve body is separate from the valve base, machining operations can be performed in the fabrication of the valve body which reduce its overall size and weight compared to conventional, one-piece throttle valves.
Additionally, there may be instances in which it is desired to exchange one valve base with another depending upon the configuration of the intake manifold on a particular engine. This can be done with the subject invention, while employing the same valve body, thus reducing the overall inventory of parts needed to accommodate different engine designs which reduces costs.
DESCRIPTION OF THE DRAWINGS
The structure, operation and advantages of the presently preferred embodiment of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a partially disassembled perspective view of the two-piece air valve of this invention and a portion of an air intake manifold to which the air valve is mounted.
FIG. 2 is a partial cross-sectional view illustrating the air valve herein; and
FIG. 3 is a plan view of the air valve of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the Figs., a throttle or air valve 10 is illustrated which is designed for mounting to the inlet end 11 of the plenum 12 of an air intake manifold 13, preferably of the type disclosed in U.S. patent application Ser. No. 08/319,294 entitled "Air Intake Manifold" filed Oct. 6, 1994, which is owned by the assignee of this invention, and the disclosure of which is incorporated by reference in its entirety herein. The air valve 10 is a two-piece construction comprising a valve base 14 and a separate valve body 16.
In the presently preferred embodiment, the valve base 14 includes a peripheral edge 18 having a number of mounting tabs 20 each formed with a throughbore 22. The throughbores 22 of mounting tabs 20 receive studs 23 carried by the plenum 12 so that the air valve 10 can be secured to the plenum 12 of the air intake manifold 13 with nuts (not shown). A gasket (not shown) is preferably interposed between the bottom surface 15 of the valve base 14 and plenum 12 to create a seal therebetween.
The center portion of valve base 14 is formed with a recessed plate 24 which is connected to the peripheral edge 18 in position below its top surface 26 so that a valve seat 28 is formed at the intersection between the recessed plate 24 and peripheral edge 18. As described in more detail below, the valve seat 28 carries an o-ring 30 which creates a seal between the valve body 16 and valve base 14.
In the embodiment of air valve 10 depicted in the Figs., four discharge bores 32 are formed in the recessed plate 24, only three of which are depicted in FIG. 1 each having an inlet end 34 and an outlet end 36. As best shown in FIG. 2, the outlet end 36 of each discharge bore 32 is formed with a radius 38, preferably of about 0.250 inches. This radius 38 extends from the bottom surface 15 of valve base 14 along the inner wall 42 of each of the discharge bores 32 in a direction generally toward the top surface 26 of the peripheral edge 18. It has been found that the formation of a smoothly curved radius 38 on outlet end 36 of discharge bores 32 reduces turbulence in the flow of air into the interior of plenum 12. It is believed that the radius 38 on outlet end 36 of discharge bores 32 reduces vortices in the air flow passing into the plenum 12, and enables the air flow to fan outwardly within the plenum interior thus further reducing turbulence. As discussed in patent application Ser. No. 08/319,294, mentioned above, the reduction of turbulence within the plenum interior increases engine performance and torque output, increases fuel efficiency and decreases emissions from the combustion process.
With reference to FIG. 2, the size of the bottom surface 15 of valve base 14 and the inlet end 11 of plenum 12 are specifically designed to compliment one another and avoid any blockage or interference with the discharge bores 32. Preferably, the wall 13 at the inlet end 11 of plenum 12 is located at, or radially outwardly from, the point of intersection 43 between the radius 38 at the outlet end 36 of each discharge bore 32 and the bottom surface 15 of valve base 14. The wall 13 is preferably formed with a radius 17 at the inlet end 11 of about 90°. It has been found that the air flow from the discharge bores 32 fans outwardly and exhibits less turbulence, as noted above, with the wall 13 of plenum 12 positioned radially outwardly from such point of intersection 43 thus avoiding any blockage or interference with the air flow passing between the air valve 10 and plenum 12. The recessed plate 24 of valve base 14 is also formed with a cross passage 46 extending between two of the discharge bores 32, and a cross passage 48 extending between the other two discharge bores 32. These cross passages 46, 48 tend to equalize the air flow within each of the discharge bores 32 so that a substantially uniform flow of air from the valve base 14 is introduced throughout the entire plenum interior.
With reference to FIGS. 1 and 2, the valve body 16 of air valve 10 comprises an upper ring 50 and an inwardly tapered, center portion 52 having opposed ribs 54, one of which is shown in FIG. 1. The valve body 16 is formed with four inlet bores 56a-d which extend from the top surface 58 of the upper ring 50 to the bottom surface 60 of the center portion 52, and a pair of air bleed holes 57. Each of the inlet bores 56a-d form an inner wall having a radiused inlet portion 62, a substantially vertically extending outlet portion 63 which terminates at bottom surface 60, and, a tapered intermediate portion 65 located between the radiused inlet portion 62 and outlet portion 63. In the presently preferred embodiment, the inlet portion 62 is formed with a radius of about 0.375 inches extending in a direction toward the outlet portion 63. The tapered intermediate portion 65 is angled radially inwardly from the inlet portion 62 to the outlet portion 63 at an angle θ with respect to vertical preferably in the range of about 5-25° and most preferably about 7°. The tapered intermediate portion 65 terminates at a vertical distance of about 1.125 inches from the top surface 58 of upper ring 50, where the outlet portion 63 begins.
As best shown in FIG. 3, each of the inlet bores 56a-d mounts a pivotal throttle blade 64a-d, respectively. Preferably, the radius of each inlet edge is approximately 90°. The throttle blades 64a and 64b are mounted by rivets 66 to a shaft 68 which is rotatably carried at opposite ends by bearings 70 and 72 mounted to the upper ring 50 of valve body 16. One end of the shaft 68 is retained within the bearing 70 by a pin (not shown), and the opposite end thereof is connected to a first throttle arm 76. Similarly, the throttle blades 64c and 64d are mounted by rivets 78 to a second shaft 80 which is rotatable within bearings 82, 84 carried by upper ring 50. One end of the second shaft 80 is mounted to a second throttle arm 86, which, in turn, is pivotally connected by a connector arm 88 to the first throttle arm 76. Preferably, screws 90 or other fasteners are employed to attach the connector arm 88 to the first and second throttle arms 76, 86. Conventionally, the throttle blades 64a-d are pivotal between a fully closed position depicted in FIG. 1 and a fully open position (not shown) by rotation of shafts 68, 80 in response to pivoting of the throttle arms 76, 86.
As best shown in FIGS. 1 and 2, the valve body 16 is mounted to the valve base 14 by inserting the center portion 52 of valve body 16 atop the recessed plate 24 and against the valve seat 28 within valve base 14. In the assembled position, the bottom surface 60 of center portion 52 makes metal-to-metal contact with the recessed plate 24, and the inlet bores 56a-d of valve body 16 align with the discharge bores 32a-d, respectively, of valve base 14. The base of center portion 52 of valve body 16 is dimensioned such that its circumferential edge snugly fits within the valve seat 28, with the o-ring seal 30 providing a seal therebetween. In order to interconnect the valve base 14 and valve body 16, screws (not shown) are inserted through each of four throughbores 92 in the recessed plate 24 of valve base 14, two of which are shown in FIG. 1, and into threaded bores (not shown) formed in the base of valve body 16.
While the invention has been described with reference to a preferred embodiment, it should 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.
For example, while the valve 10 of this invention has been described primarily as an "air valve" particularly intended for use with an air intake manifold, it is contemplated that such valve could also be utilized to introduce a mixture of fuel and air into the plenum of a manifold connected to a fuel injection system.
Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | An air valve particularly intended for use with air intake manifolds of the type employed with fuel injected, internal combustion enginers, comprising a valve base adapted to be mounted to the plenum of the air intake manifold and a separate valve body sealingly engageable with a seat formed in the valve base. The valve body is formed with a number of inlet bores, each of which carry a rotatable throttle blade, and these inlet bores align with discharge bores in the valve base each having a radiused outlet edge or lip. | 5 |
BACKGROUND OF INVENTION
[0001] This disclosure relates generally to antistatic compositions, their use in flame retardant resin compositions, and a method of manufacture thereof.
[0002] Polymeric resins are suitable for a large number of applications because of their high strength-to-weight ratio and ease of processing. However, the build up of electrostatic charges in the polymeric resin attracts dust and foreign particles, thereby spoiling the appearance of molded parts made therefrom. Moreover, the build up of electrostatic charges renders the polymeric resin unusable in certain electrical and electronic applications. It is therefore desirable to have polymeric resins that possess antistatic properties (i.e., are electrostatically conductive) and that maintain these properties at the elevated temperatures used in processing these materials.
[0003] Polymeric resins and articles having antistatic properties are typically obtained by directly blending antistatic agents with the polymeric resins during a compounding process. Unfortunately, the antistatic agent often migrates to the surface layer of the article over time, lowering the antistatic properties due to frictional wear of the surface layer. A need therefore remains for stable antistatic compositions wherein the antistatic agent remains well dispersed in the bulk of the polymeric resin during high temperature processing and subsequent use. In addition, it is desirable to have flame retardant antistatic compositions for end use applications such as electronic applications or packaging flammable materials.
SUMMARY OF INVENTION
[0004] An antistatic, impact resistant, flame retardant composition comprises a polycarbonate resin; an impact modifier comprising polysiloxane; an antistatic agent; and a flame retardant in an amount greater than or equal to about 9 wt %. Owing to its excellent antistatic, impact and flame retardant properties, the composition can be used in electrical and electronic equipment, and precision machinery where high fabrication temperatures and high usage temperatures are often encountered.
DETAILED DESCRIPTION
[0005] Antistatic compositions comprising polymeric resins and antistatic agents are often flammable, which is undesirable especially in electronic applications. The addition of large amounts of a flame retardant to reduce the flammability of the material typically has the effect of reducing the impact properties of the material. It has now been unexpectedly discovered that the addition of bisphenol A bis(diphenyl phosphate) (hereinafter BPADP) to an antistatic composition comprising a polymeric resin, an impact modifier comprising polysiloxane, and an antistatic agent such as PELESTAT 6321, commercially available from Sanyo, or PEBAX MH1657, commercially available from Atofina, can impart excellent flame retardant properties to the composition while maintaining impact properties. This combination of antistatic, impact resistance, and flame retardant properties is useful in electronic articles as well as for packaging flammables. These compositions can also be used as media optical shells for optical media and other similar data storage devices.
[0006] The term polycarbonate resin, comprises aromatic carbonate chain units and includes compositions having structural units of the formula (I):
[0007] in which at least about 60 percent of the total number of R 1 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic, or aromatic radicals.
[0008] Preferably, R 1 is an aromatic organic radical and, more preferably, a radical of the formula (II):
—A 1 —Y 1 —A 2 — (II)
[0009] wherein each of A 1 and A 2 is a monocyclic, divalent aryl radical and Y 1 is a bridging radical having one or two atoms which separate A 1 from A 2 . In an exemplary embodiment, one atom separates A 1 from A 2 . Illustrative non-limiting examples of radicals of this type are —O—, —S—, —S(O)—, —S(O 2 )—, —C(O)—, methylene, cyclohexyl-methylene, 2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene, and adamantylidene. The bridging radical Y 1 can be a hydrocarbon group or a saturated hydrocarbon group such as methylene, cyclohexylidene or isopropylidene.
[0010] Polycarbonate resins can be produced by the reaction of the carbonate precursor with dihydroxy compounds. Typically, an aqueous base such as (e.g., sodium hydroxide, potassium hydroxide, calcium hydroxide, and the like,) is mixed with an organic, water immiscible solvent such as benzene, toluene, carbon disulfide, or dichloromethane, which contains the dihydroxy compound. A phase transfer resin is generally used to facilitate the reaction. Molecular weight regulators may be added to the reactant mixture. These molecular weight regulators may be added singly or as a combination. Branching resins, described forthwith may also be added singly or in admixture. Another process for producing aromatic polycarbonate resins is the transesterification process, which involves the transesterification of an aromatic dihydroxy compound and a diester carbonate. This process is known as the melt polymerization process. The process of producing the aromatic polycarbonate resins is not critical.
[0011] As used herein, the term “dihydroxy compound” includes, for example, bisphenol compounds having general formula (III) as follows:
[0012] wherein R a and R b beach represent a halogen atom, for example chlorine or bromine, or a monovalent hydrocarbon group, preferably having from 1 to 10 carbon atoms, and may be the same or different; p and q are each independently integers from 0 to 4; Preferably, X a represents one of the groups of formula (IV):
[0013] wherein R c and R d each independently represent a hydrogen atom or a monovalent linear or cyclic hydrocarbon group and R e is a divalent hydrocarbon group.
[0014] Some illustrative, non-limiting examples of suitable dihydroxy compounds include the dihydroxy-substituted aromatic hydrocarbons disclosed by name or formula (generic or specific) in U.S. Pat. No. 4,217,438, which is incorporated herein by reference. A nonexclusive list of specific examples of the types of bisphenol compounds that may be represented by formula (III) includes 1,1-bis(4-hydroxyphenyl) methane; 1,1-bis(4-hydroxyphenyl) ethane; 2,2-bis(4-hydroxyphenyl) propane (hereinafter “bisphenol A” or “BPA”); 2,2-bis(4-hydroxyphenyl) butane; 2,2-bis(4-hydroxyphenyl) octane; 1,1-bis(4-hydroxyphenyl) propane; 1,1-bis(4-hydroxyphenyl) n-butane; bis(4-hydroxyphenyl) phenylmethane; 2,2-bis(4-hydroxy-1-methylphenyl) propane; 1,1-bis(4-hydroxy-t-butylphenyl) propane; bis (hydroxyaryl) alkanes such as 2,2-bis(4-hydroxy-3-bromophenyl) propane; 1,1-bis (4-hydroxyphenyl) cyclopentane; and bis(hydroxyaryl) cycloalkanes such as 1,1-bis(4-hydroxyphenyl) cyclohexane. Two or more different dihydric phenols may also be used.
[0015] Typical carbonate precursors include the carbonyl halides, for example carbonyl chloride (phosgene), and carbonyl bromide; the bis-haloformates, for example the bis-haloformates of dihydric phenols such as bisphenol A, hydroquinone, and the like, and the bis-haloformates of glycols such as ethylene glycol and neopentyl glycol; and the diaryl carbonates, such as diphenyl carbonate, di(tolyl) carbonate, and di(naphthyl) carbonate.
[0016] Typical branching resins such as α,α,α′,α′-tetrakis(3-methyl-4 hydroxyphenyl)-p-xylene, α,α,α′,α′-tetrakis(2-methyl-4-hydroxyphenyl)-p-xylene, α,α,α′,α′-tetrakis(2,5 dimethyl-4-hydroxyphenyl)-p-xylene, α,α,α′,α′-tetrakis(2,6 dimethyl-4-hydroxyphenyl)-p-xylene, α,α,α′,α′-tetrakis(4-hydroxyphenyl)-p-xylene, trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris-phenol TC (1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4-(4-(1,1-bis(p-hydroxyphenyl)-ethyl)alpha,alpha-dimethylbenzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, benzophenone tetracarboxylic acid and the like, can also be added to the reaction mixture. Blends of linear polycarbonate and branched polycarbonate resins can be utilized herein. The branching agent may be added at a level of about 0.05 to about 2.0 weight percent (wt %).
[0017] Some illustrative, non-limiting examples of suitable phase transfer resins include, but are not limited to, tertiary amines such as triethylamine, quaternary ammonium compounds, and quaternary phosphonium compounds.
[0018] Molecular weight regulators or chain stoppers are optional and are added to the mixture in order to arrest the progress of the polymerization. Typical molecular weight regulators such as phenol, chroman-1, p-t-butylphenol, p-bromophenol, para-cumyl-phenol, and the like may be added either singly or in admixture and are typically added in an amount of about 1 to about 10 mol % excess with respect to the BPA. The molecular weight of the polycarbonate resin is generally greater than or equal to about 5000, preferably greater than or equal to about 10,000, more preferably greater than or equal to about 15,000 g/mole. In general it is desirable to have the polycarbonate resin less than or equal to about 100,000, preferably less than or equal to about 50,000, more preferably less than or equal to about 30,000 g/mole as calculated from the viscosity of a methylene chloride solution at 25° C.
[0019] Polycarbonate resins are generally used in amounts greater than or equal to about 10 weight percent (wt %), preferably greater or equal to about 30 wt %, more preferably greater than or equal to about 40 wt % of the total composition. The polymeric resins are furthermore generally used in amounts less than or equal to about 99 weight percent wt %, preferably less than or equal to about 85 wt %, more preferably less than or equal to about 75 wt % of the total composition.
[0020] The term “antistatic agent” refers to several materials that can be either melt-processed into polymeric resins or sprayed onto commercially available polymeric forms and shapes to improve conductive properties and overall physical performance.
[0021] Examples of monomeric antistatic agents that may be used are glycerol monostearate, glycerol distearate, glycerol tristearate, ethoxylated amines, primary, secondary and tertiary amines, ethoxylated alcohols, alkyl sulfates, alkylarylsulfates, alkylphosphates, alkylaminesulfates, quaternary ammonium salts, quaternary ammonium resins, imidazoline derivatives, sorbitan esters, ethanolamides, betaines and mixtures of the foregoing. Non-limiting examples of commercial monomeric antistatic agents which may be used in polymeric resins are Pationic 1042 and PATIONIC AS 10, available from Patco, or STATEXAN ® K1, available from Bayer.
[0022] Examples of polymeric antistatic agents include: copolyesteramides such as those disclosed in U.S. Pat. Nos. 4,115,475 to Foy et al., U.S. Pat. Nos. 4,839,441 and 4,864,014 to Cuzin et al.; polyether-polyamide (polyetheramide) block copolymers such as those disclosed in U.S. Pat. No. 5,840,807 to Frey et al.; polyetheresteramide block copolymers such as those disclosed in U.S. Pat. Nos. 5,604,284; 5,652,326; and 5,886,098 to Ueda et al., U.S. Pat. Nos. 4,331,786; 4,230,838; 4,332,920 to Foy et al., and U.S. Pat. Nos. 4,195,015 to Deleens et al.; polyurethanes containing a polyalkylene glycol moiety such as those disclosed in U.S. Pat. No. 5,159,053 to Kolycheck et al., and U.S. Pat. No. 5,863,466 to Mor et al.; polyetheresters such as those disclosed in U.S. Pat. No. 5,112,940, U.S. Pat. No 4,537,596 to Muller et al., and U.S. Pat. No. 4,038,258 to Singh et al, all of which are incorporated herein by reference. Polymeric antistatic agents have been shown to be fairly thermally stable and processable in the melt state in their neat form or in blends with other polymeric resins. Examples of polyetheramides, polyetheresters and polyetheresteramides include block copolymers and graft copolymers both obtained by the reaction between a polyamide-forming compound and/or a polyester-forming compound, and a compound containing a polyalkylene oxide unit. Polyamide forming compounds include aminocarboxylic acids such as ω-aminocaproic acid, ω-aminoenanthic acid, ω-aminocaprylic acid, ω-aminopelargonic acid, ω-aminocapric acid, 11-aminoundecanoic acid and 12-aminododecanoic acid; lactams such as ε-caprolactam and enanthlactam; a salt of a diamine with a dicarboxylic acid, such as hexamethylene diamine adipate, hexamethylene diamine sebacate, and hexamethylene diamine isophthalate; and a mixture of these polyamide-forming compounds. It is preferred that the polyamide-forming compound is a caprolactam, 12-aminododecanoic acid, or a combination of hexamethylene diamine and adipate.
[0023] Polyester forming compounds include a combination of a dicarboxylic acid (or a mixture of two or more dicarboxylic acids) with an aliphatic diol (or a mixture of two or more aliphatic diols). Non-limiting examples of dicarboxylic acids include aromatic dicarboxylic acids, such as isophthalic acid, terephthalic acid, phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, diphenoxyethanedicarboxylic acid and sodium 3-sulfoisophthalate; alicyclic dicarboxylic acids, such as 1,3-cyclopentanedicarboxylic acid, 1,4cyclohexanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid and 1,3-dicarboxymethylcyclohexane; and aliphatic dicarboxylic acids, such as succinic acid, oxalic acid, adipic acid, sebacic acid and decanedicarboxylic acid. These dicarboxylic acids may be used individually or in combination. Non-limiting examples of aliphatic diols include ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,2-butanediol, 1,3-butanediol, 2,3-butanediol, 1,4-butanediol, neopentyl glycol and hexanediol. These aliphatic diols may be used individually or in combination. Preferred dicarboxylic acids are terephthalic acid, isophthalic acid, 1,4-cyclohexanedicarboxylic acid, and sebacic acid and decanedicarboxylic acid. Preferred diols are ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol and 1,4-butanediol.
[0024] Compounds containing polyalkylene oxide units such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol and a block or random copolymer of ethylene oxide and tetramethylene oxide; diamines obtained by replacing the terminal hydroxyl groups of these diols by amino groups; and dicarboxylic acids obtained by replacing the terminal hydroxyl groups of these diols by carboxylic acid groups can be used to form the polyetheramide, polyetherester and polyetheresteramide polymeric antistatic agents. These compounds containing a polyalkylene oxide unit can be used individually or in combination. Of these compounds, polyethylene glycol is preferred.
[0025] For synthesizing a polyetheramide, a polyetherester or a polyetheresteramide, there can be employed a method in which a polyamide-forming compound and/or a polyester-forming compound is reacted with a polyalkylene oxide unit-containing compound, wherein, depending on the type of the terminal groups of the polyalkylene oxide unit-containing compound, the reaction is an esterification reaction or an amidation reaction. Further, depending on the type of the reaction, a dicarboxylic acid or a diamine may also be used in the reaction.
[0026] Polymeric antistatic agents such as PELESTAT 6321, available from Sanyo, or PEBAX MH1657, available from Atofina, are non-limiting examples of commercially available polymeric antistatic agents that may be added to polymeric resins to improve conductive properties. Other commercially available antistatic agents are IRGASTAT P18 and P22 from Ciba-Geigy. Other polymeric materials that may be used as antistatic agents are doped inherently conducting polymers such as polyaniline (commercially available as PANIPOL® EB from Panipol), polypyrrole and polythiophene (commercially available from Bayer), which retain some of their intrinsic conductivity after melt processing at elevated temperatures.
[0027] In one embodiment, the antistatic agent is generally used in an amount greater than or equal to about 0.01, preferably greater or equal to about 0.1, and more preferably greater than or equal to about 1 wt % of the total composition. The antistatic agent is generally used in amount less than or equal to about 25 wt %, preferably less than or equal to about 15 wt %, and more preferably less than or equal to about 10 wt % of the total composition.
[0028] Impact modifiers used in the antistatic compositions may be copolymers comprising a polysiloxane, such as, for example, A-B-A triblock copolymers and A-B diblock copolymers. In one embodiment the impact modifier may be a polycarbonate-polysiloxane copolymer comprising a polycarbonate block and a polysiloxane block, wherein the polysiloxane block portion comprises about 0.5 to about 10 wt % of the impact modifier. In another embodiment, the impact modifiers include copolymers of one or more of an acrylic polymer or a methacrylic polymer mainly comprising an alkyl acrylate or an alkyl methacrylate, a silicone polymer mainly comprising a polysiloxane and an optional diene polymer mainly comprising a conjugated diene such as butadiene or isoprene. A preferred impact modifier of this type is polymethylmethacrylate-polyacrylic-polysiloxane copolymer, which is a core shell impact modifier wherein the shell comprises a polymethylmethacrylate graft polymer and the core is a rubbery phase comprised of a copolymer of silicone and acrylic polymers. A commercially available example of such core shell impact modifiers is Metablen® S-2001 from Mitsubishi Rayon.
[0029] Impact modifiers may be used in amounts greater than or equal to about 1, and preferably greater than or equal to about 2 weight percent (wt %). Also preferred, the impact modifier is used in amounts less than or equal to about 20, preferably less than or equal to about 15, and more preferably less than or equal to about 12 wt % of the total composition.
[0030] The antistatic composition may also comprise at least one flame retardant, generally a halogenated material, an organic phosphate, or a combination of the two. For antistatic compositions containing polyphenylene ether or a polycarbonate resin, the organic phosphate classes of materials are generally preferred. The organic phosphate is preferably an aromatic phosphate compound of the formula (V):
[0031] wherein each R is the same or different and is preferably an alkyl, a cycloalkyl, an aryl, an alkyl substituted aryl, a halogen substituted aryl, an aryl substituted alkyl, a halogen, or a combination of at least one of the foregoing phosphate compounds provided at least one R is aryl.
[0032] Examples of suitable phosphate compounds include phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5′-trimethylhexyl phosphate), ethyl diphenyl phosphate, 2-ethylhexyl bis(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, tricresyl phosphate, triphenyl phosphate, dibutylphenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5′-trimethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, and the like. The preferred phosphates are those in which each R is aryl. A preferred phosphate compound is triphenyl phosphate, which may be unsubstituted or substituted, for example, isopropylated triphenyl phosphate.
[0033] Alternatively, the organic phosphate can be a di- or polyfunctional compound or polymer having the formula (VI), (VIl), or (VIII) below:
[0034] including mixtures thereof, in which R 1 , R 3 and R 5 are independently hydrocarbon; R 2 , R 4 , R 6 and R 7 are independently hydrocarbon or hydrocarbonoxy; X 1 , X 2 and X 3 are halogen; m and r are 0 or integers from 1 to 4, and n and p are integers from 1 to 30.
[0035] Examples of di- and polyfunctional phosphate compounds include the bis (diphenyl phosphates) of resorcinol, hydroquinone and bisphenol-A, respectively, or their polymeric counterparts. Methods for the preparation of the aforementioned di- and polyfunctional phosphates are described in British Patent No. 2,043,083. Another group of useful flame-retardants include certain cyclic phosphates, for example, diphenyl pentaerythritol diphosphate, as a flame retardant resin for polyphenylene ether resins, as is described by Axelrod in U.S. Pat. No. 4,254,775.
[0036] Also suitable as flame-retardant additives are the phosphoramides of the formula (IX):
[0037] wherein each A is a 2,6-dimethylphenyl moiety or a 2,4,6-trimethylphenyl moiety. These phosphoramides are piperazine-type phosphoramides. These additives have been described in Talley, J. Chem. Eng. Data, 33, 221-222 (1988).
[0038] The flame retardant composition may contain a single phosphate compound or a mixture of two or more different types of phosphate compounds. Compositions containing essentially a single phosphate compound are preferred. Preferred phosphate flame-retardants include those based upon resorcinol such as, for example, resorcinol bis(diphenyl phosphate), as well as those based upon bisphenols such as, for example, bisphenol A bis(diphenyl phosphate). Also preferred are the aforementioned piperazine-type phosphoramides. Phosphates containing substituted phenyl groups are also preferred. In an exemplary embodiment, the organophosphate is butylated triphenyl phosphate ester. The most preferred phosphate compounds are resorcinol bis(diphenyl phosphate) (hereinafter RDP), bisphenol A bis(diphenyl phosphate) (hereinafter BPADP) and N,N′-bis[di-(2,6-xylyl)phosphoryl]-piperazine (hereinafter XPP), and mixtures thereof, with BPADP most preferred.
[0039] Halogenated materials are also a useful class of flame-retardants. These materials are preferably aromatic halogen compounds and resins of the formula (X):
[0040] wherein R is an alkylene, alkylidene or a cycloaliphatic linkage, e.g., methylene, ethylene, propylene, isopropylene, isopropylidene, butylene, isobutylene, amylene, cyclohexylene, cyclopentylidene, and the like; a linkage selected from the group consisting of either oxygen ether; carbonyl; amine; a sulfur containing linkage, e.g., sulfide, sulfoxide, sulfone; a phosphorus containing linkage; R can also consist of two or more alkylene or alkylidene linkages connected by such groups as aromatic, amino, ether, carbonyl, sulfide, sulfoxide, sulfone or a phosphorus containing linkage. Ar and Ar′ are mono- or polycarbocyclic aromatic groups such as phenylene, biphenylene, terphenylene, naphthylene, and the like. Ar and Ar′ may be the same or different. Y is a substituent selected from the group consisting of organic, inorganic or organometallic radicals including but not limited to a halogen, ether groups of the general formula OE, wherein E is a monovalent hydrocarbon radical similar to X, monovalent hydrocarbon groups of the type represented by R or other substituents, e.g., nitro, cyano, and the like, substituents being essentially inert provided there be at least one and preferably two halogen atoms per aryl nucleus. X is a monovalent hydrocarbon group such as an alkyl, e.g., methyl, ethyl, propyl, isopropyl, butyl, decyl, and the like; an aryl group, e.g., phenyl, naphthyl, biphenyl, xylyl, tolyl, and the like; an aralkyl group e.g., benzyl, ethylphenyl, and the like, a cycloaliphatic groups, e.g., cyclopentyl, cyclohexyl, and the like, and a monovalent hydrocarbon groups containing inert substituents therein. It is understood that where more than one X is used, they may be alike or different. The letter d represents a whole number ranging from 1 to a maximum equivalent to the number of replaceable hydrogens substituted on the aromatic rings comprising Ar or Ar′. The letter e represents a whole number ranging from 0 to a maximum controlled by the number of replaceable hydrogens on R. The letters a, b, and c represent whole numbers including 0. When b is not 0, neither a nor c may be 0. Otherwise either a or c, but not both, may be 0. Where b is 0, a direct carbon-carbon bond joins the aromatic groups. The hydroxyl and Y substituents on the aromatic groups, Ar and Ar′ can be varied in the ortho, meta or para positions on the aromatic rings and the groups can be in a variety of possible geometric relationship with respect to one another.
[0041] Suitable halogenated flame retardant materials include 2,2-bis-(3,5-dichlorophenyl)-propane, bis-(2-chlorophenyl)-methane, bis(2,6-dibromophenyl)-methane, 1,1-bis-(4-iodophenyl)-ethane, 1,2-bis-(2,6-dichlorophenyl)-ethane, 1,1-bis-(2-chloro-4-iodophenyl)ethane, 1,1-bis-(2-chloro-4-methylphenyl)-ethane, 1,1-bis-(3,5-dichlorophenyl)-ethane, 2,2-bis-(3-phenyl-4-bromophenyl)-ethane, 2,6-bis-(4,6-dichloronaphthyl)-propane, 2,2-bis-(2,6-dichlorophenyl)-pentane, 2,2-bis-(3,5-dichromophenyl)-hexane, bis-(4-chlorophenyl)-phenyl-methane, bis-(3,5-dichlorophenyl)-cyclohexylmethane, bis-(3-nitro-4-bromophenyl)-methane, bis-(4-hydroxy-2,6-dichloro-3-methoxyphenyl)-methane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane and 2,2 bis-(3-bromo-4-hydroxyphenyl)-propane. The preparation of these halogenated flame-retardants may be by condensation of two moles of a phenol with a single mole of a ketone or aldehyde. In place of the divalent aliphatic group in the above examples may be substituted oxygen, sulfur, sulfoxy, and the like.
[0042] Other suitable halogenated flame-retardants include 1,3-dichlorobenzene, 1,4-dibrombenzene, 1,3-dichloro-4-hydroxybenzene and biphenyls such as 2,2′-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4′-dibromobiphenyl, and 2,4′-dichlorobiphenyl as well as decabromo diphenyl oxide, and the like. Also useful are oligomeric and polymeric halogenated aromatic compounds, such as, for example, a copolycarbonate of bisphenol A and tetrabromobisphenol A and a carbonate precursor, e.g., phosgene. Metal synergists, e.g., antimony oxide, may also be used with the flame retardant.
[0043] The incorporation of flame-retardants also affords methods to increase the heat distortion temperature (HDT) of the flame retardant antistatic compositions so that the composition has a flame rating of at least V-2, preferably a flame rating of at least V-1, and more preferably a flame rating of V-0 as measured in accordance with a UL-94 protocol. While the particular amount of flame retardant used in the compositions will vary depending on the molecular weight of the organic phosphate, the amount of the flammable resin present in the composition is greater than or equal to about 9 wt % of the total composition. Also preferred, is to have the flame retardant present in an amount less than or equal to about 30, preferably less than or equal to about 25, and more preferably less than of equal to about 20 wt % of the total composition.
[0044] One method of preparing the composition includes such steps as dry blending followed by melt processing, the latter operation frequently being performed under continuous conditions such as extrusion. In another exemplary method, the components of the composition, e.g., the polycarbonate resin, impact modifier, antistatic agent and flame retardant, are fed directly into the throat of a twin screw extruder and extruded at a temperature greater than the melting point of the polycarbonate resin. It is also possible for the various components of the composition to be fed into the extruder sequentially. Additionally, some of the components such as the antioxidant and the antistatic agent may be fed into the extruder in a masterbatch form. The strand emerging from the extruder is quenched in a water bath, pelletized and subjected into additional processing such as injection molding, blow molding, vacuum forming, and the like.
[0045] This disclosure is further illustrated by the following non-limiting example.
[0046] The Table below shows antistatic flame retardant compositions comprising the antistatic agent PELESTAT NC6321 from Sanyo. BPADP obtained from Akzo-Nobel was used as the flame retardant. Lexan PC 145 (obtained from GE Plastics) was used as thermoplastic resin. Polycarbonate-polysiloxane (PC/PDMS) (obtained from GE Plastics) and Metablen® S-2001 (obtained from Mitsubishi Rayon) are used as the impact modifiers.
[0047] TSAN (a 1:1 blend of polytetrafluoroethylene and styrene acrylonitrile) was added as an anti-dip agent in an amount of about 0.6 wt %, while hindered phenol was added as the antioxidant in an amount of about 0.3 wt % in all compositions.
[0048] The samples represented in the Table were first dry blended in the appropriate quantities in a Henschel high-speed mixer. The dry blends were then extruded in a 30 mm Werner and Pfleiderer Twin Screw extruder having six barrels. The barrel temperature was maintained at 230° C., 240° C., 260° C., 260° C., 260° C., and 260° C., respectively. The die temperature was set at 260° C. and the extruder was run at 300 rpm at 50 lbs/hour. The strand of antistatic flame retardant resin emerging from the extruder was pelletized, dried at approximately 90° C. for two to four hours and subjected to injection molding on an 85 ton Van Dorn molding machine to obtain the test samples.
[0049] Samples were tested for flexural strength and flexural modulus as per ASTM D790, tensile strength and elongation as per ASTM D638, notched Izod as per ASTM D256. Flame retardancy tests were performed as per UL94 V-0-2 protocol. 2 mm or 3 mm×0.5-inch×5-inch bars were burned in the vertical position using a calibrated flame height from a Bunsen burner. The flame was applied for 10 seconds and then removed. The flame out time was recorded. The results were fed into a computer program, which predictively ascertains the probability that a particular composition will attain a V-1 or V-2 rating at a given distance from the flame. The method by which the probability is computed is described in U.S. Pat. No. 6,308,142 to Choate et al. the contents of which are incorporated by reference. A value close to 1 indicates that the composition will have a V-1 rating, while a value close to zero indicates that the composition will fail the flame retardancy test. The distance in these examples is chosen as 2 mm. Heat distortion temperature (HDT) was performed on 0.5″×0.125″×5″ bars while being subjected to 264 pounds per square inch (psi) load at a rate of 248° F./hour starting at 86° F. and finishing at 554° F. as per ASTM D648. Surface resistivity was measured as per ASTM D257 by placing 4″ diameter×0.125″ thick disks into a Keithley model 6517A electrometer equipped with a model 6524 high resistance measurement software.
TABLE 1* 2* 3* 4 5 6 7 Components Pelestat NC 6321 5 7 6 9 5 5 7 PPADP 8 8 6 12 10 12 11 CC/PDMS 0 5 5 5 2.5 0 2.5 Metablen ® S-2001 0 0 0 0 2.5 5 2.5 Polycarbonate 145 86.1 79.1 82.1 73.1 79.1 77.1 76.1 Properties Flexural Modulus (psi) 469700 379600 374700 384000 376200 449600 445900 Flexural Strength (psi) 17130 14620 14770 14340 14250 15500 15740 Tensile Strength (psi) 9652 9194 8622 9126 9103 8829 8891 Tensile Elongation (%) 139.97 60.77 130 64.31 143.92 168.36 117.81 N-Izod (ft-lb/inch) 1.24 13.1 14.37 6 14.4 15.2 14.4 p(FTP) V-1 @ 2 mm 1.00 0.61 0.64 1.00 1.00 0.99 0.95 Heat Distortion 206.2 205.4 213.3 186.4 197.4 186 189.8 Temperature (° F.) Surface Resistivity 2.33 × 10 13 7.7 × 10 12 1 × 10 13 2.3 × 10 12 3.6 × 10 13 3.7 × 10 13 6.5 × 10 12 (ohm/sq)
[0050] Samples 1, 2, and 3 shown in Table 1 were used as comparative examples, while samples 4, 5, 6, and 7 are representative of the antistatic, flame retardant compositions having high impact. In composition 1, no impact modifier was used and therefore the impact properties as measured by notched Izod were low at 1.24 ft-lbs/inch while the use of BPADP as a flame retardant is effective as can be seen from the V-1 results at 2 mm of 1.0. The surface resistivity of 2.33×10 ohm/sq is attributable to the addition of 5 wt % antistatic agent.
[0051] Composition 2 contains 5 wt % of the PC/PDMS impact modifier and hence shows a tremendous increase in impact strength from composition 1. The V-1 value however, drops to 0.61 showing reduced flame retardancy upon addition of the impact modifier, despite the use of the same amount of the flame retardant BPADP. Composition 3 contains a similar amount of impact modifier as composition 2, but contains less flame retardant and antistatic agent. This causes a poor V-1 value as well as an increase in surface resistivity.
[0052] Composition 4 demonstrates that by increasing the antistatic agent and the flame retardant content, the sample has improved antistatic properties and better flame retardant properties than composition 2. Samples 4 and 5 have the same amount of antistatic agent as composition 1 but an increased amount of flame retardant, having 10 and 12 wt % respectively. This results in a combination of improved flame retardant as well as high impact properties. Similarly, while sample 6 has the same amount of antistatic agent and impact modifier as sample 2, an increased amount of the flame retardant renders this composition excellent in its flame retardant properties in addition to the impact and surface resistivity properties.
[0053] The antistatic, impact resistant, flame retardant compositions can be advantageously used for a number of applications in the area of electronics, automobile components, packaging, and the like, where it is desirable to have notched Izod impact properties greater than or equal to about 1 ft-lb/inch, preferably greater than or equal to about 2 ft-lb/inch. The compositions will preferably have surface resistivities of less than or equal to about 10 14 ohm/square while having a flammability rating of greater than V-2.
[0054] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | An antistatic flame retardant composition comprises a polycarbonate resin; an impact modifier comprising polysiloxane; an antistatic agent; and a flame retardant in a an amount greater than or equal to about 9 wt % of the total composition. Owing to its excellent antistatic, impact and flame retardant properties, the composition can be used in electrical and electronic equipment and precision machinery where high fabrication temperatures and high usage temperatures are often encountered. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority of German Patent Application No. 101 40 864.1 filed on Aug. 21, 2001, the disclosure of which is being incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to a system for the needle-treatment of a conveyable fiber bat, and more particularly to a system which includes at least one conveying device having a plurality of needles which are pushed into and subsequently withdrawn from the fiber bat.
The fiber bat is subjected to tension during fiber-bat processing when the needles, which are inserted into the fiber bat during the needle-treatment, restrain a continuous conveyance of the fiber bat. This tension can lead to an undesirable stretching of the fiber bat in the conveying direction. U.S. Pat. No. 5,909,883A discloses a system in which the withdrawing roller drive is controlled so that the conveying speed is reduced during the needle intervention to take into account the tension on the fiber bat which increases when the needles penetrate into the material. However, this is tied to a comparably high design and control expenditure. Less complicated means for lowering the tensile stress of the fiber bat during the needle insertion are disclosed in Austrian Patent No. 259,246B1, in which one of the two rollers of a roller pair is designed with diametrically opposite arranged driver cams for the fiber bat. In dependence on the lift frequency of the needle board, the roller is operated such that a frictional connection between conveying rollers and fiber bat exists only if the needles of the needle board release the fiber bat. Such an intermittent conveying drive for the fiber bat represents an advantageous condition for a needle-treatment of the fiber bat with little tension. However, this intermittent conveying effect also requires a uniform thickness of the fiber bat that cannot be ensured in practical operations. Unavoidably thick and thin areas in the fiber bat result in irregularities in the advancement of the fiber bat and thus also in an irregular needle-treatment. Furthermore, thickened areas in the fiber bat can result in damage to the fiber bat surface, caused by the driver cams of one of the conveying rollers impacting on the fiber bat, and can lead to a mechanical overload of these conveying rollers, in particular in the bearing region. Another disadvantage is that a high operating speed is not possible with the known intermittent operation of the needle. According to a prior suggestion, the needles are rigidly arranged on the outside surface of a belt that circulates endlessly around two deflection rollers. In the process, a relative movement occurs between needles and fiber material, which pulls the fiber material out of shape. Specifically, when the needles are pushed in and pulled out of the fiber material at the two deflection locations, relative movements between the needles and the fiber material occur because of the slanted positioning of the needles relative to the fiber material. These movements lead to a stretching in the conveying direction and, in particular, to an irregular structure of the fiber material.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a device of the aforementioned type that avoids the above-mentioned disadvantages and, in particular, makes it possible to have a high needle-treatment speed and a uniform structure of the needle-treated fiber bat. The conveying device can form part of a needle-treatment system.
The above and other objects are achieved according to the invention by the provision of a system for performing a needle treatment operation on a conveyable fiber bat, comprising: at least one circulating endless conveying device having an outside constituting a conveying surface for the fiber bat and an inside; a plurality of wire needles positioned for penetrating the conveying surface from the inside toward the outside and back again, and for being pushed into and withdrawn from the fiber bat; and, means for moving the conveying surface, the fiber bat, and the needles at the same speed during the needle-treatment operation.
A high needle-treatment speed and a uniform fiber bat structure are attained with the conveying device according to the invention since the conveying surface or surfaces, the fiber bat, and the needles, during penetration and withdrawal, have the same speed in the conveying direction; moreover, the needles penetrate and are withdrawn from the fiber bat in a direction perpendicular or nearly perpendicular to the fiber bat conveying direction during the needle-treatment operation. A careful and effective needle-treatment of the fiber bat, i.e., the fiber material, thus occurs without any relative speed between the fiber bat and the needles during the conveying operation. The conveying device imparts this careful needle-treatment to a range of fiber bats, including thick fiber bats and fiber bats with short fibers. A high throughput speed can be attained with the conveying device. The extended penetration phase contributes to the high throughput speed. Further advantages of the device are low weight, compact design, and low noise during operation. The design of the device permits a modular construction. The needle treatment can be realized on one side or on two sides of the fiber bat.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a roller-carding unit with a card unit feeder and the conveying device according to the invention.
FIG. 2 is a side view of a floccule feeder directly connected to the conveying device according to the invention.
FIG. 3 a is a sectional side view of an embodiment of the conveying device shown in FIG. 3 b.
FIG. 3 b is a partial sectional front view of the conveying device shown in FIG. 3 a.
FIGS. 4 a through 4 c are sectional side views of the of the conveying device which show the position of components of the conveying device at successive times.
FIG. 5 is a side view of the conveying device which includes a circulating endless perforated belt.
FIG. 6 a is a perspective view of a portion of the endless perforated belt depicted in FIG. 5 .
FIG. 6 b is a side view of a drive mechanism for the endless perforated belt.
FIG. 7 is a perspective view of an alternate embodiment of the endless perforated belt.
FIG. 8 a is a side view of a plurality of serially connected conveying devices.
FIG. 8 b is a block diagram of a common electronic control connected to drive motors and drive mechanisms for moving the needles associated with a plurality of conveying devices according to the invention.
FIG. 9 a is a sectional side view of another embodiment of the conveying device according to the invention.
FIG. 9 b is a partial sectional front view of the embodiment of the conveying device in FIG. 9 a.
FIG. 10 is a block diagram of a common electronic control connected to drive motors and drive mechanisms for moving the needles associated with a conveying device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a roller-carding feeder 11 in conjunction with a roller-carding unit 1 . The roller-carding feeder 11 will first be described. A vertical reserve chute 2 is fed from above with the finely broken up fiber good I, for example via a condenser and through a feeding and distribution line 3 . Air outlet openings 4 ′ and 4 ″ are provided in an upper region of the reserve chute 2 through which transport air II is pulled by a suctioning device 5 following separation from fiber goods or floccules III. A feed roller (intake roller) 6 operating jointly with a feeding trough 7 closes off a lower end of the reserve chute 2 . With this slow-rotating feed roller 6 , the fiber goods III from the reserve chute 2 are supplied below to a fast-moving opening roller 8 , provided with pins or saw-tooth wire, and making contact along a portion of its circumference with a lower feeding chute 9 . The opening roller 8 , rotating in the direction of arrow 8 a , conveys the fiber goods III into the feeding chute 9 . The feed roller 6 rotates slowly in a clockwise direction (arrow 6 a ) and the opening roller 8 rotates in a counterclockwise direction (arrow 8 a ), so that opposite rotational movements are realized. The feeding chute 9 is provided at the lower end with a withdrawing roller 10 , rotating in the direction shown by the drawn arrow, and a feed trough 14 which places the fiber goods into the roller-carding unit 1 . An example of this roller-carding feeder 11 , is a SCANFEED unit manufactured by the company Trützschler in Mönchengladbach, Germany.
The feed roller 10 and the feed trough 14 of the roller-carding feeder 11 are followed in the conveying direction A of the roller-carding unit 1 by a first uptake roller 16 1 , a second uptake roller 16 2 , a licker-in cylinder 17 , a transfer roller 18 , and a main carding cylinder 19 . Two roller pairs 16 1 an 16 2 are associated with the licker-in cylinder 17 and six roller pairs are associated with the main carding cylinder 19 ; each roller pair consists of a stripping roller 21 and a clearer 22 . Immediately adjoining and cooperating with the main carding cylinder 19 is a doffer 20 and a stripping roller 21 which serves as a calender roller. Two calender rollers 23 and 24 follow the stripping roller 21 . The conveying device 15 according to the invention is located downstream of the calender rollers 23 and 24 .
Alternately, the conveying device 15 according to the invention can be installed downstream of an aerodynamic fiber-bat former (not shown herein), instead of downstream of a roller-carding unit 1 . The conveying device 15 can also follow a carding machine provided with at least one crushing cylinder for creating a heavier fiber bat.
According to FIG. 2, a floccule feeder 26 , for example, a SCANFEED FBK 5000, manufactured by the company Trützschler in Mönchengladbach, Germany, is directly connected to the conveying device 15 . Transfer devices 25 , e.g. circulating endless conveying belts and conveying rollers can be arranged between the floccule feeder 26 and the conveying device 15 according to the invention. An operating width of five meters is possible.
FIG. 3 a is a sectional side view of the conveying device and corresponds to the section IIIa taken through FIG. 3 b . FIG. 3 b is a partial sectional front view of the conveying device and corresponds to the section IIIb taken through FIG. 3 a.
According to FIG. 3 a , a rotating cylinder 26 rotates in the direction of arrow 26 ′ and is driven by a drive motor 27 . The fiber bat 37 moves in the direction indicated by arrow C towards the rotating cylinder 26 , on the surface of the outer shell surface of the rotating cylinder 26 , and away from the rotating cylinder 26 in the direction indicated by arrow D. A plurality of openings 28 penetrate through the outer shell of rotating cylinder 26 , which can be a tubular body. Four longitudinal rows of openings 28 are arranged over the circumference of the rotating cylinder 26 . As shown in FIG. 3 a , the rows are equally spaced at 90° angles around the rotating cylinder axis 29 . As seen in FIG. 3 b , the openings 28 within a row are arranged side-by-side. Within the rotating cylinder 26 are four rows of radially moveable needles 30 . The rows are arranged equally spaced at 90° angles around the rotating cylinder axis 29 . As seen over the width of the rotating cylinder 26 (see FIG. 3 b ), each row contains a plurality of needles 30 , arranged side-by-side. Each needle row 30 1 , 30 2 , 30 3 , and 30 4 is constrained by two side guides between which the needles 30 can move back and forth in the direction of arrows A and B along a straight line extending between an opening 28 and the rotating cylinder axis 29 . The free end of needles 30 can be pushed through and withdrawn from the openings 28 . The other end of the needles 30 in a needle row is embedded in a needle board 31 ; each needle row has an associated needle board. One end of a connector rod 32 is mounted such that it can pivot on a needle board 31 and the other end such that it can rotate on a needle-actuation shaft 33 ; each needle board has at least one associated connector rod 32 . The rotating cylinder 26 is provided on each of its two ends with locally fixed end plates only 34 a is shown in FIG. 3 b . A bearing 35 a is provided between the circumferential face of the end plate 34 a and the inside shell surface of the rotating cylinder 26 . A similar bearing is provided at the other end of the rotating cylinder 26 between the non-illustrated end plate and the inside shell surface of the rotating cylinder. The needle-actuation shaft 33 is received in the end plates. The rotating cylinder axis 29 and the needle-actuation shaft axis 36 are arranged parallel with respect to each other with a distance a between them.
FIGS. 4 a through 4 c show that during the needle-treatment operation the fiber bat 37 initially moves in a straight line tangentially towards the rotating cylinder 26 , as indicated by arrow C, in order to receive needle treatment. Subsequently, the fiber bat 37 moves circumferentially with the outer shell surface 26 ″ of the rotating cylinder 26 as shown by arrow E. Finally, the fiber bat 37 moves once more in a straight line away from rotating cylinder 26 in the direction of arrow D. The rotating cylinder 26 rotates with a high speed in the direction of arrow 26 ′. According to FIG. 4 a , at point in time t 1 , the needles 30 in the needle row 30 1 are positioned completely inside of the rotating cylinder 26 . The needles 30 in the needle row 30 2 penetrate the openings 28 2 and start to penetrate the fiber bat 37 in the direction of arrow A. The needles 30 in the needle row 30 3 completely penetrate the fiber bat 37 , whereas the needles 30 in the needle row 30 4 are in the process of being withdrawn from the fiber bat 37 in the direction of arrow B. According to FIG. 4 b , at a later point in time t 2 , the fiber bat 37 has been advanced in the direction of arrows C, D and E. It is essential that the conveying surface, i.e., the outer shell surface 26 ″ of rotating cylinder 26 , the fiber bat 37 , and the needles 30 have the same speed in the conveying direction during the needle treatment, from the start of penetration of the needles 30 into the fiber bat, through full penetration and complete withdrawal of the needles. The needle rows 30 1 through 30 4 in FIG. 4 b are in a different position than in FIG. 4 a . According to FIG. 4 c , the rotating cylinder 26 at an even later point in time t 3 has performed nearly a three-quarters rotation with respect to its position in FIG. 4 a . The needle rows 30 1 and 30 2 are being withdrawn from fiber bat 37 in the direction of arrow B while the needle rows 30 3 and 30 4 are moving in the direction of arrow A towards the fiber bat 37 . While the rotating cylinder 26 rotates, the needles 30 perform two movements simultaneously: they perform a back and forth movement in the direction of arrows A and B while moving along a circular path shown by arrow 26 ′.
FIGS. 3 a and 3 b show an embodiment in which all movements of the conveying device, e.g., the rotational movement of the rotating cylinder 26 and the linear movements of the needles 30 , are mechanically derived from a single drive motor.
An endless perforated belt 38 which serves as a stitch bed circulates around three deflection rollers 39 a , 39 b , and 39 c , as shown in FIG. 5 . The rotational direction of the deflection rollers 39 a , 39 b , and 39 c is indicated with the curved arrows 39 ′, 39 ″ and 39 ′″. The fiber bat 37 (not shown in FIG. 5) is guided and conveyed between the curved outside 38 ′ of the perforated belt 38 and the outer shell surface 26 ″ of rotating cylinder 26 which rotates in the direction shown by arrow 26 ′. It is essential that the perforated belt 38 , the outside 38 ′ of which forms another conveying surface, the outer shell surface 26 ″ of rotating cylinder 26 , the fiber bat, and the needles (not shown in FIG. 5) have the same speed in the conveying direction shown by arrow E during the needle-treatment. The belt forms part of the entire conveying device.
FIG. 6 a shows the deflection of the perforated belt 38 with openings 40 around a belt deflection device (not shown in FIG. 6 a ). Successive recesses 41 which penetrate through perforated belt 38 are provided in one edge region (as shown) or in both edge regions of perforated belt 38 . The edges bounding the recesses in the conveying direction of perforated belt 38 are reinforced with edge-reinforcing elements 42 a and 42 b against wear and tear. The edge-reinforcing elements 42 a and 42 b have rounded outer surfaces. As shown in FIG. 6 b , the teeth 43 a of a toothed wheel 43 extend through the recesses of the perforated belt 38 . The toothed wheel is driven (in a manner not shown herein) by a device, e.g., a drive motor, in the direction of the curved arrow 43 ′.
In another embodiment of the stitch bed shown in FIG. 7, the circulating endless perforated belt is an endless ladder belt formed by two endless toothed belts, only one belt 44 a being shown herein. A plurality of strips 45 span between the outside of the endless toothed belts. The strips 45 have openings 46 through which the needles (not shown in FIG. 7) can penetrate. Gearwheels (not shown in FIG. 7) are used to drive the toothed belts.
In yet another embodiment (not shown herein), the stitch bed is formed of a mesh material.
Belts which serve as stitch beds can be formed of any one of a number of materials, including steel.
FIG. 8 a shows a needle-treatment system composed of a plurality of conveying devices 15 a through 15 f according to the invention that are serially connected. The drive motors and drive mechanisms for moving the needles for the conveying devices 15 a through 15 f are connected to a common electronic control 51 , shown in FIG. 8 b , for coordinating the conveying and needle speeds of the conveying devices relative to each other; the conveying speeds and the needle speeds of any two of the conveying devices in the needle treatment system can be identical or different.
In the embodiment of the conveying device shown in FIGS. 9 a and 9 b , a drive motor 91 drives the rotational movement of the rotating cylinder 26 and separate drive mechanisms 92 for moving the needles drive the linear movements of the needles 30 .
In an embodiment, shown in FIG. 10, the drive motor 91 for the rotating cylinder, the drive motor or motors 101 for a circulating endless belt, and the drive mechanism or mechanisms 92 for moving the needles can be connected to a common electronic control 102 . The common electronic control 102 coordinates the drive motors 91 and 101 and drive mechanisms 92 for moving the needles to ensure that the rotating cylinder, needles, fiber bat, and circulating endless belt all travel with the same speed in the conveying direction. The common electronic control 102 controls the points in time of insertion and of removal of the needles.
The invention has been described in detail with respect to preferred embodiments, and it will now be apparent from the foregoing to those skilled in the art, that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the appended claims, is intended to cover all such changes and modifications that fall within the true spirit of the invention. | A system for the needle treatment of a conveyable fiber bat is provided with at least one conveying device having a plurality of needles that can be inserted into and withdrawn from a fiber bat. At least one rotating cylinder is provided to make possible a high needle-treatment speed and a uniform structure of the needle-felted fiber bat. The outside of this rotating cylinder forms a conveying surface for the fiber bat. The needles can pass through the conveying device from the inside toward the outside. The needles penetrate the fiber bat perpendicular to the conveying direction and then withdraw. The outside of the rotating cylinder, the fiber bat, and the needles have a similar speed in the conveying direction during the needle-treatment. | 3 |
This application is a division of application Ser. No. 08/448,123, filed May 23, 1995; which in turn is a continuation of application Ser. No. 08/351,561 filed Dec. 7, 1994, now abandoned; which is a continuation of application Ser. No. 07/795,249, filed Nov. 18, 1991, now abandoned; which is a continuation of application Ser. No. 07/782,098, filed Sep. 30, 1985, now abandoned; which is a division of application Ser. No. 695,428, filed Jan. 28, 1985, now U.S. Pat. No. 4,552,824; which is a continuation of application Ser. No. 449,842, filed Dec. 15, 1982, now abandoned; which is a division of application Ser. No. 214,045, filed Dec. 8, 1980, now U.S. Pat. No. 4,451,547; which is a division of application Ser. No. 971,114, filed Dec. 19, 1978, now U.S. Pat. No. 4,265,991.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electrophotographic photosensitive member used for forming images by using an electromagnetic wave, for example, ultraviolet ray, visible ray, infrared ray, X ray, gamma ray and the like, and a process for preparing the photosensitive member.
2. Description of the Prior Art
Heretofore, there have been used inorganic photoconductive materials such as Se, CdS, ZnO and the like and organic photoconductive materials such as poly-N-vinyl-carbazole, trinitrofluorenone and the like as a photoconductive material for photoconductive layers of electrophotographic photosensitive members.
However, they all suffer from various drawbacks.
For example, Se has only a narrow spectral sensitivity range, and when the spectral sensitivity is widened by incorporating Te or As, the light fatigue increases. Se, As and Te are harmful to man. When Se photoconductive layers are subjected to a continuous and repeating corona discharge, the electric properties are deteriorated. Se photoconductive layers are of poor solvent resistance. Even if the surface of an Se photoconductive layer is covered with a surface protective coating layer, the problems are not sufficiently solved.
Se photoconductive layers may be formed in an amorphous state so as to have a high dark resistance, but crystallization of Se occurs at a temperature as low as about 65° C. so that the amorphous Se photoconductive layers easily crystallize during handling, for example, by ambient temperature or friction heat generated by rubbing with other members during image forming steps, and the dark resistance is lowered.
ZnO and CdS are usually mixed with and dispersed in an appropriate resinous binder. The resulting binder type photoconductive layer is so porous that it is adversely affected by humidity and its electric properties are lowered and further developers enter the layer resulting in lowering release property and cleaning property. In particular, when a liquid developer is used, the liquid developer penetrates the layer to enhance the above disadvantages, CdS is poisonous to man. ZnO binder type photoconductive layers have low photosensitivity, narrow spectral sensitivity range in the visible light region, remarkable light fatigue and slow photoresponse.
Electrophotographic photosensitive members comprising organic photoconductive materials are of low humidity resistance, low corona ion resistance, low cleaning property, low photosensitivity, narrow range of spectral sensitivity in the visible light region and the spectral sensitivity range is in a shorter wavelength region. Some of the organic photoconductive materials cause cancer.
In order to solve the above mentioned problems, the present inventors have researched amorphous silicon (hereinafter called "a-Si") and succeeded in obtaining an electrophotographic photosensitive member free from these drawbacks.
Electric and optical properties of a-Si film vary depending upon the manufacturing processes and manufacturing conditions and the reproducibility is very poor (Journal of Electrochemical Society, Vol. 116, No. 1, pp 77-81, January 1969). For example, a-Si film produced by vaccum evaporation or sputtering contains a lot of defects such as voids so that the electrical and optical properties are adversely affected to a great extent. Therefore, a-Si had not been studied for a long time. However, in 1976 success of producing p-n junction of a-Si was reported (Applied Physics Letter, Vol. 28, No. 2, pp. 105-7, 15 Jan. 1976). Since then, a-Si drew attentions of scientists. In addition, luminescence which can be only weakly observed in crystalline silicon (c-Si) can be observed at a high efficiency in a-Si and therefore, a-Si has been researched for solar cells (for example, U.S. Pat. No. 4064521.
However, a-Si developed for solar cells can not be directly used for the purpose of photoconductive layers of practical electrophotographic photosensitive members.
Solar cells take out solar energy in a form of electric current and therefore, the a-Si film should have a low dark resistance for the purpose of obtaining efficiently the electric current at a good SN ratio [photo-current (Ip)/dark current (Id)], but if the resistance is so low, the photosensitivity is lowered and the SN ratio is degraded. Therefore, the dark resistance should be 10 5 -10 8 ohm.cm.
However, such degree of dark resistance is so low for photoconductive layers of electrophotographic photosensitive members that such a-Si film can not be used for the photoconductive layers.
Photoconductive materials for electrophotographic apparatuses should have gamma value at a low light exposure region of nearly 1 since the incident light is a reflection light from the surface of materials to be copied and power of the light source built in electrophotographic apparatuses is usually limited.
Conventional a-Si can not satisfy the conditions necessary for electrophotographic processes.
Another report concerning a-Si discloses that when the dark resistance is increased, the photosensitivity is lowered. For example, an a-Si film having dark resistance of about 10 10 ohm.cm shows a lowered photoconductive gain (photocurrent per incident photon). Therefore, conventional a-Si film can not be used for electrophotography even from this point of view.
Other various properties and conditions required for photoconductive layers of electrophotographic photosensitive member such as electrostatic characteristics, corona ion resistance, solvent resistance, light fatigue resistance, humidity resistance, heat resistance, abrasion resistance, cleaning properties and the like have not been known as for a-Si films at all.
The present inventors have succeeded in producing a-Si film suitable for electrophotography by a particular procedure as detailed below.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an electrophotographic photosensitive member and a process for preparing the electrophotographic photosensitive member, the process being able to be carried out in an apparatus of a closed system to avoid the undesirable effects to man and the electrophotographic member being not harmful to living things as well as man and further to environment upon the use and therefore, causing no pollution.
Another object of the present invention is to provide an electrophotographic photosensitive member which has moisture resistance, thermal resistance and constantly stable electrophotographic properties and is of all environmental type, and a process for preparing the electrophotographic photosensitive member.
A further object of the present invention is to provide an electrophotographic photosensitive member which has a high light fatigue resistance and a high corona discharging resistance, and is not deteriorated upon repeating use, and a process for preparing said member.
Still another object of the present invention is to provide an electrophotographic photosensitive member which can give high quality images having a high image density, sharp halftone and high resolution, and a process for preparing said member.
A still further object of the present invention is to provide an electrophotographic photosensitive member which has a high photosensitivity, a wide spectral sensitivity range covering almost all the visible light range and a fast photoresponse properties, and a process for preparing said member.
Still another object of the present invention is to provide an electrophotographic photosensitive member which has abrasion resistance, cleaning properties and solvent resistance and a process for preparing said member.
According to one aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber to reduce the pressure,
(b) heating a substrate for electrophotography disposed in a fixed position in said deposition chamber to 50°-350° C.,
(c) introducing a gas containing a hydrogen atom as a constituent atom into said deposition chamber,
(d) causing electric discharge in space of said deposition chamber in which at least one of silicon and a silicon compound by electric energy to ionize said gas, and
(e) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge while raising the temperature of said substrate from the starting temperature (T 1 ), to form an amorphous silicon photoconductive layer of a predetermined thickness.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber to reduce the pressure,
(b) heating a substrate for electrophotography disposed in a fixed position in said deposition chamber to 50°-350° C.,
(c) introducing a gas containing a hydrogen atom as a constituent atom into said deposition chamber,
(d) causing electric discharge in a space of said deposition chamber in which at least one of silicon and a silicon compound by electric energy to ionize said gas,
(e) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge while continuing the electric discharge for a period of time sufficient to form an amorphous silicon photoconductive layer of a predetermined thickness, and
(f) while forming said amorphous silicon photoconductive layer, raising the temperature of said substrate from the starting temperature (T 1 ) to a temperature (T 2 ) and then decreasing the temperature to a temperature lower than the temperature (T 2 ).
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a target composed of silicon and a substrate for electrophotography are disposed in fixed positions, to reduce the pressure.
(b) heating said substrate to 50°-350° C.,
(c) introducing a gas containing a hydrogen atom as a constituent atom into said deposition chamber,
(d) causing electric discharge in space of said deposition chamber in which said target is present, by electric energy to ionize said gas, and
(e) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge while continuing the electric discharge for a period of time sufficient to form an amorphous silicon photoconductive layer of a predetermined thickness.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed in a fixed position, to reduce the pressure in the deposition chamber,
(b) heating said substrate,
(c) introducing a rare gas, not less than 10% by volume of a silane gas based on the rare gas, and a gas containing an element of Group IIIA or V A of the Periodic Table as a constituent atom into said deposition chamber, and causing electric discharge with an electric current density of 0.1-10 mA/cm 2 and a voltage of 100-5000 V in space of said deposition chamber by electric energy to ionize said gases, and
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge while raising the temperature of said substrate from the starting temperature (T 1 ), to form an amorphous silicon photoconductive layer.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed in a fixed position, to reduce the pressure in the deposition chamber,
(b) heating said substrate,
(c) introducing a rare gas, not less than 10% by volume of a silane gas based on the rare gas, and a gas containing an element of Group IIIA or V A of the Periodic Table as a constituent atom into said deposition chamber, and causing electric discharge with an electric current density of 0.1-10 mA/cm 2 and a voltage of 100-5000 V in space of said deposition chamber by electric energy to ionize said gases,
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge to form an amorphous silicon photoconductive layer, and
(e) while forming said amorphous silicon layer, raising the temperature of said substrate-from the starting temperature (T 1 )to a temperature (T 2 ) and then decreasing the temperature to a temperature lower than the temperature (T 2 ).
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed in a fixed position, to reduce the pressure in the deposition chamber,
(b) heating said substrate,
(c) introducing a rare gas, not less than 10% by volume of a silane gas based on the rare gas, and a gas containing an element of Group IIIA or V A of the Periodic Table as a constituent atom into said deposition chamber, and causing electric discharge with an electric power of 0.1-300 W in space of said deposition chamber by electric energy to ionize said gas mixture,
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge while raising the temperature of said substrate from the starting temperature (T 1 ) to form an amorphous silicon photoconductive layer.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed in a fixed position, to reduce the pressure in the deposition chamber,
(b) heating said substrate,
(c) introducing a rare gas, not less than 10% by volume of a silane gas based on the rare gas, and a gas containing an element of Group IIIA of or VA of the Periodic Table as a constituent atom into said deposition chamber, and causing electric discharge with an electric power of 0.1-300 W in space of said deposition chamber by electric energy to ionize said gas mixture,
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge to form an amorphous silicon photoconductive layer, and
(e) while forming said amorphous silicon layer, raising the temperature of said substrate from the starting temperature (T 1 ) to a temperature (T 2 ) and then decreasing the temperature to a temperature lower than the temperature (T 2 ).
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed, to reduce the pressure in the deposition chamber,
(b) heating said substrate to 50°-350° C.,
(c) introducing a rare gas, not less than 10% by volume of a silane gas based on the rare gas, and a gas containing an element of Group IIIA or VA of the Periodic Table as a constituent atom into said deposition chamber, and causing electric discharge with an electric current density of 0.1-10 mA/cm 2 and a voltage of 100-5000 V in space of said deposition chamber by electric energy to ionize said gas mixture, and
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec.by utilizing said electric discharge to form an amorphous silicon photoconductive layer.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed, to reduce the pressure in the deposition chamber,
(b) heating said substrate to 50°-350° C.,
(c) introducing a rare gas, not less than 10% by volume of a silane gas based on the rare gas, and a gas containing an element of Group IIIA or VA of the Periodic Table as a constituent atom into said deposition chamber, and causing electric discharge with an electric power of 0.1-300 W in space of said deposition chamber by electric energy to ionize said gas mixture, and
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec-by utilizing said electric discharge to form an amorphous silicon photoconductive layer.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed, to reduce the pressure in the deposition chamber,
(b) heating said substrate to 50°-350° C.,
(c) introducing a rare gas and not less than 10% by volume of a silane gas based on the rare gas into said deposition chamber, and causing electric discharge with an electric current density of 0.1-10 mA/cm 2 and a voltage of 100-5000 V in space of said deposition chamber by electric energy to ionize said gases, and
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge to form an amorphous silicon photoconductive layer.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a substrate for electrophotography is disposed, to reduce the pressure in the deposition chamber,
(b) heating said substrate to 50°-350° C.,
(c) introducing a rare gas and not less than 10% by volume of a silane gas based on the rare gas into said deposition chamber, and causing electric discharge with an electric power of 0.1-300 W in space of said deposition chamber by electric energy to ionize said gases, and
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge to form an amorphous silicon photoconductive layer.
According to a further aspect of the present invention, there is provided a process for preparing an electrophotographic photosensitive member which comprises:
(a) evacuating a pressure-reducible deposition chamber in which a target composed of silicon and a substrate for electrophotography are disposed in fixed positions, to reduce the pressure,
(b) heating said substrate to 50°-350° C.,
(c) introducing a gas containing a hydrogen atom as a constituent atom, a rare gas and a gas containing an element of Group IIIA or VA of the Periodic Table as a constituent atom into said deposition chamber, and causing electric discharge in space of said deposition chamber with an electric current density of 0.1-10 mA/cm 2 and a voltage of 100-5000 V by electric energy to ionize said gases, and
(d) depositing amorphous silicon on said substrate at a deposition rate of 0.5-100 angstroms/sec. by utilizing said electric discharge to form an amorphous silicon photoconductive layer.
According to a further aspect of the present invention, there is provided an electrophotographic photosensitive member comprising a substrate for electrophotography, a barrier layer capable of preventing injection of electric carrier from said substrate side when the charging treatment is applied to said photosensitive member, and a photoconductive layer overlying said barrier layer, said photoconductive layer being formed of amorphous silicon by utilizing electric discharge, containing 10-40 atomic percent of hydrogen and being 5-80 microns in thickness.
According to a further aspect of the present invention, there is provided an electrophotographic photosensitive member comprising a substrate for electrophotography; a photoconductive layer, said photoconductive layer being formed of amorphous silicon by utilizing electric discharge, containing 10-40 atomic percent of hydrogen and being 5-80 microns in thickness; and a covering layer overlying the surface of said photoconductive layer, said covering layer being 0.5-70 microns in thickness.
According to a further aspect of the present invention, there is provided an electrophotographic photosensitive member comprising a substrate for electrophotography and a photoconductive layer, said photoconductive layer being formed of amorphous silicon by utilizing electric discharge, containing 10-40 atomic percent of hydrogen and being 5-80 microns in thickness.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 and FIG. 2 are schematic cross sectional views of embodiments of electrophotographic photosensitive members according to the present invention; and
FIG. 3, FIG. 4 and FIG. 5 are schematic diagrams of apparatuses suitable for conducting the process for preparing an electrophotographic photosensitive member according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 and FIG. 2 show representative structures of electrophotographic photosensitive members according to the present invention.
Referring to FIG. 1, electrophotographic photosensitive member 1 is composed of substrate for electrophotography 2 and photoconductive layer 3 mainly composed of amorphous silicon (hereinafter called a-Si), and the photoconductive layer 3 has free surface 4 which becomes an image bearing surface.
Substrate 2 may be electroconductive or electrically insulating. As a conductive substrate, there may be mentioned stainless steel, Al, Cr, Mo, Au, Ir, Nb, Ta, V, Ti, Pt, Pd and the like and alloys thereof. As an electrically insulating substrate, synthetic resin films or sheets such as polyesters, polyethylenes, polycarbonates, cellulose triacetate, polypropylene, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyamides and the like glass, ceramics, paper and the like. At least one surface of these electrically insulating substrates is preferably conductivized.
For example, in case of glass, its surface is conductivized with In 2 O 3 , SnO 2 or like. In case of synthetic resin film such as polyester film and the like, its surface is conductivized with Al, Ag, Pb, Zn, Ni, Au, Cr, Mo, Ir, Nb, Ta, V, Ti, Pt and the like by vapor deposition, electron beam vapor deposition, sputtering and the like, or by laminating the surface with such metal.
As a shape of the substrate, there may be used drum, belt, plate and other optional shapes. In case of a continuous high copying, an endless belt or drum shape is preferable.
The thickness of the substrate is optional. When a flexible electrophotographic photosensitive member is desired, a thickness as thin as possible is preferable, but it is usually not less than 10 microns from manufacturing, handling and mechanical strength points of view.
a-Si photoconductive layer 3 is prepared on substrate 2 with silicon and/or silane and the like silicon compound by glow discharge, sputtering, ion plating, ion implantation, and the like. These manufacturing methods may be optionally selected depending upon manufacturing conditions, capital investment, manufacture scales, electrophotographic properties and the like. Glow discharge is preferably used because controlling for obtaining desirable electrophotographic properties is relatively easy and impurities of Group III or Group V of the Periodic Table can be introduced into the a-Si layer in a substitutional type for the purpose of controlling the characteristics.
Further, according to the present invention, glow discharge and sputtering in combination can be conducted in the same system to form a-Si layer and this is a very efficient and effective method.
a-Si photoconductive layer 3 is controlled by incorporating H (hydrogen) (as the result, H is contained in a-Si layer) so as to obtain desirable dark electrical resistivity and photoconductive gain suitable for photoconductive layers of electrophotographic photosensitive members.
In the present invention, "H is contained in a-Si layer" means one of or a combination of the state, i.e. "H is bonded to Si", -and "ionized H is weakly bonded to Si in the layer", and "present in the layer in a form of H 2 ."
In order to incorporate H in a-Si photoconductive layer 3 resulting in that H is contained in a-Si layer, a silicon compound such as silanes, for example, SiH 4 , Si 2 H 6 , and the like or H 2 may be introduced to an apparatus for producing a photoconductive layer 3 upon producing the photoconductive layer 3, and then heat-decomposed or subjected to glow discharge to decompose the compound or H 2 and incorporate H in the a-Si layer as the layer grows, or H may be incorporate in the a-Si layer by ion implantation.
According to the present inventor's opinion, content of H in an a-Si photoconductive layer 3 is a very important factor affecting whether the a-Si photoconductive layer is suitable for electrography.
As a photoconductive layer for electrophotographic photosensitive members, amount of H in an a-Si layer is usually 10-40 atomic % preferably, 15-30 atomic %
Any theoretical reason why-content of H in a-Si layer is to be the above-mentioned range is not yet clear, but when the content of H is outside of the above range, a photoconductive layer made of such a-Si of an electrophotographic photosensitive member has a low dark resistance which is not suitable for the photoconductive layer and the photosensitivity is very low or is hardly observed, and further increase in carrier caused by light irradiation is very little.
For the purpose of incorporating H in a-Si layer (i.e. causing a state that H is contained in a-Si layer), when glow discharge is employed, a silicon hydride gas such as SiH 2 , Si 2 H 6 and the like may be used as the starting material for forming the a-Si layer, and therefore, H is automatically incorporated in the a-Si layer upon formation of the a-Si layer by decomposition of such silicon hydride. In order to carry out this incorporation of H more efficiently, H 2 gas may be introduced into the system where glow discharge is carried out to form a-Si layer.
Where sputtering is employed, in a rare gas such as Ar or a gas mixture atmosphere containing a rare gas sputtering is carried out with Si as a target while introducing H 2 gas SiH 4 , Si 2 H 6 and the like or introducing B 2 H 6 , pH 3 or the like into the system or introducing silicon hydride gas such as gas which can serve to doping with impurities.
Controlling an amount of H to be contained in a-Si layer can be effected by controlling the substrate temperature and/or an amount introduced into the system of a starting material used for incorporating H.
a-Si layer can be made intrinsic by appropriately doping with impurities when prepared and the type of conductivity can be controlled. Therefore, polarity of charging upon forming electrostatic images on an electrophotographic photosensitive member thus prepared can be optionally selected, that is, positive or negative polarity can be optionally selected.
In case of conventional Se photoconductive layer, only p-type or at most intrinsic type (i-type) of photoconductive layer can be obtained by controlling the substrate temperature, type of impurities, amount of dopant and other preparation conditions, and moreover, even when the p-type is prepared, the substrate temperature should be strictly controlled. In view of the foregoing, the a-Si layer is much better and more convenient than conventional Se photoconductive layers.
As an impurity used for doping a-Si layer to make the a-Si layer p-type there may be mentioned elements of Group IIIA of the Periodic Table such as B, Al, Ga, In, Tl and the like, and as an impurity for doping a-Si layer to make the a-Si layer n-type, there may be mentioned elements of Group VA of the Periodic Table such as N, P, As, Sb, Bi and the like.
These impurities are contained in the a-Si layer in an order of ppm. so that problem of pollution is not so serious as that for a main component of a photoconductive layer. However, it is naturally preferable to pay attention to such problem of pollution. From this viewpoint, B, As, P and Sb are the most appropriate taking into consideration electrical and optical characteristics of a-Si photoconductive layers to be produced.
An amount of impurity with which a-Si layers are doped may be appropriately selected depending upon electrical and optical characteristics of the a-Si photoconductive layer. In case of impurities of Group IIIA of the Periodic Table, the amount is usually 10 -6 -10 3 atomic %, preferably, 10 -5 -10 -4 atomic %, and in case of impurites of Group VA of the Periodic Table, the amount is usually 10 -8 -10 -5 atomic %, preferably 10 -8 -10 -7 atomic %.
The a-Si layers may be doped with these impurities by various methods depending upon the type of method for preparing the a-Si layer. These will be mentioned later in detail.
Referring to FIG. 1, electrophotographic photosensitive member 1 contains a-Si photoconductive layer 3 which has a free surface 4. In case of an electrophotographic photosensitive member to the surface of which charging is applied for the purpose of forming electrostatic images, it is preferable to dispose between a-Si photoconductive layer 3 and substrate 2 a barrier layer capable of suppressing injection of carriers from the side of substrate 2 upon charging for producing electrostatic images.
As a material for such barrier layer, there may be selected insulating inorganic oxides such as Al 2 O 3 , SiO, SiO 2 and the like and insulating organic compounds such as polyethylene, polycarbonate, polyurethane, polyparaxylylene and the like, Au, Ir, Pt, Rh, Pd, Mo and the like.
Thickness of the a-Si photoconductive layer is selected taking into consideration its electrostatic characteristic, using conditions, for example, whether flexibility is required. It is usually 5-80 microns, preferably, 10-70 microns, and more preferably, 10-50 microns.
As shown in FIG. 1, the a-Si photoconductive layer surface is directly exposed and refractive index (n) of a-Si layer is as high as about 3.3-3.9 and therefore, light reflection at the surface is apt to occur upon exposure as compared with conventional photoconductive layers, and light amount absorbed in a photoconductive layer is lowered resulting in increase in loss of light. In order to reduce the loss of light, it is helpful to dispose an antireflection layer on an a-Si photoconductive layer.
Materials for the antireflection layer are selected taking the following conditions into consideration.
i) No adverse effect on the a-Si photoconductive layer;
ii) High antireflecting property; and
iii) Electrophotographic characteristics such as electric resistance higher than a certain value, transparent to a light absorbed to the photoconductive layer, good Solvent resistance when used for a liquid developing process, causing no deterioration of the already prepared a-Si photoconductive layer upon preparing the antireflection layer, and the like.
Further, for the purpose of facilitating antireflection, it is desirable to select refractive index of the material which is between that of the a-Si layer and that of air. This will be clear from a simple calculation of optics.
Thickness of the antireflection layer is preferably λ/4√n where n is refractive index of the a-Si layer and λ is wavelength of exposure light, or (2k+1) times of λ/4√n where k is an integer such as 0,1, 2, 3, . . . , most preferably λ/4√n taking into consideration of light absorption of the antireflection layer itself.
Taking these optical conditions, thickness of the anti-reflection layer is preferably 50-100 mμ assuming that wavelength of the exposure light is roughly in the wavelength region of visible light.
Representative materials for an anti-reflection layer are inorganic fluorides and oxides such as MgF 2 , Al 2 O 3 , ZrO 2 , TiO 2 , ZnS, CeO 2 , CeF 2 , SiO 2 , SiO, Ta 2 O 5 , AlF 3 .3NaF and the like, and organic compounds such as polyvinyl chloride, polyamide resins, polyimide resins, polyvinylidene fluoride, melamine resins, epoxy resins, phenolic resins, cellulose acetate and the like.
The surface of a-Si photoconductive layer 3 may be provided with a surface coating layer such as a protective layer, an electrically insulating layer and the like as in conventional electrophotographic photosensitive members. FIG. 2 shows such electrophotographic photosensitive member having a covering layer.
Now referring to FIG. 2, electrophotographic photosensitive member 5 has covering layer 8 on a-Si photoconductive layer 7, but other structure is the same as that of FIG. 1.
Characteristics required of covering layer 8 vary depending upon each electrophotographic process. For example, when an electrophotographic process such as U.S. Pat. Nos. 3,666,363 and 3,734,609 is used, it is required that covering layer 8 is electrically insulating and has a sufficient electrostatic charge retaining property when subjected to charging and a thickness thicker than a certain thickness. However, when a Carlson type electrophotographic process is used, a very thin covering layer 8 is required since potentials at the light portions of electrostatic images are preferably very low. Covering layer 8 is to be prepared so as to satisfy the desired electrical characteristics and furthermore, the following are taken into consideration not adversely affecting a-Si photoconductive layers chemically and physically, electrical contact and adhesivity with a-Si photoconductive layer, moisture resistance, abrasion resistance and cleaning properties.
Representative materials for a covering layer are synthetic resins such as polyethylene terephthalate, polycarbonate, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polystyrene, polyamides, polyethylene tetrafluoride, polyethylene trifluoride chloride, polyvinyl fluoride, polyvinylidene fluoride, copolymers of propylene hexafluoride and ethylene tetrafluoride, copolymers of ethylene trifluoride and vinylidene fluoride, polybutene, polyvinyl butyral, polyurethane and the like, and cellulose derivatives such as the diacetate, triacetate and the like.
These synthetic resin and cellulose derivative in a form of film may be adhered to the surface of the a-Si photoconductive layer, or a coating liquid of these materials is coated on an a-Si photoconductive layer 5. Thickness of the covering layer may be appropriately selected depending upon the required characteristics and type of material, but it is usually 0.5-70 microns. When the covering layer is used as a protective layer, the thickness is usually, for example not more than 10 microns and when it is used as an electrically insulating layer, the thickness is usually, for example, not less than 10 microns though this value, 10 microns is not critical, but only an example because such value varies depending upon type of the material, the electrophotographic process and structure of the electrophotographic photosensitive member.
The covering layer 8 may also serve as an anti-reflection layer and thus the function is effectively widened.
Preparation of electrophotographic photosensitive member of the present invention is exemplified by a glow discharge process and a sputtering process below.
Referring to FIG. 3, there is illustrated a diagrammatical glow discharge process of capacitance type for producing an electrophotographic photosensitive member.
Glow discharge deposition chamber 10 contains substrate 11 fixed to fixing member 12 and an a-Si photoconductive layer is formed on substrate 11. Under substrate 11 is disposed heater 13 for heating substrate 11. At upper part of deposition chamber 10 are wound capacitance type electrodes 15 and 15' connected to high frequency power source 14. When the power source 14 is turned on, a high frequency voltage is applied to electrodes 15 and 15' to cause glow discharge in deposition chamber 10.
To the top portion of deposition chamber 10 is connected a gas introducing conduit to introduce gases from gas pressure vessels 16, 17 and 18 into deposition chamber 10 when required.
Flow meters 19, 20 and 21, flow rate controlling valves 22, 23 and 24, valves 25, 26 and 27 and auxiliary valve 28 are provided.
The lower portion of deposition chamber 10 is connected to an exhausting device (not shown) through main valve 29. Valve 30 serves to break vacuum in deposition chamber 10.
Cleaned substrate 11 is fixed to fixing member 12 with the cleaned surface kept upward.
Surface of substrate 11 may be cleaned as shown below. It can be cleaned with an alkali or acid, (a kind of chemical treatment), or by disposing a substrate cleaned to some extent in deposition chamber 10 at a fixed portion and then applying glow discharge. In the latter case, cleaning substrate 11 and formation of an a-Si photoconductive layer can be carried out in the same system without breaking vacuum and thereby it can be avoided that dirty matters and impurities attach to the cleaned surface. After fixing substrate 11 to fixing member 12, main valve 29 is fully opened to evacuate deposition chamber 10 to bring the pressure down to about 10 -5 Torr. Then heater 13 starts to heat substrate 11 up to a predetermined temperature, and the temperature is kept while auxiliary valve 28 is fully opened, and then valve 25 of gas pressure vessel 16 and valve 26 of gas pressure vessel 17 are fully opened. Gas pressure vessel 16 is, for example, for a diluting gas such as Ar and gas pressure vessel 17 is for a gas forming a-Si, for example, silicon hydride gas such as SiH 4 , Si 2 H 6 , Si 4 H 10 or their mixture. Pressure vessel 18 may be used, if desired, for storing a gas capable of incorporating impurities in an a-Si photoconductive layer, for example, PH 3 , P 2 H 4 , B 2 H 6 and the like. Flow rate controlling valves 22 and 23 are gradually opened while observing flow meters 19 and 20 to introduce a diluent gas, e.g., Ar, and a gas for forming a-Si, e.g., SiH 4 into deposition chamber 10. The diluting gas is not always necessary, but only SiH 4 may be introduced into the system. When Ar gas is mixed with a gas for forming a-Si, e.g. SiH 4 , and then introduced, the amount ratio may be determined depending upon each particular situation. Usually the gas for forming a-Si is more than 10 vol. % based on the diluting gas. As the diluting gas, a rare gas such as He may be used. When gases are introduced from pressure vessels 16 and 17 into deposition chamber 10, main valve 29 is adjusted to keep a particular vacuum degree, usually, an a-Si layer forming gas of 10 -12 -3 Torr. Then, to electrodes 15 and 15' is applied a high frequency voltage, for example, 0.2-30 MHz, from high frequency power source 14 to cause glow discharge in deposition chamber 10, and SiH 4 is decomposed to deposit Si on substrate 11 to form an a-Si layer.
Impurities may be introduced into an a-Si photoconductive layer to be formed by introducing a gas from pressure vessel 18 into deposition chamber 10 upon forming an a-Si photoconductive layer. By controlling valve 24, an amount of gas introduced into deposition chamber 10 from pressure vessel 18 can be controlled. Therefore, an amount of impurities incorporated in an a-Si photoconductive layer can be optionally controlled and in addition, the amount may be varied in the direction of thickness of the a-Si photoconductive layer.
In FIG. 3, the glow discharge deposition apparatus uses a glow discharge process of RF (radio frequency) capacitance type, but in place of said type process, there may be used a glow discharge process of RF inductance type or DC diode type. Electrodes for glow discharge may be disposed in or outside of deposition chamber 10.
In order to efficiently carry out glow discharge in a glow discharge apparatus of capacitance type as shown in FIG. 3, current density is usually 0.1-10 mA/cm 2 , preferably 0.1-5 mA/cm 2 , more preferably, 1-5 mA/cm 2 , of AC or DC, and further the voltage is usually 100-5000 V, preferably 390-5000 V, so as to obtain a sufficient power.
Characteristics of an a-Si photoconductive layer depend on a temperature of substrate to a great extent and therefore, it is preferable to control the temperature strictly. The temperature of substrate according to the present invention is usually 50°-350° C., preferably 100°-200° C. so as to obtain an a-Si photoconductive layer for electrophotography having desirable characteristics. In addition, the substrate temperature may be changed continuously or batchwise to produce desirable characteristics. Growing speed of the a-Si layer also affects physical properties of the resulting a-Si layer to a great extent, and according to the present invention, it is usually 0.5-100 Å/sec., preferably 1-50 Å/sec.
FIG. 4 shows a diagrammatical apparatus for producing electrophotographic photosensitive members by sputtering.
Deposition chamber 31 contains substrate 32 fixed to fixing member 33 which is conductive and is electrically insulated from deposition chamber 31. Heater 34 is disposed under substrate 32, which is to be heated by heater 34. Over substrate 32 and facing substrate 32, there is disposed polycrystal or single crystal silicon target 35. High frequency voltage is applied between fixing member 33 and silicon target 35 by high frequency power source 36.
To deposition chamber 31 are connected gas pressure vessels 37 and 38 through valves 39 and 40, flow meters 41 and 42, flow rate controlling valves 43 and 44, and auxiliary valve 45. Gases may be introduced into deposition chamber 30 when wanted.
An a-Si photoconductive layer can be formed on substrate 32 by the apparatus of FIG. 4 as shown below. Deposition chamber 31 is evacuated to the direction of arrow B to obtain an appropriate degree of vacuum. Then substrate 32 is heated to a particular temperature by heater 34.
When sputtering is employed, the temperature of substrate 32 is usually 50°-350° C., preferably, 100°-200° C. This substrate temperature affects growing speed of the a-Si layer, structure of the layer, void, physical properties of the resulting a-Si layer, and therefore, a strict control is necessary.
The substrate temperature may be kept constant during formation of an a-Si layer, or may be raised or lowered or both raised and lowered in combination as the a-Si layer grows. For example, at the beginning of formation of an a-Si layer a substrate temperature is kept at a relatively low temperature T 1 and when the a-Si layer grows to some extent, the substrate temperature is raised up to T 2 (T 2 >T 1 ) during the forming of the a-Si layer, and then at the end of the a-Si layer formation the substrate temperature is lowered down to a temperature T 3 lower than T 2 . In this way, electrical and optical properties of the a-Si photoconductive layer can be constantly or continuously changed in the direction of thickness of the layer.
Since the layer growing speed of a-Si is slower than, for example, Se, there is a fear that the a-Si formed at the beginning (a-Si near the substrate) may change its original characteristics before the layer formation is completed where the layer is thick. Therefore, it is preferable to form the layer by raising the substrate temperature from the beginning to the end so as to obtain an a-Si layer having uniform characteristics in the direction of thickness.
The substrate temperature controlling method may also be employed when glow discharge process is carried out.
After detecting that the temperature of substrate 32 is heated to a predetermined temperature, auxiliary valve 45, valves 39 and 40 are fully opened and then while main valve 46 and flow rate controlling valve 44 are controlled, silicon hydride gas such as SiH 4 and the like and/or hydrogen gas are introduced from pressure vessel 38 into deposition chamber 31 resulting in decrease in degree of vacuum and then the resulting degree of vacuum is kept.
Then, flow rate controlling valve 43 is opened and an atmosphere gas such as Ar gas is introduced from pressure vessel 37 into deposition chamber 31 until the degree of vacuum decreases. The flow rates of silicon hydride gas, hydrogen gas, and the atmosphere gas such as Ar are appropriately determined so as to I obtain desired physical properties of the a-Si photoconductive layer. For example, pressure of a mixture of an atmosphere gas and hydrogen gas in deposition chamber is usually 10 -3 -10 -1 Torr., preferably 5×10 -3 -3×10 -2 In place of Ar gas, there may be used other rare gases such as He gas.
After an atmosphere gas such as Ar and the like, and H 2 gas or silicon hydride gas are introduced into deposition chamber 31, a high frequency voltage is applied between substrate 32 is applied between fixing member 33 and silicon target 35 from a high frequency power source 36 at a predetermined frequency and voltage to discharge and the resulting atmosphere gas ion such as Ar ion serves to sputter silicon of the silicon target to form an a-Si layer on substrate 32.
FIG. 4 is explained concerning sputtering by a high frequency discharge, but there may be used there sputtering by DC discharge. In case of sputtering by high frequency discharge, the frequency is usually 0.2-30 MHz, preferably 5-20 MHz, and the current density of discharge is usually 0.1-10 mA/cm 2 , preferably 0.1-5 mA/cm 2 , more preferably 1-5 mA/cm 2 . In addition, for the purpose of obtaining sufficient power, the voltage is usually controlled to 100-5000 V, preferably 300-5000 V.
A growing speed of an a-Si layer by sputtering is mainly determined by the substrate temperature and discharging conditions, and affects physical properties of the resulting a-Si layer to a great extent. A growing speed of an a-Si layer for attaining the purpose of the present invention is usually 0.5-100 Å/sec., preferably 1-50 Å/sec. In a sputtering method as well as a glow discharge method, it is possible to control the resulting a-Si photoconductive layer to n-type or p-type by doping with impurities. Introduction of impurities in a sputtering method is similar to that in a glow discharge method. For example, a material such as PH 3 , P 2 H 4 , B 2 H 6 and the like is introduced into deposition chamber in a gaseous form upon producing an a-Si layer and the a-Si layer is doped with P or B as an impurity. Further, impurities can be introduced into an already produced a-Si layer by an ion implantation method and it is possible to control the very thin surface layer of the a-Si layer to a particular conductive type.
FIG. 5 illustrates diagrammatically a glow discharge deposition apparatus for producing an electrophotographic photosensitive member by inductance type glow discharge.
Glow discharge deposition chamber 47 contains substrate 48 on which an a-Si photoconductive layer is formed. Substrate 48 is fixed to fixing member 49. Under substrate 48 is disposed heater 50 to heat substrate 48. Inductance type electrode 52 connected to a high frequency power source 51 is wound around the upper portion of deposition chamber 47. When the power source is on, high frequency wave is applied to the electrode 52 to cause glow discharge in deposition chamber 47. To the top of deposition chamber 47 is connected a gas introducing pipe capable of introducing gases in gas pressure vessels 53, 54 and 55 when required. The gas introducing pipe is equipped with flow meters 56, 57 and 58, flow rate controlling valves 59, 60 and 61, valves 62, 63 and 64 and auxiliary valve 65.
The bottom portion of deposition chamber 47 is connected to an exhausting device (not shown) through main valve 66. Valve 67 is used for breaking vacuum in deposition chamber 47. Gases from pressure vessels 53, 54 and 55 are not directly introduced into deposition chamber 47, but are mixed in advance in this mixing tank 68 and then the resulting mixture gas is introduced into deposition chamber 47. In this way, when the gases are once introduced into mixing tank 68 and mixed at a predetermined ratio and then the resulting mixture is introduced into deposition chamber 47 from mixing tank 68, it is possible to introduce always a gas mixture of a constant mixing ratio into deposition chamber 47 at any time. This is very advantageous.
An a-Si photoconductive layer having desired characteristics is formed on substrate 48 as shown below.
Cleaned substrate 48 is fixed to fixing member 49 with the cleaned surface upward. Cleaning the surface of substrate 48 is conducted as in FIG. 3.
Deposition chamber 47 and mixing tank 68 are evacuated while main valve 66 and auxiliary valve 65 are kept fully open. The pressure in the system is brought down to about 10 -5 Torr., and then substrate 48 is heated to a predetermined temperature by heater 50 and the temperature is kept.
Then the auxiliary valve is closed and valves 62 and 63 are fully opened. Gas pressure vessel 53 contains a diluting gas such as Ar gas, gas pressure vessel 54 contains a gas for forming a-Si such as silicon hydride gas, for example, SiH 4 , Si 2 H 6 , Si 4 H 10 and mixture thereof, and gas pressure vessel 55 contains a gas for forming impurities to be introduced into the a-Si photoconductive layer, if desired, such as PH 3 , P 2 H 4 , B 2 H 6 and the like.
Flow rate controlling valves 59 and 60 are gradually opened while watching flow meters 56 and 57 and thus gases in pressure vessels 53 and 54 are fed to mixing tank 68 at a desired ratio in a desired amount to form a gas mixture, for example, a mixture of Ar and SiH 4 . Then flow rate controlling valves 59 and 60 are closed and auxiliary valve 65 is gradually opened to introduce the gas mixture into deposition chamber 47 from mixing tank 68. In this case, a diluting gas such as Ar is not always necessary and it is allowed to introduce only a gas for forming a-Si such SiH 4 and the like.
The ratio of a diluting gas to a gas for forming a-Si introduced into mixing tank 68 may be optionally selected as wanted. The ratio is usually more than 10 vol. % of a gas for forming a-Si based on a diluting gas. As the diluting gas, gas may be used in place of Ar gas. Deposition chamber 47 is maintained at a desired pressure, for example 10 -2 -3 Torr. by controlling main valve 66. Then, to electrode of induction type wound around deposition chamber 47 is applied a predetermined high frequency voltage, for example, 0.2-30 MHz, by high frequency power source 51 to cause glow discharge in deposition chamber and decompose SiH 4 gas and Si is deposited on substrate 48 to form an a-Si layer.
If it is desired to introduce impurities into an a-Si photoconductive layer, the gas in pressure vessel 55 is introduced into mixing tank 68 together with the other gases An amount of the gas for impurity-introducing can be controlled by flow rate controlling-valve 61 so that the amount of impurities introduced into the a-Si photoconductive layer can be optionally controlled.
In a glow discharge apparatus of inductance type as in FIG. 5, the high frequency power for producing an a-Si layer having desired characteristics may be determined accordingly, but it is usually 0.1-300 W, preferably 0.1-150 W, more preferably 5-50 W. And characteristics of the resulting a-Si photoconductive layer is affected by the substrate temperature upon growing the a-Si layer and the growing speed of the layer to a great extent. Therefore, these factors should be strictly controlled. Desirable conditions of substrate temperature and growing speed of a-Si layer in a glow discharge apparatus of inductance type are similar to those mentioned concerning FIG. 3.
The invention will be understood more readily by reference to the following examples; however, these examples are intended to illustrate the invention and are not to be construed to limit the scope of the invention.
EXAMPLE 1
In accordance with the procedure described below, an electrophotographic photosensitive member of the present invention was prepared by using an apparatus as shown in FIG. 3, and image forming treatment was applied to the photosensitive member.
An aluminum substrate was cleaned in such a manner that the surface of the substrate was treated with a 1% solution of NaOH and sufficiently washed with water and then dried. This substrate, which was 1 mm in thickness and 10 cm×5 cm in size, was firmly disposed at a fixed position in a fixing member 12 placed at a predetermined position in a deposition chamber 10 for glow discharge so that the substrate was kept apart from a heater 13 equipped to the fixing member 12 by about 1.0 cm.
The air in the deposition chamber 10 was evacuated by opening fully a main valve 29 to bring the chamber to a vacuum degree of about 5×10 -5 Torr. The heater 13 was then ignited to heat uniformly the aluminum substrate to 150° C., and the substrate was kept at this temperature a subsidiary valve 28 was fully opened, and subsequently a valve 25 of a bomb 16 to which Ar was charged and a valve 26 of a bomb 17 which was filled with SiH 4 were also opened fully, and thereafter, flow amount controlling valves 22, 23 were gradually opened so that Ar gas and SiH 4 gas were introduced into the deposition chamber 10 from the bombs 16, 17. At that time, the vacuum degree in the deposition chamber 10 was brought to and kept at about 0.075 Torr. by regulating the main valve 29.
A high frequency power source 14 was switched on to apply a high frequency voltage of 13.56 MHz between electrodes 15 and 15' so that a glow discharge was caused, thereby depositing and forming an a-Si type photoconductive layer on the aluminum substrate. At that time, the glow discharge was initiated with an electric current density of about 0.5 mA/cm 2 and a voltage of 500 V. Further, the growth rate of the a-Si layer was about 4 angstroms per second and the deposition was effected for 15 hours and further the thus formed a-Si layer had a thickness of 20 microns.
After completion of the deposition, while the main valve 29, valves 25 and 26, flow amount controlling valves 22 and 23, and subsidiary valve 28 were closed, a valve 30 was opened to break the vacuum state in the deposition chamber 10. The prepared photosensitive member was taken out from the apparatus.
To the a-Si type photoconductive layer surface of the photosensitive member was applied negative corona discharge with a power source voltage of 5500 V in a dark place. The image exposure was conducted in an exposure quantity of 15 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner in accordance with the cascade method. The developed image was transferred to a transfer paper and then fixed so that an extremely sharp image with a high resolution was obtained.
The image forming process as mentioned above was repeatedly carried out in order to test the durability of the photosensitive member. As a result, the image on a transfer paper obtained when such process was repeated ten thousand (10,000) times was extremely good in quality. Although such image was compared with the first image on a transfer paper obtained at the time of the initial operation of the image forming process, no difference was observed therebetween. Therefore, it was found that the photosensitive member is excellent in the corona discharging resistance, abrasion resistance, cleaning property and the like and shows extremely excellent durability. In addition, the blade cleaning was effected in cleaning the photosensitive member after the transferring step, a blade formed of urethane rubber was used.
Further, the foregoing image forming process was repeated under the same condition except that positive corona discharge was applied with a voltage of 6,000 V to the photosensitive member and a negatively charged toner was used for the developing. The thus obtained image formed on a transfer paper had an image density lower than that of the image obtained in the foregoing image forming process using negative corona discharge. As a result, it was recognized that the photosensitive member prepared in this example depends upon the polarity to be charged.
EXAMPLE 2
In accordance with the procedure and condition used in Example 1, an a-Si type layer of 20 microns in thickness was formed on the aluminum substrate. The structure was taken out from the deposition chamber 10, and polycarbonate resin was then coated onto the a-Si type layer to form an electrically insulating layer having a thickness of 15 microns after drying.
To the insulating layer surface of the electrophotographic photosensitive member obtained in the above-mentioned manner was applied positive corona discharge with a power source voltage of 6,000 V as the primary charging for 0.2 sec. so that such surface was charged to a voltage of +2,000 V. Next, negative corona discharging with a voltage of 5,500 V was carried out as the secondary charging simultaneously with image exposure in an exposure quantity of 15 lux.sec., and the whole surface of the photosensitive member was then exposed uniformly to form an electrostatic image. This image was developed with a negatively charged toner by the cascade method, and the thus developed image was transferred to a transfer paper and fixed so that an image of extremely excellent quality was obtained.
EXAMPLE 3
In the following manner similar to that in Example 1, an electrophotographic photosensitive member was prepared by using the apparatus as illustrated in FIG. 3 and the image forming treatment was applied to the photosensitive member.
An aluminum substrate having a thickness of 1 mm and a size of 10 cm×10 cm was first treated with a 1% solution of NaOH and sufficiently washed with water and dried to clean the surface of the substrate. This substrate was firmly disposed at a fixed position in a fixing member 12 placed at a predetermined position in a deposition chamber 10 for glow discharge so that it might be kept apart from a heater 13 positioned in the fixing member 12 by about 1.0 cm.
A main valve 29 was fully Opened to evacuate the air in the deposition chamber 10 so that the vacuum degree in the chamber was adjusted to about 5×10 -5 Torr. The heater 13 was then ignited to heat uniformly the aluminum substrate to 150° C., the substrate being kept at that temperature. Then, a subsidiary valve 28 was first opened fully, and successively a valve 25 of a bomb 16 containing Ar charged thereto and a valve 26 of a bomb 17 containing SiH 4 charged thereto were fully opened. Thereafter, the flow amount controlling valves 22 and 23 were gradually opened so that Ar gas and SiH 4 gas were introduced into the deposition chamber 10 from the bombs 16 and 17, respectively. At this time, the vacuum degree in the deposition chamber 10 was kept at about 0.075 Torr. by regulating the main valve 29, and while flow meters 19 and 20 were carefully observed, the flow amount controlling valves 22 and 23 were regulated to control the flow amount of the gases so that the flow amount of the SiH 4 gas might be 10% by volume based on that of the Ar gas.
A valve 27 of a bomb 18 containing B 2 H 6 charged thereto was fully opened and a flow amount controlling valve 24 was slowly opened to introduce B 2 H 6 gas into the deposition chamber 10 while the flow amount of the gas was controlled so that it might be 5×10 -3 % by volume based on the flow amount of the SiH 4 gas. In this case, the main valve 29 was regulated to retain the vacuum degree in deposition chamber 10 to 0.075 Torr.
Subsequently, a high frequency power source 14 was switched on in order to apply a high frequency voltage of 13.56 MHz between electrodes 15 and 15' to give rise to the glow discharge so that an a-Si type photoconductive layer is formed on the aluminum substrate by the deposition. At the time of the glow discharge, the current density was about 3 mA/cm 2 and the voltage 500 V. Further, the growth rate of the a-Si type layer was about 4 angstroms/sec., the period of time for the deposition 15 hours, and the thickness of the a-Si type layer 20 microns. After completion of the deposition, the main valve 29, subsidiary valve 28, flow amount controlling valves 22, 23, 24, and valves 25, 26, 27 were closed, but the valve 30 was opened to break the vacuum state in the deposition chamber 10. Then, the electrophotographic photosensitive member obtained in the above mentioned manner was taken out from the apparatus.
To the a-Si type photoconductive layer surface of the photosensitive member was applied negative corona discharge with a voltage of 5,500 V in a dark place. The image exposure was conducted in an exposure quantity of 20 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner in accordance with the cascade method. The developed image was transferred to a transfer paper and then fixed so that an excellent sharp image was obtained.
The image forming process as mentioned above was repeatedly carried out in order to test the durability of the photosensitive member. As a result, the image on a transfer paper obtained when such process was repeated ten thousand (10,000) times was extremely good in quality. Although such image was compared with the first image on a transfer paper obtained at the time of the initial operation of the image forming process, no difference was observed therebetween. Therefore, it was found that the photosensitive member is excellent in the durability. In addition, the blade cleaning was effected in cleaning the photosensitive member after the transferring step, the blade being formed of urethane rubber.
Further, positive corona discharge with a power source voltage of 6,000 V was applied to the photosensitive member in a dark place and the image exposure was conducted in an exposure amount of 20 lux.sec. to form an electrostatic image. This electrostatic image was developed with a negatively charged toner by the cascade method. The developed image was then transferred to a transfer paper and fixed so that an image with extreme sharpness was obtained.
It was found from this result and the before-mentioned result that the photosensitive member obtained in this example does not have dependability to the charged polarity, but possesses properties of a photosensitive member which produce an advantageously good image when either polarity is charged.
EXAMPLE 4
The same procedure as in Example 3 was repeated except that the flow amount of the B 2 H 6 gas was adjusted to 5×10 -4 % by volume based on the flow amount of the SiH 4 gas, to prepare an electrophotographic photosensitive member having an a-Si type photoconductive layer of 20 microns in thickness on the aluminum substrate.
In accordance with the same condition and manner as in Example 3, the image forming process was carried out by using the obtained photosensitive member to form an image on a transfer paper. As a result, the image formed by the process using positive corona discharge was excellent in quality and very sharp as compared with that obtained by the process employing negative corona discharge.
It is recognized from the result that the photosensitive member of this example depends upon the polarity to be charged. In addition, this polarity dependability is contrary to that of the photosensitive member obtained in Example 1.
EXAMPLE 5
In accordance with the procedure and condition used in Example 4, an a-Si type layer of 20 microns in thickness was formed on the aluminum substrate. The structure was then taken out from the deposition chamber 10 to the outside, and polycarbonate resin was then coated onto the a-Si type layer to form an electrically insulating layer having a thickness of 15 microns after drying.
To the insulating layer surface of the electrophotographic photosensitive member obtained in the above-mentioned manner was applied negative corona discharge with a power source voltage of 6,000 V as the primary charging for 0.2 sec. so that such surface was charged to a voltage of -2,000 V. Positive corona discharging with a voltage of 5,500 V was carried out as the secondary charging simultaneously with the image exposure in an exposure quantity of 15 lux.sec., and the whole surface of the photosensitive member was then exposed uniformly to form an electrostatic image. This image was developed with a positively charged toner by the cascade method, and the thus developed image was transferred to a transfer paper and fixed so that an image of extremely excellent quality was obtained.
EXAMPLE 6
Photosensitive members were prepared by repeating the same procedure under the same condition as in Example 1 except that the temperature of the substrate was varied as shown in Table 1 given below. The prepared photosensitive members are indicated by Sample Nos. 1-8 in Table 1.
By using the photosensitive members, the image formation was carried out under the same condition as in Example 3 to form images on transfer papers. The obtained results are as shown in Table 1.
As understood from the results, it is necessary to form the a-Si layer at a temperature of the substrate ranging from 50° C. to 350° C. for the purpose of achieving the object of the present invention.
TABLE 1______________________________________ Sample No. 1 2 3 4 5 6 7 8 Substrate temp., °C. 50 100 150 200 250 300 350 400______________________________________Image qualityCharged ⊕ X Δ Δ Δ X X X Xpolarity ⊖ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; Δ Acceptable for practical use; X Poor
EXAMPLE 7
Photosensitive members were prepared by repeating the same procedure and condition as in Example 3 except that the temperature of the substrate was varied as shown in Table 2 given below. The prepared photosensitive members are indicated by Sample Nos. 9-16 in Table 2.
By using the photosensitive members, the image formation was carried out by using the same procedure and condition as in Example 3 to form images on transfer papers. The obtained results are as shown in Table 2.
As understood from the results, it is necessary to form the a-Si layer at a temperature of the substrate ranging from 50° C. to 350° C. for the purpose of achieving the object of the present invention.
TABLE 2______________________________________ Sample No. 9 10 11 12 13 14 15 16 Substrate temp., °C. 50 100 150 200 250 300 350 400______________________________________Image qualityCharged ⊕ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ Xpolarity ⊖ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; Δ Acceptable for practical use; X Poor
EXAMPLE 8
Photosensitive members were prepared by repeating the same procedure and condition as in Example 4 except that the temperature of the substrate was varied as shown in Table 3 given below. The prepared photosensitive members are indicated by Sample Nos. 17-24 in Table 3.
By using the photosensitive members, the image formation was carried out by employing the same procedure and condition as in Example 4 to form images on transfer papers. The obtained results are as shown in Table 3.
As understood from the results, it is necessary to form the a-Si type layer at a temperature of the substrate ranging from 50° C. to 350° C. for the purpose of achieving the object of the present invention.
TABLE 3______________________________________ Sample No. 17 18 19 20 21 22 23 24 Substrate temp., °C. 50 100 150 200 250 300 350 400______________________________________Image qualityCharged ⊕ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ Xpolarity ⊖ X Δ Δ Δ X X X X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; Δ Acceptable for practical use; X Poor
EXAMPLE 9
A cylinder made of aluminum having a thickness of 2 mm and a size of 150 mm×300 mm was disposed in a deposition apparatus for glow discharge shown in FIG. 3 so that it might rotate freely, d a heater was molted so as heat the cylinder from the inside of the cylinder.
The air in a deposition chamber 10 was evacuated by opening fully a main valve 29 to bring the chamber to a vacuum degree of about 5×10 -5 Torr. The heater 13 was ignited to heat uniformly the cylinder 150° C. simultaneously with the cylinder being rotate at a speed of three revolutions per minute, and the cylinder was kept at that temperature. A subsidiary valve 28 was fully opened, and subsequently a valve 25 of a bomb 16 to which Ar was charged and a valve 26 of a bomb 17 which was filled with SiH 4 were also opened fully, and thereafter, flow amount controlling valves 22, 23 were gradually opened so that Ar gas and SiH 4 gas were introduce into the deposition chamber 10 from the bombs 16, 17. At that time, the vacuum degree in the deposition chamber 10 was brought to and kept at about 0.075 Torr. by regulating the main valve 29. Further, the flow amount of the SiH 4 gas was adjusted to 10% by volume based on that of the Ar gas.
After fully opening of a valve 27 of a bomb 18, to which B 2 H 6 was charged, a flow amount controlling valve 24 was gradually opened while a flow meter 21 was carefully observed, to adjust the flow amount of B 2 H 6 gas to 10 -5 % by volume based on that of the SiH 4 gas, thereby introducing the B 2 H 6 gas into the deposition chamber 10. Also at that time, the main valve 29 was regulated to bring the vacuum degree in the deposition chamber 10 to about 0.075 Torr.
A high frequency power source 14 was switched on to apply a high frequency voltage of 13.56 MHz between electrodes 15 and 15' so that a glow discharge was caused, thereby depositing and forming an a-Si type photoconductive layer on the cylinder substrate. At that time, the glow discharge was initiated with an electric current density of about 3 mA/cm 2 and a voltage of 1,500 V. Further, the growth rate of the a-Si type layer was about 2.5 angstroms per second and the deposition was effected for 23 hours and further the thus formed a-Si type layer had a thickness of 20 microns.
After completion of the deposition, while the main valve 29, subsidiary valve 28, flow amount controlling valves 22 and 23, valves 25 and 26 were closed, a valve 30 was opened to break the vacuum state in the deposition chamber 10.The prepared electrophotographic photosensitive member was taken out from the deposition apparatus.
To the a-Si type photoconductive layer surface of the photosensitive member was applied negative corona discharge With a power source voltage of 5,500 V in a dark place. The image exposure was conducted in an exposure quantity of 20 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner in accordance with the cascade method. The developed image was transferred to a transfer paper and then fixed so that an extremely sharp image was obtained.
The image forming process as mentioned above was repeatedly carried out in order to test the durability of the photosensitive member. As a result, the image on the transfer paper obtained when such process was repeated ten thousand (10,000) times was extremely good in quality. Although such image was compared with the first image on a transfer paper obtained at the time of the initial operation of the image forming process, no difference was observed therebetween. Therefore, it was found that the photosensitive member is extremely excellent in durability. In addition, the blade cleaning was effected in cleaning the photosensitive member after the transferring step, the blade being formed of urethane rubber.
Further, the foregoing image forming process was repeated under the same condition except that positive corona discharge was applied with a power source voltage of 6,000 V to the photosensitive member and a negatively charged toner was used for the development. The thus obtained image formed on the transfer paper had an image density lower than that of the image obtained in the foregoing image forming process using negative corona discharge. As a result, it was recognized that the photosensitive member prepared in this example depends upon the polarity to be charged.
EXAMPLE 10
Electrophotographic photosensitive members, which are indicated by Sample Nos. 25-29 in Table 4 given below, were prepared by conducting the same procedure under the same condition as in Example 3 except that the flow amount of the B 2 H 6 gas based on that of the SiH 4 gas was varied in order to control the amount of the boron (B) doped into the a-Si type layer to various values as shown in Table 4.
The image formation was effected by employing the photosensitive members under the same condition as in Example 3 to obtain images on transfer papers. The results are shown in Table 4. As is clear from the results, with respect to practically usable photosensitive member, it is desired, to dope the a-Si type layer with boron (B) in an amount of 10 -6 -10 -3 atomic percent.
TABLE 4______________________________________ Sample No. 25 26 27 28 29______________________________________Doping amount 10.sup.-6 10.sup.-5 10.sup.-4 10.sup.-3 1of B, atomic %Image quality ◯ ⊚ ⊚ ◯ X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; X Poor
EXAMPLE 11
In accordance with the procedure described below, an electrophotographic photosensitive member was prepared by using an apparatus as shown in FIG. 4, and the image forming treatment was applied to the photosensitive member.
An aluminum substrate of 1 mm in thickness and 10 cm×10 cm in size was cleaned in such a manner that the surface of the substrate was treated with a 1% solution of NaOH and sufficiently washed with water and dried, and then Mo was deposited on this substrate to about 1,000 angstroms in thickness. This substrate was firmly fixed at a predetermined position in a fixing member 33 placed in a deposition chamber 31 so that the substrate was kept apart from a heater 34 by about 1.0 cm. Also, the substrate was parted from a target 35 of polycrystalline silicon having a purity of 99.999% by about 8.5 cm.
The air in the deposition chamber 31 was evacuated to bring the chamber to a vacuum degree of about 1×10 -6 Torr. The heater 34 was ignited to heat uniformly the substrate to 150° C., and the substrate was kept at this temperature. A valve 45 was fully opened, and subsequently a valve 40 of a bomb 38 was also opened fully, and thereafter, a flow amount controlling valve 44 was gradually opened so that H 2 gas was introduced into the deposition chamber 31 from the bomb 38. At that time, the vacuum degree in the deposition chamber 31 was brought to and kept at about 5.5×10 -4 Torr. by regulating the main valve 46.
Subsequently, after fully opening of a valve 39, a flow amount controlling valve 43 was gradually opened with a flow meter 41 being carefully observed, to introduce Ar gas into the deposition chamber 31 in which the vacuum degree was adjusted to 5×10 -3 Torr.
A high frequency power source 36 was switched on to apply a high frequency voltage of 13.56 MHz, 1 KV between the aluminum substrate and polycrystalline silicon target so that a discharge was caused, thereby starting formation of an a-Si layer on the aluminum substrate. This operation was conducted continuously with a growth rate of the a-Si layer being controlled to about two angstroms per second for 30 hours. The thus formed a-Si layer was 20 microns in thickness.
To the thus prepared electrophotographic photosensitive member was applied negative corona discharge with a power source voltage of 5,500 V in a dark place. The image exposure was conducted in an exposure quantity of 15 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner in accordance with the cascade method. The developed image was transferred to a transfer paper and then fixed so that an extremely sharp image was obtained.
EXAMPLE 12
Electrophotographic photosensitive members, which are indicated by Sample Nos. 30-36 in Table 5 given below, were prepared by conducting the same procedure under the same condition as in Example 11 except that the flow amount of the H 2 gas based on that of the Ar gas was varied in order to control the amount of the hydrogen (H) doped into the a-Si type layer to various values as shown in Table 5.
The image formation was effected by employing the photosensitive members under the same condition as in Example 11 to obtain images on transfer papers. The results are shown in Table 5. As is clear from the results, with respect to practically usable photosensitive member, it is desired to dope the a-Si type layer with H in an amount of 10-40 atomic percent.
TABLE 5______________________________________ Sample No. 30 31 32 33 34 35 36______________________________________Doping amount 5 10 15 25 30 40 50of H, atomic %Image quality X ◯ ⊚ ⊚ ⊚ ◯ X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; X Poor
EXAMPLE 13
The electrophotographic photosensitive members prepared in Examples 1, 3 and 4 were each allowed to stand in an atmosphere of high temperature and humidity, i.e., at a temperature of 40° C. and relative humidity of 90 RH %. After the lapse of 96 hours, the photosensitive members were taken out into an atmosphere at a temperature of 23° C. and relative humidity of 50 RH %. Immediately thereafter, the same image forming processes as in Examples 1, 3 and 4 were conducted under the same condition by using the photosensitive members to obtain images of sharpness and good quality on transfer paper. This result showed that the photosensitive member of the present invention is very excellent also in moisture resistance.
EXAMPLE 14
An electrophotographic photosensitive member was prepared in the same manner as that in Example 1. To the member was applied negative corona discharge at a voltage of 6,000 V in a dark place and image exposure was then conducted in an exposure quantity of 20 lux.sec. to form an electrostatic image, which was then developed with a liquid developer containing a chargeable toner dispersed in a solvent of an isoparaffin type hydrocarbon. The developed image was transferred to a transfer paper followed by fixing. The fixed image was extremely high in the resolution and of good image quality with sharpness.
Further, the above described image forming process was repeated in order to test the solvent resistance, in other words, liquid developer resistance of the photosensitive member. The above-mentioned image on the transfer paper was compared with an image on a transfer paper obtained when the image forming process was repeated ten thousand (10,000) times. As a result, no difference was found therebetween, which showed that the photosensitive member of the present invention is excellent in the solvent resistance.
In addition, as the manner of cleaning the photosensitive member surface effected in the image forming process, the blade cleaning method was used, the blade being formed of urethane rubber.
EXAMPLE 15
In accordance with the procedure described below, an electrophotographic photosensitive member was prepared by using a depositing apparatus for glow discharge as illustrated in FIG. 5 and the image forming process was carried out by employing the photosensitive member.
An aluminum substrate 48 having a size of 10 cm×10 cm×1 mm already cleaned by the same surface treatment as in Example 1 was firmly disposed at a fixed position in a fixing member 49 placed in a deposition chamber 47 so that the substrate might be kept apart from a heater 50 by 1.0 cm or so.
A main valve 66 and subsidiary valve 65 were fully opened to evacuate the air in the deposition chamber 47 and mixing tank 68, thereby bringing them to the vacuum degree of about 5×10 -5 Torr. The heater 50 was then ignited to heat uniformly the aluminum substrate to 150° C. the substrate being kept at that temperature.
The subsidiary valve 65 was then closed, while a valve 62 of a bomb 53 which was filled up with Ar and valve 63 of a bomb 54 containing SiH 4 charged thereto were fully opened. Flow amount controlling valves 59, 60 for the gas bombs 53, 54 were regulated with flow meters 56, 57 being-observed so that Ar gas and SiH 4 gas were fed to the mixing tank 68 at a ratio by volume of Ar: SiH 4 =10:1. While the flow amount controlling valves 59, 60 were then closed, the subsidiary valve 65 was gradually opened to introduce a gas mixture of Ar and SiH 4 gases into the deposition chamber 47. At that time, the main valve 66 was regulated to retain the vacuum degree in the deposition chamber 47 at about 0.075 Torr.
Subsequently, a high frequency power source 51 was switched on to apply a high frequency voltage of 13.56 MHz to inductance type coil 52. As a result, a glow discharge took place, thereby forming an a-Si type photoconductive layer on the aluminum substrate by deposition. At that time, the high frequency power was about 50 W and the growth rate of the layer about three angstroms per second. Further, the period of time for the deposition was 20 hours and the formed a-Si type layer had a thickness of about 20 microns.
To the a-Si type photoconductive layer surface of the thus prepared photosensitive member was applied negative corona discharge with a source voltage of 5,500 V in a dark place. The image exposure was then effected in an exposure quantity of 15 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner by the cascade method. The developed image was transferred to a transfer paper and fixed. As a result, an image of high resolution with very sharpness was obtained.
EXAMPLE 16
In accordance with the procedure described below, an electrophotographic photosensitive member was prepared by using an apparatus as illustrated in FIG. 5 and the image forming process was carried out by employing the photosensitive member.
An aluminum substrate having a thickness of 1 mm and size of 10 cm×10 cm already was cleaned in such a manner that the surface was treated with a 1% solution of NaOH, sufficiently washed with water and dried. This substrate was firmly disposed at a predetermined position in a fixing member 49 placed in a deposition chamber 47 so that the substrate might be kept apart from a heater 50 by 1.0 cm or so.
A main valve 66 and subsidiary valve 65 were fully opened to evacuate the air in the deposition chamber 47 and mixing tank 68, thereby bringing them to the vacuum degree of about 5×10 -5 Torr. The heater 50 was then ignited to heat uniformly the aluminum substrate to 150° C., the substrate being kept at that temperature.
The subsidiary valve 65 was then closed, while a valve 62 of a bomb 53 and valve 63 of a bomb 54 were fully opened. Flow amount controlling valves 59, 60 were gradually opened with flow meters 56, 57 being observed so that Ar gas and SiH 4 gas were introduced from the bombs 53, 54, respectively, to the mixing tank 68 at a ratio by volume of Ar:SiH 4 =10:1. After a predetermined amount of the Ar and SiH 4 gases were fed to the tank 68, the flow amount controlling valves 59, 60 were then closed.
Next, a valve 64 of a bomb 55 was fully opened, and thereafter a flow amount controlling valve 61 was gradually opened to introduce B 2 H 6 gas into the mixing tank 68 from the bomb 55 while the flow amount of the B 2 H 6 gas was controlled to a ratio by volume of SiH 4 :B 2 H 6 =1:3×10 -5 . After a predetermined amount of the B 2 H 6 gas was fed to the tank 68, the valve 61 was closed. Then, the subsidiary valve 65 was gradually opened to introduce a gas mixture of Ar, SiH 4 and B 2 H 6 gases from the tank 68 into the deposition chamber 47. At this time, the main valve 66 was regulated to bring the vacuum degree in the deposition chamber 47 to 0.075 Torr.
Subsequently, a high frequency power source 51 was switched on to apply a high frequency voltage of 13.56 MHz to inductance type coil 52. As a result, a glow discharge took place, thereby forming an a-Si type photoconductive layer on the aluminum substrate by deposition. At that time, the high frequency power was about 50 W and the growth rate of the layer about 4 angstroms per second. Further, the period of time for the deposition was 15 hours and the formed a-Si type layer had a thickness of about 20 microns.
After completion of the deposition, the main valve 66 and subsidiary valve 65 were closed, but the valve 67 was opened to break the vacuum state in the deposition chamber 47. The prepared photosensitive member was taken out from the apparatus.
To the a-Si type photoconductive layer surface of the thus prepared photosensitive member was applied negative corona discharge with a source voltage of 5,500 V in a dark place. The image exposure was then effected in an exposure quantity of 20 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner by the cascade method. The developed image was transferred to a transfer-paper and fixed. As a result, an image with very sharpness was obtained.
The image forming process as mentioned above was repeatedly carried out in order to test the durability of the photosensitive member. As a result, the image on the transfer paper obtained when such process was repeated ten thousand (10,000) times was extremely good in quality. Although such image was compared with the first image on a transfer paper obtained at the time of the initial operation of the image forming process, no difference was observed therebetween. Therefore, it was found that the photosensitive member is very excellent in the durability. In addition, the blade cleaning was effected in cleaning the photosensitive member after the transferring step and the blade was formed of urethane rubber.
EXAMPLE 17
An electrophotographic photosensitive member was prepared by using the same procedure and condition as in Example 11 except that in place of the H 2 , SiH 4 was charged to the bomb 38 and SiH 4 gas was introduced into the deposition chamber 31.
The image formation was effected by using the photosensitive member in the same manner as in Example 11 under the equivalent condition. The obtained result was similar to that in Example 11.
EXAMPLE 18
In accordance with the procedure described below, an electrophotographic photosensitive member was prepared by using an apparatus as shown in FIG. 3, and the image forming treatment was applied to the photosensitive member.
An aluminum substrate of 1 mm in thickness and 10 cm×5 cm in size was cleaned in such a manner that the surface of the substrate was treated with a 1% solution of NaOH and sufficiently washed with water and then dried. This substrate was firmly fixed at a predetermined position in a fixing member 12 placed in a deposition chamber 10 for glow discharge so that the substrate was kept apart from a heater 13 equipped to the fixing member 12 by about 1.0 cm.
The air in the deposition chamber 10 was evacuated by opening fully a main valve 29 to bring the chamber to a vacuum degree of about 5×10 -5 Torr. A subsidiary valve 28 was fully opened, and subsequently a valve 25 of a bomb 16 was also opened fully, and thereafter, a flow amount controlling valve 22 was gradually opened so that Ar gas was introduced into the deposition chamber 10 from the bomb 16. At that time, the inside pressure in the deposition chamber 10 was brought to and kept at about 0.075 Torr.
A high frequency power source 14 was switched on to apply a high frequency voltage of 13.56 MHz between electrodes 15 and 15' so that a glow discharge was caused, thereby cleaning the surface of the aluminum substrate. At that time, the glow discharge was initiated with a current density of about 0.5 mA/cm 2 and a voltage of 500 V. After completion of the cleaning treatment, the subsidiary valve 28, valve 25 and flow amount controlling valve 22 were closed.
Subsequently, in accordance with the procedure and condition used in Example 1, an a-Si layer of abut 20 microns in thickness was formed on the aluminum substrate to obtain an electrophotographic photosensitive member.
The photosensitive member was used in the image forming process in the same manner and condition as in Example 1 to obtain an image transferred to a paper. Similar result to that in Example 1 was obtained. Further, as to the durability of the photosensitive, member, the same result was obtained.
EXAMPLE 19
An electrophotographic photosensitive member having an a-Si was prepared by employing the same procedure and condition as in Example 1. Deposition of Ta 2 O 5 to the surface of the photoconductive layer was effected by the electron beam deposition to form an anti-reflection layer of 70 millimicrons in thickness.
The image forming process described in Example 1 was repeated by using the thus prepared photosensitive member. As a result, it was found that the photosensitive member requires an exposure quantity of only about 12 lux.sec. to attain a transferred image density similar to that obtained in Example 1.
EXAMPLE 20
In accordance with the procedure described below, an electrophotographic photosensitive member was prepared by using an apparatus as shown in FIG. 3, and the image forming treatment was applied to the photosensitive member.
An aluminum substrate of 1 mm in thickness and 10 cm×10 cm in size was cleaned in such a manner that the surface of the substrate was treated with a 1% solution of NaOH and sufficiently washed with water and then dried. This substrate was firmly fixed at a predetermined position in a fixing member 12 placed in a deposition chamber 10 for glow discharge so that the substrate was kept apart from a heater 13 by about 1.0 cm.
The air in the deposition chamber 10 was evacuated by opening fully a main valve 29 to bring the chamber to a vacuum degree of about 5×10 -5 Torr. The heater 13 was ignited to heat uniformly the aluminum substrate to 150° C., and the substrate was kept at this temperature. A subsidiary valve 28 was fully opened, and subsequently a valve 25 of a bomb 16 and a valve 26 of a bomb 17 were also opened fully, and thereafter, flow amount controlling valves 22, 23 were gradually opened so that Ar gas and SiH 4 gas were introduced into the deposition, chamber 10 from the bombs 16 and 17, respectively. At that time, the vacuum degree in the deposition chamber 10 was brought to and kept at about 0.075 Torr by regulating the main valve 29.
A high frequency power source 14 was switched on to apply a high frequency voltage of 13.56 MHz between electrodes 15 and 15' so that a glow discharge was caused, thereby depositing and forming an a-Si type photoconductive layer on the aluminum substrate. At that time, the glow discharge was initiated with an electric current density of about 5 mA/cm 2 and a voltage of 2,000 V. Further, the growth rate of the a-Si type layer was about 4 angstroms per second and the deposition was effected for 15 hours and further the thus formed a-Si type layer had a thickness of 20 microns.
After completion of the deposition, while the main valve 29, valves 25 and 26, flow amount controlling valves 22 and 23, and subsidiary valve 28 were closed, a valve 30 was opened to break the vacuum state in the deposition chamber 10. The prepared photosensitive member was then taken out from the deposition chamber.
To the a-Si type photoconductive layer surface of the photosensitive member was applied negative corona discharge with a source voltage of 5,500 V in a dark place. The image exposure was conducted in an exposure quantity of 15 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner in accordance with the cascase method. The developed image was transferred to a transfer paper and then fixed so that a sharp image with a high resolution was obtained.
The image forming process as mentioned above was repeatedly carried out in order to test the durability of the photosensitive member. As a result, the image on the transfer paper obtained when such process was repeated ten thousand (10,000) times was extremely good in quality. Although such image was compared with the first image on a transfer paper obtained at the time of the initial operation of the image forming process, no difference was observed therebetween. Therefore, it was found that the photosensitive member is excellent in the corona discharging resistance, abrasion resistance, cleaning property and the like and shows extremely excellent durability. In addition, the blade cleaning was effected in cleaning the photosensitive member after the transferring step, the blade being formed of urethane rubber.
Further, the foregoing image forming process was repeated under the same condition except that positive corona discharge was applied with a voltage of 6,000 V to the photosensitive member and negatively charged toner was used for the development. The thus obtained image formed on the transfer paper had an image density lower than that of the image obtained in the foregoing image forming process using negative corona discharge.
As a result, it was recognized that the photosensitive member prepared in this example depends upon the polarity to be charged.
EXAMPLE 21
In accordance with the procedure and condition used in Example 20, an a-Si type layer of 20 microns in thickness was formed on the aluminum substrate. The structure was taken out from the deposition chamber 10 to the outside, and polycarbonate resin was then coated onto the a-Si type layer to form an electrically insulating layer having a thickness of 15 microns after drying.
To the insulating layer surface of the electrophotographic photosensitive member obtained in the above-mentioned manner was applied positive corona discharge with a power source voltage of 6,000 V as the primary charging for 0.2 sec. so that such surface was charged to a voltage of +2,000 V. Negative corona discharging with a voltage of 5,500 V was carried out as the secondary charging simultaneously with the image exposure in an exposure quantity of 15 lux.sec., and the whole surface of the photosensitive member was then exposed uniformly to form an electrostatic image. This image was developed with a negatively charged toner by the cascade method, and the thus developed image was transferred to a transfer paper and fixed so that an image of extremely excellent quality was obtained.
EXAMPLE 22
In the following manner similar to that in Example 20, an electrophotographic photosensitive member was prepared by using the apparatus as illustrated in FIG. 3 and the image forming treatment was applied to the photosensitive member.
An aluminum substrate having a thickness of 1 mm and a size of 10 cm×10 cm was first treated with a 1% solution of NaOH and sufficiently washed with water and dried to clean the surface of the substrate. This substrate was firmly disposed at a fixed position in a fixing member 12 placed in a deposition chamber 10 for glow discharge so that it might be kept apart from a heater 13 positioned in the fixing member 12 by about 1.0 cm.
A main valve 29 was fully opened to evacuate the air in the deposition chamber 10 so that the vacuum degree in the chamber was adjusted to about 5×10 -5 Torr. The heater 13 was ignited to heat uniformly the aluminum substrate to 150° C., the substrate being kept at that temperature. Then, a subsidiary valve 28 was first opened fully, and successively a valve 25 of a bomb 16 containing Ar charged thereto and a valve 26 of a bomb 17 containing SiH 4 charged thereto were fully opened. Thereafter, the flow amount controlling valves 22 and 23 were gradually opened so that Ar gas and SiH 4 gas were introduced into the deposition chamber 10 from the bombs 16 and 17, respectively. At this time, the vacuum degree in the deposition chamber 10 was kept at about 0.075 Torr. by regulating the main valve 29, and while flow meters 19 and 20 were carefully observed, the flow amount controlling valves 22 and 23 were regulated to control the flow amount of the gases so that the flow amount of the SiH 4 gas might Be 10% by volume based on that of the Ar gas.
A valve 27 of a bomb 18 containing B 2 H 6 charged thereto was fully opened and then a flow amount controlling valve 24 was slowly opened to introduce B 2 H 6 gas into the deposition chamber 10 while the flow amount of the gas was controlled so that it might be 5×10 -3 % by volume based on the flow amount of the SiH 4 gas. In this case, the main valve 29 was regulated to retain the vacuum degree in the deposition chamber 10 to 0.075 Torr.
Subsequently, a high frequency power source 14 was switched on in order to apply a high frequency voltage of 13.56 MHz between electrodes 15 and 15' to give rise to the glow discharge so that an a-Si type photoconductive layer is formed on the aluminum substrate by the deposition. At the time of the glow discharge, the current density was about 3 mA/cm 2 and the voltage 1,500 V. Further, the growth rate of the a-Si type layer was about 4 angstroms/sec., the period of time for the deposition 15 hours, and the thickness of the a-Si type layer 20 microns. After completion of the deposition, the main valve 29, subsidiary valve 28, flow amount controlling valves 22, 23, 24, and valves 25, 26, 27 were closed, but the valve 30 was opened to break the vacuum state in the deposition chamber 10. Then, the electrophotographic photosensitive member obtained in the above mentioned manner was taken out from the apparatus.
To the a-Si type photoconductive layer surface of the photosensitive member was applied negative corona discharge with a voltage of 5,500 V in a dark place. The image exposure was conducted in an exposure quantity of 20 lux.sec. to form an electrostatic image, which was then developed with a positively charged toner in accordance with the cascade method. The developed image was transferred to a transfer paper and then fixed so that an extremely sharp image was obtained.
The image forming process as mentioned above was repeatedly carried out in order to test the durability of the photosensitive member. As a result, the image on the transfer paper obtained when such process was repeated ten thousand (10,000) times was extremely good in quality. Although such image was compared with the first image on a transfer paper obtained at the time of the initial operation of the image forming process, no difference was observed therebetween. Therefore, it was found that the photosensitive member is very excellent in the durability. In addition, the blade cleaning was effected in cleaning the photosensitive member after the transferring step, the blade being formed of urethane rubber.
Further, positive corona discharge with a power source voltage of 6,000 V was applied to the photosensitive member in a dark place and the image exposure was conducted in an exposure quantity of 20 lux.sec. to form an electrostatic image. This electrostatic image was developed with a negatively charged toner by the cascade method. The developed image was then transferred to a transfer paper and fixed so that an image with extreme sharpness was obtained.
It was found from this result and the before-said result that the photosensitive member obtained in this example does not have dependability to the charged polarity, but it possesses properties of a photosensitive member which can be advantageously used with both polarities to be charged.
EXAMPLE 23
The same procedure as in Example 22 was repeated except that the flow amount of the B 2 H 6 gas was adjusted to 5×10 -4 % by volume based on the flow amount of the SiH 4 gas, to prepare an electrophotographic photosensitive member having an a-Si type photoconductive layer of 20 microns in thickness on the aluminum substrate.
In accordance with the same condition and manner as in Example 3, the image forming process was carried out by using the obtained photosensitive member to form an image on a transfer paper As a result, the image formed by the process using positive corona discharge was excellent in quality and very sharp as compared with that obtained by the process employing negative corona discharge.
It is recognized from the result that the photosensitive member of this example depends upon the polarity to be charged. In addition, this polarity dependability is contrary to that of the photosensitive member obtained in Example 1.
EXAMPLE 24
In accordance with the procedure and condition used in Example 23, an a-Si type layer of 20 microns in thickness was formed on the aluminum substrate. The structure was taken out from the deposition chamber 10, and polycarbonate resin was then coated onto the a-Si type layer to form an electrically insulating layer having a thickness of 15 microns after drying.
To the insulating layer surface of the electrophotographic photosensitive member obtained in the above-mentioned manner was applied negative corona discharge with a power source voltage of 6,000 V as the primary charging for 0.2 sec. so that such surface was charged to a voltage of -2,000 V. Positive corona discharging with a voltage of 5,500 V was carried out as the secondary charging simultaneously with the image exposure in an exposure quantity of 15 lux.sec., and the whole surface of the photosensitive member was then exposed uniformly to form an electro static image. This image was developed with a positively charged toner by the cascade method, and the thus developed image was transferred to a transfer paper and fixed so that an image of extremely excellent quality was obtained.
EXAMPLE 25
Photosensitive members were prepared by repeating the same procedure and condition as in Example 20 except that the temperature of the substrate was varied as shown in Table 6 given below. The prepared photosensitive members are indicated by Sample Nos. 37-44 in Table 6.
By using the photosensitive members, the image formation was carried out by employing the same manner and condition as in Example 22 to form images on transfer papers. The obtained results are as shown in Table 6.
As understood from the results, it is necessary to form the a-Si type layer at a temperature of the substrate ranging from 50° C. to 350° C. for the purpose of achieving the object of the present invention.
TABLE 6______________________________________ Sample No. 37 38 39 40 41 42 43 44 Substrate temp. °C. 50 100 150 200 250 300 350 400______________________________________Image qualityCharged ⊕ X Δ Δ Δ X X X Xpolarity ⊖ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; Δ Acceptable for practical use; X Poor
EXAMPLE 26
Photosensitive members were prepared by repeating the same procedure and condition as in Example 22 except that the temperature of the substrate was varied as shown in Table 7 given below. The prepared photosensitive members are indicated by Sample Nos. 45-52 in Table 7.
By using the photosensitive members, the image formation was carried out under the same condition as in Example 22 to form images on transfer papers. The obtained results are as shown in Table 7.
As understood from the results, it is necessary to form the a-Si type layer at a temperature of the substrate ranging from 50° C. to 350° C. for the purpose of achieving the object of the present invention.
TABLE 7______________________________________ Sample No. 45 46 47 48 49 50 51 52 Substrate temp. °C. 50 100 150 200 250 300 350 400______________________________________Image qualityCharged ⊕ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ Xpolarity ⊖ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; Δ Acceptable for practical use; X Poor
EXAMPLE 27
Photosensitive members were prepared by repeating the same procedure and condition as in Example 23 except that the temperature of the substrate was varied as shown in Table 8 given below. The prepared photosensitive members are indicated by Sample Nos. 53-60 in Table 8.
By using the photosensitive members, the image formation was carried out under the same condition as in Example 23 to form images on transfer papers. The obtained resets are as shown in Table 8.
As understood from the results, it is necessary to form the a-Si type layer at a temperature of the substrate ranging from 50 ° to 350° C. for the purpose of achieving the object of the present invention.
TABLE 8______________________________________ Sample No. 53 54 55 56 57 58 59 60 Substrate temp., °C. 50 100 150 200 250 300 350 400______________________________________Image qualityCharged ⊕ Δ ⊚ ⊚ ⊚ ◯ ◯ Δ Xpolarity ⊕ X Δ Δ Δ X X X X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; Δ Acceptable for practical use; X Poor
EXAMPLE 28
Electrophotographic photosensitive members, which are indicated by Sample Nos. 61-65 in Table 9 given below, were prepared by conducting the same procedure under the same condition as in Example 22 except that the flow amount of the B 2 H 6 gas based on that of the SiH 4 gas was varied in order to control the amount of the boron (B) doped into the a-Si type layer to various values as shown in Table 9.
The image formation was effected by employing the photosensitive members under the same condition as in Example 22 to obtain images on transfer papers. The results are shown in Table 9. As is clear from the results, with respect to practically usable photosensitive member, it is desired to dope the a-Si type layer with boron (B) in an amount of 10 -6 -10 -3 atomic percent.
TABLE 9______________________________________ Sample No. 61 62 63 64 65______________________________________Doping amount 10.sup.-6 10.sup.-5 10.sup.-4 10.sup.-3 1of B, atomic %Image quality ◯ ⊚ ⊚ ◯ X______________________________________ Image quality is that of transferred image. ⊚ Very good; ◯ Good; X Poor
EXAMPLE 29
The photosensitive members prepared in Examples 20, 22 and 23 were each allowed to stand in an atmosphere of high temperature and humidity, i.e., at a temperature of 40° C. and relative humidity of 90 RH %. After the lapse of 96 hours, the photosensitive members were taken out into an atmosphere at a temperature of 23° C. and relative humidity of 50 RH %. Immediately thereafter, the same image forming processes as in Examples 20, 22 and 23 were conducted under the same condition by using the photosensitive members to obtain images of sharpness and good quality. This result showed that the photosensitive member of the present invention is very excellent also in moisture resistance.
EXAMPLE 30
An electrophotographic photosensitive member was prepared in the same manner as that in Example 20. To the member was applied negative corona discharge with a power source voltage of 6,000 V in a dark place and the image exposure was then conducted in an exposure quantity of 20 lux.sec. to form an electrostatic image, which was then developed with a liquid developer containing a chargeable toner dispersed in a solvent of an isoparaffin type hydrocarbon. The developed image was transferred to a transfer paper followed by fixing. The fixed image was extremely high in the resolution and of good image quality with sharpness.
Further, the above described image forming process was repeated in order to test the solvent resistance, in other words, liquid developer resistance of the photosensitive member. The foregoing image on the transfer paper was compared with an image on a transfer paper obtained when the image forming process was repeated ten thousand (10,000) times. As a result, no difference was found therebetween, which showed that the photosensitive member of the present invention is excellent in the solvent resistance.
In addition, as the manner of cleaning the photosensitive member surface effected in the image forming process, the blade cleaning method was used, the blade being formed of urethane rubber.
EXAMPLE 31
An electrophotographic photosensitive member was prepared by using the same procedure and condition as in Example 1 except that the temperature of the aluminum substrate was continuously raised from 100° C. to 300° C. for the duration between the start of the a-Si layer formation and the completion thereof.
The same image forming process as in Example 1 was applied to the thus prepared photosensitive member. It was found that the photosensitive member is excellent in light fatigue resistance as compared with that of Example 1. As to the other properties, similar results were obtained.
EXAMPLE 32
An electrophotographic photosensitive member was prepared by repeating the same manner and condition as in Example 1 except that the temperature of the aluminum substrate was controlled as mentioned below. The substrate temperature was adjusted to 100° C. at the time of starting the formation of the a-Si type layer, and then continuously raised as the layer grew so that the temperature was adjusted to 300° C. immediately before expiration of the layer forming duration and subsequently decreased to 280° C. so that the image formation was completed.
The same image forming treatment as in Example 1 was conducted by using the photosensitive member thus prepared. As a result, the photosensitive member was excellent in light fatigue resistance as compared with that obtained in Example 1, and as to other properties, similar results were obtained. | A CVD process of forming a hydrogenated amorphous silicon film comprising not more than 40 atomic percent of hydrogen atoms is disclosed, which comprises introducing a silicon-containing gas and a gas containing impurity for controlling conductivity of said film into a film-forming space, wherein the concentration of the gas containing the impurity is controlled during film formation to vary the content of the impurity in the thickness direction of the amorphous silicon film. | 8 |
FIELD OF THE INVENTION
This invention relates to a process for producing clean liquid from untreated liquid, in particular for producing fresh water from salt water, by means of evaporation of the untreated liquid under partial vacuum in an evaporation device and condensation of the vapour in a condensation device connected with the vapour output of the evaporation device.
The invention further relates to a device suitable for carrying out the process, having at least one evaporation device which can be supplied with untreated liquid and in which a partial vacuum can be produced, and further having at least one condensation device which can via a connecting line be supplied with vapour from at least one upstream evaporation device.
BACKGROUND OF THE INVENTION
Such a process and device is known from DE 33 45 937 A1 where the connecting line between an evaporation device and a condensation device cannot be shut off. To produce the desirable partial vacuum, the evaporation device is connected with at least one tank which is filled with untreated liquid, and provided at a height that is at least by the water column producible by the ambient air pressure above a water level, which tank is provided with a downpipe that is immersed in the water level and can be shut off. By opening the downpipe, liquid flows off causing a partial vacuum in the evaporation device if venting thereof is prevented, which partial vacuum is in this case passed on to the condensation device via the open connecting line. The required location of the tank at a high level and the immersing of the bottom end of the downpipe in an existing water level result in a relatively large overall height of the device and high constructional expenditure. Nevertheless, due to the existing connection between the evaporation device and the condensation device, the obtainable partial vacuum is relatively small. In addition, the liquid in which the downpipe is immersed may contain gas bubbles produced by gas emission etc., which may accumulate at the bottom end of the downpipe and then rise in it, which may result in a further deterioration of the obtainable partial vacuum.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process and a device as described initially above which ensure high evaporation output at a low boiling point and thus a high degree of cost effectiveness.
According to the invention, this object is achieved, in conjunction with a process whereby an evaporating device and a condenser device have crude or clean liquid therein exposed to a partial vacuum created by volume enlargement under hermetically sealed conditions and further, in conjunction with the device whereby each evaporating device forms a vessel system comprising a pump unit connected with the bottom area of the evaporator device and having an operating chamber of variable size which vessel system can be filled with crude liquid when the operating chamber is reduced in size and is exposed to a partial vacuum in hermetically closed condition by enlarging the operating chamber, whereby the side of the condensation device forms a vessel system comprising a pump unit connected with the bottom area of the evaporation device and having an operating chamber of variable size, which vessel system can be filled with a clean liquid when the operating chamber of the condensation device vessel system is reduced in size and is exposed to a partial vacuum in hermetically closed condition by enlarging the operating chamber of the condensation device vessel system, and whereby a shut-off device is provided in the connecting line for releasing the connecting line only when the operating chambers are enlarged to maximum size.
The measures according to the present invention advantageously result in a high degree of evacuation and thus in a high evaporation output at relatively low temperatures as can advantageously be obtained using simple solar collectors or the like. The measures according to the invention may further also be realised in an advantageous manner by a highly compact and correspondingly easy-maintenance arrangement. Thus, the measures according to the invention serve to achieve the above-mentioned object of the invention in a most simple and low cost manner.
The evaporation device may advantageously comprise a heater and a separator provided downstream thereof. Such an arrangement permits the direct or indirect heating of the raw water to be vaporised outside the separator, thus allowing a high degree of freedom of design.
A further advantageous measure to improve the output may consist in cooling the condensation device during the condensation process. The heat thus generated may advantageously be used for preheating the raw water to be vaporised.
A further, particularly preferential measure may consist in that the condensation device is stimulated to perform vibrating movements during the condensation process. Thus, the formation of water droplets on the condensate side of the condensation device is prevented, which may affect the thermal transfer and thus condensation. Instead, the vibrating movement ensures that the droplets run off rapidly leaving only a very thin water layer on the condensate side.
A further advantageous measure may consist in that the vapour coming from the evaporation device is pumped into the condensation device by means of an injection device. This advantageously permits an increase in pressure within the condensation device, having a positive effect on the acceleration of the condensation process.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantageous embodiments and expedient developments of the main-claim measures are evident from the remaining sub-claims and can be derived from the description of an example given below in conjunction with the accompanying drawings wherein:
FIG. 1 shows a functional diagram of a seawater desalination plant having an evaporation and a condensation device,
FIG. 2 shows a functional diagram of a seawater desalination plant having several evaporation and condensation devices,
FIG. 3 shows a section of an injection device associated with a condensation device, and
FIG. 4 shows a side view of a vibratable condenser.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is mainly used for seawater desalination, that is to say for producing fresh water from salt water. The plant according to the invention is thus advantageously installed at the sea shore so that practically unlimited amounts of the required salt water can be taken from the sea.
Plants as described in the present invention comprise an evaporator and a condenser side each. FIG. 1 contains a dot-dash separation line A, with the evaporator side on the right-hand side of such line, and the condenser line on the left-hand side thereof. The evaporator side comprises a raw water tank 1 , designed as a trough which is open towards the top, which is suppliable with seawater via a pump 2 . Below the raw water tank 1 provision is made for a lower-level cylinder-piston unit 3 comprising a piston 4 provided in a cylinder, which piston is connected via a piston rod 5 with a piston 6 of an equal-stroke cylinder-piston unit 7 , which is actuatable by hydraulic or preferably pneumatic force, which unit is connected with a suitable energy source not shown in detail here, but shown in the present example in the form of a pressurized oil source and controllable by a control valve 8 . The cylinder-piston unit 3 comprises an operating chamber 9 , limited by the piston 4 , which can be reduced or increased in size within the associated cylinder by a movement of the piston 4 .
Above the level of the cylinder-piston unit 3 provision is made for an evaporation device 10 comprising a heater 11 and a downstream separator 12 . In the example illustrated, the heater 11 is designed as a solar collector ensuring practically direct heating by solar energy. It would of course be also conceivable to integrate the heater into a heat exchanger and to supply the heat via a secondary heating circuit, as is indicated for example on the right-hand side of FIG. 2 . The separator 12 , where water is separated from vapour, is provided above the level of the heater 11 but still below the raw water tank 1 . The evaporation unit 10 comprising the heater 11 and the separator 12 together with the operating chamber 9 constitute an inter-connected vessel system which can be shut off towards the outside. For this purpose, connecting lines exist between the operating chamber 9 and the bottom side of the heater 11 , between the top side of the heater 11 and the separator 12 and between the separator and the operating chamber 9 . The line leading from the separator 12 to the operating chamber 9 extends from the bottom of the separator 12 . The line from the heater 11 to the separator 12 exits into the top area of the separator 12 .
A supply line 13 which can be shut off by a valve arrangement is provided from the raw water tank 1 to the bottom side of the operating chamber 9 . In the example illustrated, the valve arrangement associated with the supply line 13 comprises two parallel branches provided with a valve 14 and a valve 15 , respectively, one of which, in this example valve 15 , being controllable by a level controller 16 associated with the separator 12 . An outlet nozzle 13 a , which can be shut off by a valve 17 , extends from the bottom area of the supply line 13 . A venting line 19 which can be shut off by a valve 18 extends from the top area of the separator 12 .
The condenser side comprises a clean water tank 20 provided at the same level as the raw water tank 1 , which clean water tank can be supplied with clean water via an inlet 22 which is connected with a clean water source and can be shut off by a valve 21 . Below the level of the clean water tank 20 provision is made for a condensation device 23 which in this example comprises a multitubular condenser 24 . Below the condenser 24 provision is made for a cylinder-piston unit 25 whose piston 26 limits an operating chamber 27 and is connected via a piston rod 28 with the piston 29 of an equal-stroke cylinder-piston unit 30 which is preferably actuatable in the same manner as the cylinder-piston unit 7 , which cylinder-piston unit 30 can be connected with the same hydraulic pressure medium source as the cylinder-piston unit 7 and is controllable by a control valve 31 .
A supply line 32 is provided from the clean water tank 20 to the bottom area of the operating chamber 27 . The supply line 32 can be shut off by a valve 33 . An outlet line 32 a which can be shut off by a valve 34 extends from the supply line 32 . A venting line 36 which can be shut off by a valve 35 extends from the inlet of the condenser 24 . In addition, the inlet of the condenser 24 is connected with the clean water tank 20 via an outlet line 37 comprising a check valve 38 . The check valve 38 is designed in such a manner that it opens in the direction of the clean water tank 20 .
The condenser 24 and the operating chamber 27 of the cylinder-piston unit 25 constitute a connected vessel system which can be shut off towards the outside. For this purpose, the operating chamber 27 is connected with the bottom area of the condenser 24 . The maximum volume enlargement of the operating chamber 27 obtainable by a movement of the piston 26 , which in this example is performed to the right-hand side, is expediently larger than the capacity of the condenser 24 on the condensate side.
In the embodiment shown, this cooling device contains a sprayer device 39 which can be fed with cooling water, preferably raw water, supplied by an associated cooling water pump 40 . The jet of the sprayer device impinges on the outside of the condenser 24 whose inside is exposed to vapour. A cooling water tank 41 is therefore associated with the cooling water pump 40 and can be supplied with raw water via a supply line extending from the raw water tank 1 . The cooling water flowing off from the condenser 24 is collected in a collecting trough 42 arranged underneath the condenser 24 , with a return line leading back to the cooling water tank 41 .
Associated with the vapour inlet of the condenser 24 is an injection device 43 which will be described in further detail below in conjunction with by means of FIG. 3 . This injection device comprises a venturi tube supplied with clean water. For this reason, a supply line 44 is associated with the injection device 43 , which supply line is provided with a pump 45 whose suction side is arranged adjacent to the operating chamber 27 . The injection device 43 brings about a pressure increase within the condenser 24 , thus resulting in an improved condensation effect.
To further improve the condensation effect, the condenser 24 may be designed as a vibrating condenser which during the condensation process is stimulated by a vibration generator 46 to perform vibrating movements which will be described in further detail in connection with FIG. 4 .
The evaporator side is connected with the condenser side by a connecting line 47 leading from the exit of the separator 12 to the inlet of the condenser 24 . The connecting line 47 can be shut off by a valve 48 which is expediently controllable by a controll unit preferably in the form of a PLC. This also applies accordingly to the valves 15 , 17 and 33 . The other valves may expediently be designed as manually controlled valves.
To start the plant, the raw water tank 1 is first filled with seawater by means of the associated pump 2 . The cooling water tank 41 is connected with the overflow of the raw water tank 1 . All valves are closed while the manual venting valve 17 is opened. The piston 4 of the cylinder-piston unit 3 is in its end position, here on the left-hand side, which corresponds to the smallest volume of the operating chamber 9 , as indicated in FIG. 1 . Upon opening the manual valve 14 , the condenser side is flooded until the raw water flows off at the venting line 19 . As soon as this is the case, the valves 18 and 14 will be closed.
On the condenser side, all automatic and manual valves are initially closed. First of all, by opening the valve 21 , about one third of the clean water tank 20 is filled with clean water from the outside. Afterwards, the valve 21 is closed again and the venting valve 35 opened. The piston 26 of the cylinder-piston unit 25 is in its end position, here on the left-hand side, which corresponds to the smallest volume of the operating chamber 27 . Upon opening the valve 33 provided in the supply line 32 , the entire condenser system is flooded until raw water flows off at the venting line 36 . As soon as this is the case, the valves 35 and 33 are closed.
Due to the activation of the cylinder-piston units 7 and 30 by activating or actuating the associated control valves 8 and 31 , respectively, the pistons 4 and 26 of the cylinder-piston units 3 and 25 are moved into their respective end positions opposite the end position shown in FIG. 1 , whereby the operating chambers 9 and 27 limited by the pistons 4 and 26 , respectively, are enlarged to their maximum volume. On the evaporator side the liquid level in the separator 12 drops to the operating position as illustrated. The volume enlargement obtainable by the movement of the piston 4 is accordingly smaller than the entire capacity of the separator 12 . On the condenser side the liquid level sinks below the middle of the associated cylinder-piston unit 25 . Accordingly, the volume enlargement obtainable by the movement of the piston 26 of the cylinder-piston unit 25 is greater than the internal capacity, that is to say, the condensate-side capacity, of the condenser 24 . In this case the volume enlargement described above corresponds to more than twice the capacity of the condenser 24 .
The vessel systems comprising the operating chamber 9 and the evaporation device 10 , and the operating chamber 27 and the condenser 24 , respectively, are hermetically sealed towards the outside. The volume enlargement of the operating chambers 9 and 27 result in a nearly complete vacuum, or in any case in a very high partial vacuum, in these hermetically sealed-off vessel systems, whereby the water in the entire system will boil at already relatively low temperatures.
The heating energy supplied to the evaporator 11 , in this example the directly supplied solar energy, maintains this boiling process. On the condenser side, the cooling device is started by switching on the pump 40 , while simultaneously, by switching on the pump 45 , the injection device 43 is put in operation. By opening the valve 48 provided in the connecting line 47 , vapour pours from the separator 12 into the condenser 24 . The injection device 43 causes a pressure increase which permits condensation at higher temperatures and thus increases the temperature difference between the condensation temperature and the temperature outside of the condenser. The cooling device in the embodiment illustrated, which is designed as a spraying device 39 fed with raw water, reaches a high degree of efficiency, thus improving the condensation output even further.
The water evaporating on the outside of the condenser 24 is continually replenished by water flowing from the overflow of the raw water tank 1 to the cooling water tank 41 . To further increase the output, a fan or blower might be associated with the condenser 24 whereby a cooling tower effect could be achieved.
To avoid excessive salt concentration in the cooling water tank 41 , the overflow coming from the raw water tank 1 is led directly into the suction-side range of the pump 40 . Thus, the same amount of slightly concentrated salt water in the return line of the cooling circuit will flow into the overflow extending from the cooling water tank 41 as water flows in from the raw water tank 1 .
To further increase the output of the condenser 24 , the oscillation generator may be put in operation, which is designed in such a manner that it can stimulate the associated condenser 24 to perform vibrations in a frequency range of 5 to 20,000 Hz, thus considerably increasing the effectiveness of the condenser 24 .
The boiling water in the separator 12 is maintained at a constant level by automatically supplying water from the raw water tank 1 . This is achieved by a level controller 16 associated with the separator 12 , which acts to control the valve 15 provided in the supply line 13 .
Due to the constant condensation in the condenser 24 , the liquid level on the condenser side is permanently rising. When this level has reached the bottom side of the condenser 24 , a signal emitted by a suitable level alert causes the valve 48 provided in the connecting line 47 to be closed and the control valve 31 to be reversed, whereby the piston 26 of the cylinder-piston unit 25 is moved in the direction reducing the volume of the operating chamber 27 . Thus, the collected, condensed, and therefore desalted water is pressed into the clean water tank 20 via the discharge line 37 which is provided with the check valve 38 . When the smallest volume of the operating chamber 27 is obtained, the control valve 31 is automatically reversed, thus urging the piston 26 into the opposite direction where it produces a high vacuum again. Then the valve 48 provided in the connecting line 47 can be opened again, so that a new cycle can start. On the evaporator side, the vacuum can likewise be augmented in the above-described manner by activating the cylinder-piston unit 3 while the associated vessel system is hermetically sealed.
The arrangement according to FIG. 2 differs from that in FIG. 1 merely in that provision is made for two evaporation devices 10 a , 10 b and two condenser devices 23 a , 23 b . The evaporation device 10 a is connected with the condensation device 23 a via a connecting line 47 a having a valve 48 a . The evaporation device 10 b is connected with the condensation device 23 b via a connecting line 47 b having a valve 48 b . A cylinder-piston unit 3 a , 3 b and 25 a , 25 b , is associated with each evaporation device and condensation device, respectively. A particularity in comparison with FIG. 1 consists here in that the heater 11 a of the evaporation device 10 a in this example is not heated directly but, as mentioned above, indirectly. For this purpose, provision is made for a heat exchanger, one side of which forms the heater 11 a of the evaporation device 10 a and the other side of which is located in a secondary heating circuit 51 extending via a solar collector 52 . The heater 11 b of the evaporation device 10 b and the condenser of the condensation device 23 a also form a heat exchanger 53 which has the effect that the condensation heat of the condensation device 23 is simultaneously used for heating the raw water flowing through the heater 11 b . It may be expedient to design the heat exchangers 50 and 53 as plate heat exchangers.
An injection device 43 may be associated with the vapour inlet of each of the condensation devices, as mentioned above. An example hereof is illustrated in FIG. 3 . The injection device 43 shown here comprises a venturi tube 55 having a constriction and whose interior is exposed to a clean water jet. For this purpose, the supply line 44 associated with the injection device 43 is provided with a spray nozzle 56 within the area of the above-mentioned constriction. The venturi tube 55 , in the area of the constriction, is provided with radial inlets 57 which constitute a connection with a surrounding annular space 58 communicating with the connecting line 47 . The clear water jet generated by the spray nozzle 56 produces a partial vacuum which sucks the vapour from the annular space 58 into the inside via the radial inlets 57 and presses it into the associated condenser 24 which in the example shown is a multitubular condenser, whose interior is supplied with vapour and whose outside can be cooled by air or an additional coolant.
A particularly high condenser output can be achieved, as mentioned above, by using the vibration generator 46 for stimulating the condenser to perform vibrating movements during condensation. This will prevent the formation of water droplets on the inside of the condenser tubes which would affect the condensation process.
FIG. 4 shows a condenser 24 which can be stimulated to perform vibrating movements. For this purpose, the condenser is on one side held in an oscillating bearing, and on the other side connected with the vibration generator 46 . In the example illustrated, the condenser 24 is within the area of its upper end suspended in an oscillating manner around a horizontal axis 59 on a fixed bearing bracket 60 while being connected at its bottom end with the vibration generator 46 which is likewise fixed to a bracket and provided with a recuperating spring. The inlet and outlet lines of the condenser 24 are provided with flexible fittings 62 and via those are connectable with firmly installed lines.
The frequency of the vibrations generated by the vibration generator 46 may be in the range of 5 to 20.000 Hz. The optimal frequency has to be established in each individual case by experimentation. The effectiveness of the condenser can thus be increased by up to 60%, if an appropriate frequency is selected. The reason for such improvement lies in the fact that, due to the vibrating movements, the water condensing on the inside of the condenser tubes flows off before an excessive formation of droplets, thus preventing a water-caused insulation and improving the heat passage through the condenser tubes. | When fresh water is produced from salt water or similar by evaporation of untreated or crude liquid in an evaporation device under partial vacuum and by vapor condensation in a condensation device connected with the vapor outlet of the evaporation device a high degree of evaporation and cost effectiveness can be obtained in that the evaporation device and the condensation device in a disconnected condition, are filled with crude or clean liquid, respectively, and are subsequently exposed to a partial vacuum created by volume enlargement under hermetically sealed conditions and that the evaporation device and the condensation device are not flow-connected with each other until they are under partial vacuum. | 2 |
BACKGROUND OF THE INVENTION
The background of the invention will be discussed in two parts:
1. Field of the Invention
This invention relates to machines for applying roofing material, and more particularly to a machine for joining together adjacent overlying edges of roll roofing material where the facing edges are composed in part of a bitumen material.
2. Description of the Prior Art
Roofing material has generally been composed of a tar or pitch-like material, with such roofing material being commercially available in rolls. Such materials are usually applied to a roofing substrate such as plywood or the like by rolling out one strip or sheet of material with a second strip being rolled out thereafter with the edges overlapping. Normally, prior to the rolling out of the roofing material, a liquid or molten tar-like material is applied to the substrate or roof, the roofing material is suitably positioned on this liquid or molten tar to provide adhesion to the roof with subsequent strips or sheets of material having the overlapping edges suitably sealed by a liquid or molten tar interposed between facing edges. The upper edge surface is then pressed toward the lower edge to seal the joint.
New roofing materials have been developed which are particularly suitable for gently sloping or flat roofs more commonly found in industrial or commercial buildings. One such roofing material is manufactured by Koppers Company, Inc. of Pittsburgh, Pennsylvania under the trademark "KMM", and is referred to as the KMM membrane roofing material. Two such roofing materials are available, both of these materials being five-layer laminates. The standard material is provided with a polyethylene outer surface with a layer of bitumen, a plastic core, a second layer of bitumen, and an opposing outer layer of polyethylene. The second material available under the "KMM" mark is likewise a laminate composed of a thick, flexible plastic core which is protected on each side with a layer of modified bitumen with the top surface being a heavy embossed aluminum foil, and the bottom surface being a film of polyethylene. This material supplied in roll form with a four inch edge on the upper surface being polyethylene. That is, the upper surface of aluminum foil terminates four inches before the edge with this four inches having the polyethylene membrane, this edge being adapted for adhesion to a four inch portion of the under surface of an adjacent edge upon application of heat and pressure.
Conventional methods for applying this roofing material involved the use of three, four or five men. The first step in the operation is to roll out the first strip of material. A second strip of material is then rolled out in overlying overlapping relationship consistent with the four inch polyethylene upper surface thereby preliminarily forming an edge of four inches in width with facing polyethylene surfaces. A worker then comes along and bends back four inches (or more) of the upper sheet or strip to expose the upper and lower polyethylene surface. Another worker trails behind the first worker with a propane torch to heat the upper and lower edge portions. This method is referred to as a "heat fusion" method. The application of the heat by direct flame breaks and draws apart the external plastic or polyehylene film and melts the bitumen until it is plastic enough to flow under pressure. The second worker is normally working on his hands and knees and after observing proper breakdown of the polyethylene film and proper melting of the bitumen, he then manually pushes the upper sheet into overlapping relation with the lower sheet to provide a measure of adhesion. A third worker trails behind the second worker with a propane torch to reheat the surface along the edge with a fourth worker trailing behind with a heavy weighted roller which is rolled back and forth to apply pressure to the edge.
With such a manual process, many problems result. If the second worker is applying too little heat, the polyethylene film is not breaking down properly and the bitumen is not at the proper plastic state for optimum adhesion. If he is applying too much heat, the bitumen becomes liquid rather than plastic resulting in improper adhesion as well as an unsightly flow of the bitumen out of the overlapping edge area. Likewise, if the third worker is reheating the aluminum surface at the edge improperly, the same less than optimum result is achieved. Furthermore, with the bitumen in a liquid state, the roller gathers the molten bitumen thereby requiring cleaning frequently with needless down time. Other problems can arise if the workers are not operating as a team or if the work is interrupted for any reason. Generally, an unskilled work crew using this manual method will result in unsightly edges where the bitumen material has flowed irregularly out from the overlapping region and even worse, improper adhesion resulting from lack of uniformity or consistency in the heating and rolling process results in voids and uneven distribution of the bitumen within the overlapping region. In such cases, the edges can be readily separated where improper heat and pressure has been applied. The rolling operation often times results in a gathering or puckering of the upper layer of material thus further adding to the unsightliness as well as the imperfection of the bond.
Furthermore, since roofing material is applied on the exterior of the building ambient conditions produce variables of temperature and humidity which affect the amount of heat to be applied, the timing of the application of heat and pressure as well as other factors.
It is an object of this invention to provide a new and improved machine for joining adjacent strips of roofing material together in overlapping relation.
It is another object of this invention to provide a new and improved machine for applying adjacent sheets of a roofing material together in an overlapping relation to provide a uniform bond between the adjacent surfaces of the overlapping edges.
SUMMARY OF THE INVENTION
The foregoing and other objects of the invention are accomplished by providing a machine which includes a main frame adapted to be pushed over a roof. The main frame includes a roller rotatably mounted thereto adjacent the rear end thereof and a guide wheel at the front end thereof. Interposed therebetween is a leading guide shoe adjacent the front wheel for lifting an overlapping edge of roofing material a predetermined amount with means for applying heat at a predetermined position between the upper and lower sheets of roofing material adjacent thereto. A trailing shoe mounted to the frame guides the heated sheets or strips of roofing material together with the roller being positioned to apply a selected pressure to the upper sheet to promote uniform flow of the plastic bitumen material. In a particular embodiment of the invention, means are provided for adjusting the amount of heat applied in the overlapping area of the facing surfaces of roofing material with a second means being provided for heating the trailing shoe and roller, this latter heating means being selectively employed dependig on ambient conditions. In the embodiment illustrated, the heating means employed are gas operated burners.
Other objects, features, and advantages of the invention will become apparent from a reading of the specification when taken in conjunction with the drawings in which like reference numerals refer to like elements in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a machine for applying roofing material in accordance with the invention;
FIG. 2 is a top view of the machine shown in FIG. 1;
FIG. 3 is an exaggerated cross-sectional view of a roofing material particularly suited for use with the machine of FIG. 1;
FIG. 4 is a perspective view of two adjoining sheets of roofing material such as those for which the machine of the present invention is utilized;
FIG. 5 is a diagrammatical side view illustrating the operation of the machine of this invention; and
FIG. 6 is a diagram showing the gas supply system of the machine illustrated in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIGS. 1 and 2, there is shown a roofing machine generally designated 10, in accordance with the invention. The machine 10 includes a main frame 12 comprising a pair of generally parallel side rails 14, cross support members 15 interconnecting the side rails 14 and a pair of generally parallel upwardly extending side arms 16. Interconnecting the side arm 16 adjacent the upper free ends thereof is a handle member 18 which may be generally rod-shaped with the outer ends thereof extending beyond opposing outer surfaces of the arms 16 for gripping by an operator and appropriate use as will be hereinafter described.
The lower portion of frame 12 is generally rectangular in form with the rear end thereof having an axle 20 extending therethrough for rotatably receiving thereon a roller member 22. The front end of the frame 12 has extending therethrough a pivotable rod 23. The rod 23 has welded or suitably affixed thereto adjacent one end thereof a pair of parallel bar-shaped arms 24 with the spacing therebetween sufficient for receiving a height adjusting wheel 26 which is rotatably mounted to the ends of arms 24 by means of an axle 28 in a conventional manner. Upwardly extending from the rod 23 at an angle to the arms 24 is a crank arm 30, the upper free end of which is provided with an aperture extending therethrough for pivotally receiving the bent end 32 of a connecting rod 34, the opposite end of which extends into proximity with the handle 18.
One side arm 16 has secured thereto a sector-shaped member 36 in proximity to the handle 18. An adjusting arm 38 is pivotally secured by means of pivot 40 to the apex of the sector-shaped member 36 with the arm 38 having an aperture in one end thereof for receiving a bent end 40 of the connecting rod 34. The other end of the adjusting arm 38 is provided with a handle grip 42 for enabling height adjustment of the wheel 26 in response to pivoting of the adjusting arm 38 by the operator. Facing portions of the sector-shaped member 36 and the adjusting arm 38 are provided with suitable means of frictional engagement for securing the adjusting arm 38 in a selected position. The particular means employed includes apertures 44 extending through the arc of the member 36 with an aligned pin 46 extending through the adjusting arm 38 for suitably locking the arm 38 relative to the sector-shaped member 36 for selectively positioning the wheel 26. With this configuration, the lower edge of frame 12 may be maintained a given height above the roof 50 as layers of roofing material 52 and 54 are being bonded in overlapping relation (see FIG. 1).
With the frame 12 supported at the front end by means of the height adjusting wheel 26 and at the rear end by means of roller member 22, the frame 12 can be moved by an operator gripping the handles 18 for rolling engagement with the roof 50. As best illustrated in FIG. 2, the height adjusting wheel 26 is offset to one side to roll on the lower sheet of roofing material 52 adjacent the edge of the upper sheet of roofing material 54. Disposed intermediate the wheel 26 and roller member 22 are first and second guide shoes 56 and 58. Guide shoe 56 is the lead or underlying guide shoe and is a contoured surface extending rearwardly and upwardly from a position in proximity to the roof 50 or roofing material 52. The guide shoe 56 is suitably secured to the frame 12 such as by means of an arm or fixture 60 secured to the upper surface of shoe 56 such as by means of welding in generally perpendicular relation thereto, with the other end of fixture 60 being suitably secured or welded to cross member 15. Similarly, the trailing or second guide shoe 58 is a contoured surface extending downwardly from a position in proximity to frame 12 and rearwardly toward the surface of roof 50 so that the trailing edge thereof is in proximity to and spaced from the surface of the roofing material to be applied. The trailing edge of trailing guide shoe 58 terminates in spaced proximity to the roller member 22. The second guide shoe 58 is likewise suitably secured to a second cross support member 15 of frame 12 by a second fixture 62 generally perpendicular to the upper surface of guide shoe 58 and affixed such as by welding to the shoe 58 and cross support member 15. As better illustrated in FIG. 2, the leading guide shoe 56 is positioned on frame 12 adjacent the side rail 14 closer to the wheel 26 (that is the right-hand side of the machine 10 as viewed from the operator position) with the trailing shoe 58 being positioned closer to the opposite side rail 14 (the left-hand side of the machine 10). With this particular physical arrangement, the machine is configured for movement in one direction and may be referred to as a right-hand arrangement. That is, the height adjusting wheel 26 is aligned adjacent the right-hand end of frame 12 with the lead guide shoe 56 adjacent the right-hand edge of the frame 12. A left-hand machine can likewise be made by constructing the machine 10 with the height adjusting wheel 26 and lead guide shoe 56 adjacent the left-hand side of frame 12 with the trailing guide shoe 58 positioned adjacent the right-hand side of the frame 12.
As can be seen in FIG. 2, the dimension and contour of guide shoes 56 and 58 is such that with the height adjusting wheel 26 adjacent the edge of the upper roofing material 54 and guided by the operator parallel thereto, the underlying or lead guide shoe 56 has a part of the length thereof under the upper sheet of roofing material 54 with the contoured configuration thereof gently and gradually elevating the upper layer or sheet of roofing material 54 for providing spacing between the adjacent facing areas of the overlapping edge region of the two layers of roofing material 52 and 54.
The trailing or overlying guide shoe 58 is contoured and gently sloping downwardly and rearwardly for positioning on the upper surface of the upper layer of roofing material 54 for guiding the roofing material downwardly into abutting relation with the lower sheet of roofing material 52 as the machine 10 is moved relative to the roofing surface 50.
Referring briefly to FIG. 3, one roofing material particularly suited for use with the machine 10 has a cross-section thereof illustrated. In FIG. 3, the roofing material generally designated 52 (it being understood that the roofing material 54 would be the same material) is a five-layer laminate composed of a thick, flexible plastic core 64 having bonded on either side thereof a layer of modified bitumen 66 and 68 with the top surface being a heavy embossed aluminum foil layer 70 and the bottom surface 72 being a film of polyethylene. As previously discussed, such a material is sold by the Koppers Company as "KMM Membrane" roofing material. This particular material is sold in rolls wherein the upper layer 70 has the aluminum foil terminating approximately four inches from one edge with this four inch surface having a polyethylene film in lieu of the aluminum foil. This polyethylene film is generally of the same substance and same thickness as the polyethylene film bottom layer 72 of the roofing material 52. With the upper and lower strips of roofing material 54 and 52 respectively in overlapping edge relation as shown in FIGS. 1, 2 and 4 the four inch edge 74 (the polyethylene edge) of the lower strip of roofing material 52 has four inches of the bottom polyethylene surface 72 of the upper strip of roofing material 54 in overlapping relationship therewith. The particular polyethylene film of the edge 74 and the bottom surface 72 of the upper layer of roofing material 54, upon the application of heat, breaks and draws apart to expose the bitumen layer 66 of the lower sheet of roofing material 52 and the facing bitumen layer 68 of the upper sheet of roofing material 54. Upon further proper application of a flame or heat, the facing overlapping bitumen areas become plastic and upon application of pressure the plasticized bitumen flows to provide adhesion of the upper strip of roofing material 54 to the lower strip of roofing material 52 in the overlapping edge region. Ideally, the heat and pressure will be so selected that there are no voids or gaps in the overlapping region for providing a secure bond. However, in actual practice, ambient or environmental conditions as well as the skill of the workers manually performing the process drastically affect the results.
Referring now again to FIGS. 1 and 2, the machine 10 is provided with a heating system which includes a fuel tank 76 suitably mounted on the frame 12 such as by means of a support stand 78 which may be formed of bar-shaped material suitably affixed such as by welding to the frame 12 for supporting the tank 76 adjacent the rear of frame 12 and immediately above and slightly forwardly of roller member 22. The tank 76 may contain liquified petroleum gas, propane gas or butane for example as a fuel source. The heating system, in addition, includes a first set of heating jets or burners 78, a second set of heating jets or burners 80 and a main control valve 82 mounted on handle 18 and operable by control lever 84 manually by the operator using the machine. As illustrated in FIG. 2, the control lever 84 is in proximity to the right hand end of handle 18 for pivoting by the hand of the operator to thereby operate the main control valve 82. The tank 76, may be provided with a pressure regulator 86 and a pressure gauge 88 as is conventional with such gas systems. The control valve 82, the tank 76 and the first and second sets of burners 78 and 80 are suitably interconnected by tubing 90-93. While the preceding description referred to sets of heating jets or burners, it is to be understood that only one burner 78 and one burner 80 may be used in accordance with the invention, depending on the configuration of the nozzle for providing the heat distribution required.
As illustrated in FIG. 1, the first set of heating jets or burners 78 are suitably mounted on the frame 12 on the right hand side rail 14 with the nozzles being directed downwardly and inwardly relative to the frame 12 for applying flame or heat to the facing polyethylene film layers in the overlapping edge region of the strips of roofing material 52 and 54 for breaking up the film and heating the exposed bitumen layers into a plastic state. As illustrated in FIG. 1, the positioning of the first set of burners 78 is slightly rearwardly of the leading guide shoe 56 and forwardly of the trailing guide shoe 58, that is, intermediate the first and second guide shoes. The second set of heating jets or burners 80 (only one being shown) is directed downwardly and rearwardly and is positioned generally above the trailing edge of the trailing guide shoe 58. The use of this burner 80 is optional during operation of the machine 10 as will hereinafter be described. However, it is to be noted, that in use the burner 80 applies heat to the guide shoe 58 as well as the roller member 22 and the adjacent surface of the upper layer of roofing material 54.
The heating system is diagramatically illustrated in FIG. 6 with the reference numerals on the diagram correlating to the physical structure shown in FIGS. 1 and 2. The diagram has been simplified. The gas supply tank 76 provides fuel to the line 93 through the pressure regulator 86 and gauge 88. This fuel supply is controlled by the main control or throttle valve 82. The valve 82 may be a valve which can be adjusted to provide an initial flow of gas suitable as a pilot light for the burners 78 and 80 with control of the lever 84 then providing the main fuel flow for the heating means, that is the jets or burners 78 and 80. From the throttle valve 82 the fuel is fed through a line 96 (a composite depiction of the other fuel lines) to the jet 80 through a manually controlled valve 98 and to the jets or burners 78. One of the jets 78 is depicted with a manually controlled valve 100 in series therewith. Although one jet or burner 78 may be employed, a second or even third burner 78 may be provided with a valve in series therewith. This permits combustion or flame from one or two burners 78 with the third burner 78 having the valve 100 being selectively operable by the operator to provide additional heat if required depending on ambient conditions. Similarly with respect to the burner 80, the valve 98 in series therewith permits selective use of the rear burner 80 as required by the operator depending on conditions. With this connection, if all burners are to be utilized, the valves 98 and 100 may be opened to a desired preset position (which may be maximum), and with the control valve 82 providing an initial flow of gas suitable for a pilot light, all burners 78 and 80 would have a pilot flame. The control lever 84 which controls the flow of fuel through the valve 82 can then be operated by the operator to produce the desired flame from the heating jets or burners. Other well known fuel connections and fuel components may be used for the heating system in accordance with the invention.
Referring now to FIG. 5, there is diagramatically illustrated the major operating components of the machine 10 and the physical relation between those components and the layers 52 and 54 of roofing material. As the machine 10 is advanced or moved by the operator in the direction of the arrow (that is to the right), the leading or underlying guide shoe 56 which has previously been interposed between the edge of the upper layer 54 and lower layer of roofing material 52 gradually separates or elevates the upper layer of roofing material 54 to expose to the first heating means the adjacent facing surfaces of polyethylene film. The heating means or burners 78 have the flame therefrom controlled by the operator to break apart the polyethylene film with the proper application of the flame being directed to the facing exposed layers of bitumen until it is plastic enough to flow under pressure. As the machine 10 advances, the trailing or overlying guide shoe 58 gradually guides and urges the upper layer of roofing material 54 into contact with the lower layer 52 with the roller member 22 behind the trailing edge of the shoe 58 applying pressure to promote uniform flow of the facing surfaces of now plastic bitumen. If the ambient temperature is low, the operator may optionally ignite the second heating means or burner 80. The orientation of the burner 80 is to apply flame or heat to the trailing edge of the shoe 58 as well as to the adjacent surface of the roller member 22 as well as to the upper surface of the layer or strip of roofing material 54. For thermal conductivity, as well as to prevent distortion upon application of heat, the guide shoes 56 and 58 are formed from a heat treated material such as heat treated steel. The roller member 22 in the preferred embodiment is made of solid aluminum which, during experimentation, appeared to have the proper thermal conductivity as well as weight to provide optimum results for the particular configuration of machine 10 as illustrated.
By reference to FIGS. 1 and 2, the positioning and operation of the machine 10 will be described. As previously described, a first layer of roofing material 52 is suitably bonded to the roofing surface 50 such as by means of a liquid adhesive. A second layer or strip of roofing material 54 is positioned on the roof 50 with the edge thereof overlapping the edge 74 of the adjacent strip of roofing material 52. The machine 10 is then positioned appropriately by lifting the edge of the upper layer 54 and positioning the underlying or lead guide shoe 56 therebeneath. The valving means such as main control valve 82 is then suitably initially adjusted to provide a pilot ignition flow of fuel to the main heating means or front burners 78 (as well as the rear burner 80 if desired). As can be seen in FIG. 2, in the initial or operating position, the wheel 26 is alongside, but not in contact with, the edge of the upper strip of roofing material 54; the lead guide shoe 56 extends beneath the edge of the strip of roofing material 54 a distance approximately equal to the distance of the overlapping edge; the trailing guide shoe 58 has the lower surface thereof abutting the upper surface of the material 54 a width sufficient to extend beyond both sides of the overlapping region; and the roller member 22 is initially positioned on the overlapping region and has a width at least sufficient to extend to both sides of the overlapping area. The operator then grasps the outer ends of handle 18 and pulls back or pivots the control lever 84 to provide maximum fuel flow to the front burners 78 (and rear burner 80 if desired). For a short initial interval of time, the operator does not move the machine 10 but permits it to remain there until the facing surfaces of polyethylene film are broken and drawn apart and the thus exposed bitumen heated to a plastic state. The operator then pushes the machine 10 to the right as illustrated in FIGS. 1 and 2 in a uniform manner while visually observing the flow of bitumen out from the overlapping region to determine the proper adhesion. With correct movement, the flow of bitumen can be controlled to the edge of the upper strip of roofing material with no flow beyond the edge to provide proper consistency of the thus plasticized material. Furthermore, with proper speed and heat, the upper layer or strip of roofing material 54 will have very little if any puckering or deformation at the overlapping edge region.
For the particular roofing material having an illuminized upper surface 70, and with the selection of aluminum as the material for the roller member 22, the roller member 22 has practically no plastic bitumen adhering to the surface thereof thus providing high quality application of this particular roofing material with a minimum of manpower utilizing the machine 10. By visual observation of the flow of material out from the overlapping edge region the operator can suitably adjust the speed of movement of the machine 10 to provide the optimum results. If the material flowing from the edge is irregular and molten, the operator can either increase the speed of movement or decrease the amount of heat supplied. Conversely, if the bitumen material is not adhering correctly, the operator can slow down the speed of movement of the machine 10 or increase the amount of heat. If a puckering of the upper strip of roofing material 54 is observed, the operator may adjust the height of the front end of the machine 10 by manipulation of the adjusting arm 38 to lower or raise the lead guide shoe 56 according to the position of the wheel 26. The shape and dimensions of lead guide shoe 56 and trailing guide shoe 58 are selected to provide the minimum amount of separation between the adjacent strips of roofing material sufficient to allow positioning of the burners or jets 78 for providing the flame or heat in the separated region without major distortion of the upper layer of roofing material 54 during operation. Similarly, the overall length of the machine 10 and the length of the shoes 56 and 58 have been selected for this purpose.
While a preferred embodiment has been illustrated, it is to be understood that the frame may be composed of tubular material, other materials may be selected for the roller member 22, other heating means may be employed, and the location of the valves and controls may be suitably altered. For example, valves for controlling optional burners or jets may be positioned in proximate relation to the handle 18 for ready access by the operator. While there has been shown and described a preferred embodiment, it is to be understood that various other adaptations and modifications may be made within the spirit and scope of the invention. | A machine for sealing together adjacent overlying edges of sheets of roofing material having facing bitumen compositions, the machine having a leading shoe for separating the overlying edges, heating jets or burners directed into the opening for softening the facing layers of bitumen material, a trailing guide shoe for guiding the upper sheet into contact with the lower sheet, a second set of heating jets or burners for heating the so joined edge and an adjacent roller for pressing the sheets together while providing uniform flow of the plastic heated bitumen. | 8 |
This is a division of U.S. Pat. No. 4,332,744 entitled, "Unsymmetrical Polynitrocarbonates and Methods of Preparation," which issued to William H. Gilligan and Scott L. Stafford on June 1, 1982.
BACKGROUND OF THE INVENTION
This invention relates to organic carbonates and more particularly to nitro substituted organic carbonates.
In order to prepare unsymmetrical carbonates, it is necessary to react a chloroformate of an alcohol with a second alcohol. The general method for preparing chloroformates is to react an alcohol with an excess of phosgene (poisonous gas) in the presence of a base as an acid acceptor. Inevitably a greater or lesser amount of the carbonate is formed, as a by-product, which lowers the yield and requires separation of the product. In addition, nitroalcohols in the presence of base, have a tendency to deformylate, which also lowers the yield of chloroformate. A third factor is that nitro substituted diols such as 2,2-dinitropropan-1,3-diol form as major products linear carbonates and cyclic carbonates.
SUMMARY OF THE INVENTION
An object of this invention is to provide new organic compounds.
Another object of this invention is to provide new explosive materials.
A further object of this invention is to provide unsymmetrical polynitrocarbonates.
Still another object is to provide a method of synthesizing unsymmetrical polynitrocarbonates.
Yet a further object of this invention is to provide novel symmetrical 1,3-bis(halo- and nitroalkyl carbonyldioxy)-2,2-dinitropropanes.
Still a further object of this invention is to provide a method of synthesizing novel symmetrical 1,3-bis(halo- and nitroalkyl carbonyldioxy)-2,2-dinitropropanes.
These and other objects of this invention are achieved by providing (1) novel unsymmetrical polynitrocarbonates of the formula ##STR5## by the following reaction sequence ##STR6## wherein R≠R' and wherein R and R' are each selected from the group consisting of --CH 2 C(NO 2 ) 3 , CH 2 CF(NO 2 ) 2 , --CH 2 CF 2 (NO 2 ), --CH 2 CCl(NO 2 ) 2 , --CH 2 CF 3 , --CH 2 CCl 3 , --CH 2 C(NO 2 ) 2 CH 3 , and --CH 2 CF 2 CF 2 H, and wherein R" is a lower alkyl of from 1 to 6 carbon atoms;
and (2)symmetrical 1,3-bis(halo-and nitroalkyl carbonyldioxy)-2,2-dinitropropane of the formula ##STR7## which are synthesized the following reaction sequence ##STR8## wherein R and R" are as defined above.
The carbonates of this invention are useful as energetic additives to propellants and explosives.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The reaction sequences of this invention summarized as follows:
______________________________________STEP UNSYMMETRICAL SYMMETERICAL______________________________________ ##STR9## ##STR10## (1) ##STR11## ##STR12## (2) ##STR13## ##STR14## (3) ##STR15## ##STR16##______________________________________
wherein R≠R' and R and R' can be --CH 2 C(NO 2 ) 3 ,--CH 2 CF(NO 2 ) 2 , --CH 2 CF 2 (NO 2 ), --CH 2 CCl(NO 2 ) 2 , --CH 2 CF 3 , --CH 2 CCl 3 , --CH 2 C(NO 2 ) 2 CH 3 , and --CH 2 CF 2 CF 2 H, and wherein R" is a lower alkyl group of from 1 to 6 carbon atoms, but preferably a lower alkyl of from 1 to 3 carbon atoms.
The alcohols ROH and R'OH, which may be used in the synthesis are
2,2,2-trinitroethanol,
2-fluoro-2,2-dinitroethanol,
2,2-difluoro-2-nitroethanol,
2-chloro-2,2-dinitroethanol,
2,2,2-trifluoroethanol,
2,2,2-trichloroethanol,
2,2-dinitropropanol, and
2,2,3,3-tetrafluoropropanol.
Obviously, for unsymmetrical carbonates ROH must not be the same as R'OH. Note that the alcohol used in step (1) for the production of symmetrical 1,3-bis(halo and nitroalkyl carbonyldioxy)2,2-dinitropropanes is 2,2-dinitropropan-1,3-diol.
The syntheses of the unsymmetrical and the symmetrical carbonates differ in the combination of alcohols used, but the same reaction conditions are used.
The solvents used in all reaction steps must be inert. Examples of suitable solvents are methylene chloride, chloroform, 1,2-dichloroethane, and benzene.
In step (1) a Friedl-Crafts catalyst was used in a non-basic solution. Examples of suitable catalysts are ferric chloride, stannic chloride, titanium tetrachloride, and zinc chloride. Anhydrous ferric chloride was used in the example 1-9.
Examples 1, 2, and 3 illustrate that the reaction between the alcohol and the alkyl chlorothioformate is vigorous at ambient temperature in the presence of the catalyst (anhydrous FeCl 3 ). The reaction mixtures were stirred at ambient temperature for 30 to 60 minutes and yields of 90 percent or more were obtained.
The general formulas of the products of step (1) are ##STR17## for the symmetrical synthesis. Because of the commercial availability of S-ethyl chlorothiolformate, the following products should be easiest to produce
S-ethyl 2,2,2-trinitroethyl thiolcarbonate,
S-ethyl 2-fluoro-2,2-dinitroethyl thiolcarbonate
S-ethyl 2,2-fluoro-2-nitroethyl thiolcarbonate,
S-ethyl 2-chloro-2,2-dinitroethyl thiolcarbonate,
S-ethyl 2,2,2-trifluoroethyl thiolcarbonate,
S-ethyl 2,2,2-trichloroethyl thiolcarbonate,
S-ethyl 2,2-dinitropropyl thiolcarbonate,
S-ethyl 2,2,3,3-tetrafluoropropyl thiolcarbonate.
and finally the
Bis(S-ethyl thiolcarbonate) of 2,2-dinitropropan-1,3-diol, ##STR18##
In step (2) the alkyl thiolcarbonate is refluxed with an excess of sulfuryl chloride (SO 2 Cl 2 ) in an inert solvent until the alkyl thiolcarbonate is converted to the corresponding chloroformate. In Examples 4, 5, and 6, six hours of refluxing produced the products in good yield.
For reaction step (2) the general formula for the product of the unsymmetrical process is ##STR19## wherein R is as defined above. More specifically the compounds are 2,2,2-trinitroethyl chloroformate,
2-fluoro-2,2-dinitroethyl chloroformate,
2,2-difluoro-2-nitroethyl chloroformate,
2-chloro-2,2-dinitroethyl chloroformate,
2,2,2-trifluoroethyl chloroformate,
2,2,2-trichloroethyl chloroformate,
2,2-dinitropropyl chloroformate, and
2,2,3,3-tetrafluoropropyl chloroformate.
The product of the symmetrical process is ##STR20##
In step (3) the chloroformate is reacted with an alcohol to produce the product carbonate. As illustrated by examples 7, 8, and 9, the reaction mixture should be cooled and the addition rate of the alcohol to the chloroformate should be adjusted so that the reaction mixture does not overheat. A base, such as pyridine, is added to the mixture to act as an acid acceptor for the HCl generated by the reaction.
In the case of the unsymmetrical synthesis the general reaction of step (3) is ##STR21## wherein R and R' are as defined above and R≠R'. Preferred carbonates include
2-fluoro-2,2-dinitroethyl-3,3,3-trinitroethylcarbonate
2,2-difluoro-2-nitroethyl-3,3,3-trinitroethylcarbonate,
2-chloro-2,2-dinitroethyl-3,3,3-trinitroethylcarbonate,
2,2-dinitropropyl-3,3,3-trinitroethylcarbonate,
2,2-difluoro-2-nitroethyl-3-fluoro-3,3-dinitroethylcarbonate,
2-chloro-2,2-dinitroethyl-3-fluoro-3,3-dinitroethylcarbonate,
2,2-dinitropropyl-3-fluoro-3,3-dinitroethylcarbonate,
2-chloro-2,2-dinitroethyl-3,3-difluoro-3-nitroethylcarbonate,
2,2-dinitropropyl-3,3-difluoro-3-nitroethylcarbonate and
2,2-dinitropropyl-3-chloro-3,3-dinitroethylcarbonate.
The general reaction of step (3) for the symmetrical 1,3-bis (halo- and nitroalkyl carbonyldioxy)-2,2-dinitropropanes synthesis is ##STR22## wherein R is as defined above. Specifically the symmetrical 1,3-bis(halo- and nitroalkyl carbonyldioxy)-2,2-dinitropropanes are
1,3-bis(3,3,3-trinitroethyl carbonyldioxy)-2,2- dinitropropane,
1,3-bis(3-fluoro-3,3-dinitroethyl carbonyldioxy)-2,2-dinitropropane,
1,3-bis(3,3-difluoro-3-nitroethyl carbonyldioxy)-2,2-dinitropropane,
1,3-bis(3-chloro-3,3-dinitroethyl carbonyldioxy)-2,2-dinitropropane,
1,3-bis(3,3,3-trifluoroethyl carbonyldioxy)-2,2-dinitropropane,
1,3-bis(3,3,3-trichloroethyl carbonyldioxy)-2,2-dinitropropane,
1,3-bis(3,3-dinitropropyl carbonyldioxy)-2,2-dinitropropane, and
1,3-bis(3,3,4,4-tetrafluoropropyl carbonyldioxy)-2,2-dinitropropane.
The three step process used to synthesis the unsymmetrical carbonates of this invention, may be used to synthesis a wide variety of unsymmetrical carbonates. However, the alcohol used in step (1) to prepare the S-alkyl thiolformate should have at least one electronegative substituent, such as NO 2 , F, etc. The presence of the substituent inhibits chlorination of the functional group, which otherwise would give rise to side-products.
The general nature of the invention having been set forth, the following examples are presented as specific illustrations thereof. It will be understood that the invention is not limited to these examples but is susceptible to various modifications that will be recognized by one of ordinary skill in the art.
EXAMPLE 1
S-ethyl 2,2,2-trinitroethyl thiolcarbonate ##STR23## To a stirred solution of 9.2 g of 2,2,2-trinitroethanol in 10 ml of 1,2-dichloroethane was added 6.5 ml of ethyl chlorothiolformate and one ml of a 50% anhydrous ferric chloride solution in nitromethane. A vigorous reaction immediately ensued. The solution was stirred for one hour and then taken up in methylene chloride and washed consecutively with dilute hydrochloric acid and five 60 ml portions of water. After drying with anhydrous magnesium sulfate, the organic solution was filtered and the solvents removed in vacuo. The residue was crystallized from chloroform/hexane solution to give 12.52 g (90%) of the title compound: m.p. 36°. H--NMR (acetone d 6 ): δ=5.96 (S, 2H--CH 2 C(NO 2 ) 3 ), 2.93 (q, 2H,--SCH 2 --), 1.28 (t, 3H,--CH 3 ).
Calc for C 5 H 7 N 3 O 8 S: C, 22.31, H, 2.62; N, 15.61; S, 11.91. Found: C, 22.19; H, 2.57; N, 15.30; S, 11.65.
EXAMPLE 2
S-ethyl 2-fluoro-2,2-dinitroethyl thiocarbonate ##STR24## To a stirred solution of 7.7 g (0.05 mol) fluorodinitroethanol in 10 ml of methylene chloride was added 6.5 ml of ethyl chlorothiolformate and one ml of a 50% ferric chloride solution in nitromethane. A vigorous reaction immediately ensued that was essentially over in a few minutes. To insure complete reaction, stirring was continued for 30 minutes. The reaction mixture was taken up in methylene chloride and washed consecutively with 100 ml of dilute hydrochloric acid and five 100 ml portions of water. After drying with anhydrous magnesium sulfate and filtering, the organic solvents were removed in vacuo. The residue weighing 12.07 g (99.7%) was of >98% purity by GLC analysis. H--NMR(CDCl 3 ): δ=5.24 (d, 2H, --CH 2 --CF), 2.89 (q, 2H, --S--CH 2 --), 1.30 (t, 3H,--CH 3 ).
Calcd for C 5 H 7 FN 2 O 6 S: C, 24.79; H, 2.91; F, 7.85; N, 11.57; S, 13.24.
Found: C, 24.83; H, 2.96; F, 7.69; N, 11.68; S, 13.40.
EXAMPLE 3
bis(S-ethyl thiolcarbonate) of 2,2-dinitro-1,3-propandiol ##STR25## To a stirred solution of 4.0 g (0.024 mol) of 2,2-dinitropropan-1,3-diol in 25 ml of methylene chloride/nitromethane 4/1 was added 5.8 ml ethyl chlorothiolformate and one ml of a solution of 50% ferric chloride in nitromethane. After an initial vigorous reaction, the solution was stirred for an additional 30 minutes at ambient temperature. The solution was taken up in methylene chloride and washed with a 100 ml portion of dilute hydrochloric acid and five 100 ml portions of water. After drying and filtering, the solvent was removed in in vacuo at 0.05 torr. The residue weighed 8.3 g (100%). The purity of the residue was >98% by GLC analysis. H--NMR (CDCl 3 ): δ=5.08 (S, 4H, --O--CH 2 --C(NO 2 ) 2 CH 2 O--), 2.87 (d, 4H,--S--CH 2 --), 1.29 (t, CH, --CH 3 ).
Calc. for C 9 H 14 N 2 O 8 S 2 : C, 31.57; H, 4.12; N, 8.19; S, 18.73. Found: C, 31.76; H, 4.30; N, 8.06; S, 18.77.
EXAMPLE 4
2fluoro-2,2-dinitroethyl chloroformate ##STR26## A solution of 13.82 g (0.057 mol) S-ethyl fluorodinitroethyl-thiolcarbonate in 50 ml of 1,2-dichloroethane and 20 ml of sulfuryl chloride was refluxed for 6 hours. After cooling, excess sulfuryl chloride and solvent was removed on a rotavac. The residue was distilled through a short column, 58° at 2 torr. To the yellowish distillate was added 2 ml cyclohexane and this was redistilled to give 11.59 g (94%) of product. GLC analysis indicated a purity of 99%.
I.R. (film): υ max =1780, 1605, 1310 cm -1 . H--NMR (CDCl 3 ): δ=5.36 (d, FC--CH 2 --).
EXAMPLE 5
2,2,2-trinitroethyl chloroformate ##STR27##
To a solution of S-ethyl trinitroethylthiolcarbonate (27.85 g, 0.098 mol) in 50 ml of 1,2-dichloroethane was added 30 ml of sulfuryl chloride. The reaction solution was refluxed for six hours, cooled, and volatiles removed in vacuo. The residue was distilled through a short path column, 78° at 0.8 torr, to give 24.23 g of product. GLC analysis indicated a purity of 96.5%; corr. yield was 97.4%.
I.R. (film): υ max =1783, 1608, 1300 cm -1 . H--NMR (CDCl 3 ): δ=5.73 (S, --CH 2 --).
EXAMPLE 6
2,2-dinitropropyl chloroformate ##STR28##
A solution of S-ethyl 2,2-dinitropropylthiolcarbonate in 50 ml of 1,2-dichloroethane and 20 ml of sulfuryl chloride was refluxed for 6 hours. After cooling and removal of volatiles in vacuo the residue was distilled through a short path column to give 10.65 g (90%) of product; bp 82° at 0.2 torr.
I.R. (film): υ max =1779, 1570, 1323 cm -1
H--NMR (CDCl 3 ) δ=5.08 (S, 2H, --CH 2 --), 2.25 (S, 3H,--CH 3 ).
EXAMPLE 7
1,3-bis(3,3,3-trinitroethyl carbonyldioxy)-2,2-dinitropropane ##STR29## Pyridine (2.1 ml) was added to a slurry of 2,2-dinitropropan-1,3-diol in 50 ml of CH 2 Cl 2 at 10° C. After the diol had dissolved, a solution of trinitroethyl chloroformate (6.46 g, 26.6 mmol) in 7 ml of methylene chloride was added dropwise with stirring. The temperature was held below 15° during the addition. The solution was then stirred for 3.5 hours. Volatiles were then removed and the residue was washed with dilute hydrochloric acid and water and then air dried. The solid was recrystallized from methylene chloride to give 5.1 g of product (83%), m.p. 154°-5°.
H--NMR (acetone-d 6 ): δ=5.97 (S, 4H, CH 2 C(NO 2 ) 3 ), 5.40 (S, 4H, CH 2 ) I.R. (fluorolube): υ max =1780 cm -1 .
EXAMPLE 8
2,2-dinitropropyl-3,3,3-trinitroethylcarbonate ##STR30## To a solution of trinitroethyl chloroformate (6.46 g, 26.5 mmol) and 2,2-dinitropropanol (4.5 g, 30 mmol) in 25 ml of methylene chloride was added dropwise a solution of pyridine (2.24 ml) in methylene chloride (7 ml) at or below 5°. Then the solution was stirred for 3 hr at ice bath temperature and at ambient temperature for an additional hour. The solution was taken up in methylene chloride and washed consecutively with 100 ml of dilute hydrochloric acid and five 100 ml portions of water. The organic layer was dried (magnesium sulfate), filtered, and the volatiles removed in vacuo. The solid residue was recrystalized from chloroform to give 5.68 g (60%) of product, m.p. 107°.
Calc. for C 6 H 7 N 5 O 13 : C, 20.18; H, 1.98; N, 19.61. Found: C, 19.87; H, 1.82; N, 19.85.
H--NMR(CDCl 3 ): δ=5.47 (S, 2H, CH 2 C(NO 2 ) 3 ), 5.04 (S, 2H, O--CH 2 C (NO 2 ) 2 --), 2.20 (S, 3H, --CH 3 ).
I.R. (fluorolube mull): υ max =1777 cm -1 .
EXAMPLE 9
2,2-dinitropropyl-3-fluoro-3,3-dinitroethylcarbonate ##STR31## To a solution of dinitropropyl chloroformate (5.74 g, 0.027 mol) and fluorodinitroethanol (3.08 g, 0.02 mol) in 25 ml of methylene chloride at 4° was added with stirring a solution of pyridine (1.58 ml) in methylene chloride (9 ml). The rate of addition was controlled so that the temperature did not rise above 8°. After the addition was complete the reaction mixture was stirred for 3 hours at ice bath temperature and an additional 3 hours at ambient temperature. The reaction mixture was then transferred to a separatory funnel with 50 ml of methylene chloride and washed consecutively with 100 ml of dilute hydrochloric acid and four 100 ml portions of water. The organic layer was dried (magnesium sulfate) filtered and the solvents removed in vacuo. The residue was crystallized from chloroform to give 6.0 g of product, 91% based on fluorodinitroethanol, m.p. 66°.
Calc for C 6 H 7 FN 4 O 11 ; C, 21.83; H, 2.14; F, 5.75; N 16.97. Found C, 21.98; H, 2.15; F, 6.00; N, 16.77.
H--NMR (CDCl 3 ): δ=5.25 (d, 2H, CH 2 --CF), 5.00 (S, 2H, CH 2 C(NO 2 ) 2 ), 2.19 (S, 3H, --CH 3 ).
I.R. (fluorolube mull); υ max =1780 cm -1 .
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein. | Unsymmetrical carbonates of the formula ##STR1## are prepared by the following reaction sequence ##STR2## where R and R' can each be --CH 2 C(NO 2 ) 3 , CH 2 CF(NO..2) 2 , --CH 2 CF 2 (NO 2 ), --CH 2 CCl(NO 2 ) 2 , --CH 2 CF 3 , --CH 2 CCl 3 , --CH 2 C(NO 2 ) 2 CH 3 , or --CH 2 CF 2 CF 2 H, provided that R≠R' and wherein R" is a lower alkyl group of from 1 to 6 carbon atoms.
Also included are symmetrical 1,3-bis(halo- and nitroalkyl carbonyldioxy)-2,2-dinitropropanes of the formula ##STR3## which are synthesis by the following reaction sequence ##STR4## wherein R and R" are as defined above. The carbonates of this invention are useful as energetic additives to propellants and explosive. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an information distribution system, more particularly relates to an information distribution system for distributing various types of information of newspapers, magazines, encyclopedias, security reports, etc. (hereinafter referred to as “content”) through the Internet or another open network to information receivers. This information distribution system can distribute vast amounts of content safely at a high speed.
[0003] 2. Description of the Related Art
[0004] In recent years, the spread of the Internet and other open networks (hereinafter referred to as “networks”) has led to an increase in electronic newspapers, electronic books, etc. prepared and distributed by information distributors. Homes and companies are now able to receive content such as electronic newspapers and electronic books on PCs and view them on-line or download them for viewing.
[0005] The information distribution systems of the related art, however, are configured to distribute one day's worth of a newspaper or one volume's worth of a book as it is as text data or image data, so the amount of the information transmitted becomes enormous. Accordingly, unless a broadband network or other high-speed communications line is used, it takes too a lot of time to distribute the information and therefore the systems are impractical. Further, even if using the high-speed communication lines, the amount of the information transmitted remains the same, so the problem arises of the distribution costs increasing in proportion to the amount of information transmitted. Further, the problem arises of the need to lay new high-speed communication lines.
[0006] Further, even if high-speed communication lines are already laid, the problem of the communication speed of the lines between the high-speed line network and the PCs remains.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide an information distribution system transmitting the information to be distributed converted into colors, color values, or color digital values so as to minimize the amount of information transmitted.
[0008] According to the present invention, there is provided an information distribution system for distributing newspaper, magazine, book, encyclopedia, security report, and other content provided by an information distributor to an information receiver through an open network such as the Internet. The information distribution system transmits the content to be distributed converted to colors, color values, or color digital values.
[0009] Preferably, the information distribution system divides the content to be distributed into a plurality of objects and transmits the objects converted to the colors, color values, or color digital values.
[0010] More preferably, the information distribution system divides the content into objects consisting of at least one of individual letters; entries in dictionaries such as words, phrases, personal names, place names, specialized terms, and foreign words; and word strings appearing in the content.
[0011] Alternatively or more preferably, the information distribution system provides a color conversion table for converting the content or objects to be transmitted to the colors, color values, or color digital values at the information distributor side.
[0012] Still more preferably, the information distribution system provides a color reversion table for converting back the transmitted colors, color values, or color digital values to the content or objects at the information receiver side.
[0013] Further, still more preferably, the information distribution system distributes the color reversion table to the information receiver side through the open network.
[0014] More preferably, the information distribution system outputs the content or objects converted back from the colors, color values, or color digital values by the color reversion table by display, printing, or sound.
[0015] Alternatively or still more preferably, the information distribution system makes the correspondence between the content or objects and the colors, color values, or color digital values in the color conversion table and color reversion table freely changeable.
[0016] Alternatively or still more preferably, the information distribution system makes the correspondence between the content or objects and the colors, color values, or color digital values in the color conversion table and color reversion table assignable to a hierarchical structure.
[0017] Preferably, the information distribution system distributes color reversion table designation information designating a color reversion table for use when converting back the colors, color values, or color digital values to the content or objects to information receivers before or simultaneously with transmitting the colors, color values, or color digital values.
[0018] More preferably, the color reversion table designation information is authorized to be distributed to information receivers specifically qualified by concluding a distribution agreement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other objects and features of the present invention will become clearer from the following description of the preferred embodiments given with reference to the attached drawings, wherein:
[0020] [0020]FIG. 1 is a flow chart of production of a newspaper;
[0021] [0021]FIG. 2 is a view of the configuration of a newspaper information distribution system;
[0022] [0022]FIG. 3 is a detailed view of the configuration of the system at the information distributor side;
[0023] [0023]FIG. 4 is a view of an example of a color conversion table and color reversion table;
[0024] [0024]FIG. 5 is a view of another example of a color conversion table and color reversion table;
[0025] [0025]FIG. 6 is a view of an actual example of analysis of composition; and
[0026] [0026]FIG. 7 is a detailed view of the configuration of the system at the information receiver side.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Preferred embodiments of the present invention will be described in detail below while referring to the attached figures. The configurations, relative arrangements, etc. explained in the embodiments are just explained schematically to an extent enabling understanding of the present invention. Accordingly, the present invention is not limited to the embodiments described below and may be changed in various ways to an extent not departing from the scope of the technical idea indicated in the claims. In particular, importantly, in the following explanation, reference is made to an English language newspaper information distribution system for facilitating understanding of the invention, but the invention is not limited to the same and in fact was originally designed for and may be more optimally suited to languages using more complicated writing systems employing combinations of phonetic syllabary and ideographs such as Japanese and therefore requiring much more data to encode and transmit.
[0028] [0028]FIG. 1 is a flow chart of the production of a newspaper. Step 1 consists of the collection and storage of articles and images. This step 1 collects and stores articles and images sent from news sites, branch offices, other news agencies, etc.
[0029] Step 2 consists of the editing of the articles and images. This step 2 selects and edits the suitable articles and images to be carried in the newspaper from the large number of articles and images collected and stored at step 1 .
[0030] Step 3 consists of the layout of the articles and images. This step 3 attaches headlines etc. to the articles and images edited at step 2 and lays out the pages.
[0031] Step 4 consists of the printing. This step 4 uses film of the laid out copy produced at step 3 to print the newspaper by a printing press.
[0032] Step 5 consists of the shipping step. This step 5 divides the newspapers printed at step 4 for the different destinations, then ships them to newspaper delivery centers.
[0033] Step 6 consists of the delivery step. This step 6 delivers the newspapers from the newspaper delivery centers to the different homes. Steps 1 to 6 show the process of newspaper production by paper as in the past.
[0034] Step 7 consists of the conversion of the newspaper to electronic data. In recent years, more and more electronic versions of newspapers have been produced. This step 7 delivers the electronic data of the newspaper to terminals 9 through the network 8 . The information distribution system according to the present invention is used for distribution of newspaper information from step 7 on.
[0035] [0035]FIG. 2 is a view of the configuration of a newspaper information distribution system. In this newspaper information distribution system, reference numeral 10 shows the system at the information distributor side, while reference numeral 11 shows the system at the information receiver side. The information distributor side system 10 corresponds to step 7 , while the information receiver side system 11 corresponds to any one of the above terminals 9 .
[0036] The information distributor side system 10 converts the newspaper article original data 12 to converted color data 13 by a color conversion table 13 . Details will be explained later. Further, the information receiver side system 11 converts the converted color data 14 delivered through the network 8 back to the reproduced newspaper article data 16 by a color reversion table 15 . The reproduced newspaper article data 16 is output as an image by a display 17 , output as speech or sound by a speaker 18 , or output as papers by a printer 19 . Further, it is output for recording and storage in a storage device 20 . These types of output may be performed independently or freely combined.
[0037] The color conversion table 13 encodes the newspaper article original data 12 to the converted color data 14 . The color reversion table 15 decodes the newspaper article original data 12 which had been encoded to the converted color data 14 by the color conversion table 13 to the reproduced newspaper article original data 16 . The color reversion table 15 is provided at the information receiver side system 11 by transmission over the network 8 or the mail.
[0038] [0038]FIG. 3 shows the detailed configuration of the information distributor side system 10 . In FIG. 3, reference numeral 21 shows a newspaper article original data input unit. The newspaper article original data input unit 21 may receive as input the newspaper article original data 12 .
[0039] Reference numeral 22 is an original data composition analysis unit. The original data composition analysis unit 22 analyzes the sentence structure of the newspaper article original data 12 input to the newspaper article original data input unit 21 and breaks it down into individual letters; words, phrases, personal names, place names, specialized terms, foreign words, and other entries in various types of dictionaries; or word strings frequently appearing in the newspaper article original data 12 . Note that the individual letters broken down by the original data composition analysis unit 22 are letters for each type of word such as verbs, adjectives, adverbs, etc. Further, verbs with changes in form, adjectives, adverbs, etc. are broken down for each form of use.
[0040] Reference numeral 23 is an object automatic extraction unit. The object automatic extraction unit 23 extracts the individual letters, entries in various dictionaries, or word strings broken down by the original data composition analysis unit 22 as objects.
[0041] Reference numeral 24 is an object/color conversion unit. The object/color conversion unit 24 refers to the color conversion table 13 prepared in advance to convert the objects extracted by the object automatic extraction unit 23 to colors 14 a, color values 14 b, or color digital values 14 c as converted color data 14 corresponding to the objects. Details of the colors 14 a, color values 14 b, and color digital values 14 c will be explained later. Note that in this embodiment, the explanation was given of a configuration preparing a color conversion table 13 in advance, but the present invention is not limited to this. A color conversion table 13 may be automatically generated each time a new object is extracted by the object automatic extraction unit 23 by newly assigning a color 14 a, color value 14 b, or color digital value 14 c by using a known automatic dictionary preparation method.
[0042] Reference numeral 25 is a converted color data output unit. The converted color data output unit 25 selectively outputs colors 14 a, color values 14 b, or color digital values 14 c obtained by conversion at the object/color conversion unit 24 . The selectively output colors 14 a, color values 14 b, or color digital values 14 c are transmitted to the information receiver side system 11 through the network 8 .
[0043] [0043]FIG. 4 shows an example of a color conversion table 13 and color reversion table 15 used in a newspaper information distribution system. In the conversion or reversion table, information is arranged alphabetically in two levels. In the figure, reference numeral 26 shows the rows of individual letters as a first level. Each row 26 is divided into objects 27 as a second level. Note that FIG. 4 shows part of a color conversion table 13 and color reversion table 15 , in particular shows nouns with no changes in form.
[0044] Each object 27 may be expressed by colors 14 a each comprised of two specific colors. Specifically, one object 27 is expressed by a minimum of two pixels. That is, colors 14 a are output as the converted color data 14 from the converted color data output unit 25 by the method of using the object/color conversion unit 24 read printed matter consisting of sets of color dots of one pixel per level each and then output the colors.
[0045] Assuming that printed matter consisting of sets of color dots is printed at a density of 1200 dpi, 1.44 million dots are printed per square inch. That is, in the case of the present embodiment expressing one object by two dots, it is possible to store an extremely vast amount of information of 720,000 objects on one square inch of paper. Further, if converting the printed matter to A4 size paper, it is possible to store information of about 70 million objects or as much as 97 times the above figure. If the number of individual letters used per day of a newspaper were 400,000 letters and average number of letters for one object were three, it would be possible to store about 1.4 years' worth of newspaper articles on one sheet of A4 size paper. Note that if only one level was used in the color conversion table 13 and color reversion table 15 , the amount of information stored would double of course.
[0046] Each object 27 may also be expressed by color values 14 b each comprised of a total of four freely assigned numerals, that is, two numerals for each level. That is, the color values 14 b are output as the converted color data 14 from the converted color data output unit 25 by the method of having the object/color conversion unit 24 directly output four numerals. Note that the number of numerals of each level is not limited to two. It is possible to freely set the number in accordance with the size of the color conversion table 13 and color reversion table 15 .
[0047] Each object 27 may also be expressed by color digital values 14 c each comprised of a total of 24 bits for each level, that is, a total of 48 bits of RGB data. That is, the color digital values 14 c are output as the converted color data 14 by the method of having the object/color conversion unit 24 directly output 48 bits of data. Note that the number of bits for each layer is not limited to 24 bits and can be set to any number in accordance with the size of the color conversion table 13 and color reversion table 15 .
[0048] [0048]FIG. 5 shows a table of verbs with changes in form in the table shown in FIG. 4 as an example of the color conversion table 13 and color reversion table 15 . The structure of the table in this example is the same as the example shown in FIG. 4, so the same reference numerals are assigned and detailed explanations are omitted.
[0049] Next, the color conversion tables 13 shown in FIG. 4 and FIG. 5 will be used to explain the processing in the original data composition analysis unit 22 and the object automatic extraction unit 23 . As one example, the case of analyzing newspaper article original data 12 comprised of the 34 letters of “APPLY TO BUREAU OF HOUSING FOR APARTMENT” input to the newspaper article original data input unit 21 by the original data composition analysis unit 22 will be explained using FIG. 6. As shown in FIG. 6, the original “APPLY TO BUREAU OF HOUSING FOR APARTMENT” is broken down by the original data composition analysis unit 22 , whereby five objects of object 1 to object 5 are extracted by the object automatic extraction unit 23 . Due to this, the 34 letters of the original are converted to five sets of, that is, ten, color dots and expressed by an average of 6.8 letters' worth of data per set. Note that in FIG. 6, object 2 and object 4 are particles. If preparing the color conversion table 13 in a form joining them with the previous objects, that is, the object 2 with the object 1 and the object 4 with the object 3 , it becomes possible to express the 34 letters by three sets of, that is, six, color dots.
[0050] [0050]FIG. 7 is a detailed view of the configuration of the information receiver side system 11 . In FIG. 7, reference numeral 28 shows the converted color data input unit. The converted color data input unit 28 receives as input the converted color data 14 transmitted through the network 8 .
[0051] Reference numeral 29 shows a color/object conversion unit. The color/object conversion unit 29 converts the converted color data 13 input to the converted color data input unit 28 to objects corresponding to the converted color data 14 by referring to the color reversion table 15 distributed through the network 8 or mailed in advance. Here, when using the colors 14 a as the converted color data 14 , it is also possible to output the printed matter comprised of sets of color dots before conversion to objects, then convert the printed matter to objects corresponding to the colors 14 a by the color/object conversion unit 29 .
[0052] Reference numeral 30 shows an object automatic editing unit. The object automatic editing unit 30 recomposes the objects converted at the color/object conversion unit 29 to the sentences of the newspaper article original data 12 .
[0053] Reference numeral 31 shows a newspaper article data reproduction unit. This newspaper article data reproduction unit 31 divides the sentences recomposed at the object automatic editing unit 30 into headlines, text, etc. in the same way as the conventional layout step 3 and reproduces the paper layout.
[0054] Reference numeral 32 shows a newspaper article data output unit. This newspaper article data output unit 32 outputs the reproduced newspaper article data 16 reproduced at the newspaper article data reproduction unit 31 by a display 17 , speaker 18 , printer 19 , or storage device 20 alone or in combination.
[0055] Based on the above configuration, the newspaper information is distributed upon instruction of the information distributor or request of the information receiver. Even when using color digital values 14 c comprised of two levels, the converted color data 14 transmitted through the network 8 becomes very short in length. In the case of a Japanese language system, the converted color data 14 transmitted through the network 8 becomes a maximum of three Japanese kanji ideographs' (48 bits') worth of data in length. The longer the corresponding objects 27 , the more easily it is to deliver newspaper information with a high compression rate. In particular, in the case of use of the color conversion table 13 and the color reversion table 15 as shown in FIG. 4 and FIG. 5, the compression rate becomes remarkably high.
[0056] Further, in the present embodiment, the explanation was given assuming a fixed correspondence among the objects 27 and colors 14 a, color values 14 b, and color digital values 14 c. That is, as shown in FIG. 4 and FIG. 5, objects 2 and colors 14 a, color values 14 b, and color digital values 14 c were converted back and forth in the same row. When, for example, converting back and forth between objects 27 and colors 14 a, color values 14 b, and color digital values 14 c in different lines, however, it is also possible to transmit correspondence changing information to the information receivers simultaneously with the distribution of information or in advance and make the correspondence freely changeable.
[0057] Due to this, it is possible to not transmit correspondence changing information to information receivers other than specific receivers whose distribution agreements remain valid and therefore are qualified to receive it. Therefore, information receivers whose agreements for information distribution have expired cannot correctly reproduce the newspaper information, and illegitimate viewing of newspaper information can be prevented.
[0058] In the present embodiment, the color conversion table 13 and the color reversion table 15 were explained as single tables, but it is also possible to prepare a plurality of color conversion tables 13 and distribute a plurality of color reversion tables 15 corresponding to them. In this case, it is sufficient to transmit color reversion table designating information indicating which color reversion table to use at the time of distribution of information simultaneous with the distribution of information or in advance.
[0059] While the invention has been described with reference to a specific embodiment chosen for purpose of illustration, the present invention is not limited to the newspaper information distribution system in the embodiment. It may also be applied to an information distribution system for various content including vast amounts of information such as of magazines, books, encyclopedias, security reports and the like. It should be apparent that numerous modifications could be made thereto by those skilled in the art without departing from the basic concept and scope of the invention.
[0060] According to the present invention, it is possible to transmit the tremendous amounts of data about various content of newspapers, magazines, books, encyclopedias, security reports, etc. in a radically compressed form on the Internet or another open network. Therefore, it is possible to distribute information at a high speed even by a conventional communications line rather than a high-speed communications line of a broadband network etc. The data transmitted over the network is converted color data which in itself is not data of any meaning, so it is possible to distribute information safely without leakage of the content of the information to a third party. Further, it is possible to easily manage the color reversion table distributed to the information receivers.
[0061] The present disclosure relates to subject matter contained in Japanese Patent Application No. 2001-158864, filed on May 28, 2001, the disclosure of which is expressly incorporated herein by reference in its entirety. | An information distribution system configured to deliver various types of content provided by an information distributor to information receivers through a network and transmitting the content to be distributed converted to colors, color values, or color digital values. By converting the content to colors, color values, or color digital values, it is possible to reduce the amount of information transmitted. Due to this, it becomes possible to shorten the time required for distribution of content and to improve practicality. Further, it becomes possible to reduce the distribution costs. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The dental casting apparatus and method of the present invention involves a new apparatus and method for making one or more dies for crowns, bridges, and false teeth.
2. Background Art
The conventional system used in the United States for making dies for teeth is labor intensive. Initially, an impression of the patient's jaw is made and the impression is allowed to harden. The impression is then filled with wet stone, which must also be allowed to harden, forming a casting. The casting is then removed from the impression, a flat bottom portion and an outside wall for the casting are both formed by grinding out excess stone. An inside wall is formed for the casting by applying a lathe to remove excess stone. The casting is then cleaned by using pressurized air, and the casting is allowed to dry.
The individual pins are then drilled in the casting with a pindex machine: index pins are inserted and glued into a base for the casting, and doll pins are inserted into the upper portion of the casting. Typically the base is made from yellow stone, and the upper portion of the casting is made from green stone. A lubricant is then applied to the upper portion of the casting.
Recently, a new approach to making these dental castings has been developed, wherein the stone is embedded in a first member, which the first member is retained within a second member. These new systems use armatures disposed on the second member which cooperatively engage an undercut of the first member. The use of these armatures is limiting in that all of the dies must either be engaged or disengaged from the first member. There is no way to disengage only one die while the other dies remain firmly engaged.
In addition, if these new materials are reused for different patients, the accuracy of the dental castings made therefrom will diminish. Typically, the stone used to make the casting degrades over a period of time. As the stone wears, the stone chips and pieces become lodged within the various grooves of these members and are difficult to dislodge.
Also, most impressions are partial, and there may be no need to make a dental casting of an entire jaw. Current state-of-the-art makes no provision for a partial impression, as the patient must endure the discomfort of a full impression, and the dental technician must labor over a full impression when only one or two dies are needed.
Although these new dental casting systems are promising as far as eliminating much of the labor involved in making impressions, these materials are extremely expensive and the reduction in the labor costs are offset by increased equipment expenditures. Dental laboratories must continue to find new labor-saving techniques to reduce their costs, since the costs of labor and materials continue to rise, and it is difficult to pass these increasing costs along to the dentist and the patient.
What is needed is an apparatus to form a dental casting, the apparatus eliminating much of the labor in current techniques, the apparatus using materials that are inexpensive to manufacture, the materials being disposable after a single use, the apparatus enabling a partial impression to be made for the numerous instances when only one or two dies are needed, and the apparatus enabling a single die to be removed therefrom without disengaging neighboring dies therefrom.
SUMMARY OF THE INVENTION
The apparatus of the present invention overcomes the numerous shortcomings already mentioned, as is hereafter set forth.
The apparatus comprises a track and tray. The track has an inner and outer track wall and a first and a second end portion which combine to generally define a chamber. A hardenable stone material is embeddable within the chamber of the track. A plurality of individual dies are formed when the stone material hardens within the track to form a dental casting. As the stone and the track are sectioned to form a plurality of dies, each die includes a portion of the track. The tray has an inner tray wall and an outer tray wall which combine to generally define a recessed portion. The dies are positionable within the recessed portion, and the individual dies are readily engageable and disengageable therefrom.
The apparatus preferably includes cooperative retention means disposed on the track and the tray for securely retaining the dies of the dental casting system within the tray, in such a manner that any die can be individually removed from the tray without loosening an adjacent die.
The retaining means preferably includes a plurality of finger members disposed on the tray, the tray having a finger member for each die, as each die is secured by a different finger member. Each finger member includes a generally rounded portion. The outer wall of the lower member of each of the dies preferably has a rounded groove disposed therein. The rounded portion of each of the finger members snap-fits into the rounded groove of one of the dies.
For a more complete explanation of the dental casting apparatus and method of the present invention, reference is made to the following detailed description and accompanying drawings in which the presently preferred embodiments of the invention are illustrated by way of example. As the invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it is expressly understood that the drawings are for purposes of illustration and description only, and are not intended as a definition of the limits of the invention. Throughout the following description and drawings, identical reference numbers refer to the same components throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an assembly view of the preferred embodiment of the dental casting apparatus of the present invention depicting a track and a tray;
FIG. 2 is an assembly view of another embodiment of the present invention depicting a partial track and a partial tray;
FIG. 3 is a cut-away overhead view of the dental casting apparatus of FIG. 1 depicting a half view of the track embedded within a half view of the tray;
FIG. 4 is a sectional view of the track positioned within the tray taken along section 4--4 of FIG. 3;
FIG. 5 is a sectional view of the track positioned within the tray taken along section 5--5 of FIG. 3;
FIG. 6 is an exploded perspective view of still another embodiment of the dental casting of the present invention, depicting a shim disposed between each pair of adjacent dies, the dies being individually secureable within the tray;
FIG. 7 is an overhead view of the dental casting of FIG. 6, with a shim disposed between each pair of adjacent dies;
FIG. 8 is an exploded end sectional view depicting a die disengaged from the tray of FIG. 1; and
FIG. 9 is an exploded end sectional view depicting a die engaged within the tray of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
Referring now the drawings, FIG. 3 depicts the preferred embodiment of the dental casting apparatus 15 of the present invention, which includes a tray 20, a track 30 which is positionable within the tray 20, and cooperative retention means 50 for retaining the track 30 within the tray 20.
The track 30 is preferably in the shape of a horse-shoe, and includes a chamber 32. The chamber 32 is generally defined by an inner track wall 34 and an outer track wall 36, and a first end portion 33 and a second end portion 35. The chamber 32 is generally in the shape of the patient's jaw, or a portion thereof. The dental casting 60 of the hardened wet stone is disposed in the chamber 32. The dental casting 60 is formed from an impression of the patient's jaw, as is subsequently set forth herein. The hardenable wet stone material is well known in the art as conventional stone currently being used by dental laboratories. The dental casting 60 comprises a plurality of dies, including a first die 61 and a second die 62, the first die 61 being disposed adjacent to the second die 62 (see FIG. 3).
The track 30 preferably includes a stabilizer bar 38, the stabilizer bar 38 being an integral part of the track 30. The purpose of the stabilizer bar 38 is to minimize deformation of the track 30 when the wet stone hardens within chamber 32. The stabilizer bar 38 extends from the first end portion 33 to the second end portion 35. The stabilizer bar 38 maintains a fixed distance between the first end portion 33 and the second end portion 35 of the track 30 to prevent deformation thereof, enabling the track 30 to subsequently snap-fit into tray 20. The stabilizer bar 38 may be readily detached from the track 30, after the wet stone material hardens within the track 30, by using a pair of heavy duty clippers. The track 30 is preferably made of ABS plastic and is not reusable.
The tray 20 includes a recessed portion 26 surrounded by an inner tray wall 22 and an outer tray wall 24. The chamber 32 of the track 30 is positionable within the recessed portion 26 of the tray 20. The recessed portion 26 of the tray may be separated into a plurality of compartments 28, each compartment 28 retaining therein one die. The tray 20 preferably is of unitary construction, and is made of a flexible plastic material, such as ABS plastic, that may be formed by an injection molding process. The tray 20 is securely retained to a conventional articulator 90, which is used to simulate the movement of a human jaw. Plaster is preferably applied to the upper surface 92 of the articulator 90, and the tray 20 is subsequently positioned thereon (see FIGS. 3, 4, and 5). Preferably, the tray material is preferably more flexible than the track material, and the tray 20 is reusable. In actual practice, this is accomplished when the track 30 is filled with stone, causing the track material to lose some flexibility.
The dental casting apparatus 15 also includes a retaining means 50. The retaining means 50 enables the first die 61 to be readily disengaged from the tray 20 as the second die 62 is securely retained therewithin.
The retaining means 50 preferably involves a cooperative engagement between the track 30 and the tray 20. A first cooperative engagement member 39 may be integral with the track 30 and a second cooperative engagement member 51 may be integral with the tray 20. The cooperative engagement preferably is a plurality of snap-fittings 54, the number of snap-fittings 54 generally corresponding to the number of dies. A plurality of finger members, such as that shown at 51, are disposed within the tray 20. The first die 61 is retainable by a first finger member 71, the second die 62 is retainable by a second finger member 72, and so on. The first finger member 71 includes a generally rounded portion 55. The outer wall 36 of the track 30 has a rounded groove 39 disposed therein. The rounded portion 55 of each finger member snap-fits into the rounded groove 39 of the track 30. The first die 61 may be dislodged from the track 30 to retentively and removably lock the die into place in the track 30 by applying a grasping force thereto, the direction of which is away from the tray 20 to dislodge the rounded portion 55 from the groove 39.
Each die, as illustrated by the first die 61, comprises an upper member 65 and a lower member 66. The upper member 65 of the die is embedded to the lower member 66. A plurality of flexible retention pins 67 disposed on the track 30 are preferably, deflected into the stone when the wet stone is poured therein. When the stone material subsequently hardens within the track 30 the retention pins 67 extend into the upper member 65, and, thus, prevent the upper member 65 of the die from being separated therefrom. Accordingly, the upper member 65 is permanently embedded to plastic lower member 66.
The dental casting apparatus 15 is preferably available in an adult size and a children's size, the children's size being large enough to duplicate the jaw of a child, who is old enough to be acquiring a permanent set of teeth that may need to be crowned or replaced. The track 30 is preferably horse-shoe shaped as shown in FIG. 1. However, since 70 to 80 percent of all impressions are partials, the dental casting apparatus 15 may be similar in shape to a portion of patient's jaw, such as one-half of a jaw, and comprise a track-half 37 embedded within a tray half 27 (see FIG. 2).
To remove a die 61 from the dental casting apparatus 15 of the present invention, the dental technician pulls the die 61 that is to be removed from the tray 20 (see FIGS. 8 and 9) away from the tray 20. As the rounded groove 39 is pulled away from the finger member 71, the die 61 is disengaged from the tray 20. As a result of the individual snap-fittings 54 between the individual dies 61 and the tray 20, the die 62, which is adjacent to the die 61 being removed, is securely retained within the tray 20. Similarly, to position the die 61 into the tray 20, the die 61 is initially aligned relative to the tray 20, and the die 61 is inserted into the tray 20 as the snap fitting 54 engages the die 61 and locks the die 61 into place.
To make a die of a tooth in accordance with the teachings of the present invention, an impression of the patient's mouth is initially made, and the impression is allowed to harden (not shown). The chamber of the impression is then filled with wet stone, as the chamber 32 in the track 30 is also filled with wet stone. The wet stone in the track 30 and wet stone in the impression are then aligned and joined together. The excess wet stone is trimmed and eliminated therefrom using a saw blade, and the wet stone is allowed to harden and the impression is removed from the dental cast 60. A saw blade penetrates through the hardened stone and the track 30, making a plurality of vertical cuts, preferably so that each die includes the shape of the upper portion of a single tooth. The individual dies are then assembled into the tray 20.
In an alternate embodiment, the retaining means 80 comprises a shim 82 that is positionable between each pair of adjacent dies 161, 162, as is shown in FIGS. 6 and 7.
The wet stone material is poured into the track 30, the track 30 being in the shape of either a full jaw or a portion thereof. The dental cast 60 comprises a plurality of dies positioned within the tray 20, and one or more shims 82 positioned between each pair of dies. The die 61 includes a portion 64 that is the shape of a portion of a tooth. Since the dies 61 and 62 are physically separated by the cutting edge of a saw blade (not shown), the cut is generally parallel to the axis of each die, and results in each die having a flat side portion 65. The dies are positionable within the track 30 in a location that is similar to the relative position of the teeth in the jaw of the patient.
Each shim 82 has opposed surfaces 83 and 84 which are generally flat, and the thickness of the shim 82 is essentially equal to the distance between the two flat surfaces 83 and 84. In this embodiment, the thickness of the shim 82 is ,also, generally equal to the distance between the first die 161 and the second die 162 when the first die 61 and the second die 62 are retained within the track 30. The thickness of the shim 82 is essentially equal to a kerf of the saw blade that physically separates the first die 61 from the second die 62. In actual practice, the thickness of the shim 82 is about one-ten thousandth of an inch less than the saw blade to enable the individual dies to be removed therefrom. Preferably, the two surfaces 83 and 84 of the shim 82 each have a tacky, self-adhesive material disposed thereon to adhere to the flat side portions 68 of the die between which the shim 82 is positioned within the track 30. To disengage a die 161 from the tray 20, the shim 82 connecting the first die 161 to an adjacent die 162 is pulled out and the die 161 is then removed. Adjacent dies still have a shim 82 on the opposite side thereof to securely retain them within the tray 20.
While the dental casting apparatus and method has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the disclosure therein. It is intended that the metes and bounds of the invention be determined by the appended claims rather than by the language of the above specification, and that all such alternatives, modifications, and variations which form a functional or conjointly cooperative equivalent are intended to be included within the spirit and scope of these claims. | This dental casting apparatus includes a track, and a tray. The track has an inner and an outer track wall and a first and a second end portion which combine to define a chamber. A hardenable wet stone material is positionable within the chamber of the track. After the stone is allowed to harden within the track, a sharp knife cuts through the stone and the track to form a plurality of dies. The tray has an inner tray wall and outer tray wall which combine to define a recessed portion. The individual dies are positionable within the tray recessed portion, and are readily engageable and disengageable therefrom. The dental casting apparatus also includes a mechanism for securely retaining the dies to the tray in such a manner that each die can be individually removed from the tray without disengaging adjacent dies. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to animal restraints and, more specifically, to a leash for pets having a plurality of compartments and functions that may be expediently and conveniently accessed by the user to cleanup after or care for their pet.
Comprising the leash is a retractable leash with a clip and latch for restraining a pet, a clip on/off fluid reservoir with a fold out bowl that is stored in the handle to provide nourishment for the pet on the go, and a waste bag storage area for storing of waste bags.
Additionally the present invention has means for attaching and detaching the fluid reservoir by means of clips should the user decide it is un-needed.
2. Description of the Prior Art
There are other leash devices designed for tethering pets. While these leash devices may be suitable for the purposes for which they where designed, they would not be as suitable for the purposes of the present invention as heretofore described.
It is thus desirable to provide a pet leash incorporating an extendable, retractable leash and disposable bag storage housing freeing the user from carrying the disposable bag prior to use.
It is further desirable to incorporate detachable reservoir housing for storage of a fluid, preferably water, and a collapsible dish stored within the pet lease hand grip for use as desired.
SUMMARY OF THE PRESENT INVENTION
A primary object of the present invention is to provide a pet leash for tethering an animal incorporating dispensing means for storing and dispensing at least one disposable bag, reservoir means for storing and dispensing a dispensable product and collapsible dish means for holding the dispensable product.
Another object of the present invention is to provide a pet leash for tethering an animal wherein said dispensing means comprises a post mounting means for spooling the at least one disposable bag thereon and engagable clip means for selectively securing a disposable-bag cover to said pet leash with said cover optionally providing slot means for retrieving the at least one disposable bag therefrom.
Yet another object of the present invention is to provide a pet leash for tethering an animal having a foldable dish in its handle for serving a pet food or water.
Still yet another object of the present invention is to provide a pet leash for tethering an animal wherein said reservoir means for storing and dispensing a dispensable product comprises a detachable reservoir having cap sealing means providing selective access to a dispensable product including water and/or food.
Another object of the present invention is to provide a pet leash for tethering an animal wherein said collapsible dish means comprises a folded dish, preferably stored in the hand grip of the pet leash that is selectively retrievable for holding the dispensable product contained within the reservoir.
Additional objects of the present invention will appear as the description proceeds.
The present invention overcomes the shortcomings of the prior art by providing a pet leash for tethering an animal with a plurality of components to better care for a pet on the go. The pet leash incorporates dispensable disposable bag(s), reservoir for storing a dispensable product, such as water and/or food and detachable deployable dish for holding the dispensable product.
The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying drawing, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawing, like reference characters designate the same or similar parts throughout the several views.
The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawing in which:
FIG. 1 is an illustrative view of the pet leash in use.
FIG. 2 is an illustrative view of the pet leash.
FIG. 3 is a partial exploded view of the pet leash of the present invention.
FIG. 4 is an exploded view of the pet leash of the present invention.
FIG. 5 is an exploded view of the pet leash of the present invention.
FIG. 6 is an exploded view of the pet leash of the present invention.
FIG. 7 is an exploded view of the pet leash showing the dish of the present invention.
FIG. 8 is an exploded view of the pet leash of the present invention.
FIG. 9 is an exploded view of the pet leash of the present invention in use.
DESCRIPTION OF THE REFERENCED NUMERALS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the Multi-Purpose Pet Leash of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures.
10 Multi-Purpose Pet Leash of the present invention 12 user 14 pet 16 retractable pet tether 18 leash housing 20 collapsible dish 22 fluid reservoir 24 waste bag 26 waste bag housing 28 reservoir cap member 30 reservoir latch 32 reservoir clip 34 leash latch 36 leash fastener 38 access port 40 waste bag spool 42 waste bag housing clips 44 handle 46 collapsed position of 20 48 deployed position of 20 50 conduit 52 foldable section of 20 54 gasket of 20 56 stop gasket of 50 58 waste bag gap
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following discussion describes in detail one embodiment of the invention. This discussion should not be construed, however, as limiting the invention to those particular embodiments, practitioners skilled in the art will recognize numerous other embodiments as well. For definition of the complete scope of the invention, the reader is directed to appended claims.
FIG. 1 is an illustrative view of the multi-purpose pet leash 10 in use. Shown is the user 12 walking his dog 14 with a multi-purpose pet leash 10 having spring biased means for extending and retracting the spring loaded retractable pet tether 16 from the leash housing portion 18 to a desired length. Further incorporated is a fluid reservoir and collapsible dish 20 so that a user 12 can provide their pet 14 with water and/or food while walking and at least one spooled waste bag housed within a waste bag holder.
FIG. 2 is an illustrative view of the multi-purpose pet leash 10 . The present invention is a pet leash having a retractable tether portion 16 and a leash housing 18 with collapsible detachable bowl 20 so that a user can provide the pet with water and/or food as needed and further providing at least one pet waste bag 24 stored within the waste bag housing 26 . The fluid reservoir 22 is secured and released from the leash housing 18 by a reservoir latch 30 and clips 32 . A removable reservoir cap 28 provides access therein. At least one waste bag 24 is contained within the waste bag housing 26 . The tether 16 is locked and released by the user with a leash latch 34 and a leash faster 36 is disposed on the distal end of the tether 16 for attachment to a pet's collar.
FIG. 3 is a partial exploded view of the multi-purpose pet leash 10 of the present invention. Shown are the clips 32 of the fluid reservoir 22 being detached from the leash housing 18 while pivoting on the leash reservoir latch 34 . Also shown is the dish 20 releasably stored within the leash housing 18 and deployable therefrom.
FIG. 4 is an exploded view of the multi-purpose pet leash 10 of the present invention. Shown is the fluid reservoir 22 detached from the leash housing 18 by the reservoir latch 30 and clips 32 so that a quantity of water and/or food can be dispensed through the access port 38 covered by the cap 28 into the dish 20 once detached and deployed from its seated position within the leash housing 18 .
FIG. 5 is an exploded view of the multi-purpose pet leash 10 of the present invention. Shown is the multi-purpose pet leash 10 with the liquid reservoir 22 and waste bag housing 26 removed from the leash housing 18 . At least one waste bag is posted onto a spool 40 for when needed to bag pet waste. Also shown are waste bag housing clips 42 for fastening the waste bag housing 26 to the leash housing 18 . The collapsible dish 20 is stored within the handle 44 of the leash housing 18
FIG. 6 is an exploded view of the multi-purpose pet leash 10 of the present invention. Shown is an exploded view of the waste bag housing 26 removed from the leash housing 18 . The present invention provides storage for pet waste bags 24 with at least one placed on a spool 40 and having waste bag housing clips 42 for fastening the waste bag housing 26 to the leash housing 18 . The waste bags 24 are distributed through a waste bag gap 58 disposed on the side of said waste bag housing 26 .
FIG. 7 is an exploded view of the multi-purpose pet leash 10 showing the dish 20 of the present invention. The present invention provided a collapsible dish 20 stored within the handle 44 of the leash housing 18 of the pet leash that can be withdrawn from its collapsed seated position 46 and deployed 48 to its bowl-like state for receiving a quantity of fluid from the fluid reservoir 22 .
FIG. 8 is an exploded view of the multi-purpose pet leash 10 of the present invention. Shown is the pet leash having a liquid reservoir 22 and collapsed dish 20 that is storable within the handle 44 of the leash housing 18 until needed wherethen the collapsed dish 46 is removed and deployed 48 to its bowl-like state for receiving an amount of fluid or granular product from the reservoir 22 .
FIG. 9 is an exploded view of the multi-purpose pet leash 10 of the present invention in use. Shown is the pet leash having a dispensable product reservoir 22 and collapsible dish 20 storable within the handle 44 in the leash housing 18 until needed wherethen the collapsed dish is removed and deployed to its bowl-like state for receiving an amount of dispensable product from the reservoir 22 . The dish 20 is divided into a plurality of foldable sections 52 with peripherally disposed gaskets 54 . Shown is a conduit 50 in communication with the access port 38 for aiding in the distribution of the contents contained therein. The conduit 50 has a stop gasket 56 disposed on the distal end thereof to prevent the conduit 50 from falling inside the reservoir 22 and to form a seal when the cap is screwed thereon.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, 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 in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A multi-purpose pet leash for tethering an animal with a plurality of components to better care for a pet on the go. The pet leash incorporates dispensable disposable bag(s), reservoir for storing a dispensable product, such as water and/or food and detachable deployable dish for holding the dispensable product. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Provisional Application Ser. Nos. 60/884,707, filed Jan. 12, 2007 and 60/888,347, filed Feb. 6, 2007.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to nuclear reactor containment arrangements, and more particularly to permanent seal rings extending across an annular thermal expansion gap between a peripheral wall of a nuclear reactor vessel and a containment wall wherein the seal ring provides a water tight seal across the expansion gap allowing for lateral and vertical translation of the reactor vessel relative to the containment wall.
2. Description of the Prior Art
Refueling of pressurized water reactors is an established routine operation carried out with a high degree of reliability. For normal load requirements, refueling is provided approximately every 12 to 22 months. The complete refueling operation normally takes approximately four weeks.
In a number of nuclear containment arrangements the reactor vessel is positioned within a concrete cavity having an upper annular portion above the vessel which defines a refueling canal. The canal is maintained dry during reactor operations; however, during refueling of the nuclear power plant, the canal is filled with water. The water level is high enough to provide adequate shielding in order to maintain the radiation levels within acceptable limits when the fuel assemblies are removed completely from the vessel. Boric acid is added to the water to ensure sub-critical conditions during refueling. At the beginning of the refueling operation, before the refueling canal is flooded, the reactor vessel flange is sealed to the lower portion of the refueling canal. Originally, this seal was achieved by a clamped gasket seal ring which prevents leakage of refueling water to the well in which the reactor vessel is seated. This gasket was fastened and sealed after reactor cool down prior to flooding of the canal. Typically this removable seal ring was made up of four large diameter elastomer gaskets which are susceptible to leakage and must be replaced at each refueling operation.
The annular thermal expansion gap between the reactor vessel and the concrete wall surrounding the reactor vessel is provided to accommodate thermal expansion of the vessel and other vessel movements such as in a seismic event and permit cooling of the cavity walls and the excore detectors embedded within the concrete cavity walls. Pressurized water reactor plants have two basic expansion gap sizes, i.e., wide and narrow. The wide gaps tend to be in the range of two to three feet, while narrow gaps tend to be in the range of two to four inches. In all plants, the gap area must be sealed during refueling. While the upper portion of the cavity, i.e., the refueling canal may be flooded, no water is permitted in the lower portion of the cavity. Typically, the reactor vessel has a horizontally extending flange and the containment wall surrounding the reactor cavity has a horizontally extending ledge or shelf at the floor of the refueling canal at about the same elevation as the flange, which the temporary seal ring spanned during refueling.
In plants with wide thermal expansion gaps permanent seal rings such as those described in U.S. Pat. Nos. 5,323,427; 4,905,260; 4,904,442; 4,747,993; and 4,170,517 have been employed to reduce the time required for the refueling operation. However, permanent seal rings need to allow for thermal expansion of the reactor vessel that reduces the gap between the peripheral wall of the reactor vessel and the containment wall in the area of the reactor well, and also ideally accommodate some vertical and lateral movement of the reactor vessel relative to the containment wall. In addition, the seal ring should be able to withstand heavy blows from objects such as fuel assemblies, accidentally dropped during refueling. A permanent seal ring also must permit the passage of cooling air from the lower reactor cavity along the wall surrounding the vessel up to the refueling canal. Thus, the seal ring must have (1) strength to retain the large volume of water used in the refueling operation; (2) flexibility to accommodate movement of the reactor vessel within the containment wall; (3) structural integrity to resist damage from falling objects; and (4) an air path between the lower reactor cavity and the refueling canal for cooling of the cavity walls during reactor operation. The foregoing patents describe various designs that achieved these objectives for wide gap plants; however, do not satisfy all of these objectives for narrow expansion gap plants. There are approximately 40 plants in the United States that have narrow expansion gaps that could take advantage of a permanent seal fixture if a design was available that could achieve all of the foregoing objectives.
Accordingly, it is an object of this invention to provide such a design that will satisfy all of the foregoing objectives for narrow expansion gap plants.
SUMMARY OF THE INVENTION
The foregoing objectives are achieved by employing an annular stainless steel ring which sealingly engages and is affixed to and extends between the refueling ledge adjacent the reactor vessel flange and the containment wall at the floor of the refueling canal. The annular ring seal includes a rigid cantilevered annular support that is anchored at a first end to one of the floor of the refueling canal or the refueling ledge and extends above and over the expansion gap preferably extending over at least a portion of the other of the floor of the refueling canal or the refueling ledge. A distal portion of the rigid cantilevered annular support has one end of a generally C-shaped flexure member attached thereto. Another end of the C-shaped flexure member is anchored to the other of the floor of the refueling canal or the refueling ledge.
In the preferred embodiment the rigid cantilever annular support includes a substantially horizontal foot that is anchored to one of either the floor of the refueling canal or the refueling ledge. A leg having one end connected to the foot extends from the foot in a generally vertical direction and is attached at an elevation spaced from the foot to an arm or top plate which extends laterally out in a generally radial direction over the expansion gap. Desirably the arm or top plate extends radially in a horizontal direction. Preferably, the foot extends from the leg radially toward the expansion gap and is bolted to the surface on the one of the floor of the refueling canal or the refueling ledge. A seal weld is supplied around the interface between the rigid cantilevered annular support and the one of the floor of the refueling canal or the refueling ledge. Alternately, the foot can be attached by a structural weld.
In an alternate embodiment, an end of the arm opposite the distal end that extends over the expansion gap, extends radially past the leg and is attached to a distal end of an L shaped flexure member that has another end anchored to the one of the floor of the refueling canal or the refueling ledge. In still another embodiment the first end of the generally C-shaped flexure member is attached to the rigid cantilevered annular support through a substantially vertically extending flexure link.
The embodiments of this invention thus permit hatch openings to be placed in the arm or top plate of the rigid cantilevered annular support of sufficient size as to not add additional constrictions to the cooling air flow in a narrow gap plant arrangement, without sacrificing the structural strength and flexibility of the seal.
BRIEF DESCRIPTION OF THE DRAWINGS
A further understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic view of the reactor containment, partially in section, incorporating this invention;
FIG. 2 is a side view of a portion of the reactor well about the thermal expansion gap showing a preferred embodiment of the annular seal ring of this invention;
FIG. 3 is a side view of the portion of the reactor weld shown in FIG. 2 illustrating the air path through the seal of one embodiment of this invention;
FIG. 4 is a plan view of the permanent cavity seal ring of this invention showing the air hatch placement;
FIG. 5 is a side view of a portion of the reactor containment about the thermal expansion gap that shows a second embodiment of this invention;
FIG. 6 is a side view of a portion of the reactor containment about the thermal expansion gap illustrating a third embodiment of this invention;
FIG. 7 is a side view of a portion of the reactor containment illustrated in FIG. 5 showing the coolant air path through the permanent cavity seal ring of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention provides a nuclear reactor vessel to cavity seal arrangement that forms a permanent flexible seal between the reactor vessel and the reactor refueling canal floor that is capable of being used in nuclear plants that have a narrow expansion gap. The design of the seal of this invention will affect a water tight seal for the refueling canal during refueling operations while accommodating material expansions and contractions that occur during normal reactor operations and enable sufficient coolant air flow, without destroying the water tight integrity of the seal.
The environment in which the invention operates can best be understood by reference to the side view, partially in cross-section, of a reactor containment illustrated in FIG. 1 , which shows a nuclear steam generating system of the pressurized water type incorporating the permanent water tight seal ring of this invention. A pressurized vessel 10 is shown which forms a pressurized container when sealed by its head assembly 12 . The vessel has cooling flow inlet nozzles 20 and cooling flow outlet nozzles 14 formed integral with and through its cylindrical walls. As is known in the art, the vessel 10 contains a nuclear core (not shown) consisting mainly of a plurality of clad nuclear fuel elements which generates substantial amounts of heat depending primarily upon the position of control means, the pressure vessel housing 18 of which is shown. The heat generated by the reactor core is conveyed from the core by coolant flow entering through inlet nozzles 20 and exiting through outlet nozzles 14 .
The flow exiting through outlet nozzles 14 is conveyed through hot leg conduit 28 to a heat exchange steam generator 22 . The steam generator 22 is of the type wherein heated coolant flow is conveyed through tubes (not shown) which are in heat exchange relationship with water which is utilized to produce steam. The steam produced by the steam generator 22 is commonly utilized to drive a turbine (not shown) for the production of electricity. The flow is conveyed from the steam generator 22 through cold leg conduit 24 through a pump 26 from which it proceeds through a cold leg conduit to the inlet nozzles 20 . Thus, it can be seen that a closed recycling primary or steam generating loop is provided with coolant piping communicably coupling the vessel 10 , the steam generator 22 , and the pump 26 . The generating system illustrated in FIG. 1 has three such closed fluid flow systems or loops. The number of such systems should be understood to vary from plant to plant, but commonly 2, 3 or 4 are employed.
Within the containment 42 the reactor vessel 10 and head enclosure 12 are maintained within a separate reactor cavity surrounded by a concrete wall 30 . The reactor cavity is divided into a lower portion 32 which completely surrounds the vessel structure and an upper portion 34 which is commonly utilized as a refueling canal. During reactor operation air flow communication is maintained between the lower reactor vessel well 32 and the refueling canal 34 to assist cooling of the concrete walls of the reactor cavity and the excore detectors 44 embedded within the concrete walls. The air flow is facilitated by exhaust fans positioned within the containment 42 outside of the concrete barrier 30 . During refueling operations the reactor vessel flange 36 is sealed to the reactor cavity shelf 40 which is the floor of the refueling canal. In FIG. 1 a wide expansion gap 46 is shown for clarity. For plants with such wide gaps 46 permanent seal rings of the type previously described would normally be employed. By placing a fixture over the gap 46 the heat emanating around the reactor vessel is constricted. For a wide gap plant having an annulus width in the order of three feet the permanent seal fixture designs generally use welded, flexible steel pieces on the side, with several large hatches on a top steel plate. Before refueling, the hatches are locked into position to create a water tight seal. After the refueling canal is drained, the hatches are removed and stored to allow air flow during standard operation.
Because the wide gaps are large, sizing and placing hatches to allow for adequate air flow is relatively easy. However, the narrow gaps are so small that hatches become a limiting design factor. Without enough hatches, the air flow during reactor operation is significantly constricted. Of particular concern is the structural strength of the permanent seal fixture. One wide gap seal fixture that is commonly used is shown in U.S. Pat. No. 4,904,442, which employs two steel legs supporting a rigid top plate. Attached to a top plate on either side are two L-shaped flexures. The main structure supports the load, but is not fixed to the refueling ledge or compartment floor. The flexures which are made up of thin sheet metal are the only portion fixed to the refueling ledge and refueling canal floor, creating the water tight seal, while allowing the seal structure to deflect as necessary to accommodate movement of the vessel. The two legs are not welded to the ledge. Instead, the two flexures are welded to the top plate and ledge. This allows the seal structure to have the needed support for dropped load cases such as catastrophic drop of a fuel assembly. However, the structure can also move as needed for expansion due to loads such as operational temperature change and seismic activity.
The largest problem with applying the structure of the wide gap permanent fixture seal to a narrow gap plant is one of heat flow. The two legs and the top plate trap heat. To alleviate this problem the design of this invention removed one leg. In doing so, the remaining leg and top plate were modified to accommodate design structural loads. In addition, a new flexure design was developed that would withstand the movement caused by required design load cases and allow more area to accommodate cooling air flow.
In the design of this invention, the hatches have also become a structural concern because they occupy a good deal of the volume of the top plate. Similar to the wide gap design, hatches are used to allow air flow through the structure during normal operation. However, the hatches for the wide gap structure take up a smaller portion of the top plate than those required for the narrow gap structure. Traditionally, the hatch plates are not as thick as the top plate to which they are attached. This means that in the narrow expansion gap design a significant amount of support material is lost causing more stress reactive sections.
The narrow expansion gap seal design of this invention installed in the plant refueling configuration, i.e., hatch cover plates installed, is shown in FIG. 2 . The reactor vessel 10 is shown centered in the lower portion 32 of the reactor cavity surrounded by insulation 68 . A refueling ledge 66 is shown as an extension of the reactor vessel flange 36 and extends radially from the flange 36 towards the containment cavity wall 30 where it defines the cavity thermal expansion gap 46 between the refueling ledge 66 and an embedment plate 64 anchored in the containment wall 30 . A steel liner 70 covers the outside of the concrete containment wall. The permanent reactor cavity seal ring of this invention 78 is shown anchored to the embedment plate 64 by bolts 60 which pass through a foot 48 of a cantilevered portion of the seal 78 . The foot 48 is welded to one end of a leg portion 50 of the cantilevered section which is in turn welded to a horizontally extending arm or top plate 52 , which extends over the expansion gap 46 and, preferably, over at least a portion of the refueling ledge 66 . The top plate 52 has a hatch 54 which is held in place by bolts 56 which compress seal rings 58 to create a water tight seal. A seal weld 80 surrounds the intersection of the foot 48 and the embedment plate 64 . A flexure member 62 is connected at one end to the arm 52 within the vicinity of the distal end 82 of the arm 52 . The flexure member 74 is a generally C-shaped member that is connected at its other end to the upper surface of the refueling ledge 66 .
The thin gauge, e.g., less than about 0.2″ (0.51 cm) construction of the C-shaped flexure is designed to accommodate the radial and vertical thermal expansion of the reactor vessel. It combines the function of the L-shaped flexures used in the wide gap permanent cavity seal ring described in U.S. Pat. No. 4,747,993. The thin gauge C-shaped flexure is protected from an inadvertent fuel assembly drop by the robust top plate 54 . Preferably the permanent reactor cavity seal is constructed out of stainless steel.
After refueling when the spent fuel canal 34 is drained the air hatches 54 are removed to provide a flow path for the reactor cavity cooling air. FIG. 3 illustrates the cooling air flow path with the hatch cover plates removed during plant operation. FIG. 4 shows a typical orientation of the hatch 54 openings in plan view.
An alternate design is illustrated in FIG. 5 which uses a C-shaped outer flexure 74 welded to the refueling cavity embedment ring 64 and an L-shaped inner flexure 86 having a short leg 88 welded to the reactor vessel refueling ledge 66 and a long leg 90 secured to the extended portion 84 of the arm 54 . In this embodiment the cantilevered annular support 47 which is made up of the leg 50 and arm or top plate 52 rests on the refueling ledge 66 and the bottom link 72 of the outer C-shaped flexure 62 is secured to the embedment plate 64 . Like reference characters are used for the corresponding elements shown in FIG. 5 that are common to both FIGS. 2 and 5 . The embodiment shown FIG. 5 differs from that shown in FIG. 2 in several other respects as well. For example, the C-shaped flexure 62 in the embodiment shown in FIG. 5 is facing away from the reactor vessel 10 while in FIG. 2 the C-shaped flexure is facing towards the reactor vessel 10 . Furthermore, the arm or top plate 52 in the embodiment shown in FIG. 5 has a segment 84 that extends beyond the leg 50 in a direction away from the C-shaped flexure 62 . The inner L-shaped flexure functions similarly to that described in U.S. Pat. No. 4,904,442. The design shown in FIG. 5 shares many of the same attributes as that described above with respect to FIG. 2 , but also provides additional flexibility due to the increase total length of the flexure material associated with the combination of two flexures 86 and 62 . This design would use a support leg 50 that rests directly on the reactor refueling ledge to provide the required support for the seal ring during refueling operations when the refueling cavity is flooded. The water tight seal is achieved with the fully welded inner and outer flexures 86 and 62 .
FIG. 6 illustrates an optional design for the outer flexure 62 . This design has an added flexure link 92 inserted between the distal end 84 of the horizontal arm 52 and the upper link 76 of the C-shaped flexure 62 . The shape of the flexure 62 is modified to allow for a larger hatch 54 thus enabling a larger air opening in the top plate 52 . The modified flexure shape shown in FIG. 6 maintains the same flexure characteristics as the C-shaped design shown in FIG. 5 . A larger opening may be required for some applications to compensate for the increased pressure drop in the reactor cavity air cooling system associated with the seal ring. FIG. 7 shows the reactor cavity air flow path through the two flexure seal design shown in FIGS. 5 and 6 , during plant operation.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular embodiments disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. | A permanent cavity seal ring that replaces the function of the temporary cavity seal ring typically used in narrow thermal expansion gap pressurized water reactors, to seal the gap between the reactor cavity well and the reactor during refueling. The permanent seal ring uses a C-shaped flexure that is shielded by a rigid cantilevered support arm from any accidentally dropped equipment from above in the refueling canal. The construction accommodates the thermal expansion of the reactor vessel while permitting the reactor cavity cooling air to exit the annulus between the vessel and the reactor cavity wall during plant operation, without a significant increase in pressure drop. | 8 |
BACKGROUND OF THE INVENTION
The present invention concerns a procedure for treating cellulose derivative fibres. More specifically, the invention concerns a procedure for regulating the properties of cellulose carbamate fibres. Furthermore, the invention concerns a novel procedure for manufacturing regenerated cellulose fibres.
In the Finnish patent application No. 61,033 and U.S. Pat. No. 4,404,369 is disclosed a procedure for manufacturing an alkali-soluble cellulose derivative from cellulose and urea at elevated temperature. The procedure is based on the fact that on heating urea to its melting point or to a higher temperature it begins to decompose into isocyanic acid and ammonia. Isocyanic acid in itself is not a particularly stable compound; it tends to trimerize into isocyanuric acid. Furthermore, isocyanic acid also tends to react with urea, whereby biuret is formed. Isocyanic acid also reacts with cellulose, producing an alkali-soluble cellulose derivative which is called cellulose carbamate. The reaction may be written as follows: ##STR1## The cellulose compound thus produced, cellulose carbamate, may be dried subsequent to washing and stored even over prolonged periods, or it may be dissolved in an aqueous alkali solution for manufacturing fibres, for instance. From this solution can be manufactured cellulose carbamate fibres or films by spinning or by extruding, in like manner as in the viscose manufacturing process. The keeping quality of cellulose carbamate and its transportability in dry state afford a great advantage compared with cellulose xanthate in the viscose process, which cannot be stored nor transported, not even in solution form.
If, for instance, continuous fibre or filament manufactured from cellulose carbamate appropriate for textile uses is desired, the carbamate is first dissolved in alkali, e.g. in aqueous sodium hydroxide solution. From this solution may then be precipitated fibre or film, for instance in like manner as in the manufacturing of viscose fibre cellulose is regenerated from the NaOH solution of cellulose xanthate. In this connection, the cellulose carbamate solution is spun through spinnerets into an acid precipitation bath, which causes precipitation of the cellulose carbamate. The precipitation may also be accomplished into lower alcohols such as methanol, ethanol or butanol, or into hot aqueous salt solutions.
SUMMARY OF THE INVENTION
The properties of precipitated fibres are substantially influenced by the nitrogen content of the fibre, that is, the number of carbamate groups in the cellulose chain. It has been found that the carbamate groups increase the sensitivity of the fibres to water and, simultaneously, they impair the wet properties of the fibres. In some cases, this is even an advantage, whereas in other cases it is detrimental because, for instance in textile uses, the fibres are most often expected to have good wet strength.
The object of the present invention is a procedure by which the properties of cellulose carbamate fibres, in particular their wet properties, can be regulated as desired so that fibres suitable for each purpose are obtained. The procedure according to the invention for regulating the properties of cellulose carbamate fibres is characterized in that the fibres are treated with alkali or with an organic base.
By the aid of an alkali treatment according to the invention, the carbamate groups of the cellulose carbamate can be removed to the desired degree. Thus for instance the wet strength of the fibres substantially increases, while the wet stretchability decreases. If, again, for instance fibres for non-woven purposes are desired which have good water absorption capacity and swelling capacity, the alkali treatment of the invention may be carried out in a milder form. It is possible to carry the alkali treatment of cellulose carbamate fibres so far that a near complete removal of the carbamate groups from the fibres takes place. A fibre has then been obtained of which the solubility in alkali has gone down to the same level as that of regenerated cellulose fibres obtained by the viscose method, that is, less than 10%. In fact, a regenerated cellulose fibre is concerned, manufactured if a different way from the regenerated cellulose fibre of the viscose method. Thus, an object of the invention is a new process for manufacturing regenerated cellulose fibres comprising the treatment of cellulose carbamate fibres with an alkali or an organic base for substantially removing the carbamate group from the fibres. In a broader sense, by the invention is provided a new process for manufacturing regenerated cellulose fibres, this process being characterized by the following steps: dissolving cellulose carbamate in alkali, spinning or precipitating the carbamate solution to cellulose carbamate fibres or filaments, and conversion of the cellulose carbamate fibres or filaments to regenerated cellulose by treating the fibres with alkali or with an organic base. In the different steps of the process, any procedures or means may be used which result in accomplishment of said method steps, and as examples may be mentioned the procedures disclosed in the Finnish Pat. No. 61033 and U.S. Pat. Nos. 4,404,361, 4,486,585 and 4,456,749.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Towards regulating the properties of cellulose carbamate fibres as taught by the invention, any alkali or organic base may be used. Sodium hydroxide and potassium hydroxide are suitable alkalis, and among organic bases may be mentioned as examples tetramethylammonium hydroxide and ethylene diamine. The amount of alkali or base required depends on the alkali used in each case. When using sodium hydroxide, the concentration of the alkali solution is preferably less than 2%, because larger NaOH quantities may adversely affect the properties of the fibre. The suitable NaOH quantity is in the range 0.1 to 2%. Potassium hydroxide does not act as powerfully as sodium hydroxide, and when it is used the suitable quantity is in the range of 0.1 to 4%. Organic bases are not as powerful as the above-mentioned, and therefore, the concentration range appropriate in their case may vary in the range of 0.1 to 10%.
The treatment time and temperature depend greatly on how large a proportion of the carbamate groups one desires to eliminate. For instance, a treatment at room temperature may be applied, although in that case the required treatment times may become quite long. The treatment times can be shortened by raising the temperature, even down to a few minutes. A temperature suitable in practice is mostly from room temperature to 100° C., but higher temperatures may be used if treatment means capable of containing pressure are at disposal.
The invention is described more in detail in the embodiment examples included. The percentages stated in the examples are to be understood as percent by weight. The wet strengths of staple fibres mentioned in the examples were determined by procedures which are readable in: BISFA (International Bureau for the Standardization of Man-Made Fibers), Internationally agreed method for testing regenerated cellulose and acetate staple fibres, 1970 Edition. The fibres were air-conditioned at 23° C. and 50% relative humidity.
EXAMPLE 1
Cellulose carbamate fibers were manufactured as follows. Bleached spruce sulphate cellulose (400 g) with DP brought to the level of 390 by the aid of γ radiation was impregnated at -40° C. with 3.3 liters of liquid ammonia in which had been dissolved 400 g urea. The cellulose was kept in this solution below the boiling point of ammonia for six hours, whereafter it was taken into room temperature. On evaporation of the ammonia, the urea cellulose was placed in a vacuum oven at 135° C. for three hours. An air flow produced by a water jet pump passed through the oven all the time.
The reaction product was washed with methanol, three times with water and once with methanol. The air-dry product had DP 340 and nitrogen content 1.7%. A solution was prepared by dissolving the cellulose carbamate thus manufactured in 10% NaOH solution, containing also ZnO for better solubility. The carbamate content of the solution was 5.5% and the ball viscosity, 50 seconds. Of the solution was determined the clogging number by the procedure presented in: H. Sihtola, Paperi ja Puu 44 (1962), No. 5, p. 295-300. The clogging number of the solution was found to be 495. The solution was pressed into sulphuric acid solution through a spinneret with 100 holes having diameter 0.09 mm. The precipitating solution contained 10% sulphuric acid, 7% aluminium sulphate and 20% sodium sulphate.
In connection with precipitation, the fibres were stretched 0-80% to improve their strength properties. Subsequent to washing and drying, cellulose carbamate fibres A-G were obtained which were used in the other examples. In Table I are presented the manufacturing conditions of the fibres.
TABLE I______________________________________DISSOLVING PRECIPITATIONFIBRE NaOH (%) ZnO (%) Stretching (%)______________________________________A 10 1.0 0B 10 1.0 50C 10 1.0 75D 10 1.0 80E 10 1.5 0F 10 1.5 50G 10 1.5 75______________________________________
EXAMPLE 2
Fibres manufactured as in Example 1 were treated with NaOH solutions having various concentrations. The wet properties of the fibres were determined before and after the alkali treatment. The alkali solubility of the fibres was determined using the standard method SCAN - C2:61 and 5.5% NaOH solution.
In Table II following below are presented the properties of the fibres and after the NaOH treatment. The table reveals that alkali treatment of cellulose carbamate fibres improves the fibres' wet strength properties if the alkali concentration is at a reasonable level. When the alkali concentration goes up to 2%, the strength properties of the fibres deteriorate. When the alkali treatment is carried out at elevated temperature, better strength properties are achieved with considerably shorter treatment times. Stretching the fibres at the spinning phase also has a beneficial effect on the strength properties.
EXAMPLE 3
As in Example 2, NaOH treatments of cellulose carbamate fibres were carried out using elevated temperatures. Table III gives the properties of the fibres before and after the alkali treatment. The table reveals that remarkably short treatment times are achieved using the temperature 100° C.
EXAMPLE 4
As in Example 2, alkali treatments of cellulose carbamate fibres were carried out. Potassium hydroxide was used for alkali. Table IV presents the properties of the fibres before and after the alkali treatment.
The results reveal that potassium hydroxide is not quite as efficient as sodium hydroxide. Higher alkali concentrations than in the case of NaOH may be used in the treatment.
EXAMPLE 5
As in Example 2, alkali treatments of cellulose carbamate fibres were carried out. Tetramethylammonium hydroxide was used as alkali. Table V presents the properties of the fibres before and after the alkali treatment.
EXAMPLE 6
Fibres manufactured as in Example 1 were treated with NaOH so that a substantial part of the carbamate groups were removed and the alkali solubility of the fibres was lowered to the level of regenerated fibres obtained in the viscose process. In Table VI are presented the properties of the fibres before the alkali treatment and the properties of the regenerated fibres after the alkali treatment.
TABLE II__________________________________________________________________________FIBRE CHARACTERISTICS BEFORE FIBRE CHARACTERISTICS AFTERALKALI TREATMENT ALKALI ALKALI TREATMENT Modulus TREATMENT Modulus Alkali Nitrogen Wet Distens. when Alkali Temper- Alkali Nitrogen Wet Distens. whenFi- solubil. content strength when wet conc. ature Time solubil. content strength when wetbre % % cN/dtex wet % cN/dtex % °C. h % % cN/dtex wet cN/dtex__________________________________________________________________________A 86.3 1.1 0.8 53 3 0.5 23 70 75.0 0.3 0.8 17 8C 86.9 " 0.9 10 13 0.5 " " 52.9 0.3 1.4 10 14" " " " " " 2.0 " " 6.7 0.2 0.9 9 9D 86.8 1.0 1.1 15 14 0.25 40 5 77.1 0.8 1.3 13 14" " " " " " 0.50 " " 62.3 0.5 1.2 10 15" " " " " " 0.75 " " 44.8 0.5 1.4 11 16__________________________________________________________________________
TABLE III__________________________________________________________________________FIBRE CHARACTERISTICS BEFORE ALKALI FIBRE CHARACTERISTICS AFTERALKALI TREATMENT TREATMENT ALKALI TREATMENT Alakli Nitrogen Wet Distens. Alkali Temper- Alkali Nitrogen Wet Distens.Fi- solubil. content strength when Modulus conc. ature Time solubil. content strength when Modulusbre % % cN/dtex wet % cN/dtex % °C. h % % cN/dtex wet cN/dtex__________________________________________________________________________E 88.0 1.1 0.7 73 2 0.5 60 24 21.2 0.2 0.8 43 3F " " 0.9 30 7 " " " 18.7 " 1.2 13 12G " " 1.0 18 11 " " " 17.0 0.3 1.5 10 16D 86.8 1.0 1.1 15 14 " 100 0.05 39.1 0.4 1.5 12 15" " " " " " " " 0.2 8.5 0.1 1.5 9 19__________________________________________________________________________
TABLE IV__________________________________________________________________________FIBRE CHARACTERISTICS BEFORE FIBRE CHARACTERISTICS AFTERALKALI TREATMENT ALKALI ALKALI TREATMENT Modulus TREATMENT Modulus Alkali Nitrogen Wet Distens. when Alkali Temper- Alkali Nitrogen Wet Distens. whenFi- solubil. content strength when wet conc. ature Time solubil. content strength when wetbre % % cN/dtex wet % cN/dtex % °C. h % % cN/dtex wet cN/dtex__________________________________________________________________________B 88.0 1.1 0.8 32 7 0.5 22 72 77.6 0.6 1.0 19 10" " " " " " 1.0 " " 59.5 0.5 1.0 18 9" " " " " " 2.0 " " 29.5 0.4 1.1 15 10F " " 0.9 30 " 0.5 100 0.2 38.5 0.3 1.1 12 11" " " " " " " " 1.0 12.1 0.2 1.2 12 12" " " " " " 2.0 " 0.2 22.0 0.3 1.1 12 11" " " " " " " " 1.0 7.3 0.2 1.2 12 11__________________________________________________________________________
TABLE V__________________________________________________________________________FIBRE CHARACTERISTICS BEFORE FIBRE CHARACTERISTICS AFTERALAKLI TREATMENT ALKALI ALKALI TREATMENT Modulus TREATMENT Modulus Alakli Nitrogen Wet Distens. when Alakli Temper- Alkali Nitrogen Wet Distens. whenFi- solubil. content strength when wet conc. ature Time solubil. content strength when wetbre % % cN/dtex wet % cN/dtex % °C. h % % cN/dtex wet cN/dtex__________________________________________________________________________F 88.0 1.1 0.9 30 7 0.5 22 72 88.0 0.6 1.0 21 6" " " " " " 1.0 " " 74.6 0.5 1.0 18 7" " " " " " 2.0 " " 67.0 0.3 1.0 18 7" " " " " " 0.5 100 0.2 50.0 0.3 1.0 18 9" " " " " " 2.0 " 0.5 16.8 0 1.2 13 11" " " " " " " " 1.0 -11.7 0.1 1.0 11 11__________________________________________________________________________
TABLE VI__________________________________________________________________________FIBRE CHARACTERISTICS BEFORE ALKALI FIBRE CHARACTERISTICS AFTERALKALI TREATMENT TREATMENT ALKALI TREATMENT Alkali Nitrogen Wet Alkali Temper- Alkali Nitrogen WetFi- solubil. content strength Distens. Modulus conc. ature Time solubil. content strength Distens. Modulusbre % % cN/dtex % cN/dtex % °C. h % % cN/dtex % cN/dtex__________________________________________________________________________A 86.3 1.1 0.8 53 3 2.0 23 70 7.1 0.1 0.7 17 8D 86.8 1.0 1.1 15 14 0.5 100 0.25 6.1 0 1.6 10 15" " " " " " " " 1.0 3.8 0 1.4 8 17__________________________________________________________________________ | The present invention concerns improving the properties of cellulose carbamate fibres. The wet strength properties in particular can be improved by treating the fibres with alkalis or organic bases, aiming to reduce the number of carbamate groups. The procedure may also be applied in the manufacturing of regenerated cellulose fibres. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/978,272 filed Apr. 11, 2014, incorporated herein by reference in its entirety.
TECHNICAL FIELD
The invention relates to hydrocarbon streams and methods for making them where the hydrocarbon streams contain a drag reducing composition, and more particularly relates, in one non-limiting embodiment, to hydrocarbon streams and methods for making them where the hydrocarbon streams contain a drag reducing composition that comprises a latex, and in an additional non-limiting embodiment relates to improved drag reducing latexes.
TECHNICAL BACKGROUND
The use of drag reducing agents to reduce the effect of friction (“drag”) experienced by a liquid hydrocarbon, such as crude oil, flowing through a hydrocarbon transportation pipeline is well-known in the art. Reduction of the drag decreases the amount of energy needed to accomplish such flow, and therefore also decreases the costs associated with pumping. These materials, often called drag reducing agents (DRAs), can take various forms, including certain polymers in the forms of latexes, oil soluble suspensions, emulsions, pellets, gels, microfine powders and particulate slurries. Particulate slurries that comprise ground polymers are often one of the most cost effective forms. One goal is a DRA that rapidly dissolves in the flowing hydrocarbon and that has a polymer content sufficient to ensure that the desired level of drag reduction is achieved.
However, in the case of the DRA being a latex, latex formulations are well known to have the problem of the latex particles agglomerating during pumping operations. These agglomerated particles tend to be very hard and consequently may plug check valves in injection pump equipment leading to injection failure. The latex particles may agglomerate or accumulate or collect into masses that cause other flow assurance problems. While “flow assurance” and “assured flow” are terms used in the oil and gas industry to mean ensuring successful and economical flow of a hydrocarbon stream from a subterranean reservoir to the point of sale, these terms as used herein are defined to mean ensuring successful flow of a latex DRA, whether the latex DRA is neat or is in a drag reducing composition or is within a hydrocarbon stream.
Thus, it would be desirable if a hydrocarbon stream and a method for producing such a stream could be developed that prevents or inhibits latex DRA particles from agglomerating to an extent that they become troublesome or inhibits or prevents flow economically.
SUMMARY
There is provided, in one form, a method of preparing a hydrocarbon composition including introducing into a liquid hydrocarbon an effective amount of a drag reducing composition to reduce the drag of the hydrocarbon composition. The liquid hydrocarbon may include, but is not necessarily limited to, crude oil, heavy oil, gasoline, diesel fuel, fuel oil, naphtha, asphalt, and mixtures thereof. The drag reducing composition includes a drag reducing latex that in turn comprises at least one plasticizer in an amount effective to improve the ability to pump the drag reducing latex into the hydrocarbon composition, for instance with assured flow.
In another non-limiting embodiment, there is provided a hydrocarbon composition having reduced drag, which the hydrocarbon composition includes a liquid hydrocarbon that may include, but is not necessarily limited to, crude oil, heavy oil, gasoline, diesel fuel, fuel oil, naphtha, asphalt, and mixtures thereof. The hydrocarbon composition also includes a drag reducing composition which in turn includes a drag reducing latex comprising at least one plasticizer in an amount effective to improve the ability to pump the drag reducing latex into the hydrocarbon composition with assured flow.
DETAILED DESCRIPTION
It has been discovered that the addition of one or more plasticizers to a latex drag reducing additive (DRA) causes the latex DRA particles to swell and also to soften. Even if these swollen latex polymer particles agglomerate, the flexibility imparted by the plasticization effect, allows them to pass through the check valves of a flow line without plugging them and leading to pump failure.
The liquid hydrocarbons which compose the hydrocarbon composition may include, but are not necessarily limited to, crude oil, heavy oil, gasoline, diesel fuel, fuel oil, naphtha, asphalt, and mixtures thereof. “Crude oil” is defined to include heavy crude oil. As defined herein, the hydrocarbon composition includes hydrocarbon streams whether flowing or at rest, and also includes hydrocarbons above ground and below ground (e.g., pipelines), in rail cars, tank trucks, barges, ships including those undergoing loading or unloading, as well as oilfield down hole crude oil applications, as well as transfer lines from storage to refineries, from refinery to storage of produced products, tank to tank transfer in refinery process units, and combinations of these.
The latex DRA particles may be formed by polymerizing at least one monomer selected from the group consisting of acrylates, methacrylates including, but not necessarily limited to, 2-ethylhexyl methacrylate, isobutyl methacrylate, butyl methacrylate, styrene, acrylic acid, and combinations thereof. More specifically, the latex DRA polymers are typically formed by polymerizing 2-ethylhexyl methacrylate, isobutyl methacrylate, butyl methacrylate, acrylates including, but not necessarily limited to, 2-ethylhexyl acrylate, isobutyl acrylate, butyl acrylate—generally C1 to C6 alcohol esters of acrylic acid or methacrylic acid, where styrene and acrylic acid are also added in small amounts to make a terpolymer. The latex DRA particles are made to have high molecular weights, defined herein as in excess of five million g/mol. In another non-limiting embodiment the polymer has a weight average molecular weight of at least 1×10 6 g/mol, alternatively at least 5×10 6 g/mol, and in another non-restrictive version at least 6×10 6 g/mol. After the high molecular weight latex is made, an oil soluble amine-containing compound is added as a dissolution enhancing agent. Suitable compounds include, but are not necessarily limited to mono, di, and tri polyetheramines (such as those comprising the Eastman JEFFAMINE® product line) as well as other oil soluble polyamines.
As noted, it has been discovered that a plasticizer, such as 2-ethylhexyl alcohol, may be added to the latex on the order of about 10 wt % alcohol to about 90 wt % latex. This incorporation or addition may be done inline using static mixers or may be added to an agitated tank containing the latex DRA particles. After mixing is complete, the latex may be put into an injection test rig, where it is pumped against a high pressure relief valve to simulate injection into a pipeline, such as is done in the injection of latex DRA particles into a flowing hydrocarbon stream, such as crude oil. Pressures and flow rates are monitored for deviations from expectations. A pressure spike or flow rate decrease would indicate problem.
Several examples in the literature suggest specially modified diaphragm pumps may be suitable for overcoming the latex plugging issues described above. However, the novel compositions described herein provides a method to use conventional drag reducer injection pumps to deliver latex drag reducer into pipelines in a reliable manner.
More specifically, the at least one plasticizer may include, but is not necessarily limited to glycols, polyglycols, glycol ethers, esters, aliphatic alcohols (e.g. 2-ethylhexyl alcohol, isoheptanol, isohexanol, isodecanol, 1-hexanol, 1-octanol, nonanol), paraffinic and isoparaffinic solvents, white and mineral spirit blends, aromatic alcohols, ketones, aldehydes, aromatic solvents (e.g. toluene, xylene and mixtures thereof), and combinations thereof.
The weight ratio of the at least one plasticizer to the latex may range from about 1/99 independently to about 30/70; alternatively from about 5/95 independently to about 20/80; and in a different non-limiting embodiment from about 7/93 independently to about 10/90. The use of the term “independently” herein with respect to a range means that any lower threshold may be combined with any upper threshold to provide a suitable alternative range.
The effective amount of the drag reducing composition, also called plasticized latex herein, in the hydrocarbon to reduce drag (lower friction) of the hydrocarbon may range from about 500 independently to about 1 ppm, alternatively from about 25 independently to about 150 ppm plasticized latex. It will be appreciated that the optimum amount of drag reducing composition for any situation will depend on a number of factors including, but not necessarily limited to, the composition of the liquid hydrocarbon, the properties of the hydrocarbon, the composition of the drag reducer, the temperature of the hydrocarbon, the flow rate of the hydrocarbon, and combinations of these. It will be appreciated that DRA products typically only work if they are injected into a stream flowing under turbulent conditions. Turbulent conditions are driven by flow rate. However, it will be appreciated that the drag reducing compositions described herein may exhibit benefit not only in the fully turbulent regime, but also more generally, and particularly in the transitional flow region between turbulent and laminar flow conditions. It may be possible that true turbulent flow conditions may not exist, but drag reducing may still occur depending on a particular combination of flow rate, temperature, viscosity and/or other factors.
The plasticizer may be added after the latex particles are already formed, or alternatively, may be added to the monomer prior to polymerization. In other words, in this latter embodiment, it is possible to get the same plasticizing effect by diluting the monomer with a solvent on the front end of the process of making the latex. A solvent would need to be selected that is substantially insoluble in water and is a solvent for both the monomer and the polymer being produced. Essentially, instead of conducting the reaction where the dispersed phase is 100% monomer, a mixture of monomer and plasticizer/solvent would be used, in a non-limiting example, 80 wt % monomer and 20 wt % solvent. Suitable solvents may include, but are not necessarily limited to, kerosene, toluene, xylene, C6-C16 alkanes or cycloalkanes, toluene, mineral oil solvents, and the like and combinations thereof. In another non-limiting embodiment, the lower threshold of the weight ratio of at least one plasticizer to monomer ranges from about 1/99 independently to about 20/80; alternatively from about 10/90 independently to about 5/95.
Upon completion of the polymerization reaction, the monomer might fully (100%) convert to polymer, but the plasticizer/solvent will restrict the % polymer in each latex particle to 80 wt % (the monomer percentage in the original mixture). It would be expected to have the same plasticization effect of, say, post-adding 10% kerosene to a finished latex polymer which has 40% latex polymer (at 100% conversion). So in this case the plasticized latex polymer would be 40 parts polymer and 10 parts kerosene and therefore 80% polymer and 20% kerosene.
In another non-limiting embodiment, the drag reducing latex may be made in a winterized version, meaning that it may be stored and used at colder temperatures while maintaining its stability, that is, that one or more of the component parts do not freeze or otherwise become unsuitable for use. For instance, a water-based or water-containing latex may have the plasticizer added to it, and for a winterized latex, part of the water may be replaced before the polymerization reaction starts with a winterizing additive including, but not necessarily limited to, ethylene glycol, propylene glycol, and mixtures thereof. The polymerization reaction would then proceed in a similar fashion to make the latex polymer, and the plasticizer would be added later. Alternatively, in the embodiment mentioned above for diluting the monomer to get the plasticization effect, part of the water would be replaced prior to latex polymerization with the a winterizing additive including, but not necessarily limited to ethylene glycol, propylene glycol, and mixtures thereof.
The latex DRA polymers, described herein, are especially effective in reducing drag in heavy crude oil which has high asphaltene content. “High asphaltene content” is defined here as at least about 3 wt %, in one non-restrictive version at least about 5 wt %, alternatively at least 10 wt %, even over 20 wt %. Alternative definitions of “high asphaltene content” include an API gravity of 26° or less; in another non-limiting embodiment an API gravity of 22° or lower. Asphaltenic heavy crude oil is typically diluted with gasoline or naphtha by about 30 wt % to reduce the viscosity enough to be able to pump the heavy crude oil. The diluent is recycled and adds considerable expense to the task of pumping high asphaltenic crude oils. Suitable diluents include, but are not necessarily limited to, gasoline, natural gasoline, naphtha, condensate, and combinations thereof. More specifically, the naphtha usually comes from an oilfield heavy crude oil upgrader unit. The diluents are often recycled too. Diluents are added to the heavy crude oil to dilute it so it can be shipped through a pipeline, from Canada to the USA for example. In the USA, the naphtha is stripped off and sent back to Canada to be reused to dilute more heavy crude oil and send it down the pipeline. Certain asphaltene inhibitors and demulsifiers, including but not necessarily limited to, combinations of oxyalkylated alkyl phenol formaldehyde resins, oxyalkylated polyamines, and oxyalkylated glycols have shown performance as viscosity reduction additives, where adding up to 1 wt % of a viscosity reducer could give the same effect as 5 wt % diluent. There can thus be determined a point at which there is an economic advantage to adding viscosity reducer so that the amount of diluent added may be reduced.
Further, a combination of viscosity reducer for asphaltenic heavy crude oil and latex drag reducer would be especially beneficial because more heavy crude oil could then be transported with less diluent and also at higher throughputs. The latex drag reducers used in this embodiment would be the same ones noted as suitable above. In this embodiment for high asphaltenic crude oils, a weight ratio of 95/5 to 80/20 for the latex to plasticizer may be suitable. The viscosity reducer, also known as asphaltene stabilizers, may include, but are not necessarily limited to, phenol formaldehyde resins phenol formaldehyde resins substituted with alkyl groups ranging from butyl to dodecyl, phenol formaldehyde resins oxyalkylated with an alkylene oxide selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide styrene oxide, glycidyl ethers, diglycidyl ethers, and combinations thereof, where the ratio of alkylene oxide to phenol ranges from 1 to 20 per mole of alkylene oxide to phenol, Mannich reaction products (i.e. reaction products of a phenol with formaldehyde and a polyamine including, but not necessarily limited to, ethylenediamine or diethylenetriamine, triethylenetetraamine), bases selected from the group consisting of imidazolines, polyamines, tetra ethyl pentamine, magnesium overbases, and combinations thereof.
If the asphaltenes drop out of the crude oil when it is diluted, the viscosity will increase dramatically. Thus, by including these asphaltene stabilizers/viscosity reducers, the viscosity may be kept “lower” and hence there is a better opportunity to reduce the drag of the crude oil with the latex drag reducer. In one non-limiting embodiment the weight ratio of plasticized latex/asphaltene stabilizer ranges from about 95/5 plasticized latex/asphaltene stabilizer independently to about 50/50 on a weight basis to about 0.001/99.999 on a weight basis; alternatively from about 95/5 independently to about 1/99.
In one non-limiting embodiment the at least one viscosity reducer is present in the asphaltenic hydrocarbon in an amount from about 1 ppm independently to about 10,000 ppm, alternatively from about 100 ppm independently to about 1000 ppm.
When the plasticizer described herein is used in the latex DRA particles in these crude oils with high asphaltenic contents, the amount of diluent is reduced as compared to an otherwise identical hydrocarbon stream absent the plasticizer, where the hydrocarbon stream and the otherwise identical hydrocarbon stream have essentially the same drag characteristics when pumped under essentially the same conditions. Alternatively, the total amount of diluent in the hydrocarbon stream that may be reduced may range from about 2 wt % independently to about 5 wt %. A reduction in diluent content of from about 3 to about 5 wt % is the amount seen in past testing on heavy Canadian crude oil less than the diluent present in the otherwise identical hydrocarbon stream, where the amount of diluent present in the otherwise identical hydrocarbon stream ranges from 5 wt % to about 30 wt %.
The invention will now be described with respect to particular Examples that are not intended to limit the invention but simply to illustrate it further in various non-limiting embodiments. Unless otherwise noted, all percentages (%) are weight %.
Example 1
Preparing an Approximate 100 Gallon (379 L) Drag Reducing Latex Batch
The drag reducing latex composition was made in a 150 gallon (568 liter) stainless steel reactor. The reactor was thoroughly cleaned and purged prior to manufacture of the product. The reactor was washed with deionized water before charging the raw materials. Only deionized water should be used in the manufacturing of this product, in most non-limiting embodiments. The following steps outline the typical steps.
A surfactant solution of the composition of Table I was charged to the reactor. STANFAX 1025 is available from PARA-CHEM®. TRITON X-100 is a nonionic octylphenol ethoxylate surfactant available from Dow Chemical Company.
TABLE I
Surfactant Solution
Component
Amount in lbs
Amount in kgs
STANFAX 1025 (Sodium
72.27
32.78
lauryl sulfate solution)
TRITON X-100
11.85
5.38
Sodium phosphate monobasic
0.75
0.34
Sodium phosphate dibasic
0.75
0.34
Deionized Water
344.62
156.32
Sodium Bromate
0.73
0.33
The charge was followed by a monomer solution with the composition of Table II
TABLE II
Monomer Solution
Component
Amount in lbs
Amount in kgs
Styrene
0.28
0.13
2-Ethylhexyl methacrylate
282.67
128.22
Acrylic Acid
0.28
0.13
The reactor agitator was then turned ON to emulsify the monomer/surfactant solution mixture.
Nitrogen was added to the reactor subsurface to remove any dissolved oxygen, which was measure by an oxygen sensor. Nitrogen sparge was continued for at least 30 minutes past the sensor reaching its low detection limit.
The reactor was then cooled down to 40° F. (4.4° C.) while continuing to sparge with nitrogen.
The reactor was held at 40° F. (4.4° C.) for the duration of the reaction, which was initiated by adding the initiator solution described in Table III, ensuring that the vessel containing the initiator solution was purged with nitrogen prior to beginning infusion.
TABLE III
Composition of the Initiator Solution
Component
Amount in lbs
Amount in SI units
Sodium metabisulfite
0.02
9.1 g
Deionized water
5.69
2.58 kg
The initiator solution was fed into the reactor at a rate of 25% of its volume per hour, in this case a rate of approximately 0.17 gallons per hour (0.64 L/hr).
Once the exotherm began, as detected by measuring the temperature of the reactor contents, the temperature was monitored and the initiator solution was continually fed until about 0.5 gallons (about 1.9 liters) had been added.
After the exotherm had peaked and the temperature of the reactor contents dropped back to 40° F. (4.4° C.), the reactor's temperature was raised to 90° F. (32° C.) and the initiator solution was fed until it been fully consumed.
The reactor contents were then cooled to ambient temperature.
JEFFAMINE® T-403 polyetheramine and 2-ethylhexanol were added to the product and mixed into the product before discharging, in the amounts shown in TABLE IV.
TABLE IV
Component
Amount in lbs
Amount in SI units
JEFFAMINE T-403
0.08
36 g
2-Ethylhexanol
80
36 kg
The product was discharged through a 10 micron bag filter into a storage container.
Example 2
Pumping Plasticized and Non-Plasticized Drag Reducing Latex Compositions
Non-plasticized drag reducing latex compositions were prepared similar to Example 1, except that 2-ethylhexanol was not added at the end. Several batches were made of each composition to accumulate for a 250 gallon (946 liter) tote. Pump testing was conducted using a standard C-Frame FLO Injection skid which features plunger pumps and liquid ends with suction and discharge check valves. The test regimen was as follows. The tote containing approximately 250 gallons (946 liters) of product was connected to the suction of the injection skid using a flexible hose. The desired flow rate in gallons per hour (GPH, or liters per hour LPH) was set on the controller and could be monitored using the mass meter. The mass meter is also capable of totaling the volume of material pumped. The discharge of the pump skid featured a high pressure relief valve, which applied back pressure, to simulate injection into a high pressure pipeline. The discharge from the high pressure relief valve then went back into the 250 gallon (946 liter) tote. The key parameter for success in this Example was the number of gallons of product injected without the pump failing.
Test #1 was conducted as described above using a non-plasticized drag reducing latex composition, starting at 43 GPH (163 LPH) flow rate and then lowered to 25 GPH (94 LPH). The injection system shutdown after 116 gallons (439 liters) injected. The pump inlet, outlet and check valves were broken down for inspection. Hard and brittle pieces of polymer were found inside the check valves. This is not desirable.
Test #2 was conducted using a non-plasticized drag reducing latex composition, similar to the first test, except now a diaphragm booster pump, placed between the tote and the injection skid, was used to feed the injection pumps. The booster pump was set at 40 psig (0.27 MPa) and the flow rate was set at 50 GPH (189 LPH). The injection failed after 86 gallons (326 liters) of product was injection. The pump inlet, outlet and check valves were broken down for inspection. Hard and brittle pieces of polymer were found inside the check valves again. In addition, the plunger and packing were also inspected and it was found that the latex polymer was agglomerating and fusing into a hard polymer at the plunger/packing interface. These hard and brittle polymer pieces were then dislodging and getting trapped inside the check valves leading to injection failure.
Test #3 utilized the inventive plasticized drag reducing latex composition described in Example 1. The test was started at a flow rate of 67 GPH (254 liters) and 163 gallons (617 liters) were pumped before the skid was intentionally turned off at the end of the day. The skid was turned ON the next day and intentionally stopped at 516 gallons (1.95 kiloliters) total injected. The skid was restarted and stopped on the following day with the total at 1004 gallons (3.801 kiloliters). With this confidence the injection skid was restarted the following day to left to run continuously for another 10 days. In this period, the flow rate was initially adjusted down 20 GPH (76 LPH) and then increased to 50 GPH (189 liters) in increments of 10 GPH (38 LPH) every 24 hours or so. This was done to simulate conditions where the treatment rates would be changing. Further the flow rates were decreased stage-wise back to 20 GPH (76 LPH). At the end of the approximate 2 week period in Test #3, the injection skid had pumped 6062 gallons (22.95 kiloliters) of the plasticized drag reducing latex without a single failure and 5058 of those gallons (19.15 kiloliters) had been pumped in one continuous run. In conclusion, the comparative data from the three tests clearly indicates that the inventive plasticization effect greatly improves the pumpability of the drag reducing latex formulation. Stated another way, the inventive composition and method provided assured flow.
Many modifications may be made in the methods and compositions of this invention without departing from the spirit and scope thereof that are defined only in the appended claims. For example, the hydrocarbon types, drag reducing latexes, monomers, plasticizers, diluents, polyetheramines, and viscosity reducers (stabilizers) may be different from those mentioned and used here, and used in different proportions from those mentioned and used here, and still be within the methods and compositions described.
The words “comprising” and “comprises” as used throughout the claims is interpreted as “including but not limited to”.
The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. For instance, there may be provided a hydrocarbon stream having reduced drag that consists essentially of or consists of a liquid hydrocarbon selected from the group consisting of crude oil, heavy oil, gasoline, diesel fuel, fuel oil, naphtha, and mixtures thereof and an effective amount of a drag reducing composition to reduce the drag of the hydrocarbon, where the drag reducing composition comprises, consists essentially of or consists of a drag reducing latex comprising at least one plasticizer in an amount effective to improve the ability to pump the latex into the hydrocarbon stream, e.g. with assured flow.
In another non-limiting embodiment there may be alternatively provided a method of preparing a hydrocarbon composition consisting essentially of or consisting of introducing into a liquid hydrocarbon an effective amount of a drag reducing composition to reduce the drag of the hydrocarbon composition where the liquid hydrocarbon is selected from the group consisting of crude oil, heavy oil, gasoline, diesel fuel, fuel oil, naphtha, and mixtures thereof, and where the drag reducing composition comprises, consists essentially of or consists of a drag reducing latex comprising at least one plasticizer in an amount effective to improve the ability to pump the latex into the hydrocarbon stream, e.g. with assured flow. | Hydrocarbon streams, such as crude oil streams, may have reduced drag when an effective amount to reduce drag of a drag reducing composition is added to a liquid hydrocarbon, where the drag reducing composition includes a drag reducing latex comprising at least one plasticizer in an amount effective to improve the ability to pump the latex into a hydrocarbon composition or stream with assured flow of the latex. Latex formulations are known to cause agglomerated particles during pumping operations, and the agglomerated hard particles tend to plug check valves in injection pump equipment, but the inclusion of at least one plasticizer reduces or prevents such problems. | 2 |
BACKGROUND TO THE INVENTION
1. Field of the Invention
The present disclosure relates to concrete testing methods and systems and, more particularly, provides a method and system for producing reproducible concrete test cylinders.
2. Background of the Invention
In the construction of highways, buildings, and other structures utilizing concrete, it is necessary from time to time to test the strength of a sample of the poured concrete to ensure that it has sufficient structural strength required for a particular installation. The most common method of testing concrete has been to take a sample of fresh concrete from a mix at a construction site.
Specifically, fresh concrete is poured into a concrete test cylinder mold to form a cylindrical concrete test cylinder. Upon completion of the cylinder fabrication process, the poured concrete extends above the top of the concrete test cylinder mold. At this point, the concrete that extends above the top of the concrete test cylinder is manually struck off with a tamping rod. The concrete remaining in the test cylinder mold is then left to set. The following day the concrete test cylinder molds may be picked up and delivered to a laboratory where the concrete test cylinders are cured under laboratory conditions.
After curing, the concrete is removed from the cylinder and is tested for compressive strength. The compressive strength of the concrete test cylinders is a representation of the strength of the concrete placed in the structure.
The problem with the prior art concrete test cylinders that are produced in conventional concrete test cylinder molds is that the concrete test cylinders produced are subjected to fluctuating temperatures during their formation and cure and/or to temperature ranges that adversely affect the overall structural integrity of the concrete test cylinder. Additionally, the strength of conventionally formed concrete test cylinders is compromised due to the change in the specimen's water content, as some traditionally used molds may absorb water from the concrete test mix.
Another problem encountered by prior art molds used in the formation of concrete test cylinders is that such molds do not offer regularity and/or standardization in height, diameter, and smoothness. Accordingly, the prior art does not ensure that every sample is of the same height, diameter, and level. As a result, some concrete test cylinders are non-planar or have an oval diameter at the top of the mold. Accordingly, the accuracy of the test of the concrete test cylinder is reduced since the overall compressive strength of the concrete test cylinder can be erratic due to distribution caused by handling or transportation of the concrete test cylinder. Therefore, there exists a need in the art to improve the uniformity of a concrete test cylinder through the use of an efficient and cost effective product.
Nothing in the prior art provides the benefits attendant with the present invention. Therefore, it is an object of the present invention to provide an improvement which overcomes the inadequacies of the prior art devices and which is a significant contribution to the advancement of the art.
SUMMARY OF THE INVENTION
The above mentioned disadvantages and draw-backs of the prior art are alleviated or greatly overcome by a concrete test cylinder mold which is especially designed and adapted to produce reliable concrete test cylinders. The concrete test cylinder molds of the present disclosure are made from expandable polystyrene, and are formed of sufficient thickness on the top, side and bottom to hold the concrete cylinder test mix to a specific size while the mix cures. The expandable polystyrene is a natural insulator and can maintain the curing temperature far better than presently known molds. Additionally, as the expandable polystyrene has a minimal compressive strength, as compared to the compressive strength of the concrete, there is no need to remove the concrete test cylinder from the mold during compressive strength testing. The density of the expandable polystyrene is also selected to prevent the mold from absorbing water from the concrete test sample. The mold is configured to prevent tipping and to prevent injury to the concrete test cylinder during fabrication, handling, transport, and testing of the cylinder. In an exemplary embodiment, a release agent may be used to coat the mold to prevent the concrete from bonding to the mold during cure time; alternatively or additionally, a thin plastic sheet may be disposed on the inside surface of the mold to prevent such bonding.
These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects obtained by its use, reference should be had to the accompanying drawings and descriptive matter, in which there is illustrated and described preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of these and other objects of the present invention, reference will be made to the detailed description of the present invention which is to be read in association with the accompanying drawings, wherein:
FIGS. 1 and 2 are schematics depicting an exemplary test cylinder mold;
FIG. 3 is a schematic depicting a longitudinal section of the test cylinder mold depicted in FIGS. 1 and 2 ;
FIG. 4 is a schematic depicting an elevational view of a portion of the test cylinder mold depicted in FIGS. 1-3 ;
FIG. 5 is a schematic depicting an elevational view of a bottom side of the test cylinder mold depicted in FIGS. 1-3 ;
FIG. 6 is a schematic depicting a longitudinal section of the test cylinder mold depicted in FIGS. 1-3 ;
FIG. 7 is a schematic depicting an elevational view of a top side of an exemplary lid;
FIG. 8 is a schematic depicting an elevational view of a bottom side of the lid depicted in FIG. 4 ;
FIGS. 9 and 10 are schematics depicting an exemplary heat shield;
FIG. 11 is a schematic depicting an elevational top view of a portion of the exemplary heat shield depicted in FIGS. 9 and 10 ;
FIG. 12 is a schematic depicting an elevational bottom view of a portion of the heat shield depicted in FIGS. 9 and 10 ;
FIG. 13 is a schematic depicting a longitudinal section of the heat shield depicted in FIGS. 11 and 12 ; and
FIGS. 14-16 are schematics depicting an exemplary cap for the heat shield depicted in FIGS. 11-13 ;
FIG. 17 is a schematic depicting a longitudinal section of an exemplary system; and
FIG. 18 is a schematic depicting an exploded view of the system depicted in FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
Disclosed herein is a concrete test cylinder mold that is specially configured to produce a concrete test cylinder that accurately and reliably reflects the properties of a concrete mix used at a work site for a particular construction. Further disclosed herein is a concrete test system comprising a concrete test cylinder mold and a concrete test cylinder, wherein the concrete test system may be subjected to compression testing useful in determining the compressive strength of the concrete test cylinder. Further disclosed herein is a concrete test assembly useful in forming the concrete test cylinder, wherein the assembly comprises the concrete test cylinder mold, the concrete test mix, and a heat shield. The heat shield is specially designed to further insulate the concrete test mix during cure of the concrete test mix.
The inventive concepts shall be more particularly described with reference to the drawings, wherein it is to be understood that the invention is not to be limited thereby, but shall include all modifications and variations thereto as would be evident to a person of ordinary skill in the art upon reading the present disclosure.
Referring to FIGS. 1-6 , an exemplary concrete test cylinder mold 10 comprises a main body 12 . Main body 12 has a generally frusto-conical shaped side wall 14 having an exterior side 15 oppositely situated to an interior side 17 , and an anterior terminal end 21 oppositely situated to a posterior terminal end 25 . Side wall 14 tapers inwardly as it extends from posterior terminal end 25 to anterior terminal end 21 , and, therefore, posterior terminal end 25 has an outer diameter greater than an outer diameter of anterior terminal end 21 . Main body 12 further comprises a generally cylindrical-shaped chamber 27 surrounded by interior side 17 and which extends the length of interior side 17 .
Main body 12 further comprises a plurality of grooves 30 . Each of the grooves of plurality 30 is formed through an outer edge 22 of anterior terminal end 25 and extends longitudinally on exterior side 15 of side wall 14 short of extending through posterior terminal end 25 . In a preferred embodiment, the grooves of plurality 30 are radially and regularly spaced around exterior side 15 of main body 12 , and are formed parallel with one another. Plurality of grooves 30 assists in the removal of the concrete test cylinder from mold 10 , such as may be desired after the concrete test cylinder has been tested for compressive strength.
Concrete test cylinder mold 10 further comprises a base 32 . Base 32 comprises a substantially circular-shaped body having a top side 51 oppositely situated to a bottom side 53 and joined thereto via a side wall 55 that is contiguously formed with and substantially perpendicular to top and bottom sides 51 and 53 . Side wall 55 comprises an outer diameter greater than an outer diameter of side wall 14 . Top side 51 is contiguously and coaxially formed with posterior terminal end 25 of side wall 14 , such that side wall 14 is recessed relative to side wall 55 .
Main body 12 and base 32 are formed of expanded polystyrene. In an exemplary embodiment, the expandable polystyrene has a density of about 1.5 pounds per cubic foot. Furthermore, in an exemplary embodiment, the expandable polystyrene used to form mold 10 comprises beads having a range in diameter of about 0.063 inch to about 0.188 inch, wherein about 0.063 inch to about 0.125 inch is more preferred, and about 0.063 inch to about 0.100 inch is especially preferred. The expandable polystyrene is preferably formed of a modified grade of expandable polystyrene, and, hence, has fire retardant properties.
Referring to FIGS. 7 and 8 , concrete test cylinder mold 10 may further comprise a lid 100 which may be secured over anterior terminal end 21 of main body 12 . Lid 100 comprises a generally circular shaped body 102 having a top face 104 oppositely situated to a bottom face 106 . Lid 100 further comprises an annular shaped side wall 108 . Side wall 108 comprises an interior side 110 contiguously formed with an outer perimeter of bottom face 106 , and an exterior side 112 contiguously formed with an outer perimeter of top face 104 . An annular-shaped bottom wall 114 is contiguously formed with and positioned transversely to side wall 108 . Bottom wall 114 comprises a sloped portion 115 contiguously formed with a substantially planar portion 117 , wherein sloped portion 115 is also contiguously formed with interior side 110 and slopes upwardly from interior side 110 towards substantially planar portion 117 . Substantially planar portion 117 is contiguously formed with exterior side 112 and is parallel to top and bottom faces 104 and 106 . A space 116 is formed between and extends from bottom face 106 and bottom wall 114 .
Referring to FIG. 3 , lid 100 is configured and dimensioned such that when received by concrete test cylinder mold 10 , side wall 108 overhangs exterior side 15 of side wall 14 of mold 10 , interior side 110 of side wall 108 physically abuts exterior side 15 of side wall 14 , and bottom face 106 physically abuts anterior terminal end 125 . Bottom face 106 and top side 51 of base 32 are preferably in parallel alignment with one another to thereby ensure that the top and bottom sides of the concrete test cylinder formed within mold 10 are parallel with each other, thereby assisting in the creation of a uniformly shaped concrete test cylinder.
To form the concrete test cylinder, a concrete mix is poured into chamber 27 of mold 10 . The concrete mix may be evenly distributed within chamber 27 via a rod member as is conventionally known in the art. Lid 100 may be positioned on main body 12 of mold 10 as described above, and the concrete mix may be allowed to cure to form the concrete test cylinder.
In an exemplary embodiment, prior to placement of the concrete mix into mold 10 , at least one of main body 12 , base 32 , and lid 100 , and more preferably at least main body 12 of mold 10 , is coated with a release agent. The release agent serves to lubricate the expanded polystyrene. Additionally or alternatively, a thin plastic sheet may be placed on the inside surface of at least one of main body 12 , base 32 , and lid 100 of mold. Either or body of the release agent and the thin plastic sheet serves to prevent the concrete from sticking to mold 10 during the concrete's curing time within mold 10 .
The mold described herein protects the concrete mix inside the mold from temperature swings and from damage during handling. The density of the expandable polystyrene used to form the mold is high enough to prevent the expandable polystyrene from drawing water away from the concrete mix. Standard compressive tests can be performed on the mold and the concrete test cylinder formed therein using the same procedures as are done with traditionally used plastic or metal containers. The ability of the heat of hydration of the concrete while curing in the mold formed of expandable polystyrene allows the temperature of the concrete mix to cure at a more uniform temperature for a longer period of time as compared to the temperature of concrete cured in conventional molds, particularly when the molds are exposed to temperatures below 32 degrees Fahrenheit, as the expandable polystyrene maintains the heat of hydration within the mold during curing.
An outer protective heat shield formed of expandable polystyrene can provide an additional method to maintain the concrete cylinder at a temperature higher than current cylinder designs under cold weather conditions. Accordingly, further disclosed herein is a heat shield that is specially designed to be used in combination with the mold disclosed herein to further enhance the conditions under which the concrete test cylinder is formed, and to, thereby, protect the integrity of the concrete test cylinder during its formation.
Referring to FIGS. 9-13 , an exemplary heat shield 200 comprises a generally cylindrical shaped body 202 having a side wall 204 . Side wall 204 has an anterior terminal end 203 oppositely situated to a posterior terminal end 205 . Side wall 204 further has an exterior side 206 oppositely situated to an interior side 208 , wherein interior side 208 surrounds a chamber 210 . Body 202 further comprises an open-ended top side 212 contiguously formed with anterior terminal end 203 and having an opening 209 coaxial with chamber 210 . Top side 212 has an outer edge 214 oppositely situated to an inner edge 216 , wherein inner edge 216 is contiguously formed with interior side 208 and outer edge 214 is contiguously formed with exterior side 206 . Posterior terminal end 205 turns substantially perpendicularly inwardly towards chamber 210 to form a bottom side 220 of bottom 202 . Bottom side 220 turns substantially perpendicularly away from top side 212 to form a footing 224 .
Footing 224 has a lower substantially ring-shaped member 225 . Member 205 comprises a top side 226 oppositely situated to a bottom side 228 , and a substantially annular-shaped side wall 207 contiguously formed with top and bottom sides 226 and 228 and positioned transversely thereto. Top side 226 is coplanar with bottom side 220 of body 202 . Side wall 207 comprises an exterior side 234 oppositely situated to an interior side 232 . Exterior side 234 is directed to exterior side 206 and is recessed relative thereto, thereby forming an outer flange 236 between exterior side 206 and exterior side 234 . Member 205 further comprises an opening 230 formed through top and bottom sides 226 and 228 and immediately surrounded by interior side 232 , wherein opening 230 is coaxial with chamber 210 and has a diameter less than the diameter of chamber 210 .
Heat shield 200 further comprises an interior annular member 238 which is contiguously and continuously formed along a perimeter of interior side 208 of side wall 204 , and which is contiguously and continuously formed with top side 226 of footing 224 . Interior annular member 238 comprises an interior side wall 248 contiguously formed with top side 226 of footing 224 and which extends substantially perpendicularly therefrom towards top side 212 of heat shield 200 . Interior annular member 238 further comprises a top side 244 which is perpendicularly formed with interior side wall 248 and that is contiguously formed with interior side 208 of side wall 204 .
Referring to FIGS. 14-16 , heat shield 200 may further comprise a cap 260 which may be secured to body 202 of heat shield 200 . Cap 260 comprises a generally circular shaped upper member 262 having a top side 264 oppositely situated to a bottom side 266 and joined thereto by a side wall 268 . Centrally disposed and contiguously formed on bottom side 266 is a lower member 270 having a generally annular shaped configuration. Lower member 270 has an annular shaped exterior side wall 272 oppositely situated to an annular shaped interior side wall 274 .
Cap 260 further comprises a generally annular shaped lip 278 contiguously formed with lower member 270 and positioned opposite to upper member 262 . Lip 278 comprises a face 280 that is directed opposite to upper member 262 and transversely to side walls 272 and 274 of lower member 270 , and which is recessed relative to exterior and interior side walls 272 and 274 . Cap 260 further comprises a space 276 immediately surrounded by interior side wall 274 and that extends from bottom side 266 of upper member 262 to face 280 of lip 278 .
Upper member 262 comprises an outer diameter greater than an outer diameter of lower member 270 . Accordingly, exterior side wall 272 of lower member 270 is recessed relative to side wall 268 of upper member 262 .
Cap 260 further comprises a plurality of channels 284 . Each channel of plurality 284 extends from top side 264 of upper member 262 to face 280 of lip 278 , and through lower member 270 . Plurality of channels 284 allows air to enter an air space between exterior side 15 of mold 10 and interior side 208 of heat shield 200 . This embodiment is particularly useful where air activated heat pads are used as an additional source for heat as will be described below in further detail.
In an exemplary embodiment, heat shield 200 , which includes body 202 , footing 224 , interior annular member 238 , and cap 260 , comprises expandable polystyrene, wherein an exemplary expandable polystyrene has a density of about 1.5 pounds per cubic foot, and has the same properties as was described above with reference to mold 10 .
Referring to FIGS. 17 and 18 , an exemplary system 300 comprises concrete test cylinder mold 10 and heat shield 200 . Heat shield 200 receives mold 10 through chamber 210 . When properly disposed within body 202 of heat shield 200 , bottom side 53 of base 52 of mold 10 is disposed on top side 226 of footing 224 such that side wall 55 of base 52 physically abuts interior side wall 248 of interior annular member 238 . An air space 302 is created between interior side wall 208 of heat shield 200 and exterior side 15 of mold 10 . Cap 260 is positioned atop body 202 such that bottom side 266 of cap 260 physically abuts top side 212 of body 202 and anterior terminal end 21 of mold 10 , and such that lower member 270 of cap 260 extends within air space 302 such that exterior side wall 272 physically abuts interior side 208 of body 202 and interior side wall 274 physically abuts exterior side 15 of mold 10 . Plurality of channels 284 are in fluid communication with air space 302 .
In another exemplary embodiment, system 300 may further comprise one or more heating pads that may be disposed within air space 302 to input thermal energy into system 300 to maintain proper curing temperature within the system as the concrete poured within mold 10 cures. The heating pads may be activated by, e.g., at least one of electrical, mechanical means, and chemical means. Exemplary chemically-activated heating pads may comprise at least one of, e.g., iron powder, activated carbon, remiculite, a salt, and the like. When the one or more chemically-activated heating pads are exposed to air, which enters system 300 via holes 284 , a chemical reaction occurs which produces heat. Alternatively or additionally, the one or more chemically-activated heating pads may have one or more pouches that start the heating process when the materials within the one or more pouches are placed into air space 302 .
The concrete test cylinder mold of the present disclosure has several advantages over currently known molds. For example, the expandable polystyrene used to form the mold comprises a density which has been optimized to prevent the mold from absorbing water in the concrete test mix.
Additionally, use of expandable polystyrene in the formation of the mold provides an insulating effect, thereby insulating the concrete test mix from dramatic fluctuations in temperature, thereby maintaining the integrity of the concrete test mix during its formation into the concrete test cylinder. Additionally, ASTM standards require that the concrete test cylinder formed within a mold be allowed to cure for up to 48 hours at an exterior temperature range of between about 60 degrees Fahrenheit to about 80 degrees Fahrenheit. Therefore, as expandable polystyrene has strong insulating properties, the molds disclosed herein may be used to cure the concrete test cylinders at any time of the calendar year as they readily can meet the ASTM's temperature range.
In addition to the benefits derived from the use of expandable polystyrene, the mold of the present disclosure has certain advantages based upon its physical design. For example, the mold of the present disclosure comprises a base that is configured to rest firmly on the ground when in use and to resist tipping over when the concrete test mix is poured into the mold. Additionally, the mold is constructed to survive rough handling during consolidation of the poured concrete mix into the mold, e.g., when the concrete mix is subjected to blows from a rod used to mix and consolidate the concrete test mix in the mold, and during the removal, transport, and delivery of the mold and concrete mix to the testing facility, and to protect the concrete test cylinder from damage. Nonetheless, in an exemplary embodiment, the mold may include a support member disposed within the chamber of the mold and positioned on the top side of the base. The support member is designed to protect the mold from forces sustained by the mold when the tamping rod is used with excessive force. In an exemplary embodiment, the support member comprises a generally disc-shaped configuration and is formed of a plastic material.
The mold is further designed to facilitate the placement and visibility of a label thereon, wherein the label bears information relevant to the testing and/or identification of the concrete test cylinder. Additionally, the lid and the base of the mold are configured to assure that the surfaces are parallel to one another once the cover is placed on the cylinder thereby ensuring that the concrete test cylinder has a uniform configuration. Additionally, the lid is designed to fit firmly on the mold to prevent accidental dislodgement.
As the compressive strength of the mold formed out of expandable polystyrene is minimal and insignificant compared to the compressive strength of the concrete test cylinder (i.e., the compressive strength of the concrete test cylinder is at a minimum of about 281 times stronger than the compressive strength of the mold), when the concrete test cylinder is ready for testing, the complete system, e.g., the mold and the concrete test cylinder, may be placed in a conventionally known and used compression testing machine and the compressive strength may be tested by conventional means. For example, an exemplary method for testing the compressive strength of the concrete test cylinder includes providing a compression testing machine having rings located at the top and bottom of the machine, wherein, during compression, the rings applies a uniform load to the concrete test cylinder. The compression testing machine may be hydraulic and may gradually add weight to the top of the concrete test cylinder and the gauge measures the weight that the concrete test cylinder is bearing. The gauge then measures the weight at which the concrete test cylinder fails, which is the weight at which the concrete test cylinder cracks and breaks. Different compositions of concrete made for different applications have different weight requirements, which may range from about 1,000 pounds per square foot to about 10,000 pounds per square foot.
The foregoing description of the preferred embodiment of the invention is to be considered as illustrative and not as limiting. Various other changes and modifications will occur to those skilled in the art for performing substantially the same function, in substantially the same way, to achieve substantially the same result without departing from the true scope of the invention as defined in the appended claims. | A concrete test cylinder mold formed of expandable polystyrene and which is used to form geometrically uniform concrete test cylinders that accurately reflect the structural properties of the concrete mix used to form the test cylinders despite fluctuations in temperature to which the test cylinder may be exposed during formation within the mold. The mold is constructed and configured such that compression testing of the concrete test cylinder may be conducted while the cylinder is still in the mold. A specially designed heat shield may be used in unison with the concrete test mold to form, at least in part, a system by which heat further may be retained within the system during formation of the concrete test cylinder. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a goods-handling door of the type having a raisable curtain that comprises a deformable insulating curtain. Such doors are to be found in industrial premises, where they serve to keep different spaces apart in factories or in warehouses. There exist systems for raising the curtains in such doors quickly (by folding them up concertina-like or by winding them up), thereby enabling vehicles to pass through the doors without being significantly slowed down.
2. Description of Prior Art
In such an application, it is important to be able to see through the curtain so as to avoid collisions between vehicles moving towards the door from opposite sides. Simultaneously the curtain is required to provide good insulation, both thermally and acoustically.
European patent EP 0 076 349 discloses a door curtain that satisfies those two requirements. It is made up of two transparent flexible skins that are held together in spaced-apart regions, thereby defining pockets between them. The various pockets are filled with strips of insulating material such as polyurethane foam. The strips are pierced by holes to provide a degree of visibility.
That type of curtain suffers from a drawback that stems from the mechanical properties of foam. The foam is not mechanically strong and it becomes compacted within the pockets under the effect of its own weight. To remedy that problem, it is the practice to use panels of foam that extend over the entire curtain. The two skins disposed on either side are then pinched together in spaced-apart regions, thereby obtaining a kind of quilting effect.
Other known curtains suffer in turn from a drawback that stems from the mechanical properties of foam. This time it is the poor ability of foam to withstand repeated deformation that presents difficulties. Goods-handling doors of the kind described are designed to open and close often, e.g., in the range 100 to 1,000 times per day. As a result, the foam, which is folded or bent on numerous occasions, very quickly starts to tear. This happens in particular around the bridges left between the visibility holes or at the places where the skins are pinched together. The appearance of a door is quickly spoiled in this way.
The problem which arises is that of finding an insulating deformable curtain that has better endurance than prior art curtains. It must also be compatible with visibility requirements.
SUMMARY OF THE INVENTION
Document DE-A-3 248 083 discloses a goods-handling door including a movable curtain having two side edges, which curtain includes two parallel waterproof flexible skins sandwiched over horizontal rectilinear spacers that are spaced apart from one another in the vertical direction of the curtain, and which are spaced apart so as to define an intermediate space between the two skins which is filled with air. However that disposition does not prevent heat exchange by convection at the edges of the curtain between outside air and the air contained in the intermediate space since the two skins are not fixed together at the side edges of the curtain.
An object of the present invention is to avoid that drawback.
The present invention provides a goods-handling door comprising a moving curtain having two side edges, said curtain comprising two airtight flexible skins lying parallel to each other and having horizontal rectilinear spacers sandwiched between them, the spacers being spaced apart from one another up the curtain and defining air-filled intermediate spaces between the two skins, the door being characterized in that each spacer is constituted by a section member of substantially U-shaped or V-shaped section having a bottom and two branches, the two skins being applied on opposite sides of the spreaders, extending apart from each other over the branches of each spacer so as to delimit the intermediate spaces, and coming towards each other over the bottoms of the spacers, thereby separating the intermediate spaces, the spreaders being disposed in pairs with the spreaders in each pair being spaced apart by a first distance, the pairs of spreaders being spaced apart from one another by a second distance which is greater than the first distance, the respective bottoms of the two spacers in a pair of spacers facing each other and the branches of each spacer in a pair pointing away from the other spacer in the same pair, the two skins remaining close to each other between the two spacers in each pair, and the two skins being fixed to each other in substantially airtight manner along the two side edges of the curtain.
In a preferred embodiment, the two spreaders in a pair are interconnected by a web, the two skins bearing against opposite sides of the web. To avoid the skins defining the intermediate space filled with air being subjected to great stress while the curtain is being folded up or wound up, bending of the spreader webs is to be encouraged. In the context of the present invention this can be done by making said webs out of a flexible material or else by providing hinges therein. In this way, the two spreaders of a pair can move towards each other while the skins delimiting the intermediate space between two consecutive pairs behave like plates that are practically rigid, since the air trapped therein opposes deformation thereof.
Such a structure is particularly adapted alternative embodiment easy manufacture of the curtain. For example, in a known method, one of the skins is laid on a worksurface. The worksurface includes recesses each adapted to receive one of the faces of a pair of spreaders. The skin lines the recesses, and then the spreaders are placed thereon, and then the second skin is laid over the spreaders and over the first skin. It then remains to secure the skins to the pairs of spreaders, e.g. at the webs thereof. Welding techniques using heat or ultrasound, or gluing techniques may be used for this purpose. Finally, it may be advantageous to reinforce the fastening zones by applying protective strips to either side of the curtain, which strips may be transparent or otherwise.
In a variant, the material between the branches of the U-shape or of the V-shape is resilient to a greater or lesser extent. The spreaders may also further include at least one partition that extends from the bottom of the U-shaped or V-shapes between the branches thereof, with another skin being secured to said partition so as to compartmentalize the intermediate spaces lengthwise. The presence of at least one third skin in such a curtain is advantageous for insulation purposes. It serves to maintain a plurality of separate layers of air within the curtain. For a given thickness of curtain, heat exchange by convection across the intermediate space between the skin is thus reduced. As a result the temperature gradient that the curtain can preserve is increased. This disposition also contributes to obtaining better sound-proofing.
The use of this type of curtain in making goods-handling doors further presents other advantages. For example, the spreaders confer relative stiffness to the curtain when it is deployed. This enables the curtain to withstand wind, even when the curtain is large in size. However, such stiffness remains limited, such that when a shock is applied to the curtain, it deforms temporarily, thereby avoiding permanent damage. In other words, most of the qualities required of a goods-handling door are thus achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention appear on reading the following detailed description given with reference to the accompanying drawings which show embodiments of the present invention by way of example. Elements in the drawings are denoted by like numbers throughout. In the drawings:
FIG. 1 is a perspective view of a portion of a curtain for a goods-handling door of the present invention;
FIG. 2 shows a detail of the FIG. 1 curtain, this detail comprises a pair of spreaders shown in cross-section;
FIGS. 3 to 5 are cross-sections similar to FIG. 2, but applicable to other spreaders that can be used in the present invention;
FIG. 6 is a perspective view of a goods-handling door of the present invention;
FIG. 7 is a cross-section through the door of FIG. 6 when its curtain is raised; and
FIGS. 8 to 10 are cross-sections similar to those of FIGS. 2 to 5, but applicable to other spreaders suitable for use in the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 shows a curtain 5 which, in accordance with the present invention, comprises two parallel flexible skins 1 and 2. In places, the two skins are at a distance apart from each other, thereby leaving an intermediate space 4 between them. To this end, spreaders 10 are interposed between the two skins. In the embodiments of the invention shown in the accompanying drawings, the spreaders 10 are rectilinear and are disposed parallel to one another.
They are disposed in pairs 15, with one of these pairs being more clearly visible in the cross-section of FIG. 2 which shows a first embodiment of a spreader 10a. The spreader comprises a section member having a U-shaped section including a bottom (that is rounded in the present case) together with two arms 11a and 12a. The bottoms of the two spreaders 10a in a pair face each other. They are connected together in this case by a web 14a.
Other embodiments of the spreaders 10 are shown in FIGS. 3 to 5. They all have in common the use of a web generally denoted 14 for interconnecting the bottoms of the two spreaders generally denoted 10 in a pair generally denoted 15, but the spreaders 10 now have V-shaped cross-sections. In FIG. 3, the V-shape has two branches denoted 11 and 12. In FIG. 4, the V-shape is solid. In FIG. 5, the space between the two branches denotes 11 and 12 of the V-shape is filled with a material that is advantageously resilient. In any event, the section members forming the spreaders denoted 10 can be manufactured in long lengths by means of a die. In other words, they are particularly cheap to manufacture. (Hereinafter, elements in the various Figures will be understood by including a letter subscript indicative of the corresponding Figure after each number).
The skins 1 and 2 press against opposite sides of the spreaders 10 in pair 15. The skins are thus held apart adjacent to the branches 11 and 12 of the U-shape or of the V-shape. In contrast, they come closer together on either side of the bottoms of the spreaders and they then press against opposite sides of the web 14. As a result the intermediate space 4 is interrupted each time there is a pair 15 of spacers 10.
In order to enable such a curtain 5 to perform its insulation function, it is important for the intermediate space 4 to remain filled with air. This makes it necessary firstly to use skins that are sufficiently airtight. In addition, the space 4 is closed in airtight manner along the side edges of the curtain 5. Finally, it is preferable for the interruptions in the intermediate space 4 level with the pairs 15 of spreaders 10 to be airtight as well. This can be achieved, for example, by welding or by gluing the skins 1 and 2 to the spreaders 10 or to the web 14 or to both of them. Where necessary, protective strips 21 and 22 may be applied in like manner on either side of the sandwich formed by the two skins and the pairs of spreaders, as shown in FIG. 2.
Insofar as the interruptions in the intermediate space 4 provide less insulation, it is advantageous to keep them small. The distance between the spreaders 10 in a pair 15 consequently needs to be considerably smaller than the distance between two opposing spreaders 15.
The same remark applies to achieving visibility through the curtain. Visibility can easily be achieved by using skins that are transparent (e.g. made of PVC). The pairs 15 of spreaders 10 are made of a material that is not necessarily transparent (plastic, metal alloy, wood, etc.). It is therefore appropriate to keep them spaced apart as far as possible.
However, when the side edges of the curtain 5 are closed to form closed air pockets, this disposition is in contradiction with the requirements that the curtain 5 as a whole should be deformable. The air trapped in the intermediate spaces 4 opposes bending of the skins 1 and 2 that delimit the spaces 4. This type of curtain therefore provides for the pairs 15 of spreaders to be bendable. For the embodiments mentioned so far with reference to FIGS. 2 to 5, this means that the web 14 must be sufficiently flexible or else a hinge (not shown) must be provided therein so as to allow the two spreaders 10 in a pair 15 to move towards each other.
FIG. 6 shows a raisable curtain door 100 using the curtain 5 as described above. The curtain-raising system may be constituted by a shaft located beneath the lintel 103 of the door 100 and driven by an electric motor, in particular. When the curtain 5 is down, e.g. hanging from the shaft, its spreaders 10 are horizontal. It is therefore suitable for being rolled up onto the shaft. In which case (not shown), it is preferable for the distances between the pairs 15 of spreaders 10 to be smaller, the closer the spreaders are to the shaft. This facilitates deformation of the curtain into a roll that does not take up too much space.
The raising system may also be constituted by straps 6 running vertically over one face of the curtain 5. The curtain 5 should also be provided with horizontal stiffeners 16 that engage the straps 6. To do this, D-rings 7 may be secured to the stiffeners 16, with the straps 6 being passed through the D-rings so that they can slide relative to the stiffeners while continuing to be guided thereby. The straps 6 are advantageously fixed to the bottom of the curtain 5, and they are organized to be wound onto a shaft disposed above the curtain but beneath the lintel 103 of the door 100, and driven by an electric motor. Under such circumstances, the curtain 5 is raised by being folded up concertina-like.
The cross-section of FIG. 7 shows how the curtain 5 can be folded up. The intermediate spaces 4 remain more or less undeformed between the various breaks therebetween, while the webs 14 bend, in each case between the spreaders 10 of a pair 15. FIG. 7 also shows that the stiffeners 16 may be constituted by bars that are secured to the webs 14. The curtain 5 requires one stiffener 16 for every other pair 15 of spreaders 10 so as to ensure that the straps 6 cause the curtain to fold up appropriately. As shown in FIG. 6 (see the cutaway portion of the upright 101 of the door 100), the stiffener bars 16 advantageously extend beyond opposite sides of the curtain 5 so as to engage in slideways 102 located on either side thereof, thereby serving to guide the curtain.
FIGS. 8 and 9 are cross-sections through other embodiments of the pairs 15 of spreaders 10 which are even more suitable for bending for folding purposes as described above. The spreaders 10 are constituted by solid section members in this case. They are advantageously obtained from section members of rectangular section, with one of the long sides of the rectangular section having been pinched so as to obtain a shape reminescent of a curly brace symbol. Within a pair 15, the pointed middles of the two curly braces of the spreaders 10 point towards each other.
Unlike the other embodiments disclosed herein, these two embodiments do not have a web 14 between the spacers 10. It is the two skins 1 and 2 that are sandwiched around the spreaders 10 that interconnect them. To do this, the skins bear directly against each other over the entire distance between the two spreaders of a pair. A bar 16 used for stiffening purposes may be inserted between the skins 1 and 2, as shown in the section of FIG. 9.
Finally, FIG. 10 shows another embodiment of the spreaders 10. The section is comparable to that of FIG. 2 and it can be seen that there is now a partition 13 that extends between the branches 11 and 12 of each spreader 10. The partition may project from the bottom of the corresponding U-shape so as to be parallel with the web 14. The partition 13 can then be used for securing (by gluing, welding, etc.) an intermediate skin 3 which then subdivides each intermediate space 4 into two airtight longitudinal compartments. The air contained in the intermediate space 4 is thus split into two layers. This disposition limits convective heat exchange through the intermediate space 4 such that for a given thickness, the curtain 5 provides greater insulating power. There is nothing to prevent the number of layers of air being increased by increasing the number of intermediate skins, each being secured to a corresponding partition projecting from the bottom of the spreader between its branches.
This latter type of curtain 5 is also advantageous for sound proofing. Under such circumstances, it may be even more effective to use strips of relatively rigid plastic material for splitting up the intermediate spaces into compartments. However assembly is then more complicated, thus making the resulting curtain more expensive.
Although the curtain 5 is described above solely in the context of a raisable curtain door, it may also be implemented in a curtain door that is horizontally movable, in which case the spreaders 10 are preferably disposed vertically. | A goods-handling door for separating different spaces in factories or warehouses includes a curtain that can be raised by being wound up or by being folded up concertina-like. The curtain is insulating both with respect to heat and with respect to noise, while being transparent so that one vehicle can be seen by another if they approach the door from opposite sides. The door includes two airtight flexible skins that lie parallel to each other and that sandwich spreaders between them. The spreaders are spaced apart and define intermediate spaces between the two skins. The spaces are filled with air, which provides the required insulation. Since the two skins are transparent, the door is transparent in the vicinity of the intermediate spaces. | 4 |
[0001] This application is related to U.S. patent application Ser. No. 14/078,780, Nov. 13, 2013, which claims the benefit of U.S. Provisional Application No. 60/726,144, filed Nov. 14, 2012. The entire disclosure of which is incorporated by reference herein.
[0002] This application is also related to U.S. patent application Ser. No. 12/649,800, now U.S. Pat. No. 8,281,800, filed Dec. 20, 2009, which is a continuation of U.S. patent application Ser. No. 12/115,223, now U.S. Pat. No. 8,151,821, filed May 31, 2012, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/947,902, filed Jul. 3, 2007, the entire disclosures of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0003] Embodiments of the present invention are generally related to devices for securing faucets, wall hydrants, or other fluid delivery devices, to a building surface. One embodiment of the present invention is directed to a mounting assembly that secures a wall faucet to an uneven building surface.
BACKGROUND OF THE INVENTION
[0004] Wall faucets are often found mounted to the exterior of a dwelling. Wall faucets include a flange designed to interconnect to an exterior dwelling surface. The wall faucet also includes a fluid delivery tube interconnected to the dwelling's water source on one end and to a valve-controlled hose bib at the other end. Traditionally, flanges are directly mounted to the exterior building surface, e.g., siding, which may provide a strong and stable interface for the wall faucet flange. Siding, however, is not the only common exterior building surface employed. For example, often wall faucets must be interconnected to stone, brick, mortar, stucco, etc., which is difficult to interconnect to, and which may not provide a sound wall faucet interconnection.
[0005] Commonly, a plurality of elongated screws are used to interconnect the faucet flange to a mounting surface, which is acceptable if the faucet flange is abutted to the mounting surface. If, however, the faucet flange must be spaced from the mounting surface, because, for example, a stone exterior surface is present, longer screws must be used to reach the interior surface. This mounting method results in an unstable wall faucet as loads are reacted some distance from the connection point. One of ordinary skill in the art can envision that a hose interconnected to the wall faucet is subject to forces generated by moving or pulling the hose. Over time, these forces will weaken the interconnection of the faucet to the dwelling and may cause the faucet flange to dislocate from the exterior building surface. If a faucet assembly should separate from the dwelling, water, insects, or other outdoor contaminants can enter the dwelling. The wall faucet could also separate from the fluid supply line, thereby causing water/mold damage. To address these issues, grout, mortar, or other formable substances are used to secure the fluid tube and faucet flange to the exterior building surface. This additional work increases the time and cost of installation, and is a temporary fix.
[0006] Devices in the prior art have been used to offset a faucet flange from an interior building surface to accommodate a brick exterior. For example, the hose bib supporter of PerfectSett made by JCT Innovations, LLC includes a rectangular shaped face offset from a plate interconnected to the outer surface of the wall, board, or sheathing of a building. The face provides a location for interconnection of a faucet assembly. One drawback of the PerfectSett device is it does not provide selective adjustments and only accommodates exterior building surfaces of a predetermined and consistent thickness.
[0007] Thus it is a long felt need in the field of outdoor plumbing to provide a stable interconnection scheme for attaching wall faucets to the exterior surface of a dwelling. The following disclosure describes an improved system and method for interconnecting a wall faucet to an exterior building surface that addresses and overcomes the problems of the prior art.
SUMMARY OF THE INVENTION
[0008] Some aspects of the various embodiments of the present invention described herein can generally be categorized as improvements or modifications to the inventions described in the U.S. Patent Application Publication No. 2014/0131545, which is the publication of U.S. patent application Ser. No. 14/078,780. That is, the concepts discussed herein can be used with the inventions and concepts described in U.S. Patent Application Publication No. 2014/0131545.
[0009] It is one aspect of embodiments of the present invention to provide a wall faucet support. One embodiment of the present invention employs a mounting sleeve associated with a fluid tube of the wall faucet. The mounting sleeve is interconnected to a supporting bracket that interconnects to an interior building surface, thereby increasing wall faucet stability. The mounting sleeve secures the fluid delivery tube and provides a location for interconnection of a faucet flange by way of a sleeve flange. Some embodiments of the present invention employ a selectively adjustable mounting sleeve such that the faucet flange may be selectively spaced from the outer surface of the dwelling and not interconnected directly to it. Other embodiments contemplate a fixed distance between the sleeve flange and the bracket, which is ideal for accommodating exterior building surfaces with consistent thicknesses, e.g., brick.
[0010] It is another aspect of some embodiments of the present invention to provide a system for interconnecting a wall faucet to a building that increases mount stability. More specifically, embodiments of the present invention employ a bracket interconnected to an interior (or exterior) building surface. For example, the bracket of the invention may be interconnected to the inside or outside of any building member, such as 2×4 studs, sill plates, a concrete basement wall, a foundation member, headers, sheathing, etc. Interconnecting a bracket to a structural element improves the stability of the faucet assembly. That is, as opposed to prior art systems that interconnect a the faucet flange directly to an exterior building surface, the mounting sleeve employed in various embodiments of the present invention is maintained within a bracket, thus supplying a sufficient support to the faucet assembly. In such a manner the above-identified issues related to interconnecting a faucet to mortar, rock, stone, bricks, stucco, etc., are reduced if not eliminated. The method and associated apparatus of embodiments of the present invention for securing a tube within mounting sleeve, which is then interconnected to a rigidly interconnected bracket, is superior over prior art methods and systems of interconnection.
[0011] It is another aspect of some embodiments of the present invention to provide a mounting system that allows for ease of faucet installation. More specifically, embodiments of the present invention may be installed before or after the siding or other exterior building surface is installed. The bracket that secures the mounting sleeve may be installed by the framers, siding installers, or plumbers. Guess work as to the location of the faucet is reduced. This aspect of the present invention is made possible because the faucet need not be initially installed to install the bracket and to locate the mounting sleeve. After installation of the mounting sleeve, it may be removed from the bracket and associated with the faucet tube and flange and interconnected to the bracket.
[0012] It is still yet another aspect of embodiments of the present invention to provide a mounting system and method that provides the ability to selectively adjust the location of the faucet. More specifically, embodiments of the present invention provide a mounting sleeve adapted to move in relation to a fixed bracket. This aspect of the invention ultimately allows for the flange of the faucet to be offset (in various dimensions, but particularly along an axis perpendicular from the dwelling wall) from an interior or exterior wall of the dwelling to accommodate the thickness and surface texture of exterior building material such as stone, etc. In operation, if the faucet is not located as envisioned relative to the exterior building surface, readjustments are possible that do not require extensive structural modifications as would be necessary with prior art systems.
[0013] It is another aspect of embodiments of the present invention to provide a faucet assembly attachment scheme that improves mounting options, wherein the faucet may be interconnected to an irregular surface easily. That is, as briefly described above; the mounting device of one embodiment includes an adjustable mounting sleeve that allows for selective adjustments of the location of the faucet flange, e.g., within a predetermined scope of dimensions from a first anticipated final position. Thus an installer can easily customize the location of the flange such that it is aesthetically pleasing and structurally stable. Embodiments of the present invention also employ a mounting sleeve with a measurement indication mechanism. Preferably, a linear scale is provided associated with each sleeve, e.g., imprinted thereon, molded thereto, etc., to facilitate the installation of a plurality of faucets about the exterior of a building. After one mounting sleeve is interconnected and correctly offset from a house, the remainder of mounting sleeves will be more quickly installed because the required offset is readily known by inspection of the linear scale. Installers will also be able to facilitate installation of mounting sleeves through experience by knowing generally how much offset should be used for a particular building surface, which will reduce time and cost of installing faucets.
[0014] Embodiments of the present invention employ components that can be easily replaced. For example, if after installing the mounting sleeve relative to the bracket it is found the offset is incorrect, quick adjustments may be made. More specifically, it is contemplated that the length of the mounting sleeve can easily made to accommodate unique sizes of bricks, stone, etc. If this is difficult due, for example, to debris or grout residing in the grooves of the mounting sleeve, it can be discarded and a second replacement mounting sleeve can be interconnected to the existing bracket.
[0015] It is yet another aspect of embodiments of the present invention to prevent water, debris, animals, insects, etc. from entering the dwelling through the faucet connection. That is, when a faucet of the prior art becomes loose or disconnects from the exterior of the dwelling, gaps form that allow the above-mentioned foreign objects to enter the dwelling. For example, gaps between the flange and the building surface allow moisture to penetrate between the faucet flange and the exterior building surfaces. Embodiments of the present invention provide a system and method that minimizes gaps between the external building surface and the faucet associated thereto. More specifically, as the mounting sleeve of embodiments of the present invention is of generally continuous shape (preferably cylindrical, but other shapes are contemplated), the installer can finish, with insulation, foam, mortar etc., up to the outer surface of the mounting sleeve, which reduces or eliminates gaps between the faucet assembly and the exterior building surfaces. A related aspect of the present invention is that the shape of the mounting sleeve and described finishing creates a cleaner appearance that is more aesthetically pleasing.
[0016] It is another aspect of the present invention that the embodiments described herein are constructed of common materials, such as plastic, steel, aluminum, rubber (or other flexible materials), vulcanized rubber, wood, or any other common building materials that comply with applicable building codes. Preferably, the mounting sleeve and associated bracket are made of rigid plastic, which is non-corrosive and provides the needed rigidity to secure the faucet assembly.
[0017] It is still yet another aspect of the present invention to provide a system that utilizes components that are customizable. More specifically, the mounting sleeves of embodiments of the present invention may be made of any color of plastic to blend in with the exterior building surface or wall faucet assembly, thereby adding to the aesthetically pleasing appearance of the finished assembly.
[0018] It is another aspect of embodiments of the present invention to provide a mounting sleeve that can accommodate faucets having flanges of various shapes. More specifically, some faucets possess a handle laterally offset from the faucet outlet whereby access to the handle is improved. To further increase access and to remove obstructions between the faucet and the faucet outlet, the outlet may be angled as well such that the flow of water from the faucet outlet is at an angle relative to the vertical direction. Faucets of this type also may include an elliptical or oval handle that allows the user to more easily grip and turn the handle. Thus, one embodiment of the present invention includes a flange interconnected to the mounting sleeve adapted to receive faucet flanges that are other than circular. More specifically, the faucets described above, often have an elongated flange to accommodate an enlarged housing wherein the faucet outlet and handle are interconnected thereto. One can appreciate that a mounting sleeve having a mounting sleeve having a circular flange would not adequately accommodate this enlarged flange, thus embodiments of the present invention include an enlarged flange of any shape that is customizable to a faucet flange. It is a related aspect of the invention to provide a generic faucet flange that accommodates more than one type, make or model of faucet. Alternatively, one of skill in the art will appreciate that the faucet flange may be customized to fit only a specific faucet.
[0019] It is another aspect of embodiments of the present invention to provide a wall faucet interconnection device, comprising: a mounting sleeve having a first end with a mounting flange and a second end, the mounting sleeve having a plurality of grooves positioned at least about a portion of an outer surface thereof; a bracket having a boss extending therefrom that interconnects with said mounting sleeve, said boss having a selectively deflectable tab that includes an end for selective engagement into a groove of said plurality of grooves; a locking ring that selectively interconnects to said boss, said locking ring restricting movement of said deflectable tab; and a seal with an inner portion that is adapted to interconnect to a fluid tube of the wall faucet to said mounting sleeve, and an outer portion that receives a clamp that compresses said seal about the fluid tube.
[0020] It is still yet another aspect of embodiments of the present invention to provide a faucet assembly mounting device, comprising: a mounting sleeve having a first end with a means for supporting a faucet and a second end; a bracket having a boss extending therefrom that selectively interconnects to said mounting sleeve, said boss having a member for selective engagement with said mounting sleeve; and a locking device operatively interconnected to said boss, said locking device restricting movement of said member.
[0021] It is another aspect of embodiments of the present invention to provide a wall faucet mounting system, comprising: a tube that includes a plurality of first locking members; a mounting bracket having a rear surface and an opening that extends through said mounting bracket; a bracket tube extending from said rear surface of said mounting bracket, wherein said bracket tube is in communication with said opening in said mounting bracket such that said tube is slidingly disposed within said mounting bracket, wherein said bracket tube comprises a first resilient member comprising a second locking member configured to releasably engage a respective one of said plurality of first locking members; and a locking device disposed about said bracket tube that restricts movement of said second locking members.
[0022] The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] 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 of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
[0024] FIG. 1 is an exploded perspective view of one embodiment of the present invention;
[0025] FIG. 2 is a perspective view showing the mounting sleeve one embodiment of the present invention interconnected to a wall; and
[0026] FIG. 3 is a partial side cross-sectional view showing one embodiment of the present invention interconnected to a wall.
[0027] To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein:
[0000]
#
Component
2
Mounting sleeve
6
Building surface
10
Bracket
14
Tab
18
Groove
22
Locking ring
26
Seal
30
Fluid tube
34
Wall faucet
38
Mounting sleeve Inner Diameter
42
Faucet flange
46
Mounting flange
50
Hole
54
Offset indicator
58
Hole
60
Fastener
61
Outer surface
62
Interior building surface
66
Boss
70
Flange
74
Inner boss surface
78
Slot
82
Clamp
84
Fluid supply interface
88
Inner seal portion
92
Outer seal portion
96
Seal inner diameter
98
Outer diameter
106
Groove
[0028] It should be understood that the drawings are not necessarily to scale, but that relative dimensions can be nevertheless be determined thereby. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0029] FIGS. 1-3 show the mounting sleeve 2 of one embodiment of the present invention and the components used to interconnect the mounting sleeve 2 to a building surface 6 . The mounting sleeve 2 selectively interconnects to a bracket 10 . The bracket 10 includes at least one tab 14 for selective engagement with a groove 18 or grooves in the mounting sleeve 2 , which fixes the mounting sleeve 2 to the bracket 10 . The mounting sleeve 2 is further secured to the bracket 10 by providing a locking ring 22 that prevents the tabs 14 from disengaging from the grooves 18 , which would allow the mounting sleeve 2 to slide freely relative to the bracket 10 . A seal 26 is used to interconnect a fluid tube 30 associated with a wall faucet 34 to the inner diameter 38 of the mounting sleeve 2 , which secures the wall faucet 34 to the mounting sleeve 2 . A faucet flange 42 of the wall faucet 34 is also interconnected to a mounting flange 46 of the mounting sleeve 2 .
[0030] The mounting sleeve 2 includes a mounting flange 46 at its first end adapted to interface with the faucet flange 42 associated with the wall faucet 34 . Accordingly, the mounting flange 46 includes a plurality of holes 50 or nut plates to receive fasteners (not shown) normally used to secure the faucet flange 42 to a wall, for example. Further, the mounting sleeve 2 includes offset 54 indicators that allow individuals to assess the distance between the mounting flange 46 and the bracket 10 . In this fashion, the mounting flange 46 is offset from the bracket 10 to accommodate the exterior building surfaces 6 , such as siding, stone, or brick. The mounting sleeve 2 may be hollow. Alternatively, the mounting sleeve 2 may include a plurality of inner walls or other structures that may engage the wall faucet fluid tube 30 to increase tube stability relative to the mounting sleeve 2 .
[0031] The bracket 10 includes a plurality of holes 58 that receive fasteners 60 that interconnect the bracket 10 to an interior building surface 62 . The bracket 10 of one embodiment of the present invention includes an outwardly-extending boss 66 with the operatively interconnected tabs 14 . Tabs 14 may have inwardly extending projections that selectively engage the grooves 18 of the mounting sleeve 2 , which secures the mounting sleeve 2 to the bracket 10 . Although the wall mounting sleeve 2 is shown to extend generally perpendicular from the bracket 10 , one of ordinary skill in the art will appreciate that the mounting sleeve may be angled relative to the bracket so the associated fluid tube 30 is tilted a predetermined amount to ensure that fluid leaks from the wall faucet 34 when it is shut off.
[0032] As the tabs 14 may disengage from the mounting sleeve grooves 18 , some prior art systems employ a glue to interconnect the tab 14 to the mounting sleeve 2 , e.g., fix the mounting sleeve 2 to the bracket 10 . One improvement to the prior art system employed by some embodiments of the present invention is the locking ring 22 . In operation, the locking ring 22 is positioned over the mounting sleeve 6 and the boss 66 and is situated over the tabs 14 so they cannot deflect outwardly, which would remove the tab ends from the groove 18 . The locking ring 22 may include a flange 70 that abuts an inner boss surface (see FIG. 3 ) to prevent the locking ring 22 from sliding too far up the boss 66 to a position adjacent to the bracket, which could allow the tabs to be removed from the grooves 18 . The locking ring 22 may include a slot 78 to facilitate expansion of the locking ring 22 , and allow the locking ring 22 to slide over the boss 66 . Those of ordinary skill in the art will appreciate that a clamp 82 , e.g. c-clamp or band, may be used to ensure engagement of the tabs to the grooves instead of the locking ring.
[0033] As described above, the mounting flange 46 is designed to receive and secure the faucet flange 42 that secures the wall faucet and the fluid supply tube 30 . To ensure a tight interconnection between the faucet tube 30 and the mounting sleeve 2 , the end adjacent to a fluid supply interface 84 of the faucet tube must also be secured. Embodiments of the present invention address this issue by providing the seal 26 . The seal 26 includes an inner seal portion and an outer seal portion 92 . The seal has inner diameter 96 that coincides with the outer diameter 98 of the fluid tube 30 . The inner seal portion 88 has an outer diameter 100 that coincides with the mounting sleeve inner diameter 38 . The outer seal portion 92 has an outer diameter equal to or greater than that of the mounting sleeve 2 .
[0034] To secure the seal 26 to the mounting sleeve 2 and the fluid tube 30 , a clamp 82 is provided that when interconnected about the outer seal portion 92 will deform the seal 26 about the fluid tube 30 . When interconnected, the fluid tube 30 will be fixed via the inner seal portion 88 to the mounting sleeve 2 , which securely fastens both sides of the fluid tube 30 to the mounting sleeve 2 . The clamp 82 inner diameter may be selectively enlarged with finger pressure, for example, so that it can be received over the outer seal portion 92 . When pressure is removed, the clamp 82 will retract to compress the seal 26 .
[0035] FIG. 3 illustrates the connection of the mounting sleeve 2 to an interior building surface 62 . In operation, an opening is created in the interior building surface 62 . A corresponding opening is also created in the outer building surface 6 , if needed. That is, in some situations, the outer building surface 6 is made of brick or stone, wherein the mounting flange may be integrated directly within the exterior building surface 6 and surrounded by mortar, for example. Next, the bracket boss 66 is placed within the opening in the building surface and the bracket 10 is interconnected to an outer side of the inner building surface 6 by way of the plurality of fasteners 62 . Alternatively, the boss can be made to extend away from the exterior building surface and concealed by stone and mortar, for example. The mounting sleeve 2 is then positioned through the opening in the outer building surface 6 and the mounting flange 46 is positioned adjacent to the outer building surface 6 , which moves the mounting sleeve 2 through the boss 66 . Once the predetermined offset between the mounting flange 46 and the outer surface 61 of the internal building surface 62 is achieved, the tabs 14 will be received by grooves 18 on the mounting sleeve 2 , which secures the mounting flange 46 at the predetermined offset. The locking ring 22 is then placed over the mounting sleeve 2 and the boss 66 , which maintains the tabs 14 within the grooves 18 . The wall faucet 34 , with interconnected fluid tube 30 is then received by the mounting sleeve 2 and the faucet flange 42 is abutted to the mounting flange 46 . The faucet flange is secured to the mounting flange 46 by at least one fastener 62 . Finally, the seal 26 is received over the supply interface 84 and positioned about the fluid tube 30 , wherein the inner seal portion 88 is placed between the mounting sleeve 2 and the fluid tube 30 . The clamp (not shown) is then positioned in a clamp groove 106 of the outer seal portion 92 to secure the fluid tube 30 to the mounting sleeve 2 .
[0036] If the initially set offset is incorrect, the locking ring 22 may be removed from the boss 66 as the locking ring 22 is not glued or permanently attached to the boss 66 . After the locking ring 22 is removed, the mounting sleeve 2 may be selectively interconnected to the boss 66 at a different location.
[0037] One of ordinary skill in the art will appreciate that the faucet mounting flange 46 may be made of various sizes and configurations to accommodate wall faucets 34 of other designs than that shown. Alternatively, the faucet mounting flange 42 may be made to accommodate only one type of wall faucet.
[0038] The mounting sleeve 3 of some embodiments of the present invention is generally cylindrical, wherein counter from some prior art devices, a keyway or key is not employed. Thus, the mounting sleeve 2 can rotate freely within the bracket. This functionality allows the mounting sleeve to address non-ideal interconnection schemes. For example, the internal building surface to which the bracket 10 is interconnected may not be ideal (e.g., not level) wherein slight modifications to the orientation of the bracket may be required to ensure it is properly interconnected to the internal building surface 6 . If this is the situation, the bracket 10 may have to be rotated to allow for interconnection to the internal building surface 6 . Employing a mounting sleeve with a keyway will prevent the wall faucet to assume an ideal and aesthetically pleasing orientation when interconnected to the mounting flange. Stated differently, if a keyway is employed, the bracket must be oriented perfectly, or the mounting flange will be skewed as the mounting flange's orientation is dictated by the keyway or key. To enhance this functionality, one embodiment employs grooves that extend all, or substantially all, the way around the mounting sleeve. Such grooves will be engaged by the tabs, regardless of boss orientation.
[0039] While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. In addition, one skilled in the art will appreciate that aspects of other inventions may be incorporated and are added in combination to the embodiments of the present invention disclosed herein. For example, aspects of the inventions disclosed in, for example, U.S. Pat. Nos. 6,142,172 and 6,431,204, both of which being incorporated by reference herein, which concern wall faucets, may be incorporated into embodiments of the present invention. | A system for mounting a faucet assembly to the exterior portion of a dwelling is provided. A mounting sleeve is employed that is associated with a tube of a faucet assembly that is generally positioned outside of a dwelling. The tube is rigidly interconnected to a mounting sleeve that is supported by a bracket that allows for selective adjustments. That is, the mounting sleeve may be selectively offset from the interior surface of the dwelling, thereby accommodating exterior building surfaces with irregular shapes such as stone, brick, mortar, stucco, etc. The mounting system provides additional rigidity to the faucet assembly/dwelling interconnection. | 4 |
FIELD OF THE DISCLOSURE
[0001] The present disclosure generally relates to processes for making catch basin constructions. In particular, the present disclosure relates to the provision of novel enhanced maintenance access hatches in catch basin apparatus used in sewer-types of structures which may be disposed simply without adding cost or time constraints.
[0002] The present disclosure further relates to catch basin construction processes, apparatus and improvements allowing for ongoing flow while selectively screening undesired elements from transmission to a drain, using access hatch elements.
BACKGROUND OF THE DISCLOSURE
[0003] Filtration systems have been known throughout history for blocking ingress and egress selectively. Sewer systems and their related drains are a product of modern society, often having a need to be disposed within, for example, city streets in a metropolitan area. Combinations of these two usually distinct types of systems have yet to adequately address industrially efficient construction processes, products thereby or functionally utile improvements of the same.
SUMMARY
[0004] The present disclosure works in conjunction with conventional drainage systems, for example, sewers which drain from the street and catch basin systems. While it is known for drainage systems to work in conjunction with such street based systems, a fluid drainage system according to the instant disclosure uses novel mechanisms to handle any number of types of detritus without compromise to the flow-rate in ways not available prior to the advent of the instant teachings, including for example maintenance access hatches diverters and screen inserts.
[0005] For example, by using the combination of at least one diverter and a sieve-element to divide a primary and at least a secondary collection area, the present disclosure overcomes the longstanding need to be able to get between, behind under or in back of the sieve-member and remove debris and detritus by way of a specialized maintenance access hatch permitting ingress and egress, which is easily assembled and installed.
[0006] The present disclosure manages the issue of having a continuous flow-path while being able to stem the flow of large pieces of debris, and being able to render those pieces which may become lodged readily removable. This is done in straight-forward fashion, enabling those charged with removing potentially clogging pieces of debris to have ready access to the area proximate to the drain which is at the bottom of the system. According to a feature of the present disclosure there is provided an enhanced catch basin filtration system defined by a sieve element located within the catch basin, for maintaining a flow path from a gutter inlet to a downstream outlet pipe having a mouth. The sieve element has at least one maintenance access hatch located within said sieve member. The maintenance access hatch is sized large enough to allow for maintenance and cleaning equipment to reach through the hatch. Furthermore, the mouth of the downstream outlet pipe can have a variety of locations within the surface area of the catch basin such as the catch basin floor or inner walls. Also, the sieve element can further include an overflow wall.
[0007] According to a feature of the present disclosure, the sieve element can have many forms and structures. Including, but not limited to a rectangular frame with perforations or apertures, a basket or container with perforations or apertures. One purpose of the sieve element is to filter and separate incoming debris. This may be accomplished by the sieve element having perforations and apertures so that the sieve element can hold debris while allowing liquid to pass through the perforations or apertures. Thus, the perforations and apertures can be sized accordingly. Furthermore, depending on the user's desires, the sieve element may or may not be fixedly attached to the inner structure of the catch basin.
[0008] Furthermore, the maintenance access hatch can have many forms and structures. Including, but not limited to, a lid covering an aperture, a covering, a removable cut-out, a door, a flap, an aperture with a covering, or any other structure that allows access through the sieve element permitting ingress and egress through the sieve element. The maintenance access hatch can have perforations and apertures similar in size to the perforations and apertures of the sieve element.
[0009] As known, debris can accumulate below the sieve element or within a drain opening in a catch basin. This can cause blockage and backup of the filtration system. Thus, one purpose of the maintenance aces hatch is to enable a user to remove, lift, turn, slide, open, or otherwise manipulate the hatch so that the user can access the area underneath the sieve element and/or the drain opening. This allows the user to be able to clean out any debris causing a blockage or to be able to prevent an accumulation of debris which can lead to blockage. Accordingly, one feature of the present disclosure provides that the maintenance access hatch is sized large enough to allow for maintenance and cleaning equipment to reach through the hatch.
[0010] According to a feature of the present disclosure, the catch basin filtration system can further include a manhole located on the street surface, above the catch basin curb inlet. In another feature, the manhole and maintenance access hatch can be aligned with each other so that a user can easily access the maintenance access hatch from the manhole. Furthermore, the manhole, maintenance access hatch, and the drain opening can be aligned with each other so that a user can easily access the drain opening by manipulating the maintenance access hatch from the manhole. In one feature, such access contemplates the ability to use various maintenance and cleaning tools sized to be able to reach the drain opening or access hatch from the manhole or street surface.
[0011] According to a feature of the present disclosure there is provided a process for constructing a catch basin filtration system within a conventional sewer system defined by a street based inlet and an outlet drainage below the street level comprising the steps of providing a sieve element having a maintenance access hatch therein, providing a diverter assembly for directing incoming matter from the curb inlet to the sieve element, attaching the sieve element to the inner walls of the catch basin, and attaching the diverter assembly proximate to the street based inlet.
[0012] According to a feature of the present disclosure there is provided a method for providing a continuous flow path with enhanced catch basin apparatus, comprising diverting select portions of incoming matter into a supplemental collection area, collecting incoming streams of large pieces of matter in a primary collection area, opening, removing, or otherwise manipulating a maintenance access hatch and removing desired amounts of the select portions of incoming matter, and repeating the preceding steps.
[0013] According to a feature of the present disclosure there is provided a maintenance access hatch which provides access to trash blocking a drain outlet, comprising, in combination a cover assembly, movable from a first to a second position, a locking mechanism, for releasing a removably attachable cover assembly, and each of the cover assembly and locking mechanisms can be operated by human or supplemental mechanical means.
[0014] According to a feature of the present disclosure there is provided an apparatus for providing access to debris blocking a drain outlet in a catch basin system, comprising a sieve element located within said catch basin, wherein said sieve element is located between a curb inlet and said drain outlet, a maintenance access hatch located within said sieve element, and wherein said maintenance access hatch is manipulable so that a user can access the debris blocking said drain outlet.
[0015] According to a feature of the present disclosure there is provided a catch basin for selectively removing gross particulate matter of a predetermined dimension from a flow path, wherein said flow path travels from a curb inlet to a drain opening located within the catch basin, the improvement comprising a sieve element located within the catch basin and above the catch basin floor. The sieve element filters matter from the flow path and the sieve-element further comprises a maintenance access hatch. A user can manipulate the maintenance access hatch in order to access the catch basin floor and/or drain opening.
[0016] According to a feature of the present disclosure there is provided an apparatus for filtering trash in a catch basin, wherein the catch basin has inner walls, a floor, an inlet opening, and a drain opening, and wherein said apparatus comprises one or more conventional support/hatches for securing one or more parts of the apparatus inside the catch basin, a trash collecting container located within the catch basin, wherein the container comprises a filter sheet forming at least part of the bottom of the container, said filter sheet having a plurality of apertures through it, wherein the bottom of the container is located above the floor a sufficient amount to provide clearance for fluid and at least some of the trash to flow along the floor and into the drain opening, and an overflow wall, wherein the overflow wall is a wall of the container, is located between the filter sheet on the inside of the container and an overflow area on the outside of the container, and has a top that is low enough for excess fluid and excess trash to pass over the overflow wall into the overflow area, wherein said excess fluid and excess trash are the fluid and trash respectively that has accumulated in the container beyond a predetermined maximum capacity of the container, a diverter, wherein said diverter is located and oriented relative to the inlet opening for diverting at least some inbound fluid-borne trash away from entering the overflow area and toward entering the container.
[0017] According to a feature of the present disclosure there is provided an apparatus for filtering trash in a catch basin, comprising a trash collecting container located and support/hatched by conventional support/hatches within a catch basin, the catch basin having an inlet opening, one or more inner walls, a floor, and a drain opening, wherein the container comprises one or more filter sheets, each of the filter sheets having a plurality of apertures through it, said apertures being of a size and shape that will allow fluid to pass through the filter sheet but block such passage of at least some trash; wherein the one or more filter sheets form at least part of the bottom of the container, and the one or more filter sheets are located above the floor and higher than the lowest part of the drain opening, container walls, wherein the container walls form the lateral bounds of the container and comprise an overflow wall, wherein the top of the overflow wall is lower than the tops of all the container walls that are not overflow walls, and wherein the top of the overflow wall is lower than the bottom of the inlet opening, a relief channel located within the catch basin but outside the container, wherein the relief channel encloses an overflow area and leads to the drain opening, wherein the overflow area is the area into which the fluid and the trash that overflows the overflow wall passes, and wherein the minimum inside dimensions of the relief channel are large enough to allow passage through the relief channel of at least some of the fluid and at least some of the trash that overflows the overflow wall, and a diverter located within the catch basin, wherein the diverter is connected to at least one of the inner walls at a location whereby the diverter will intercept at least some of the trash that enters the catch basin through the inlet opening at a point where it would fall outside the container if the diverter were not present, wherein the diverter is located higher than the top of the overflow wall, wherein at least part of the diverter extends within the lateral bounds of the container, and wherein the diverter is oriented to divert at least some of the trash into the container.
[0018] According to a feature of the present disclosure there is provided an apparatus for filtering trash in a catch basin, comprising a trash collecting container located and support/hatched by conventional support/hatches within a catch basin, the catch basin having an inlet opening, one or more inner walls, a floor, and a drain opening, wherein the container comprises one or more filter sheets, each of the filter sheets having a plurality of apertures through it, said apertures being of a size and shape that will allow fluid to pass through the filter sheet but block such passage of at least some trash; wherein the one ore more filter sheets form at least part of the bottom of the container, the one or more filter sheets are located above the floor and higher than the lowest part of the drain opening, and the bottom of the container covers at least seventy percent of the floor, container walls, wherein the container walls from the lateral bounds of the container and comprise an overflow wall, wherein the top of the overflow wall is lower than the tops of all the container walls that are not overflow walls, and wherein the top of the overflow wall is lower than the bottom of the inlet opening, wherein at least one of the container walls comprises a plurality of apertures through it, said apertures being of a size and shape that allows fluid to pass through said at least one container wall but blocks such passage of at least some trash, and wherein at least one of the container walls comprises at least a portion of one of the inner walls, a relief channel located within the catch basin but outside the container, wherein the relief channel comprises an overflow channel and a floor channel, wherein the overflow channel encloses an overflow area, the overflow area being the area into which the fluid and the trash that overflows the overflow wall passes, and leads downwardly and connects with the floor channel, wherein the floor channel runs between the floor and the bottom of the container from the overflow channel to the drain opening, and wherein the minimum inside dimensions of the relief channel are large enough to allow passage through the relief channel of the fluid in a volume needed to match a predetermined requirement for rate of drainage from the catch basin, and the trash of a size and shape that is within a predetermined requirement for trash to be permitted into the drain opening, wherein both of said predetermined requirements are limited by the maximum capacity of the drain opening and its associated drainage system, and a diverter located within the catch basin, wherein the diverter is connected to at least one of the inner walls at a location whereby the diverter will intercept at least some of the trash that enters the catch basin through the inlet opening at a point where it would fall outside the container if the diverter were not present, wherein the diverter is located higher than the top of the overflow walls and at least part of the diverter extends within the lateral bounds of the container, wherein the diverter is oriented to divert at least some of the trash into the container, and wherein the diverter has a plurality of apertures through it, said apertures being of a size and shape that allows fluid to pass through the diverter but blocks such passage of at least some trash.
[0019] Briefly stated, novel enhanced catch basin constructions, especially for use with conventional sewers, feature a supplemental maintenance access hatch, which when combined with a diverter and a sieve-like screen member facilitate ready access to and removal of trash/debris/detritus lodged proximate to an outlet drain or catch basin floor to maintain a continuous flow path and preclude blockage. Readily removable covers or lids for the supplemental access hatches allow workers, tools or later developed extraction schemes to maintain flow through debris collection spaces in catch basins. Methods of constructing and using the same feature these novel mechanisms.
[0020] Likewise, those skilled in the art shall understand that such improved catch basin technology overcomes the longstanding issues associated with spaces too small for workers to reach into to remove pieces of debris which become difficulty lodged. An additional aspect of the present disclosure is that it does not require further attachments, assemblies or supplemental pieces at the ingress, or for example, at the “curb” in a conventional city-type of sewer inlet. This feature is useful and enhances industrial efficiency.
[0021] Further, since many conventional, for example, metropolitan sewer systems, have many different locations needing to be improved, ready installation capacity, ease-of-use and transport/hatch make the teachings of the present invention attractive to users. It is also known to artisans how the solution offered by the instant teachings can have a ‘universal’ aspect, in it functions in conjunction, with—or is readily adaptable to many different related types of systems.
[0022] Finally, owing to the modularity of the components according to the instant teachings plethoric combinations and subcombinations are available. For example, for use with conventional metropolitan sewer systems those having a modicum of skill shall understand that at least one diverter is easily curb-mounted with most existing systems, as is a sieve member combination. Furthermore, the maintenance access hatch can be easily adapted and in/or installed into many existing types of catch basin filtration systems. Being modular provides for easy and facile transport/hatch, shipping, storage and related conveniences.
[0023] The present invention will be more clearly understood by reference to this specification in view of the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a schematic view of a catch basin insert having a sieve element and a diverter, according to one embodiment of the instant disclosure;
[0025] FIG. 2 is a schematic view of a sieve element, according to one embodiment of the instant disclosure;
[0026] FIGS. 3A through 3C are detailed schematic views of a maintenance access hatch, according to one embodiment of the instant disclosure;
[0027] FIG. 4 is a plan view of a catch basin insert having a sieve element and a diverter, according to one embodiment of the instant disclosure;
[0028] FIG. 5 is a view taken through Section A:A of the plan view of a catch basin insert having a sieve element and a diverter as shown in FIG. 4 , according to one embodiment of the instant disclosure;
[0029] FIG. 6 is a view taken through Section B:B, according to embodiments of the instant disclosure;
[0030] FIG. 7 is a plan view of a sieve element support frame, according to one embodiment of the present disclosure;
[0031] FIG. 8 is a view taken through Section A:A of the plan view of FIG. 7 .
[0032] FIG. 9 is a perspective view of one embodiment of the disclosed apparatus, which embodiment is adapted for attachment to the inner walls of a street storm-water catch basin having a curb inlet opening and a left-located drain opening, as seen prior to the invention's installation.
[0033] FIG. 10 is a perspective view of a catch basin in which the embodiment seen in FIG. 9 is installed, showing only the part of the apparatus that is visible from this view, said part being the diverter (a portion of it visible through the curb inlet opening), and showing a manhole cover that is located directly above the catch basin's drain opening.
[0034] FIG. 11 is a top view of the embodiment in FIG. 1 after it has been installed, as seen through horizontal cross-sectional cut I-I.
[0035] FIG. 12 is a back view of the embodiment in FIG. 1 after it has been installed, as seen through vertical cross-sectional cut II-II.
[0036] FIG. 13 is a left side view of the embodiment in FIG. 1 after it has been installed, as seen through vertical cross-sectional cut III-III.
[0037] FIG. 14 is a close up top view of a portion of the embodiment in FIG. 1 after it has been installed, as seen through horizontal cross-sectional cut I-I, showing the filter hole cover in an open position.
[0038] FIG. 15 is a perspective view of a second embodiment of the invention apparatus, which embodiment is adapted for attachment to the inner walls of a catch basin having a curb inlet opening and center-located drain opening, as seen prior to the invention's installation.
[0039] FIG. 16 is a perspective view of a catch basin in which the embodiment seen in FIG. 15 is installed, showing only the part of the apparatus that is visible from this view, said part being the diverter (a portion of it visible through the curb inlet opening), and showing a manhole directly above the location of the catch basin's drain pipe opening.
[0040] FIG. 17 is a back view of the embodiment in FIG. 15 after it has been installed, as seen through vertical cross-sectional cut IV-IV.
[0041] FIG. 18 is a perspective view of another embodiment which is adapted for attachment to the inner walls of a catch basin having a top inlet opening and a left-located drain pipe opening, as seen prior to the invention's installation.
[0042] FIG. 19 is a perspective view of a catch basin in which the embodiment seen in FIG. 18 is installed, showing only the part of the apparatus that is visible in this view, said part being the diverter (a portion of it is visible through the top inlet opening, with the surface grate that normally covers the opening lifted above its normal position), and showing the top inlet opening being large enough to eliminate the need for a manhole.
[0043] FIG. 20 is a left side view of the embodiment in FIG. 10 after it has been installed, as seen through vertical cross-sectional cut V-V. (Note that “left” is defined herein to be left when viewing from the center of the street).
DETAILED DESCRIPTION
[0044] The present inventor has discovered that it is possible to construct novel catch basin apparatus in an industrially efficient manner by understanding the fundamental structural aspects of existing systems including ways to maintain flow and collect detritus which allow for removal of pieces that block flow or clog outlet drains. Likewise, access hatch mechanisms which combined with diverters and screens are useful when processed for constructing and installing components that render such systems more utile are employed. For example, by combining a diverting mechanism and device with a maintenance access hatch and a screen insert or sieve element or member many of the outstanding issues with conventional sewer systems can be ameliorated.
[0045] The basic teachings of constructing a catch basin sieve element and anchoring the same in a desired orientation, and including ways to direct debris and facilitate its removal, have not heretofore been made commercially practical.
[0046] Referring to the drawings, FIG. 1 shows a general schematic view of a typical street based sewer assembly 100 with an associated catch basin structure. Such an arrangement is used in, for example, metropolitan and suburban areas for managing the flow of water and the debris which often becomes disposed within the same.
[0047] Maintenance access hatch 101 is an aperture through screen insert 102 enabling ready access to the area underneath screen insert 102 . The screen insert is one, but not limited to, example of a type of sieve element. According to an embodiment of the instant disclosure a diameter of maintenance access hatch 101 may be equivalent to, greater than, or smaller than the diameter of outlet pipe 111 . In further embodiments, the access hatch may be a cut-out, a lid, a door, a flap, an aperture with a covering, or any other structure which allows access through the sieve element and permits ingress and egress through the sieve element.
[0048] One embodiment includes a plurality of fixation mechanisms, for example, self drilling metal screws 105 , which are spaced around the perimeter of screen insert/sieve element 102 . For example, at 8 inch spaced intervals, along catch basin insert frame support/hatch, between proximate end of catch basin insert from 104 .
[0049] Likewise, the distance between the distal edges of the catch basin insert 103 , can be proportionate to the size of outlet pipe 111 diameter. In a typical example, as shown in the first two figures, the trash/debris diverter appurtenance 109 extends from proximate end of catch basin insert frame 104 at a sloped angle and it may be disposed at a first end of curb inlet 108 .
[0050] Manhole cover 107 extends from the sidewalk 117 into a first reservoir space of the catch basin as shown in FIG. 2 . Catch basin insert is disposed in typical street sewer assembly 100 and anchored by, for example, an adhesive apoxy anchor system (HILTI HIT RE 500) in combination with threaded rods, nuts and washers.
[0051] Referring still to FIG. 2 corner and cross member joints 110 may be welded at each corner for structural integrity, and height 112 varied to fit the desired subterranean space. In a typical example, the distance between screw inserts 113 spans a distance of at least about 16 inches and extends between self drilling metal screws.
[0052] FIGS. 3A, 3B , and 3 C demonstrate one way that maintenance access hatch 101 is constructed and may be readily removed using eyebolt 114 , as will be known to artisans. Maintenance access hatch cover 138 moves from a first position to a second position, as seen permitting ingress and egress.
[0053] Further embodiments include many different ways of constructing the maintenance access hatch and gaining access through the sieve element. In one embodiment, the access hatch is a cut-out of the sieve element. In another embodiment, the maintenance aces hatch is a door or flap within the sieve element. The present disclosure contemplates many structures for the maintenance access hatch located on a sieve element which permit ingress and egress through the hatch so that the user can access the area beneath the sieve element and/or the catch basin drain opening.
[0054] Referring now to the first view in FIG. 3A , for example, a 5 mm screen access hatch is removably fashioned with metal screws, a ¼ inch gap on top of a 2 inch steel angle using ¾ inch by 2 inch eyebolt 114 . Likewise a ¾ nut with pressure washer and a flat washer for the ¼ inch gap 119 provides for the ability to remove the screen access hatch 101 .
[0055] The second, or bottom view of maintenance access hatch 101 shows welded members 122 which abuttingly engage the bottom portion of rotatable leading edge 123 of maintenance access hatch 101 . The third, top view, again shows eyebolt 114 , which is opened to remove maintenance access hatch 101 by a 90° rotation.
[0056] Turning to FIG. 3B the aperture which is maintenance access hatch 101 is shown. In a typical construction according to the instant teachings, the diameter may be—for example, twelve inches across for a 5 mm screen insert. In an open position, maintenance hatch cover 138 has leading edge 123 aligned with its receptacle.
[0057] Turning to FIG. 3C , leading edge 123 on maintenance access hatch cover 138 rotates 90° to move to a closed position. Those skilled in the art readily understand the ease of removal of maintenance access cover 138 in an open position.
[0058] FIG. 4 is a plan view of screen insert/sieve element 102 , showing maintenance hole aperture 115 which houses manhole cover 107 , disposed proximate to self drilling metal screws around the perimeter of screen insert 102 . Maintenance access batch 101 is arranged relative to a front side catch of catch basin opening 116 , and sidewalk with trash/debris diverter appurtenance 109 disposal of opposite sidewalk 117 , path of run-off water is shown by the single arrow and storm runoff by two arrows.
[0059] Turning to FIG. 5 , a sectional view taken through A:A of FIG. 4 is shown. In this view front of catch basin opening 116 is shown adjacent curb face 118 , with the direction of storm runoff indicated by two arrows, and outlet pipe 111 showing the direction of flow with one arrow.
[0060] Referring to FIG. 6 , the view through section B:B of the prior two figures is offered for consideration. Outlet pipe 111 is shown revealing its dimensions relative to a first and of screen 102 . Likewise shown in the respective location of each of manhole cover 107 , and trash/debris diverter appurtenance 109 .
[0061] FIG. 7 and FIG. 8 show a screen insert 102 in plan view with maintenance hole 115 and sidewalk 117 . In one embodiment of the instant disclosure a spacing interval of, for example, seven feet extends from catch basin screen support/hatch frame 104 and includes a plurality of cross members 121 .
[0062] FIG. 8 likewise shows a view through section A:A culling at screen insert/sieve element support/hatch frame 104 . Unlike known systems, maintenance access hatch (not shown, but see FIG. 1-4 and 9 , 11 , 12 - 17 , 19 - 20 ) provides for a unique ability to maintain flow and keep the catch basin apparatus functioning. In combination with a diverter, the present disclosure enables trash/debris/detritus to be sucked into a primary and supplemental container, which in combination with an access hatch, as discussed, makes removal of blockages easier.
[0063] FIGS. 9-14 show a first embodiment, referred to herein as a left-drain filter 21 , as it would appear in an installation configuration but (as illustrated in FIG. 9 ) without being installed in any catch basin and (as illustrated in FIGS. 10-14 ) after being installed into a left-drain catch basin 22 . The left-drain filter 21 is configured for installation into the left-drain catch basin 22 , which has a floor 23 and a drain opening 24 in the left portion of the floor 23 . The left-drain catch basin 22 is designed for fluid to enter through a curb-inlet opening 25 and to exit through the drain opening 24 located in the left portion of the catch basin.
[0064] FIGS. 14-17 show another alternate embodiment, referred to herein as a center-drain filter 26 , as it would appear in its installation configuration but (as illustrated in FIG. 14 ) without being installed in any catch basin and (as illustrated in FIGS. 16-17 ) after being installed into a center-drain catch basin 27 , which is designed for fluid to enter through the curb-inlet opening 25 and to exit through its drain opening 24 located in the central portion of the catch basin.
[0065] And, FIGS. 18-20 show a further alternate embodiment, referred to herein as a top-inlet filter 28 , as it would appear in its installation configuration but (as illustrated in FIG. 18 ) without being installed in any catch basin and (as illustrated in FIGS. 19-20 ) after being installed into a top-inlet catch basin 29 . The top-inlet filter 28 is configured for installation into the top-inlet catch basin 29 , which is designed for fluid to enter through a top-inlet opening 210 and to exit through its drain opening 24 located, in this embodiment, in the back portion of the catch basin.
[0066] In FIGS. 10-14 , 16 - 17 , and 19 - 20 , the installation environment is shown as comprising a street 211 connected to an inlet apron 212 and a gutter 213 , with a curb 214 connecting the gutter to a sidewalk 215 support/hatched on an earthen foundation 216 . The inlet apron 212 shown in FIGS. 19-20 is part of the catch basin, whereas the inlet apron 212 can, alternatively, be a separate piece as shown in FIGS. 10-14 and 16 - 17 . However, all inlet aprons 212 shown in the accompanying figures receive fluid (and any trash carried with the fluid) from the street and the gutter, and direct the fluid (and trash) into the catch basin by sloping downwardly toward the catch basin inlet opening.
[0067] Although the apparatus can be adapted to accommodate catch basins with a different number of inner walls, each catch basin shown in the accompanying figures has four inner walls 217 . Furthermore, alternate embodiments contemplate a sieve element which is not fixedly attached to the catch basin, but otherwise secured within the catch basin. The apparatus is shown installed in each of those catch basins by using angle-iron support/hatches 218 with support/hatch bolts 219 passing through bolt holes 220 in a flange of the support/hatch 218 and into anchors 221 that have been placed in three of the inner walls 217 if each catch basin. (It should be understood that, although the support/hatch bolts 219 and anchors 221 are shown only in FIG. 14 , support/hatch bolt 219 and anchor 221 combinations are located approximately equally spaced apart along the flange of each installed support/hatch 218 that is in direct contact with an inner wall 217 . Locations intended for said support/hatch bolt 219 and anchor 221 combinations are shown in the accompanying figures simply by showing the locations of the bolt holes 220 where practical to do so, on the scale of those figures. Due to the large quantity of them, only a few of the locations of the blot holes 220 are identified by reference number. It is believed that those skilled in the art understand or can readily determine the appropriate number and locations for the bolts and their anchors, and the size and other characteristics of them, for securing support/hatches within a catch basin.)
[0068] One exemplary implementation of a sieve element is a filter sheet 222 . Filter sheets 222 can then rest upon the support/hatches (or may be secured by any conventional means such as screwing the filter sheets 222 into the support/hatches 218 ), with the plane of each filter sheet 222 located at a predetermined appropriate level above the floor 23 and oriented substantially parallel to the part of the floor 23 that is directly beneath the filter sheet 222 . The appropriate level may provide at least enough clearance to permit a sufficient volume of fluid to flow along the floor 23 into the drain opening 24 to match the capacity of the drain opening 24 . The capacity of the drain opening 24 is limited by such things as its size and the characteristics of the drain pipe 223 being used. The appropriate level also can be based on other criteria as desired by the user. Such other criteria may include factoring in the volume and quantity of trash that is likely to overflow and pass with the fluid into the space between the floor 23 and the one or more filter sheets 222 . Of course, any conventional means may be used for support/hatching and securing the filter sheets 222 in their positions.
[0069] As best seen in FIGS. 9, 11 , 12 - 15 , and 18 , the filter sheets 222 have a plurality of apertures 224 through them, so that fluid will pass through while trash will be retained for subsequent removal. (Note that due to the large quantity of them, only a few of the apertures 224 shown in the accompanying figures are identified by reference number. And, of course, the apertures 224 are to be distinguished from the circles shown on the support/hatches 218 , which only illustrate that the support/hatch bolts 219 are located and may be equally spaced apart along the vertical flange of the support/hatches 218 .) The size and shape, pattern, combination and other selectable features for the apertures 224 are contemplated by the present invention as being optional to the user, depending on the particular results he or she may desire. It is believed, however, that apertures 224 ranging in size (measured as the smallest dimension across the opening) from ¼ inch to 1½ inches work well for blocking the passage of trash into municipal street storm-water catch basins. Of course, larger or smaller apertures, or combinations of apertures, may be used without departing from the present invention.
[0070] Another exemplary implement of a sieve element is a filter sheet 222 having an overflow wall 225 . FIG. 1 shows an overflow wall 225 and a curb-inlet diverter 226 . As shown, the curb-inlet diverter 226 comprises two sheets secured together at right angles (by, for example, using screws to secure one edge of one sheet to one flange on a section of angle iron and to secure one edge of the other sheet to the other flange). When installed into the left-drain catch basin 22 , the curb-inlet diverter 226 is oriented to form a channel that diverts incoming fluid and trash to the filter side of the overflow wall 225 (which is the side opposite the overflow area 228 ). As seen in FIG. 2 , the curb-inlet diverter 226 is located against the inner wall 217 on the front side of the left-drain catch basin 22 , generally by securing it in a manner similar to the one used for securing the filter sheets. And, the curb-inlet diverter 226 is the only part of the left-drain filter 21 that might be easily seen from the street 211 . In one embodiment, the location for the curb-inlet diverter 226 is at or near the upstream end of the catch basin. Also, as is shown by a close look at FIGS. 19-10 , 12 , and 15 - 17 , the curb-inlet diverter 226 is sloped slightly downwardly as it extends toward the filter side of the overflow wall 225 , which helps keep the diverter clear of accumulated trash. Of course, the degree of the slope can, in other embodiments, vary depending on anticipated flow conditions and other criteria, as desired by the user. Furthermore, the diverter may or may not be attached to the sieve element. Note further, that the overflow wall 225 and the curb-inlet diverter 226 may be made of the same material as the filter sheets or sieve elements are made of, with apertures, so that the filtering process can occur at the diverter and overflow wall as well as at the filter sheets. Again, however, other embodiments may utilize other materials for construction of the overflow wall and/or the diverter without departing from the present invention.
[0071] FIG. 11 looks down through sectional cut I-I, which is a substantially horizontal cut immediately below the inside ceiling 227 of the left-drain catch basin 22 . In FIG. 11 , the curb-inlet diverter 226 is seen as being secured to the inner walls 217 on the front and right sides of the left-drain catch basin 22 . The space between the overflow wall 225 and the inner wall 217 on the right side of the catch basin forms an overflow area 228 , into which fluid and trash can overflow from the filter side of the overflow wall 225 when the capacity of the filter is exceeded. Under those circumstances, as seen in FIGS. 12, 13 , and 14 , overflowing fluid and trash are able to flow along the floor 23 beneath the filter sheets 222 and enter the drain pipe 223 .
[0072] FIG. 11 also illustrates the large area coverage of the filter sheets 222 , which, in one embodiment, form a snug fit to the inner walls 217 on the front, left, and back sides of the catch basin. In this embodiment the filter sheets 222 are bounded by the three inner walls 217 and the overflow wall 225 and may cover approximately 80 percent of the floor 23 , thereby providing a very large filtering and holding capacity. Although no top view of the other embodiments, which are the subject of FIGS. 15-20 , is shown, FIG. 11 is illustrative of the capacity of the other embodiments provide by also having filter sheets 222 fully cover the floor area on the filter side of the overflow wall 225 . Of course, additional embodiments not specifically described or shown herein may cover different portions of the floor area without departing from the present invention.
[0073] FIG. 11 also shows a filter hole cover 229 in its closed position, which filter hole cover 229 has a pivot bolt 230 and a handle 231 to facilitate rotation of the filter hole cover 229 into its open position to expose a filter hole 232 , as illustrated in FIG. 14 . In one embodiment, the filter hole 232 is directly above the drain opening 24 , where the drain pipe 223 commences. A filter hole is only one example of a configuration of the maintenance access hatch. An embodiment having the filter hole 232 is preferable to an embodiment not having them, since the drain pipe 223 must occasionally be accessed and cleaned. To do this, maintenance personnel generally must gain access to the drain pipe 223 by removing the manhole cover 233 and introducing clean out equipment into the catch basin through the manhole 234 . If there is a filter hole 232 and filter hole cover 229 , maintenance personnel can easily access the drain pipe 223 by moving the filter hole cover 229 to an open position, whereas they would otherwise generally need to move an entire filter sheet 222 . In one embodiment, the filter hole cover is movably connected to the container bottom, covers the filter hole, and can be moved by human power to uncover the filter hole enough to enable the clean-out equipment to be inserted through the filter hole and into the drain opening.
[0074] In one embodiment, the filter hole 232 and the manhole 234 are located directly above the drain opening 24 . Although, the other embodiments described or shown herein also have filter holes 232 covered by filter hole covers 229 , additional embodiments may have multiple filter holes or no filter hole at all, or may have the filter hole(s) located elsewhere within the catch basin, have no filter hole cover, or have any combination thereof, without departing from the present invention.
[0075] As seen in FIGS. 15-17 , the center-drain filter 26 is quite similar to the left-drain filter 21 . The difference lies in the fact that the center-drain filter 26 is adapted for installation into the center-drain catch basin 27 rather than the left-drain catch basin 22 . For such adaptation, the center-drain filter 26 has its lowest point located over the centrally located drain opening 24 , with one or more filter sheets 222 added on the left side of the drain opening 24 , with one or more filter sheets 222 added on the left side of the drain opening 24 . In one embodiment, the added filter sheets slope upward, substantially parallel to the slope of the floor 23 , until they reach the inner wall 217 at the left end of the center-drain catch basin 27 .
[0076] The top-inlet filter 28 , as shown in FIGS. 18 and 19 has a top-inlet diverter 235 rather than a curb-inlet diverter 226 . The top-inlet diverter 235 may extend from the inner wall 217 at the front of the top-inlet catch basin 29 , inwardly into the top-inlet catch basin 29 while down sloping modestly to end at a point on the filter side of the overflow wall 225 . (A 2 percent to 20 percent down slope is believed advantageous, but the present invention encompasses milder and steeper down slopes that may be deemed more suitable by the user.) In one embodiment, the top-inlet diverter 235 also extends laterally to cover the entire overflow area 228 , with the top-inlet diverter 235 reaching several inches beyond the overflow wall 225 to help assure trash is not allowed to directly enter the overflow area 228 . The top-inlet diverter 235 also is shown as being separated vertically from the top of the overflow wall 225 to provide sufficient space between the top-inlet diverter 235 and the overflow wall 225 for fluid and trash to overflow the top-inlet filter 28 via the overflow wall 225 without significant impediment by the top-inlet diverter 235 .
[0077] Like the curb-inlet diverter 226 , the top-inlet diverter 235 works to divert incoming trash away from the overflow area 228 to the filter side of the overflow wall 225 . Also, the top-inlet diverter 235 of an embodiment is made using the same material, with apertures, as is used for making the filter sheets 222 , so that the filtering process begins as the entering fluid and trash impact the top-inlet diverter 235 . (The same preference for use of material with apertures applies to the overflow wall and the diverter in other embodiments. For example, this preference is discussed and applied above with respect to the left-drain filter 21 , shown in FIGS. 9-14 , and is also intended to apply to the center-drain filter 26 , shown in FIGS. 15-17 .
[0078] As shown in FIGS. 19 and 20 , a large surface grate 236 can be located in the top-inlet opening 210 , within the street environment, to facilitate handling large volumes of fluid and to allow access by maintenance personnel into the top-inlet catch basin 29 without need for a manhole.
[0079] The support/hatches 218 , filter sheets 222 , the other parts of the apparatus, and the means for connecting them together and securing them to the inner walls 217 are, in an embodiment, made of hot dipped galvanized steel, although they can be made of any other conventional material that is strong and durable in the presence of the fluids reasonably expected to pass through the catch basin in which they are installed, with due consideration to the potential for corrosion and/or electrolytes particularly when using more than one type of metal in the construction of the apparatus. Such other conventional materials include stainless steel, aluminum, plastics, carbon fibers, and composites. The means for connecting the parts of the apparatus to one another or to the catch basin can be any conventional connecting means such as, without limitation, bolts, screws, welds, clamps, and/or adhesives.
[0080] The support/hatches 218 shown herein as angle irons may be installed with the vertical side of the angle iron pointed up or down. The accompanying figures show the vertical side point up on the support/hatches 218 used to support/hatch the filter sheets 222 . Nevertheless, an alternative embodiment with the vertical side of the support/hatches 218 pointing down would appear advantageous in order to cause less interference between the support/hatch bolts 219 and the filter sheets 222 . (A sample of this alternative orientation of the vertical side of the support/hatches is found in the curb-inlet diverter 226 shown in FIGS. 1 , 3 - 5 , 7 and 9 , which has the vertical side of the support/hatches 18 pointing down.)
[0081] Of course, catch basins may have designs with such things as their size, shape, and/or orientation, or the location, number, and/or size of their inlet openings or drain openings being different from any of those described or shown herein. It should be understood, however, that the present invention contemplates and includes all conventional adjustments in the embodiments described or shown herein (including such adjustments in the size, orientation, portions, and relative positioning of parts) made to accommodate those differences in catch basin designs. For example, an alternative catch basin design may provide a shelf, ledge, or groove, or combination thereof, built into one or more of its inner walls as a resting place for the support/hatches or even for the filter sheets without support/hatches. An embodiment adapted for installation in such a catch basin design could be made with reduced, or without any, use of other means (such as the support/hatch bolt/anchor combinations) for securing the support/hatches and/or filter sheets, without departing from the present invention.
[0082] While the apparatus and method have been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims. | Novel enhanced catch basin constructions, especially for use with conventional sewers, feature a supplemental maintenance access hatch, which, when combined with a diverter and a sieve-like screen element facilitate ready access to and removal of trash/debris/detritus lodged proximate to an outlet drain or bottom of a catch basin to maintain a continuous flow path and preclude blockage. Readily removable covers for the supplemental maintenance access hatches allow workers, tools or later developed extraction schemes to maintain flow through both primary and supplemental debris collection spaces in catch basins. Methods of constructing and using the same feature these novel mechanisms. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 08/639,509 filed Apr. 29, 1996, abandoned, which is a continuation of application Ser. No. 08/410,890 filed Mar. 27, 1995, abandoned, which is a division of application Ser. No. 08/192,023 filed Feb. 3, 1994, pending, which is a division of application Ser. No. 07/973,931 filed Nov. 10, 1992, U.S. Pat. No. 5,302,891, which is a continuation of application Ser. No. 07/709,858 filed Jun. 4, 1991, abandoned.
FIELD OF THE INVENTION
This invention relates to electrical test equipment for semiconductor devices. More specifically, the invention relates to an apparatus and method to perform dynamic burn-in and full electrical/performance/speed testing on discrete nonpackaged or semi-packaged dice.
BACKGROUND OF THE INVENTION
Semiconductor devices are subjected to a series of test procedures in order to assure quality and reliability. This testing procedure conventionally includes "probe testing", in which individual dice, while still on a wafer, are initially tested to determine functionality and speed. Probe cards are used to electrically test die at that level. The electrical connection interfaces with only a single die at a time in wafer; not discrete die.
If the wafer has a yield of functional dice which indicates that quality of the functional dice is likely to be good, each individual die is assembled in a package to form a semiconductor device. Conventionally, the packaging includes a lead frame and a plastic or ceramic housing.
The packaged devices are then subjected to another series of tests, which include burn-in and discrete testing. Discrete testing permits the devices to be tested for speed and for errors which may occur after assembly and after burn-in. Burn-in accelerates failure mechanisms by electrically exercising the devices (UUT) at elevated temperatures, thus eliminating potential failures which would not otherwise be apparent at nominal test conditions.
Variations on these procedures permit devices assembled onto circuit arrangements, such as memory boards, to be burned-in, along with the memory board in order to assure reliability of the circuit, as populated with devices. This closed assembly testing assumes that the devices are discretely packaged in order that it can then be performed more readily.
It is proposed that multiple integrated circuit devices be packaged as a single unit. This can be accomplished with or without conventional lead frames. This creates two problems for being conventional test methods. Firstly, discrete testing is more difficult because the conventional lead frame package is not used. Furthermore, when multiple devices are assembled into a single package, the performance of the package is reduced to that of the die with the lowest performance. In other words, the ability to presort the individual dice is limited that obtained through probe testing. Secondly, the packaging may have other limitations which are aggravated by burn-in stress conditions so that the packaging becomes a limitation for burn-in testing.
A form of hybrid integrated circuit incorporates a plurality of dice in a single package. This increases density of packaging and permits matched components on different dice to be packaged as a single part. The yield rate of such an assembly is likely to be at least a multiple of the yield rates of its component dice. As mentioned, if performance of the dice is factored in, the yield is likely to become significantly lower than the multiple of the component yield rates.
On the other hand, if the test results of burned in dice are available, the component yield rates can be increased. It is further possible to match components by matching various characterizations (such as signal timing and response times), thereby providing more margin for proper response.
Such hybrid integrated circuits, as well as other configurations establish a need for burned in semiconductor dice. Ideally, it would be desirable to permit testing of individual dice in a manner similar to that accomplished with discrete packaged semiconductor devices.
In U.S. Pat. No. 4,899,107, commonly assigned, a reusable burn-in/test fixture for discrete TAB die is provided. The fixture consists of two halves, one of which is a die cavity plate for receiving semiconductor dice as the units under test (UUT); and the other half establishes electrical contact with the dice and with a burn-in oven
The first half of the test fixture contains cavities in which die are inserted circuit side up. The die will rest on a floating platform. The second half has a rigid high temperature rated substrate, on which are mounted probes for each corresponding die pad. Each of a plurality of probes is connected to an electrical trace on the substrate (similar to a P.C. board) so that each die pad of each die is electrically isolated from one another for high speed functional testing purposes. The probe tips are arranged in an array to accommodate eight or sixteen dice.
The two halves of the test fixture are joined so that each pad on each die aligns with a corresponding probe tip. The test fixture is configured to house groups of 8 or 16 die for maximum efficiency of the functional testers.
There are some testing and related procedures when the parts are singulated. For this reason, it is inconvenient to retain multiple die in a single test fixture.
TAB tape is normally bonded at bondpads in order to establish electrical connections which exhibits long term reliability without requiring that external pressure be applied to the assembly. The bonding of the TAB tape establishes a mechanical connection which can cause the bond pads to lift off of (become detached from) the die when the TAB tape is removed.
The bondpads are conductive areas on the face of the die which are used as an interconnect for connecting the circuitry on the die to the outside world. Normally, conductors are bonded to the bondpads, but it is possible to establish electrical contact through the bondpads by biasing conductors against the bondpads without actual bonding.
SUMMARY OF THE INVENTION
It has been found desireable to perform testing and related procedures in discrete fixtures prior to final assembly. In order to accomplish this, a two piece reusable burn-in/test fixture for discrete die is provided. The fixture consists of two halves, one of which is a die cavity plate for receiving a semiconductor die as the units under test (UUT).
In a first embodiment, a die is placed face up in a cavity in a first half of the fixture. A die contact member is used to establish contact with bondpads on the die, and to conduct between the bondpads and external connector leads on the fixture.
The contact between the bondpads and the external connector leads is preferably established by utilizing non-bonded TAB (tape automated bonding) technology. Conductors on the non-bonded TAB tape extend from the bondpads to connection points, and the connection points conduct to contacts, which are in turn in communication with the external connector leads.
The non-bonded TAB tape is essentially similar to conventional TAB interconnect methods, except that its connection function may be performed without permanently bonding the TAB tape to the die. In order to maintain contact with circuitry on the die, the non-bonded TAB tape is biased against the die when the burn-in/test fixture is assembled. The non-bonded contact of the non-bonded TAB tape applies primarily to the die pads. Contact between the tape and other conductors may also be non-bonded contact, although the attachment of the TAB tape to the fixture may be effected either without permanent bonding, or by bonding techniques. The non-bonded TAB tape is biased against the die, preferably by a compressible elastomeric pad.
In the preferred form of that embodiment, the external connector leads are connector pins, which preferably are in a DIP (dual inline plug) or QFP (quad flat pack) configuration. The pins terminate as the connection points.
In an alternate form of that embodiment, the conductors on the non-bonded TAB tape conduct to the top of the tape, and attachment of the second half of the fixture establishes an electrical connection between the conductors and the external connection leads, either through the second half or through a separate conductor.
The fixture establishes electrical contact with the a single die and with a burn-in oven, as well as permitting testing of dice in discretely packaged form.
In another embodiment of the invention, a two piece reusable burn-in/test fixture for discrete die is provided. The first half of the test fixture contains a cavity in which a die is inserted circuit side up. The die will rest on a floating platform. The second half has a probe for each die pad. Each probe is connected to an electrical connector which can be used for attachment to a burn-in board and may be used for connection to a discrete circuit tester.
The probes can take several forms. Deposited conductors would be similar to the use of non-bonded TAB tape, except that the deposited conductors could be located on a fixed substrate. Conductive elastomers may be used, in which the conductive elastomer is used to establish electrical communication between the die, at the bondpads, and the external connection leads. Biased metal probes, such as probe wires, may be used.
In a third embodiment, the die is placed face up in a cavity in a first half of the fixture. A second half of the fixture includes external connector leads and is used to establish contact with bondpads on the die. Attachment of the die to the external connection leads is established either through contact points on the second half, or through an intermediate member, such as a non-bonded TAB tape.
In a fourth embodiment, the die is placed face down in a fixture which includes die receiving cavity. Contact with bondpads on the die are established in order that the bondpads are in electrical communication with external connector leads on the fixture.
In that embodiment, the probes and the electrical connector are located on the second half. In the preferred form of that embodiment, the electrical connector extends upward from the face of the circuit side of the die, so that the fixture is normally connected to a tester with the integrated circuit side of the die facing down.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 show a preferred embodiment of the inventive burn-in fixture;
FIG. 3 shows details of non-bonded TAB tape used with the invention;
FIG. 4 shows a modification to the embodiment of FIGS. 1 and 2, in which a modified cover plate has conductive polymer contacts.
FIG. 5 shows an embodiment in which a die cavity housing is used for connections between the die and external connection pins;
FIG. 6 shows an alternate embodiment of a test package, in which an upper portion is used to connect the die to external test circuitry;
FIG. 7 shows a modification to the embodiment of FIGS. 1 and 2, in which contact pins are used for connections between the die and external connection pins; and
FIG. 8 shows a modification of the invention, in which flexible tape is used to directly connect the die to an external connector connected to external test circuitry.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the inventive burn-in fixture 11 includes a die cavity plate, 13 and a cover 15. The die cavity plate 13 includes a die receiving cavity 17.
The die receiving cavity 17 has dimensions which are at least sufficient to accommodate a die 21. The die 21 is to be connected at bondpads 27, which are typically 0.1 mm wide. For this reason, it is advantageous to provide a spacer plate 29 which fits within the die receiving cavity 17 and the die 21, and which precisely positions the die 21 for subsequent alignment. The die cavity plate also has a slot 31 which permits convenient access to the bottom of the die 21 in order that the die 21 may be lifted out of the die receiving cavity 21.
A plurality of external connector leads 33 extend from the burn in fixture 11. As can be seen in FIG. 2, in the preferred embodiment, the external connector leads 33 are attached to the die cavity plate 13, and extend therefrom. The external connector leads 33 are shown as connector pins, which preferably are in a DIP (dual inline plug) or QFP (quad flat pack) configuration.
The external connector leads 33 are secured by the die cavity plate 13 and terminate on the die cavity plate 13 with contact pads 37. The contact pads 37 are in approximate planar alignment with the bondpads 27.
Referring to FIGS. 1 and 2, contact between the bondpads 27 and the external connector leads 33 is established by non-bonded TAB (tape automated bonding) tape 41, shown in FIG. 3.
The non-bonded TAB tape 41 is essentially similar to conventional TAB tape methods, except that its connection function may be performed without bonding the TAB tape 41 to the die 21. In order to maintain contact with the bondpads 27, the non-bonded TAB tape 41 is biased against the die 21 when the burn-in/test fixture 11 is assembled. This enables the non-bonded TAB tape 41 to be lifted from the die 21 without destroying the bondpads 27.
The non-bonded TAB tape 41 includes a plastic film 43, preferably formed of polyamide, onto which are formed a plurality of conductive traces 45. The conductive traces 45 have bumps 47, 48 which are intended for registration with a bondpad 27 or a contact pad 37. The conductive traces 45 therefore are able to conduct signals between the bondpads 27 and the contact pads 37.
It is possible to bond the TAB tape 41 to the bondpads 27, if such a bond could be made reversible. That would require that the bond be generally weaker than the attachment of the bondpad 27 to the die 21. This would necessitate a weak bond, or an other means to permit the die to be separated from the fixture 11.
It is also possible to permanently bond the TAB tape 41 to the die 21, and to retain the attachment to the TAB tape 41 to the die 21 subsequent to burn in.
The cover 15 includes a rigid cover plate 51 and a resilient compressible elastomeric strip 53, which serves as a biasing member 53. When the cover plate 51 is secured to the die cavity plate 13, the resilient biasing member 53 biases the non-bonded TAB tape 41 against the die 21. This establishes an ohmic contact between the bondpads 27 and the conductive traces on the non-bonded TAB tape 41, without the TAB tape 41 being bonded to the bondpads 27.
The non-bonded contact of the non-bonded TAB tape 41 applies primarily to the bondpads 27. Contact between the TAB tape 41 and the contact pads 37 on the fixture 11 may be effected by bonding techniques. Such bonding is not expected to deteriorate the fixture 11, even though the fixture is used multiple times. If bonding is used for such contact, then the conductive material from the TAB tape may remain with the fixture 11, but without detriment to the operation of the fixture 11.
Positioning pins 57 are used to align the cover plate 51 with the die cavity plate 13. A clamp 61 then secures the cover plate 51 in place over the die cavity plate 13. The clamp 61 may consist of a wire clasp which may either be latched into place against itself, as shown, or is fitted into parallel horizontal locations in the die cavity plate 13 and the cover plate 51. With the cover plate 51 in place, conductors on the non-bonded TAB tape 41 extend from the bondpads 27 to the contact pads 37, so that the bondpads 27 are in electrical communication with the external connector leads 33.
FIG. 4 shows a modification to the embodiment of FIGS. 1 and 2, in which a modified cover plate 71 uses conductive polymer contacts 73 in order to establish contact with the bondpads 27. Contact with the external connector leads 33 is established by electrical contacts 75 on the cover plate 71, and these contacts 75 may be either conductive polymer or metallic.
FIG. 5 shows an embodiment in which a die cavity housing 91 has conductive polymer contacts 93. The die 21 is placed face down, so as to establish connect ion between the bondpads 27 and the polymer contacts 93.
In an alternate embodiment of a package 101, shown in FIG. 6, a die receiving housing 103 is used to retain a die 21, and an upper portion 105 is used to connect the die 21 to external test circuitry, by the use of external connector pins 107. The die receiving housing 103 contains a die receiving cavity 109, which supports the die 21 in alignment with electrical contacts 111 which contact bondpads 27 on the die 21. A biasing plate 115 biases the die 21 against the contacts 111. In one embodiment of this configuration, the contacts 111 are metallic, although other conductors may be used for the contacts 111. As an example, it is possible to use conductive polymer for the contacts 111.
In an embodiment shown in FIG. 7, contact pins 123 are used to connect to the bondpads 27 on the die 21. The contact pins 123 are mounted to a dielectric cover 125, and electrical continuity between the contact pins 123 and base portions 127 of external connector pins 129 is established when the cover 125 is mounted to a die cavity housing 131. A resilient pad 135 secures the die 21 in position in the housing 131.
The contacts 123 are pin type contacts, which are similar to probe contacts. Because of the relatively precise alignment of the cover 125 with respect to the die 21, it is possible to design the contacts 123 to have a relatively low biasing force, while still maintaining good ohmic contact between the bondpads 27 and the contacts 123.
FIG. 8 shows a configuration in which a housing fixture 141 merely retains the die 21 in a predetermined positional alignment, and in electrical communication with non-bonded TAB tape 143. The TAB tape 143 extends beyond the confines of the fixture 141 and terminates in an external connector 147.
While specific locations for bondpads had not been specified, it is possible to test a variety of configurations, including the conventional arrangement of bondpads at the ends of the die 21. The invention may also be used for testing die configured for LOC (leads over chip), as well as other designs. In each of the above examples, the assembled fixture is adapted into conventional test equipment, such as a burn-in oven. What has been described is a very specific configuration of a test fixture. Clearly, modification to the existing apparatus can be made within the scope of the invention. Accordingly, the invention should be read only as limited by the claims. | A reusable burn-in/test fixture for discrete TAB die consists of two halves. The first half of the test fixture contains cavity in which die is inserted. When the two halves are assembled, the fixture establishes electrical contact with the die and with a burn-in oven. The test fixture need not be opened until the burn-in and electrical test are completed. The fixture permits the die to be characterized prior to assembly. | 7 |
This is a continuation of Ser. No. 107,834, filed on Oct. 6, 1987 filed as PCT/FI87/00021 on Feb. 10, 1987, published as WO87/04655 on Aug. 13, 1987, now U.S. Pat. No. 4,827,816.
The present invention relates to a cutting apparatus, to especially a tube cutting apparatus.
The publication SE-421 499 discloses a cutting apparatus having a cutting blade and means for rotating the tube to be cut during the cutting operation. The cutting blade and the means for rotating the tube are disposed separately from each other and each of them has its own driving mechanism. The cutting blade is arranged to be moved pivotally in a direction perpendicular to the longitudinal axis of the tube during the cutting operation. The constructions of such prior the art apparatus is deficient as far as the function and construction is concerned.
BACKGROUND OF THE INVENTION
The object of this invention is to provide a cutting apparatus, by means of which a simple and functionally reliable cutting is possible. The cutting apparatus will be particularly suitable for rigid tubes, of which cores or barrels made of board can be mentioned as an example.
SUMMARY OF THE PRESENT INVENTION
The apparatus according to present invention comprises means, which support the tube during the cutting operation and at the same time enable the rotatory movement of the tube about its longitudinal axis The apparatus further comprises a cutting blade and means for rotating the tube, which both are disposed substantially concentrically onto a common shaft. Connected with this shaft, there are both means for rotating the shaft about its longitudinal axis and means for moving the shaft in a direction perpendicular to the longitudinal axis of the tube to be cut.
The means for rotating the tube has a greater diameter than the cutting blade and it has a certain elasticity in a direction perpendicular to the shaft. In this case the means for rotating the tube reaches first the surface of the tube during the first stage of the cutting operation and the tube starts to rotate about its longitudinal axis with a peripheral speed equal to that of the rotating means. The rotatory movement of the shaft is thus transmitted to the tube, which starts to rotate supported by its support means. When the movement of the shaft towards the longitudinal axis of the tube to be cut is continued, the rotating means, due to the elasticity in the radial direction allows the cutting blade to start to effect on the cutting point of the tube by the cutting edge while the tube continues to rotate about its longitudinal axis. This is possible because the contact between the outer surface of the tube to be cut and the elastic means mounted on the shaft is maintained. After the blade has carried out the cutting operation, the shaft is moved away from the center axis of the tube and at the same time the member rotating the tube is expanding in its radial direction to its original dimensions. The means guarantees in the final stage of this movement, that the blade will be detached from the cutting point, because this elastic means is the last to be in contact with the outer surface of the tube after the cutting has been done. In a summary, the rotatory movement of the tube about its longitudinal axis, the rotatory movement of the cutting blade, the feed movement during the cutting and a reliable return movement after the cutting, are all achieved by means of a simple construction.
According to a preferred embodiment of the present invention, the elastic member for rotating the tube is an inflatable tire placed round the center wheel, which is fixed to the shaft This makes the realization of the invention possible in a constructionally simple and reliable way.
The present invention will be described in more detail in the following description with reference to the accompanying drawings. In the drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus using the cutting device according to the invention and
FIG. 2 is a partial sectional view of the cutting device seen in a direction perpendicular to the longitudinal axes of the shaft and the tube to be cut.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus illustrated in FIG. 1 comprises an elongate body member 1, which is shown partially cut and in which the cutting assembly for cutting the tubular blank 3 (represented by broken lines) is mounted. The body construction 1 comprises vertical rollers 4 acting as means for supporting the tubular blank 3 to be cut. The rollers are aligned one after the other in the longitudinal direction of the tubular blank 3 and are arranged at the both sides of the tubular blank so that the rollers can rotate about their longitudinal axes parallel to the longitudinal axis of the tubular blank 3. The tubular blank to be cut rests on these rollers. The tubular blank 3 to be cut is fed towards the cutting assembly 2 successively in accordance with the length of the pieces to be severed off the tubular blank. The feeding operation is carried out by the feed assembly 5 for the tubular blank and it comprises a pusher head 6, which is arranged to be moved in the direction of the feed shown by arrow 7, for example by means of a belt drive 8 shown in the figure and the pusher head 6 is guided by rails (not shown). The feed assembly comprises further a back stop 9 adjustable in the longitudinal direction of the tubular blank and contacting the front end 10 of the tubular blank 3 after each feeding movement of the pusher head 6 in the feed direction 7. The back stop 9 is coupled to the drive motor of the belt 8 of the pusher head 6 and the motor will stop as the front end 10 of the tubular blank 3 contacts the back stop 9.
The apparatus further comprises an intermediate storage 12 for the severed tubular pieces 11. The pieces 11 are transferred from the body member 1 for example by means of a pusher (not shown in the drawings) before a new feeding movement of the tubular blank. In the construction shown by FIG. 1, the pusher head 6 abuts the rear end 13 of the tubular blank 3. It is clear, that the feed assembly 5, as far as the pusher head 6 is concerned, can be constructionally realized also in various other ways.
FIG. 1 shows further an assembly for bringing the stopping piece 14 used in the cutting operation to the cutting point as well as for holding the stopping piece at the cutting point The stopping piece 14 is a formed piece having a cross section, which corresponds substantially to the cross section of the core hole of the tubular blank 3 to be cut. The stopping piece 14 has usually the shape of a cylinder and its front end in the feed direction is preferably rounded. A flexible elongate member 15, such as a wire rope, a chain or the like is fixed to its rear end in feed direction. The flexible member 15 is connected with a collecting member 16, such as a reel, which is arranged to rotate about a horizontal shaft 17 mounted in the body construction 1. The flexible member 15 is wound and unwound on its outer periphery.
The flexible member 15 can be a wire rope or the like. The force needed for the transfer is obtained by blowing air with a air compressing device 18 in to the tubular blank to be cut. The device comprises a tank 19 and a hose 20 for the compressed air as well as a hole 21 going through the pusher head 6 and in connection with the core hole of the tubular blank 3 to be cut. By means of the compressed air, a force directed onto the rear surface of the stopping piece 14 is obtained and the stopping piece 14 moves under this influence from the rear end 13 of the tubular blank 3 to the cutting point and at the same time the flexible member unwinds from the collecting member 16, whose rotation about its shaft 17 is so restricted, that the stopping piece 14 stops at the cutting point held by the flexible member. The flexible member extends through the pusher head 6 for example through the hole 21 or through a separate hole (not shown in FIG. 1). The abutting surface of the pusher head 6 is dimensioned at the rear end 13 of the tubular blank 3 so, that it covers the core hole of the tubular blank thus increasing the effect of the compressed air on the stopping piece.
The stopping piece 14 can be brought to the cutting point also by merely pushing with a chain. There are commercially available chains, by means of which pushing forces directed to the chain can be transmitted at least to a certain extent. As the outer surface of the stopping piece is formed so that its frictional characteristics will be adapted to the characteristics of the inner surface of the tubular blank to obtain a minimum friction between the inner surface of the tubular blank 3 and the outer surface of the stopping piece 14, the chain is not subjected to any greater bearing stress
FIG. 1 shows further the storage for stopping pieces on the right side of the compressed air device 18.
The storage contains various stopping pieces 14', whose dimensions fit with the tubes of different sizes. A new tubular blank can be fed onto the rollers 4 of the apparatus in the direction of arrow S.
The stopping piece 14 as well as assemblies associated therewith are described in more detail in a co-pending FI-patent application No. 860630 by the same applicant, relating to a tube cutting apparatus.
The cutting assembly 2 comprises an upright beam 22 fixed on the body member 1 and bearing at its upper portion a horizontal beam 23 directed towards the body member 1. Underneath the horizontal beam 23, a moving beam 24 is pivotally fixed to the 15 upright beam 22 at a point of articulation 25, and it is pivotable in a vertical plane. The pivotal movement and at the same time the feed movement of the cutting device 26 towards the central axis of the tubular blank 3 is effected by an operational device 27, such as a pneumatic cylinder, which is disposed between the horizontal beam 23 and the moving beam 24.
FIG. 2 shows the structure the cutting device 26 in more detail as a partially sectional view seeing in a direction perpendicular to the longitudinal directions of the shaft 28 and the central axis of the tubular blank 3. The shaft 28 is rotatably mounted in the moving beam 24 by means of a bearing 30. The drive motor 31 of the shaft 28 is secured to the moving beam 24 with fixing means 32, 33. The drive shaft 34 of the motor 31 can be coupled to the shaft 28 with any previously known clutch means. On the opposite side of the moving beam 24 remote from the drive motor 31, a bearing 35 is disposed allowing the means 36 to rotate relative to the side surface of the moving beam 24. The means 36 is separated from the cutting blade 38 with the aid of a intermediate bushing 37 and the parts 36, 37 and 38 are secured on the shaft 28 by a fixing nut 39, which through a base plate 40 effects on the said parts pressing these to a combination acting as an integral unit.
The cutting assembly can be naturally realized constructionally in many various ways. An essential feature of this kind of construction is, that the cutting assembly can be transferred as an integral unit towards the tubular blank 3 as shown by arrow 41 and at the same time the assembly constituted of the means 36 and the cutting blade 38 can be rotated about the shaft 28 as shown by arrow 42.
The means 36 can be for example an inflatable rubber tire 43 placed round the center wheel 44 on the shaft 28. The air space within the tire makes the compression of the tire possible as the shaft 28 is fed in the direction of arrow 41. The shape of the cross section of the tire at the end stage of the cutting operation is represented by broken lines 45. The cutting blade 38 has preferably a circular and disc-like shape and its cutting edge is located on its outer periphery The diameter of the cutting blade is smaller than the outer diameter of the means 36 as the means 36 is in its rest position free of contact with the outer surface of the tubular blank 3. Due to this feature, a distance R shown in FIG. 2 exists, because the means 36 and the cutting blade 38 are fixed concentrically on the shaft 28 and this distance makes the above described function during the cutting operation possible. The cutting point is represented in FIG. 2 by a broken line 46.
It is clear, that the cutting device can be provided also in apparatuses different from that presented in the above description. Also the cutting assembly 2 and the construction of the cutting device 26 must be regarded as one of the various possibilities within the scope of the invention. | A tube cutting apparatus includes a stopping element positioned inside the tubular blank to be cut. The stopping element is movable inside the tube to cutting position. The stopping member is transferred and held at the cutting position by a flexible member attached to the stopping member. A collecting member is provided to reel in and store the flexible member when the stopping member is moved to a stored position. | 8 |
The invention herein described was made in the course of or under a contract or subcontract thereunder with the National Science Foundation.
BACKGROUND OF THE INVENTION
A recently developed type of secondary or rechargeable electrical conversion device comprises: (1) an anodic reaction zone containing a molten alkali metal anode-reactant, e.g., sodium, in electrical contact with an external circuit; (2) a cathodic reaction zone containing [a] a cathodic reactant comprising sulfur or a mixture of sulfur and molten polysulfide, which is electrochemically reversible reactive with the anodic reactant; [b] a solid electrolyte comprising a cation-permeable barrier to mass liquid transfer interposed between and in contact with the anodic and the cathodic reaction zones; and [c] electrode devices within the cathodic reaction zone for transporting electrons to and from the vicinity of the cation-permeable barrier. As used herein the term "reactant" is intended to mean both reactants and reaction products.
During the discharge cycle of such a device, molten alkali metal atoms such as sodium surrender an electron to an external circuit and the resulting cation passes through the solid electrolyte barrier and into the liquid electrolyte to unite with polysulfide ions. The polysulfide ions are formed by charge transfer on the electrode by reaction of the cathodic reactant with the electrons conducted through the electrode from the external circuit. Because the ionic conductivity of the liquid electrolyte is less than the electronic conductivity of the electrode material, it is desirable during discharge that both electrons and sulfur be applied to and distributed along the surface of the electrode in the vicinity of the cation-permeable solid electrolyte.
During the charge cycle of such a device when a negative potential larger than the open circuit cell voltage is applied to the anode the opposite process occurs. Thus, electrons are removed from the alkali metal polysulfide by charge transfer at the surface of the electrode and are conducted through the electrode material to the external circuit, and the alkali metal cation is conducted through the liquid electrolyte and solid electrolyte to the anode where it accepts an electron from the external circuit. Because of the aforementioned relative conductivities of the ionic and electronic phases, this charging process occurs preferentially in the vicinity of the solid electrolyte and leaves behind molten elemental sulfer.
It is the principal object of this invention to provide a structure for containing an alkali metal battery in which electrical insulation is provided between the anodic and cathodic reaction zones and a secure seal is formed so that the reactants are not lost from the battery.
SUMMARY OF THE INVENTION
This invention is directed to a structure for containing an alkali metal battery and, more particularly, to a structure for containing such a battery which provides effective electrical insulation of the battery's anodic and cathodic zones and a seal against loss of reactants from such zones.
In accordance with the general principles of this invention, a structure for containing an alkali metal battery includes a ceramic ring having top and bottom surfaces. An inner casing formed of a solid alkali ion-conductive material and having an open end and a closed end is attached near its open end to an interior surface of the ceramic ring so that the inner casing extends downwardly from the bottom surface of the ceramic ring.
A first metal outer casing with an open end and a closed end surrounds the inner casing and is speced therefrom. The open end of the first casing is located adjacent the bottom surface of the ceramic ring. A second metal outer casing has an open end and a closed end. The open end of the second metal outer casing is located adjacent the top surface of the ceramic ring. A pressure accepting shoulder is formed on the second metal outer casing near its open end.
A metal pressure sleeve has both an open end and an end having a pressure applying shoulder formed thereon. The open end of the pressure sleeve encircles the first metal casing and is bonded thereto at such a position that the pressure applying shoulder thereof applys pressure to said pressure accepting shoulder of the second metal outer casing. This action brings the open ends of the first and the second metal outer casings respectively into engagement with the bottom and the top surfaces of the ceramic ring to provide liquid tight seals therebetween. Electrical insulation is provided between the pressure applying shoulder and the pressure receiving shoulder for electrically insulating the first metal outer casing from the second metal outer casing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view, in cross-section, of the alkali metal battery of this invention in a disassembled condition.
FIG. 2 is an elevation view, in cross-section, of the hermetically sealed alkali metal battery of this invention in an assembled condition.
FIGS. 3 and 4 are elevation views, in cross-section, of alternate forms of construction for a portion of the alkali metal battery of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The type of secondary electrical conversion batteries to which this invention relates are disclosed in the following U.S. Pat. Nos.: 3,404,035; 3,404,036; 3,446,677; 3,458,356; 3,468,709; 3,468,719; 3,475,220; 3,475,223; 3,475,225; 3,535,163 3,719,531; and 3,811,493.
In FIGS. 1 and 2 there is seen a hermetically sealed alkali metal battery designated generally by numeral 10. This battery includes a ceramic ring 12 which has a top surface 14 and a bottom surface 16. The ceramic material may be formed from a material such as alpha alumina of high purity, such as 99.8%.
An inner casing 18 of a solid alkali ion-conductive material is in the form of a closed end tube. This casing is used as a reaction zone separator and is made from a material which will permit the transfer of ions of an anodic reactant therethrough to a cathodic reactant. The barrier may have a thickness in the range of about 20 to 2,000 microns and may be made of material such as glasses and polycrystalline ceramic materials as is well known in the art. One material which is extremely useful is beta-type alumina or sodium beta-type alumina. The inner casing is bonded near its open end within and to an interior surface 20 of the ceramic ring 12 by means of a glass seal 22 so that the inner casing extends downwardly from the bottom surface 16 of the ceramic ring.
A first outer metal casing 24 has an open end 26 and a closed end 28. This casing surrounds the inner casing 18 and is spaced therefrom. This casing is made from metal such as 446 stainless steel. The first metal casing has an enlarged diameter portion 30 near its open end 26. The purpose of this enlargement will be described later.
A second metal casing 32 also has an open end 34 and a closed end 36. As viewed in FIG. 2, this second metal outer casing is located with its open end in contact with the top 14 of the ceramic ring 12. The second metal outer casing member also has a pressure accepting shoulder 38 formed about the diameter of the casing near its open end. The purpose of this shoulder will be described later. The shoulder also has an electrical insulating member 39 thereon. This can be made of nickel oxide for example. The second metal casing may be made from the same material as the first metal casing.
A metal pressure sleeve 40 has a lower open end 42 which has the same internal diameter as the outside diameter of the enlarged diameter portion 30 of the first metal casing 24. The lower end of the pressure sleeve has a first set of openings 44 therethrough on opposite sides thereof as well as a second set of openings 46 on opposite sides thereof. The purpose of both sets of openings will be described later. The pressure sleeve also has an upper open end 48. A pressure applying shoulder 50 is formed on the upper open end of the pressure sleeve.
Having generally described the parts of the assembly making up the alkali metal battery of my invention, I will now describe how the battery is assembled.
Reference is made to FIG. 2. In order to assemble an alkali metal battery 10 of this invention, the closed end of 28 of the first metal casing 24 is positioned in a holding fixture 60. The ceramic ring, with the inner casing 18 projecting downwardly therefrom, is placed inside the first metal casing so that the bottom surface 16 of the ceramic ring comes in contact with the edge defining the open end 26 of the first metal casing. The second metal casing 32 is positioned such that its open end 34 comes in contact with the top 14 of the ceramic ring 12. The pressure sleeve 40 is then positioned over the second metal casing and pulling members 62 having projecting portions 64 thereon are arranged so that the projecting portions thereof are received within the first set of openings 44 in the lower open end 42 of the pressure sleeve 40.
The pulling members 62 are moved downwardly as viewed in FIG. 2. Such action brings the pressure applying shoulder 50 of the pressure sleeve 40 into engagement with the pressure accepting shoulder 38 of the second metal casing 32, such action putting the pressure sleeve into tension. This action brings both the open end 34 of the second metal casing into engagement with the top surface 14 of the ceramic ring 12 and the open end 26 of the first metal casing 24 firmly into engagement with the bottom 16 of the ceramic ring putting these casings into compression. As the pulling members 62 hold the pressure applying shoulder 50 and the pressure accepting shoulder 38 with the interposed electrical insulating member 39 in a pressure contact relationship, weldments are formed between the pressure sleeve 40 and the first metal casing 24. These weldments are formed at the second set of openings 46 which are located over the enlarged diameter portion 30 of the first metal casing. When the weldments have been formed, the pulling members 62 are released and removed from the openings 44 but the various parts of the battery remain in tension and compression. This completes the assembly of the battery 10.
In FIG. 3, a slightly different approach to sealing an alkali metal battery is shown which uses the same general concept as shown in FIGS. 1 and 2. In this FIG. 3, similar numbers depict similar parts. With reference to FIG. 3, a pressure sleeve 140 has a pressure applying shoulder 142 and a pressure accepting shoulder 144. In this design, there is a metal O-ring 146, a wedge 148 and an electrical insulator band 150 between the pressure applying shoulder 142 and the pressure accepting shoulder 38. A pressure applying ring 152 encircles and engages the pressure accepting shoulder 144 of the pressure sleeve 140. When the first metal casing 24 is seated on a stationary surface and pressure applied by the pressure applying ring 150, the pressure applying shoulder 142 acts on the O-ring 146, the wedge 148, the insulator band 150 and the pressure accepting shoulder 38 of the second metal casing 32. This action forces the open end of the first metal casing into contact with the top surface 14 of the ceramic ring 12 and the open end of the first metal casing 24 into engagement with the bottom surface 16 of the ceramic ring. When these elements are all in firm contact, the pressure sleeve 140 is welded near its bottom end by a weldment 154 to the first metal casing thereby to complete assembly of the hermetically sealed alkali metal battery.
In FIG. 4, another embodiment of the apparatus of this invention is disclosed. In this embodiment, a pressure sleeve 240 has a pressure applying shoulder 242 which acts on an insulator band 244 and an O-ring 246 to apply pressure to a portion of the open end of the second metal casing 32 folded under the O-ring. Pressure, of course, is applied on the pressure sleeve in the directions of the arrows in FIG. 4 to form a hermetic seal. As in the other embodiments, the pressure sleeve 240 is welded to the first outer metal casing 24 when all of the elements have been drawn into proper sealing contact.
There has been disclosed herein a sealed alkali metal battery system. Many modifications of this system may be made by those skilled in the art which fall within the true spirit of this invention. It is intended that all such modifications be included wthin the scope of the appended claims. | The invention is embodied in a hermetically sealed alkali metal battery container. Two opposed outer metallic casings each having an open end and a closed end are hermetically sealed to a ceramic ring which supports an inner casing of a solid alkali ion-conductive material. The hermetic seal is accomplished by means of a pressure accepting shoulder formed on one of the casings and a metal pressure sleeve which acts on the shoulder to draw the open ends of each of the casings into sealing engagement respectively with upper and lower surfaces of the ceramic ring. | 7 |
FIELD OF THE INVENTION
The invention is connected to biodegradable films made containing proteins, particularly containing caseinate, and their method of manufacture.
BACKGROUND
Plastic materials are very present in our environment. They are found everywhere and they contribute considerably to improve the well-being of humans. The reasons justifying their industrial and domestic uses are that plastics are light materials, resistant, chemically inert and economical to produce.
The extent and usefulness of plastic materials are incalculable. In spite of their benefits, they presently cause a serious problem of environmental pollution which can no longer be ignore. The recycling or the re-use of some plastic compounds only partially improves the situation, thus the interest to develop partially or totally biodegradable films.
At present, consumers require greater quality and longer shelf lives for their foodstuffs. At the same time, they demand a reduction in the quantity of packing materials used. Plastic represents one of the principal components used for the packaging of our consumer products. In 1992, according to Canada's Green Plan, packaging accounted for approximately 30% of solid waste of Canadian municipalities. As packaging and other plastics are basically resistant to the attacks of bacteria present in nature, it is no longer ecologically acceptable to dispose of our plastic wastes by burying them underground or discharging into the ocean. Alternatives to these means of disposal are thus recycling, incineration, composting and biological breakdown. Following the sensitizing of federal authorities to this problem, a national protocol on packaging was signed in April 1990 which aims at reducing wastes coming from packaging by 50% before the year 2000 (Supply and Services Canada).
Over the last few years, the general population has become more sensitized to the problems of pollution caused by plastics. This made it possible to develop starch based plastic films which are currently on the market (Pledge, 1990). The presence of starch contributes to facilitate the microbial attack via the enzymatic systems. The ultimate result sought by the addition of starch is the loss of structural integrity which translates into a loss in the molecular weight of plastic films.
At present, an active research continues in order to produce a biodegradable film which would not be detrimental for the environment and which would have the characteristics of plastic packaging. Then, one must look for a compound which would be initially biodegradable, which would resist thermal denaturation and which would show certain properties of plastic packaging.
The majority of films which are considered biodegradable are formed simply by the solubilization of degradable components in a suitable solvent. Until now, research was undertaken on films containing polysaccharides, proteins and lipids alone or in combination. Usually, the fool films are formed starting from polymers of high molecular weight in order to provide a sufficiently resistant and adherent matrix. The characteristics of the matrix will depend on the chemical structure of the polymer, on the presence of plasticizing agents and on the way in which the film is applied to the surface of products. The application of coating films to the surface of products is done by steeping, pulverization or extrusion. The principal properties sought for packaging films are resistance, malleability, impermeability to gases and moisture and the possibilities of conditioning.
A polymer is obtained by the polymerization of a monomer in order to form continuous and/or branched polymeric chains. In the case of plastic components, this polymerization is generally carried out either by heat (thermoplastic) as for the poly-iminocarbonate (Li and Kohn, 1989), or by a photosynthesis with ultraviolet radiation as for the formation of acrylic resin and methacrylic (Ciardelli et al., 1989). It is also possible to obtain polyurethane by gamma irradiation (Shintani and Nakamura, 1991). At more than 25 kGy, the effect of irradiation on polymer is limited mainly to intermolecular polymerization with little or no degradation. Proteinic polymerization can be also carried out by enzymatic processes. Indeed, collagen polymers (Richard-Blum and Ville, 1988), casein α sl , (Moloki and Al, 1987) and fibrin (Kasai and Al, 1983) were obtained in this way.
A film's cohesive strength is linked to its polymeric and chemical structure, to the nature of solvent used, to the presence of plasticizing agents or additives and to the surrounding conditions during the formation of the film (Kester and Fennema, 1986).
A direct link exists between the cohesion of film and the length and the polarity of the chains of the polymer. A uniform distribution of the polar groupings along the polymeric chains increases cohesion by increasing the probability of ionic interactions and hydrogen bonding between the chains (Banker, 1966). Generally, when one increases the cohesive structure of a film, a reduction in its flexibility, its porosity and its permeability to gas, vapor and aqueous solutions is observed (Kester and Fennema, 1986). For example, the stability of the tertiary structure of a protein affects the formation of a film and the properties resulting from film, that is, molecular flexibility, contributes to the formation of cohesive films (Graham and Phillips, 1980).
The solvents used for the formation of edible films are limited to water, ethanol or a combination of both (Kester and Fennema, 1986). Tests with ammonia and acetic acid were carried out but a problem with odor limits their use. After its evaporation, ammonia has a persistent odor which is evident on the end product (Gontard et al., 1992).
The plasticizing agents are usually grouped in the polyol family such as glycerol, sucrose and others. They can be introduced in order to give flexibility to films thereby improving their mechanical properties. The plasticizing characteristic is obtained by reducing the intermolecular forces thus affecting the film structure and increasing the mobility of the polymer chains. However, the relaxation of the film structure reduces the ability of film to act as a barrier to the diffusion of several gases and vapors (Gennadios and Weller, 1990; Peyron, 1991).
Environmental conditions influence film cohesiveness. Excessive temperatures during drying result in rapid solvent evaporation. Theses conditions can prematurely immobilize the polymeric chains before they have gathered to form a continuous and coherent film (Banker, 1996). This can generate certain defects like micro-perforations or a non-uniform thickness which inevitably will increase the permeability of film.
Polysaccharide-Based Films
Many polysaccharides were experimentally evaluated for their capacity to form films. Among others, one thinks of alginate, pectin, carrageenans, starch and cellulose derivatives. Polysaccharide polymers show excellent O 2 impermeability, however, they offer minimal resistance to moisture due to their absorbent character. Only films containing cellulose derivatives have remarkable impermeability to water (Kanig and Goodman, 1962; Kester and Fennema, 1986; Peyron, 1991). The principal inconvenience of polymers containing polysaccharides is that they are poor barrier to micro-organisms (Kester and Fennema, 1986; Peyron, 1991; Torres and Karel, 1985). Tests carried out with coated ground beef showed these films to be an effective protection against oxidation but showed no protection against surface bacteria (Peyron, 1991).
Lipid and Wax Based Films
Lipid based films offer excellent impermeability to moisture because of their low polarity (Feuge, 1955, Kester and Fennema, 1986; Peyron, 1991).
So far, a great range of lipids were used for the preparation of film consisting of monoglycerides, natural waxes and surface agents.
Monoglycerides
A characteristic of solid state monoglycerides is their elastic property. The majority of lipids of this type can extent up to 120% of their initial length before they break whereas acetylated glycerol monostearate can extend up to 800% its initial length before it breaks (Kester and Fennema, 1986; Peyron, 1991). It is thus a product which can be stretched easily and which shows strength with respect to mechanical constraints. These characteristics are interesting for the production of coating film.
The permeability of films produced using acetylated monoglycerides to steam is largely lower than films containing polysaccharides but it is nevertheless higher than those films containing cellulose derivatives (Kanig and Goodman, 1962). Resistance of acetylated monoglycerides to moisture transport is very dependent on the gradient of steam pressure on each side of the film (Lovergren and Feuge, 1954). Coating by acetoglyceride films made it possible to show that these provided a certain protection against surface microbial contamination (Peyron, 1991).
Natural Waxes
Natural waxes are more resistant to moisture transport than all other lipidic or non-lipidic films. On the other hand, the waxes do not adhere very well to very wet surfaces due to their very hydrophobic character (Kester and Fennema, 1988). In order to avoid any process of anaerobic degradation during the coating of a food, it is sometimes preferable to add acetylated monoglycerides to waxes in order to increase their flexibility and therefore to decrease their resistance to water and gas permeability (Kester and Fennema, 1986; Peyron, 1991).
Surface Agents
Surface agents or surface-active lipids reduce water activity (a w which represents available water) on the surface of a foodstuff. They have the property to reduce the rate of moisture loss during storage. The a w variable influences the deterioration mechanisms of foodstuffs. A weak a w value delays microbial growth as well as surface chemical and enzymatic reaction (Kester and Fennema, 1986). Therefore, coating food with a surface agent should contribute to modify these modes of deterioration by controlling the migration of water on the surface of food.
The ability to reduce evaporation is influenced by the structure of the surface agent used. The most effective surface agents are those which have a chain of 16 to 18 carbons. The presence of a double bond in the carbon chain strongly decreases the proofing properties of the coating (Kester and Fennema, 1986; Peyron, 1991).
Proteinic Films
Proteinic films offer better mechanical properties but their permeability to gases and moisture are variable. An acid treatment (towards the isoelectric point) improves resistance to moisture transport since this treatment decreases the mobility of the polymer chains (Kester and Fennema, 1986; Peyron, 1991).
Whey Proteins
Whey (mainly α-lactalbumine and β-lactoglobuline) or small-milk proteins, form a thermoirreversible gel, which is pH-dependent and heat sensitive (Schmidt and Morris, 1984; Vuillemard and Al, 1989). As an example, heating of whey proteins at temperature between 70 and 85° C. and to a concentration higher than 5%, forms a thermoirreversible gel. This gel develops by the formation of new intermolecular disulphide bonds (Vuillemard and Al, 1989).
The gelling process of whey proteins is strongly influenced by the pH of the medium during heating since a pH≧6.5 decreases the intermolecular interaction (Schmidt and Morris, 1984; Xiong, 1992). High ionic forces seem to increase proteinic stability probably through an increase of the proteins' capacity of hydration (solubility) (Xiong, 1992).
Soya Proteins
Soya proteins primarily form a hydrogel and are very susceptible to denaturation (Schmidt and Morris, 1984). These proteins are made up of 4 sub-units (2S, 7S, 11S and 15S), of high molecular weights (300,000 to 600,000) and have highly complex quaternary structures (Delisle, 1984). Generally, the gelling of soya proteins is a thermally induced phenomenon by the preparation of solution containing a concentration of at least 7% protein and at temperatures of 100° C. or more. Technical problems have limited the use of soya proteins to dairy product applications such as "tofu" and various cheeses (Schmidt and Morris, 1984).
Gluten
Gluten proteins, such as gliadine and glutenine, originate in corn flour. Gliadine is mainly hydrophobic and viscous whereas glutenine is absorbent and elastic. The elastic and cohesive characters of gluten are mainly due to the presence of disulphide bridges (Gennadios and Weller, 1990). Gluten concentration as well as the pH of proteinic solutions are the principal factors affecting the mechanical properties of gluten films. pH and the ethanol concentration affect opacity, solubility and the permeability of films to steam (Gontard and Al, 1992). Films containing gluten remain very promising but their permeability to water currently limits their development (Gennadios and Weller, 1990; Gontard and Al, 1992).
Zeine
Zeine is a protein isolated from corn. It is soluble in ethanol. It forms films with very good barrier properties to steam but its study is still limited (Kanig and Goodman, 1962; Kester and Fennema, 1986).
Casein
Bovine casein is an abundant, economic and easily accessible protein. Casein alone roughly accounts for 80% of the total proteins in cow's milk (Schmidt and Morris, 1984). It can be isolated from skimmed milk either by acidification with mineral acid, or by acidification with mixed bacterial cultures (Vuillemard and Al, 1989). The cost of 454 g of whole casein or caseinate amounts to approximately 4.
It is a phosphoprotein with amphiphilic characteristics which binds strongly to the Ca 2+ and Zn 2+ ions (Schmidt and Morris, 1984; Vuillemard et al., 1989). Due to their absorbent character, casein films do not produce an effective barrier to moisture. On the other hand, it can act as an emulsifying agent and create a stable casein-lipid emulsion (Avena-Bustillos and Krochta, 1993). The gas and moisture barrier properties of casein-based films can be improved by the polymerization of the protein with calcium (Ca 2+ ) but also by adjusting the pH of the medium at the isoelectric point of casein. The adjustment at the isoelectric point optimizes the protein--protein interactions, modifies the molecular configuration and would influence the mass transfer properties (Krochta, 1991 and Avena-Bustillos and Krochta, 1993).
Dairy proteins, including casein, remain a promising choice for possible production of edible film formation to meet the demands of environmentalists on packaging (McHugh and Krochta, 1994).
Composite Films
Edible films can be of heterogenous nature i.e. formed starting from a mixture of polysaccharides, proteins and/or lipids. This approach allows for the beneficial use of the functional characteristics of each film component. The preparation of composite films imposes an emulsification of the lipidic material in an aqueous phase. The preparation technique of hydrophobic films influences its barrier properties. A film formed starting from a dispersed distribution of the hydrophobic material offers weak barrier properties to steam, compared to films with a continuous layer (Martin-Polo et al., 1992). A dispersed distribution is due to the difference in polarity between the support (example: methyl cellulose) and the hydrophobic material (technique of emulsion).
Sometimes, a period of heating is necessary in order to liquefy waxes or the lipids used. This can create a thermal denaturation, structural modifications of the other components (polysaccharides or proteins) and, in some cases, the evaporation of part of the solvent (Kester and Fennema, 1986; Peyron, 1991). The pH of the medium can strongly influence the solubility of a film component as well as its concentration. Then, the choice of components, their concentrations and the conditions of the medium is crucial for the formation of film.
An example of composite film is that developed by Kamper and Fennema (198a and b). Their film is composed of ester cellulose and a mixture of fatty acid (palmitic and stearic acids). This film shows a permeability to steam comparable to that of inedible vinyl polychloride films (VPC) and low density polyethylenes (LDPE).
The composite protein-lipid films developed by Sian and Ishak (1990) which were made from soya bean milk show a dependence of films to the pH of the medium. The films prepared with a basic pH contain a greater proportion of proteins, minerals, carbohydrates and water and less fat content than those formed with an acidic pH. A basic pH causes an increase in the emulsifying capacity of the proteins which tends to disperse the fat globules in milk. Thus, the films made with basic pH, will incorporate less fat content. With an acidic pH (lower than the isoelectric area), the moisture content of films is very weak since acidification encourages the precipitation of proteins and the formation of insoluble complexes (Sian and Ishak, 1990).
In order to reduce packaging waste, research continues on plastic film formation in the presence of starch. They are composite but inedible films. The addition of starch is polyethylene films tends to produce a porous structure. As the covalent bonds between starch and polyethylene are not truly formed during conditioning, the incorporation of starch produces discontinuities in the film matrix (Lim et al., 1992). The small starch particles produce less severe discontinuities in the matrix than the large particles.
The presence of starch is certainly not without effect on the mechanical properties of polyethylene films. As the starch contents increase, the stretching strength, the percentage of elongation and opacity decrease, whereas the thickness of film increases. The loss of elastic properties is less with smaller starch particles than large one (Lim et al., 1992).
Selection of Substrates for the Formation of a Film
According to various studies on edible films, it seems that dairy proteins have good properties for the formation of a film. Casein salts seem to be a judicious choice because of their greater solubility than native casein. A minimal quantity of proteins is necessary in order to obtain a film which can be manipulated while still having resistance and adequate flexibility. This source of proteins is, moreover, very accessible and inexpensive. Because of these considerations, we chose caseinate extracts for the formation of a proteinic film.
Casein and Caseinates
Bovine casein is composed of four major proteinic complexes, named α A1 and 2, β- and κ-caseins. All in all, a casein molecule consists of a primarily hydrophobic core of α and of β-casein and surrounded by κ-casein on the surface (Schmidt and Morris, 1984). The stability of micelles is ensured by the κ-caseins and the calcium colloidal phosphates found on the periphery (Schmidt and Morris, 1984). Casein contains many uniformly distributed proline residues. That gives it an open structure thus limiting the formation of alpha helixes and beta layers (Modler, 1985). This open conformation shows a certain resistance to the thermal denaturation and offers an easy access to the enzymatic attacks (Schmidt and Morris, 1984; Vuillemard et al., 1989, McHugh and Krochta, 1994).
Caseinates are obtained either by the acidification with mineral acid (HCl or H 2 SO 4 ), or by the acidification by mixed cultures made up of Streptococcus subspecies lactis and/or cremoris, at the isoelectric point of casein (pH of 4,6). The neutralization of the insoluble precipitates of casein or lactic acids by alkalis allows for the dissolution in salts of sodium of calcium, potassium, magnesium, or ammonium (Schmidt and Morris, 1984; Vuillemard et al., 1989; McHugh and Krochta, 1994). The solubilized caseinates are dehydrated thereafter. Salts of caseins thus obtained are soluble with pH higher than 5.5
The Polymerization Process
The polymerization of proteinic solution is possible via hydroxyl radicals (•OH). These radicals are formed by the radiolysis of water, induced by gamma radiation of Co 60 (Fricke and Hart, 1966).
Reaction Mechanisms
The irradiation of a Co 60 protein solution in the presence of nitrogen protoxide (100% N 2 O) produces mainly •OH radicals thanks to the interaction of the solvated electron with a molecule of N 2 O.
Irradiation under 100% N 2 O produces approximately 8% of hydrogen radical (•H) (Adams et al., 1971; Singh and Singh, 1983; Singh and Vadasz, 1983). However, irradiation of a bovine serum albumin solution (BAS) under an atmosphere of 100% N 2 O or 100% N 2 and in the presence of radicalizing absorber (for example: T-butyl alcohol, mannitol, uric acid) showed that the •H radical is not involved in the formation of covalent bonds or the process of fragmentation (Davies et al., 1987a).
N 2 O is a very stable gas and is generally inert at room temperature. Its dissociation begins at more than 300 degrees Celsius where it becomes a powerful oxidizing agent (Merck & Co., Inc., 1960).
Irradiation in the presence of oxygen (O 2 ) produces superoxide radicalizing ions (•O 2 ) either by the direct interaction of e - uq with an O 2 molecule, or by the indirect interaction of an •H radical with an O 2 molecule.
TABLE 1______________________________________Reactional mechanism of the solvate elcctron and the·H radical with the oxygen of the medium e.sup.-.sub.aq + O.sub.2 → ·O.sub.2.sup.- ·H + O.sub.2 → ·HO.sub.2 → ·O.sub.2.sup.- + H.sup.+______________________________________
At neutral pH, the radical hydrodioxyle (•HO 2 ) is quickly deprotonized (pK a 4.8) to form even more superoxide radicals (Ferradini and Pucheault, 1983 and Fridovich, 1983).
The exposure to •OH radicals alone induces a polymerization with little or no fragmentation, whereas the simultaneous exposure to the radicals •OH+•O 2 - (+O 2 ) induced, at the same time, a polymerization and a fragmentation. The exposure to the radicalizing ion •O 2 - only, does not have any effect on the molecular weight (Davies, 1987). In a process of polymerization, one desires the creation of covalent bonds and to avoid fragmentation. Thus, the use of •OH radicals alone is essential for the formation of a polymer. Therefore, irradiation under an atmosphere saturated with N 2 O is of primary importance.
Interactions of Amino Acids with Free Radicals
Some amino acids are more likely than others to interact with •OH radicals. It is the case with molecules of cysteine, histidine, tryptophan and tyrosin (Delincee, 1983; Yamamoto, 1977). The tyrosin molecules can be formed by the addition of a hydroxyl grouping (OH) on a phenylalanine molecule during irradiation. All the amino acid residues can interact with •OH radicals and become radicals themselves. However, in the majority of cases, the amino acid radicals decrease (lose their radicalizing state) without having interacted with the medium (Davies et al., 1987a).
The exposure of protein to •OH radicals under an N 2 O atmosphere simultaneously produces the formation of a new connection and a loss of tryptophan residue (Davies et al., 1987a). In addition, this new connection, which forms bityrosine, has a covalent nature and is formed between two tyrosin residues.
The tyrosyl radical is formed by the subtraction of a hydrogen atom on the hydroxyl function of the tyrosin residue by the •OH radical. The tyrosyl radical thus formed can react with another tyrosyl radical or a tyrosin molecule, to form a stable biphenolic compound. An ortho-orientator effect is involved in the formation of new biphenolic connections, the form 2,2'-biphenyl appears to be the main connection produced (Prutz, 1983).
It is thus easy to note that the coupling in the para position (4 and 4') of the tyrosyls shows a stearic obstruction by the R residue. Then, the enolisation of quinones, mainly formed in the coupling reaction, is limited when the 4 or 4' position is involved. There are trace amounts of the phenoxy-phenol 0-2' form whereas the peroxide form (0,0') is not found (Prutz, 1983).
The formation of bityrosine is more an intermolecular connection than intramolecular and it represents an important factor in the polymerization process of proteins treated with •OH radicals (Davies, 1987).
Nearly 90% of the proteinic polymerization induced by the •OH radical is attributed to the formation of new intermolecular covalent bonds other than the disulphide bridges. The remaining 10%, represents the aggregation generated by the noncovalent interactions and the disulphide bridges (Davies, 1987).
Studies undertaken in the presence of radicalizing inhibitors (mannitol, T-butyl alcohol with or without the presence of nitrogen) showed that the •OH radical is the principal agent responsible for the destruction of tryptophan residues under irradiation in the presence of N 2 O (100%) (Davies et al., 1987a). The radicals •H, •O 2 - and e - aq are not involved directly in a degradation mechanism with a tryptophan residue (Davies et al., 1987a). Radical •O 2 - and oxygen (O 2 ) can interact on the products initially processed by the •OH radical resulting thus from an effect of amplification on the proteinic damage, i.e., the tryptophan loss and the formation of bityrosine (Davies et al., 1987a).
The phenomena of polymerization induced by the •OH radical and the fragmentation induced by the •OH+O 2 - (O 2 ) radicals were found on 16 different proteins (Davies, 1987). The modifications of the primary structure like the tryptophan loss and the formation of bityrosine are also observed on these same 16 proteins (Davies, 1987; Davies et al., 1987a). Then, it is probable that the effects of the oxygen radicals on the secondary and tertiary structures observed on a model protein like BAS, can spread to the whole of the proteins (Davies and Delsignore, 1987).
The Influence of Plasticizing Agents
The addition of a polyalcohol (sugars or glycerol) in a proteinic medium, improves the stability of protein and acts as a plasticizing agent when it is present in a proteinic polymer (Lee and Timasheff, 1981). This plasticizing agent is introduced to the polymer structure and can join with it in order to reduce cohesion in the structure in order to extend it, slacken it and soften it, thus changing the physical chemical properties of the polymer (Banker, 1966). The polyalcohol will support the original or folded state of the globular protein rather than a denatured state. These molecules generate cohesive forces responsible for the increase in tension forces on the hydration interface of the protein (Arakawa and Timasheff, 1982; Gekko and Morikawa, 1981).
Some polyalcohols can act like absorbers of •OH radicals and can therefore inhibit the polymerization process.
Davies et al. (1987a) showed that the modifications of the primary sequence in amino acids of BAS are inhibited by more than 90% by the addition of 1 mM of mannitol (polyalcohol) during exposure to •OH or •OH+•O 2 - (+O 2 ) radicals. A similar phenomenon is observed during the irradiation of casein in the presence of lactose (Umemoto et al., 1968). Increasing the concentration of mannitol from 10 to 100 mM has only a weak effect on the process of radicalizing inhibition (Davies et al., 1987a).
Mannitol is known to be a powerful biological antioxidant. It can thus quickly absorb •OH radicals. By this fact, it strongly inhibits the production of bityrosine and it protects effectively against the loss of tryptophan during the exposure of protein (BAS) to •OH radicals (Davies et al., 1987a).
In regarding glycerol as a polyalcohol, particular attention will have to be given in order to evaluate its antioxidant capacity at the time of the exposure to •OH radicals.
Protein-Polyalcohol Interaction
In general, the major part of the hydrophobic groupings are isolated inside globular protein whereas the absorbent groupings are found on the surface. On the other hand, a great proportion of proteinic surface is regarded as being hydrophobic. This surface is occupied by atoms or functional groupings which are unsuitable for hydrogen bonding (Bull and Breese, 1968).
Certain non-polar residues located on the surface migrate with difficulty inside protein due to the high compaction of the protein's three-dimensional structure (Gekko and Morikawa, 1981). Consequently, water and some cosolvants such as polyhydric compounds (sugars, glycerol and other polyalcohols) must be excluded from the non-polar areas of the protein surface. This exclusion depends on the absorbent character of the polyhydric compound, this is, the more absorbent the compound is, the more strongly it will be excluded from the hydrophobic surface. Then, the preferential hydration of a protein in a polyhydric aqueous solution is the result of a fragile balance between three forces: repulsion and attraction between the protein and the polyhydric compound and the steric obstruction effect (Gekko and Morikawa, 1981).
Glycerol Action Mechanism
Glycerol induces a proteinic stabilization by decreasing the surface stress of water surrounding proteins. The preferential interaction of a protein in an aqueous glycerol solution is due to the repulsion forces between glycerol (an absorbent compound) and the non-polar areas located on the surface of the protein (Gekko and Morikawa, 1981).
Gekko and Timasheff (1981) showed that the chemical potential (or the coefficient of activity) of a protein increases with the increase in glycerol concentration in the medium. An increase in the chemical potential of an aqueous solution corresponds to a reduction in its solubility in this medium. Then, the presence of glycerol in an aqueous medium would increase the hydrophobic property of the protein. This would result in unfavourable thermodynamic interactions between proteins and glycerol (Gekko and Timasheff, 1981). Thus the non-polar areas of protein, located on the surface, will interact unfavourably with the water-glycerol solvent. These hydrophobic areas, located on the surface of the protein, will be attracted towards the inside, that is to say towards the non-polar areas. However, the covalent bonds between the amino acids of the protein generate a strong compaction and a steric obstruction, thus inhibiting the migration towards the interior of these hydrophobic areas (Gekko and Timasheff, 1981). Therefore, glycerol and water molecules will be distributed outside the protein thus keeping constant the chemical potential of the components. The preferential interactions phenomenon of the components of a solvent is thus expressed generally by variations of the chemical potential (Gekko and Timasheff, 1981).
Glycerol must then penetrate inside the water envelope surrounding the protein so that it occupies an integral part of this dissolved envelope. This implies that there must be a fragile balance between the repulsion of the non-polar areas, the attraction of the polar areas located on the surface of the protein and the attraction phenomenon between glycerol and water molecules. Then, the interactions between glycerol and the protein are primarily non-specific. These effects are valid only for large concentrations of glycerol, about one to four molarity (Gekko and Morikawa, 1981).
The Influence of Buffers
Buffers generate important modifications on the formation rate of bityrosine and on tryptophan loss. The Tris and HEPES buffers (4-(2-hydroxyethyl)-1-piperazineethanesulfonique acid) show a significant protection against tryptophan loss and the production of bityrosine whereas the carbonate buffer favours tryptophan loss and increases the production of bityrosine. This increase reflects more the implication of carbonate during dosages rather than a real production of bityrosine (Davies et al., 1987a). The phosphate buffer presents the most similarity with water but it is necessary to consider a possible iron contamination in all phosphate salts. The presence of iron can falsely show a production of bityrosine during dosages (Davies et al., 1987a and Davies and Delsignore, 1987).
As the exposure of a buffer-free BAS solution to •OH radicals does not show pH variation (Davies et al., 1987a), the presence of a phosphate buffer is not justified considering the risks of being confronted with iron contamination.
Biodegradability
All commercial plastic packaging is not biodegradable because their molecular weights are too high and their structures are too rigid to be attacked by micro-organisms. Linear polyethylene is the only plastic packaging having biological breakdown potential when its molecular weight is drastically reduced by photodegradation (Klemchuk, 1990).
Biodegradation is a process by which bacteria, moulds, yeasts and their enzymes consume a substance as a source of food so that the original form of this substance disappears (Klemchuk, 1990). Under appropriate conditions, a biodegradation process from two to three years is a reasonable period for the assimilation and the complete disappearance of the product (Klemchuk, 1990).
Tests carried out with moulds showed that only aliphatic polyesters and aliphatic polyurethanes are biodegradable under 85% relative humidity at 28-30° C. Nonetheless, until now, these polymers have not been marketed on a large scale as packaging (Klemchuk, 1990).
Research on the biodegradability of polyethylene films in the presence of starch, with activated charcoal, was undertaken by the team of Ndon (Ndon et al., 1992). Their work made it possible to show that the degradation of carbon coming from starch present in plastic is weak compared to the conversion of carbon coming from pure starch. The rate of degradation and the extent of carbon molecule withdrawal are higher under aerobic conditions than under anaerobic conditions. The study of the distribution of molecular weights of plastics does not indicate any decomposition of polyethylene.
Susceptibility to Proteolysis
Davies et al. (1987; 1987b) showed that when BAS was treated with •OH radicals, it became more susceptible to proteolysis by cellular enzymes. According to these authors, the simple process of denaturation (unfolding or increase in the hydrophobicity) can explain the strong increase in susceptibility to proteolysis. The oxidation and proteolyses reactions seem to be connected (Davies, 1987). Indeed, it was observed that Escherichia coli, cellular extracts of human and rabbit erythrocytes and rabbit reticulocytes all recognize and degrade proteins modified by oxidation. However, the recognition and degradation mechanisms of proteins modified by the cellular enzymes are poorly understood (Davies, 1987).
Casein is an excellent proteinic substrate. Its open conformation provides it with easy access to enzymatic attack and this, even before its exposure to •OH radicals (Davies, 1987).
Biodegradation by Pseudomonas
Pseudomonas is recognized as being a type of bacterial which can synthesize a very diverse number of enzymes. Being psychrotrophic, it is responsible for the putrefaction of refrigerated foods. It can however decompose certain chemicals like pesticides and is resistant to certain disinfectants (compounds of quaternary ammonium) and antibiotics (Tortora et al., 1989). It is found in a majority of natural sites (water-ground-air), foodstuffs (milk-dairy products-egg-meats) and in some animals (Palleroni, 1984). Pseudomonas is a Gram-stick, chimioorganotrophe, aerobic and mobile with one or more polar flagellums. It can grow between 4 and 43° C. but does not tolerate acidic media (Palleroni, 1984). Certain species of Pseudomonas are chimiolithotrophes optional.
The majority of the Pseudomonas species degrade κ-casein before the population reaches 10 4 UFC/ml. β-casein is more susceptible to degradation than α for the majority of species. This phenomenon is only observed when the bacterial population is higher than 10 6 -10 7 UFC/ml (Adams et al., 1976).
The use of Pseudomonas for the degradation of various components is very interesting given its resistance to various stress conditions (For example: temperature, carbon source) and its capacity to synthesize an significant amount of enzymes (Tortora et al., 1989).
SYNOPSIS OF THE INVENTION
The subject of this invention is a manufacturing process of biodegradable proteinic films which contain caseinates, allowing for the fast, simple and inexpensive formation of proteinic films. Glycerol acts like a plasticizing agent in order to add flexibility and to facilitate the handling of film. The process of polymerization by irradiation improves the mechanical properties of film while insuring the polymerization process via hydroxyl radicals. The irradiation of a caseinate-glycerol-water mixture allows for the creation of a proteinic film with good elasticity, resistance and deformation properties. Glycerol unexpectedly improves polymerization of the molecules without harming the film's properties.
The film itself is also the subject of this invention. The film which is obtained is sterile, viscoelastic, and resistant to rupture; it is adequately impermeable to water, gases and the micro-organisms. It is biodegradable, non-toxic and even edible.
The manufacturing process of this film is thus unique in that it is a good compromise of maintaining both cohesion and elasticity. Indeed, cohesion is obtained without compromising flexibility, porosity and permeability to gases and water which are all parameters known to be affected by an increase in cohesion.
DESCRIPTION OF THE INVENTION
An explicit description of the material and various techniques used will be presented and illustrated in the following figures. This description does not limit the scope of the invention but rather is provided as an illustration.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1: Diagram of the assembly used for making the films.
FIG. 2: Curve of relieving and equation for the calculation of the coefficient of relieving (Peleg, 1979).
FIG. 3: F/E Ration (Rupture strength versus film thickness ratio) as a function of the irradiation dose received for the 110, 180 and 380 alanates, for protein concentrations of 5.0% P/P and 7.5% P/P.
FIG. 4: Deformation at rupture according to the amount of irradiation received for the alanates 110, 180 and 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 5: Rate of formation of bityrosine according to the amount of irradiation received for alanates 110, 180 and 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 6: Oxidation of tryptophan according to the amount of irradiation
FIG. 7: Tryptophan dosage according to the amount of irradiation received for alanates 110, 180 and 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 8: F/E ration (ration of the breaking load versus the thickness of film) according to the amount of received irradiation and glycerol contents for alanate 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 9: Deformation according to the amount of received irradiation and glycerol contents for alanate 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 10: Viscoelasticity according to the amount of received irradiation and glycerol contents for alanate 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 11: Rate of formation of bityrosine according to the amount of received irradiation and glycerol contents for alanate 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 12: Tryptophan proportioning according to the amount of received irradiation and the glycerol contents for alanate 380 with protein concentrations of 5.0% P/P and 7.5% P/P
FIG. 13: Test #1 of the growth of Pseudomonas fragi in the presence and absence of a film sample of alanate 380 composed of 5.0% P/P proteins and 2.5% P/P of glycerol, 20 kGy irradiation
FIG. 14: Test #2 of the growth of Pseudomonas fragi in the presence and absence of a film sample of alanate 380 composed of 5.0% P/P of proteins and 2.5% P/P of glycerol, 20 kGy irradiation
FIG. 15: Test #3 of the growth of Pseudomonas fragi in the presence and absence of a film sample of alanate 380 composed of 5.0% P/P of proteins and 2.5% P/P of glycerol, 20 kGy irradiation
EXAMPLE 1
Preparation of the Protein Solutions
In this research project, three caseinates (see compositions at table 2) were initially used, that is, two sodium caseinates (alanate-110 and 180) and a calcium caseinate (alanate-380, New Zealand Milk Products, Inc. CA, USA). The protein contents are certified higher than 91.0% and this purity was laboratory tested (LECO, FP-428, ML, USA). Purity is 94,099%, 94,526% and 93,575% for alanates 110, 180 and 380 respectively. These results in total nitrogen contents will be retained for the calculation of the protein concentrations (% P/P) at the time of the formulation of the various compositions of the solutions.
TABLE 2______________________________________Composition of the three caseinates(alanates) used in this research project. ALANATE ALANATE ALANATEELEMENTS 110 180 380______________________________________PROTEINS 91.1 91.1 91.8(N × 6.38) %MINERALS (%) 3.6 3.5 3.8MOISTURE (%) 4.1 4.0 3.9LIPIDS (%) 1.1 1.1 0.7LACTOSE (%) 0.1 0.1 0.1pH (5% AT 20° C.) 6.6 6.6 7.0______________________________________
The values of the various components of three caseinates come from the product bulletins provided by New Zealand Milk Products, Inc., CA, USA.
Before the period of irradiation, the caseinates are dissolved in distilled water, previously filtered by inverse osmosis. Solubilization is made continuously under magnetic agitation and without heat. Two concentrations are used: 5.0% and 7.5% P/P of proteins. A concentration lower than 5% generates films of inadequate thickness for handling whereas a concentration higher than 7.5%, produced films that were too thick. These two concentrations are selected strictly to validate the film properties, they are otherwise not restrictive.
According to the composition of the medium, a quantity of glycerol (purity ≧95%; A & C, Montreal, Canada) can be added to concentrations of 1.0%, 2.5% and 5.0% P/P. A glycerol concentration higher than 5.0% P/P produces films in a gel state, which are therefore difficult to handle adequately.
After complete solubilization of proteins, a 15 minutes vacuum, under magnetic agitation, is applied; followed immediately by an N 2 O bubbling (LINDE, Union Carbide, Toronto, Canada) for a second 15 minutes period under agitation. After the gasing stage, the solution is transferred in screw-top test tubes, under N 2 O flow. The test tubes are sealed with paraffin and are then irradiated.
EXAMPLE 2
Irradiation of the Proteinic Solutions
The irradiation is carried out in a Co 60 irradiator of the Gammacell 220 type (NORDION INTERNATIONAL INC, located in the Canada Irradiation Center (C.I.C), Laval, Canada) at an average dosage of 2, 18 kGy/h for amounts of irradiation of 4, 8, 12, 15, 20, 30 and 40 kGy.
For the irradiation, the test tubes are placed in a glass beaker located in the center of the irradiation room. In this way, the test tubes are in the zone of 100±5% of the dose according to the isodose curves of the Gammacell 220 irradiator.
After each irradiation period, a 20 to 30 minute wait in darkness is allocated so that the longest radicalizing reactions are completed and to avoid photodecomposition of the biphenyls (Lehrer and Fasman, 1967; Prutz, 1983).
EXAMPLE 3
Formation of Film
Before and after each irradiation, the pH (Corning pH-meter, PS 15) and the Brix degree of the solutions (Fisher refractometer, 13-946-70c, No 4754, Montreal, CANADA) are checked in order to quickly evaluate any change during the irradiation.
The pH measurement ensures the constancy of the pH solutions, before and after each irradiation. The refractometer allows the evaluation of the quantity of soluble solids present in the solutions. Its use makes it possible to see any variations of the quantity of solubilized solids before and after irradiation.
A homogenisation of the solutions by successive inversions is carried out before each recording of the data in order to prevent the formation of a protein deposit.
After verifying the pH and Brix degree, five milliliters (5 ml) of the protein solution is pipetted and uniformly deposited in a support of polymethacrylate (Plexiglas). Detailed attention is given in order to avoid the formation of air bubbles. The support has an internal diameter of 8.5 cm for a surface of 56.7 cm 2 (see FIG. 1). Thereafter, the support is kept level as much as possible. A 12 to 14 hour drying period (that is to say overnight) at room temperature, is allocated in order to obtain the film. This method of film formation is adapted from the Gontard (1992) and Krochta (1991) research teams.
After drying, the film is withdrawn from its support and its thickness is measured using a Digimatic Indicator (Mitutoyo, Japan).
EXAMPLE 4
Mechanical Properties
All the films produced in this manner are cut to obtain a sample with a 4.0 cm diameter. Thereafter, the samples are humidified and balanced during 48 hours, at 25 C., in a desiccator containing a solution saturated with sodium bromide (Gontard et al., 1992). This handling ensures an atmosphere of 56% relative humidity (Ganzer and Rebenfield, 1987) and this water content was measured. The humidified samples are then firmly immobilized between two Plexiglas plates exposing a surface of 3.2 cm in diameter for the measurement of the mechanical properties.
For all tested films, two mechanical properties were determined: breaking load and strain at failure. For certain films containing glycerol, a third mechanical property was evaluated, Viscoelasticity. These three properties are measured using a Voland Texturometer (Stevens-LFRA Texture Analyser, TA-1000 model, N.Y., USA) connected to a printer (Texture Technologies Corp., L 6512 model, N.Y., USA). A punch of two millimeter (2 mm) diameter is used for all measurements. Some trials were carried out with a 3 mm diameter punch and the readings exceeded the maximum detection limit of the texturometer. The calculation of the results is always according to the punch's descent speed and the tape speed of the printer paper. Before each use, the texturometer is calibrated against a mass standard (100 to 1000 g) and the speed of the printer is verified as a function of time.
For the three mechanical properties, the tests were carried out in triplicate. The average obtained, as well as its standard deviation, were represented on a graph.
a) Breaking Load and the Strain at Failure
The breaking load and the strain at failure are calculated simultaneously for all the samples. The speed of descent of the punch is 1.0 mm/s and the unfolding speed of the printer paper is 50 cm/min. The push of the punch is recorded in grams and is converted into units of force (N).
b) Viscoelasticity
the viscoelasticity of a film is measured by the relaxation curve obtained following the application of a force maintained by the punch on the film. The speed of descent of the punch is of 1.0 mm/s and that of the unfolding of the printer paper is 10 cm/min. In the present case, the deformation is three millimeters (3 mm) and the forces measured at time 0 and 60 seconds are retained for the calculation of the relaxation coefficient Y(1 min) (Peleg, 1979) according to the equation defined in FIG. 2.
In accordance with this equation, the relaxation coefficient of relieving Y(1 min) varies between 1 and 0. An elastic film will show a low Y(1 min) ration since the initial and final forces would then be nearly identical.
During relaxation, energy is dissipated thus creating irreversible internal disturbances. A continuously decreasing tension is necessary to maintain the sample in its deformed state (Gontard et al., 1992).
EXAMPLE 5
Dosages by Fluorometry
A fraction of the irradiated protein solution is kept in the liquid state in order to measure the rates of bityrosine formation and tryptophan loss. In all cases, dosages are performed within 24 hours following the period of irradiation.
Before carrying out the dosages, a 1/100 dilution is performed using a HEPES buffer (A & C, Montreal, Canada) 20 mM, pH 7.0 (Davies et al., 1987a), in order to avoid a saturation of the apparatus.
The bityrosine formation and tryptophan loss measurements are followed by fluorescence (Davies et al., 1987a) with the help of a spectrofluorometer (Spectrofluorometer 2070, Varian, CA, USA). The spectrofluorometer is equipped with a xenon lamp (75 W) and the capacity of the cell is 15 μl. The detectors are photomultipliers for excitation and emission and the detectability threshold 0.03 quinine sulfate ppb in a solution of H 2 SO 4 0.1M (values reported by Varian). The spectrofluorometer is connected to a HPLC (Liquid Chromatograph: VISTA 5500, Varian, CA, USA) which is connected to an auto-injection system (Auto Sampler 9090, Varian, CA, USA). this entire system is in permanent communication with a computer terminal (COMPAQ/Deskpro 486/33M) which allows for the acquisition and the processing of data (Varian Star Workstation, Copyright 1989-1992, Varian Associates, Inc, CA, USA).
During dosages, no separation column is used but only a fixed flow of one milliliter per minute (1 ml/min). The injection volume is 90 μl and a 100 μl twist is used to receive the injection. The period for data acquisition is fixed at 90 seconds in duration. The rates of bityrosine formation or tryptophan loss are obtained by the calculation of the surface under the curve in arbitrary surface units.
As dosages are purely qualitative, we concentrated mainly on the stability and the reproductive capacity of the apparatus. Thus, several series of dosages on the three caseinates used and on a tryptophan solution (Sigma, Mississauga, CANADA) were made at the tryptophan excitation and emission wavelengths. For three different concentrations, the results showed a variance lower than 4% between dosages and a variation equal or lower than 8.5% between the three concentrations for the same caseinate. The variation between the concentrations would be mainly justified by predosage handling.
Tests have shown that the HEPES buffer (20 mM, pH 7.0), glycerol (2.5%) or a mixture of the two do not generate characteristic signals, truly higher than the background noise, for the various wavelengths used for irradiated and non-irradiated solutions.
For all the various compositions of the solutions, the rates of bityrosine formation and tryptophan loss were measured in triplicate. The average and the standard deviations were represented on a graph.
a) Bityrosine Dosage
The rate of bityrosine formation is measured at the excitation and emission wavelengths of 305 nm and 415 nm (±5 nm) respectively. These wavelengths were determined using an irradiated tyrosin solution (50 ppm) (Sigma, Mississauga, CANADA). The casing of the apparatus is adjusted to 1 and an attenuation factor of 4 is applied. As we did not find bityrosine commercial standards, our results could only be interpreted in a qualitative way.
b) Tryptophan Dosage
The rate of tryptophan loss is followed at the excitation and emission wavelengths of 255 nm and 351 nm (±5 nm) respectively. These wavelengths were established using an irradiated tryptophan solution (50 ppm). The casing of the apparatus is 1 and an attenuation factor of 32 is applied. The oxidation of a solution of tryptophan residue by •OH radicals is directly connected to the loss of intensity of the fluorescence signal during its dosage (Davies et al., 1987a).
As dosage by fluorescence is much more complex with proteins than with only one amino acid (Davies et al., 1987a), we did not try to convert the fluorescence intensity into quantities of tryptophan residues, but we only noted experimentally a possible loss of the signal.
EXAMPLE 6
Checking of the Biodegradability
The biodegradability was verified using Pseudomonas fragi because this bacterial species is frequently used in the laboratory and also because the Pseudomonas stock is recognized as a bacterium which is able to synthesize a very wide number of enzymes (Tortora, G. J. et al., 1989). The foremost synthesized proteases for the biodegradation of casein are metalloproteases and serine proteases (Alichanidis and Andrews, 1977; Davies, 1987; Davies et al., 1987b).
Three tests were carried out in triplicate:
1. film sample +0.85%-NaCl (negative control)
2. P. fragi+0.85%-NaCl (control)
3. film sample+P. fragi+0.85%-NaCl
Each medium contains 99 ml water with 0.85% P/V of NaCl (Anachemia, Montreal, Canada) and according to the case, 1 ml of inoculum or a film sample or, both are added. The mediums are incubated at 25±2° C. and are continuously under agitation (140±5 rpm).
Only one type of film was selected in this section. It is composed of 5.0% P/P calcium caseinate with 2.5% P/P glycerol and irradiated at 20 kGy. The samples are prepared according to the methods described in example 1 to 3. An irradiation dose of 20 kGy is considered a sterilization dose. Naturally, a precaution specific to the maintenance of sterility is applied.
The inoculation of the mediums is done starting from a mother culture whose time of incubation is 16 to 18 hours. Beforehand, the mother culture was inoculated twice in a nutritive bubble (Nutrient Broth, Difco Laboratories, Detroit, USA) in order to adapt the stock and to collect it in an exponential growth phase.
One milliliter (1 ml) of this mother culture is taken and diluted until a factor of 1/10 4 with a saline solution (0.85%-NaCl). Three successive centrifugations are made at 3000 rpm for 10 minutes, at 4° C. After each centrifugation, nine of the ten milliliters are withdrawn and replaced by physiological [distilled?] water, then homogenized with the vortex. The inoculation of the mediums is done after the third centrifugation and dissolution. From these handlings and dilutions, the initial counts of the mediums are roughly 100 UFC/ml.
The bacterial counts are done in duplicate on "Trypsic Soy Agar" medium (TSA, Ditco Laboratories, Detroit, USA). The counting method used is that advised by the Health Protection Branch (Health and Welfare Canada, 1979). The inoculum is deposited on the surface of the agar by smearing. Incubation is done at 23° C.±2° C. and the bacterial counts are checked at 24 and 48 hours after setting on the plate. Bacterial counts which ranged between 30 and 300 were retained.
EXAMPLE 7
Statistical Analyses
The results obtained are analyzed statistically by variance analysis and the DUNCAN multiple comparison test with P σ 0.05, whereas the STUDENT statistical analysis is used only during the variance analysis and test of comparison per pair with P σ 0.05 (Snedecor and Cochran, 1978).
Results
This section will be divided into three main parts. The first part will present the results of a series of experiments on the evaluation of the behavior of the three caseinates used according to the amount of irradiation. After discussing these results, a selection of one of the three caseinates will be made for the continuation of the experimentation. In the second part, we will discuss a second series of experiments on the behavior of the caseinate chosen in the presence of glycerol and according to the amount of irradiation given. Finally, in the third part, measurements of the biodegradability will be presented.
Observations and Visual Aspect of the Films
Before claborating on the results, we would like to describe to the reader the physical and visual aspects of the films. At first sight, the non-irradiated films are transparent and the colourless as are the caseinate films without glycerol, irradiated at 4 to 12 kGy. On the other hand, in the absence of a plasticizing agent, the fragility of these films is so great that they cannot be handled without damaging them. These observations apply for the two protein concentrations used (5.0% P/P and 7.5% P/P).
The irradiation causes a yellowing of the films formed in the presence of glycerol and this rate of yellowing seems to be proportional to the amount of irradiation received. The presence of glycerol tends to create a certain opacity and it seems to be proportional to the glycerol content. Whereas for the same glycerol concentration, protein content affects the aspect of film for the same amount of irradiation. At 2.5% P/P or 5.0% P/P of glycerol, the films produced with 7.5% P/P of proteins are more transparent than those produced with 5.0% P/P. Therefore the glycerol/protein ratio seems to be a factor influencing the opacity of films.
According to the glycerol and protein contents, the thickness varies from 27 to 64 μm with a variation equal or lower than 8% (see table 3). Coating film must be as thin as possible and preferably its thickness must be equal or lower than 50 μm. A thicker edible film would likely affect the aesthetic properties of the packed product or its components.
Naturally, glycerol content modifies the texture of the film and with a concentration of 5.0% P/P, its handling requires more delicacy. Whatever the composition or the amount of irradiation, no film, once formed, released perceptible odors.
TABLE 3______________________________________Variation of the thickness of films according to their proteincomposition with or without glycerol on all the irradiation doses.% P/P ALANATE/ THICKNESS DOSE% P/P GLYCEROL (μm) (kGy)______________________________________5.0%-110/0% 27 ± 2 0 to 25.0%-180/0% 27 ± 2 0 to 125.0%-380/0% 28 ± 2 0 to 127.5%-110/0% 44 ± 2 0 to 127.5%-180/0% 42 ± 2 0 to 127.5%-380/0% 41 ± 2 0 to 125.0%-380/1.0% 32 ± 2 0 to 125.0%-380/2.5% 38 ± 3 0 to 405.0%-380/5.0% 44 ± 2 0 to 407.5%-380/2.5% 62 ± 5 0 to 207.5%-380/5.0% 64 ± 5 0 to 40______________________________________ 5.0%-110/0% means 5.0% P/P of protein 110 with 0% P/P glycol.
Comparison of the Three Proteins
In this first part, a comparison of two mechanical properties and characteristics of fluorescence were observed with the aim of selecting one of three caseinates for the continuation of the experiments.
Initially, the breaking force as a function of the amount of irradiation will be discussed; followed by strain at failure in function to the dose and finally, the dosages by fluorescence according to the amounts received, will be presented. For these three points of comparisons, two protein concentrations were studied in the absence of a plasticizing agent.
a) Breaking Force (Load??)
As there is a direct relation between the breaking load and the thickness of film, we decided to calculate the ration of one to the other. This was done in order to avoid possible variations of force which are simply due to variations of thickness. This ratio is represented by the symbol F/E and is expressed in N/μm.
With a concentration of 5.0% P/P, the F/E ratio varies from 14.7 to 17.4 for the three caseinates and for irradiation doses. There is no significant difference (P>0.05) for the F/E ratio, in function of the irradiation dose, between the three caseinates at this concentration. There is only one exception for the 12 kGy dose where there is a significant variation (P>0.05) between sodium caseinates (alanate 180) and calcium (alanate 380) (see table 4 and FIG. 3). On the other hand, without being clearly dissociated, calcium caseinate (alanate 380) shows a higher F/E ratio than those of the two sodium caseinates for the irradiation doses of 4, 8 and 12 kGy (see table 4).
For the 7.5% concentration, the F/E ratio varies from 14.2 to 17.4 for the three caseinates for all three irradiation doses. With this concentration, the calcium caseinate (alanate 380) has a relationship F/E significantly higher (P 0.05) to the two other sodium caseinates (alanates 110 and 180) during the irradiation between 4 and 12 kGy (see table 5 and FIG. 3). With 0 kGy, there is no significant difference (P>0.05) between caseinates of sodium (alanate 110) and calcium (alanate 380). The films formed starting from calcium caseinate (alanate 380) require a larger force for rupture compared to those made from the two sodium caseinates (alanates 110 and 180) (see table 5).
For the three caseinates, there is no significant difference (P>0.05) for the F/E ratio between the two protein concentrations used (5.0% and 7.5%) and this, according to the amounts of irradiation (0 to 12 kGy). The only exceptions are sodium caseinate (alanate 110) at 12 kGy and calcium caseinate (alanate 380) at 8 kGy where the difference is considered significant (P σ 0.05).
Thus, the irradiation of calcium caseinate (alanate 380) to a concentration of 7.5% protein creates a film more resistant to rupture than the two other proteins. Whereas at a concentration of 5.0%, there is no significant difference (P>0.05) between three caseinates.
TABLE 4______________________________________F/E ratio according to the amount of irradiationreceived for alanates 110, 180 and 380with a concentratian of 5.0% P/P of proteins. F/Ex 100 F/Ex 100 F/Ex 100 (N/μm) (N/μm) (N/μm)DOSE ALANATE- ALANATE- ALANATE-(kGy) 110 180 380______________________________________0 16.9 ± 0.4.sup.1,a 16.2 ± 0.4.sup.3,a 16.8 ± 0.9.sup.5,a4 14.6 ± 0.1.sup.2,b 15.0 ± 0.3.sup.4,b 16.3 ± 1.5.sup.5,b8 16.0 ± 1.6.sup.1,2,c 15.3 ± 0.7.sup.4,c 17.4 ± 0.5.sup.5,c12 16.0 ± 0.8.sup.1,2,de 14.7 ± 0.2.sup.4,d 17.2 ± 1.0.sup.5,e______________________________________
The term F/E expresses the ratio of the breaking load versus the thickness of film. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). for each column, tow averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 5______________________________________F/E ratio according to the amount of irradiationreceived for alanates 110, 180 and 380with a concentration of 7.5% P/P of proteins. F/Ex 100 F/Ex 100 F/Ex 100 (N/μm) (N/μm) (N/μm)DOSE ALANATE- ALANATE- ALANATE-(kGy) 110 180 380______________________________________0 15.6 ± 0.9.sup.1,ab 14.5 ± 1.8.sup.3,a 17.4 ± 0.4.sup.4,h4 14.9 ± 0.4.sup.1,2,c 14.5 ± 0.2.sup.3,c 16.4 ± 0.0.sup.5,d8 14.3 ± 0.0.sup.2,c 14.2 ± 0.2.sup.3,c 16.3 ± 0.2.sup.5,f12 14.2 ± 0.3.sup.2,g 14.3 ± 0.5.sup.3,g 16.7 ± 0.2.sup.5,h______________________________________
The term F/E expresses the ration of the breaking load versus the thickness of film. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
b) The Strain at Failure
With a concentration of 5.0% P/P, the deformation is approximately 2,3±0,1 mm for the three caseinates and for all levels of irradiation. There significant variations (P>0.05) for the three caseinates as a function of the doses of irradiation except for calcium caseinate between the amounts of 4 and 12 kGy (see table 6). At 7.5% P/P proteins, the deformation is approximately 2,6±0,2 mm for all three caseinates and for all amounts of irradiation. For the same amount of irradiation, there is no significant difference (P>0.05) between the three caseinates. On the other hand, for the sodium caseinates (alanate 110) and calcium (alanate 380), there is a significant variation (P>0.05) between the amounts of 0 and 12 kGy (see table 7).
For the two concentrations used, there is no significant difference (P>0.05) between the three caseinates for the deforming capacity as a function of the amounts of irradiation (see FIG. 4). The deformation is greater by some tenths of millimeters for a concentration of 7.5% compared to 5.0% but this variation is not considered significant (P>0.05) (see tables 6 and 7).
TABLE 6______________________________________Strain at failure according to the amount ofirradiation received for alanates 110, 180 and 380with a concentration of 5.0% protein P/P. DEFORMATION DEFORMATION DEFORMATIONDOSE (mm) (mm) (mm)(kGy) ALANATE-110 ALANATE-110 ALANATE-110______________________________________0 2.4 ± 0.2.sup.1,a 2.3 ± 0.2.sup.2,a 2.3 ± 0.1.sup.3,4,a4 2.3 ± 0.1.sup.1,b 2.3 ± 0.1.sup.2,b 2.2 ± 0.1.sup.3,b8 2.3 ± 0.1.sup.1,c 2.3 ± 0.1.sup.2,c 2.3 ± 0.2.sup.3,4,c,12 2.4 ± 0.3.sup.1,d 2.3 ± 0.2.sup.2,d 2.4 ± 0.1.sup.4,d______________________________________
For each line, tow averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 7______________________________________Strain at failure according to the amount ofirradiation received for alanates 110, 180 and 380with a concentration of 7.5% protein P/P. DEFORMATION DEFORMATION DEFORMATIONDOSE (mm) (mm) (mm)(kGy) ALANATE-110 ALANATE-110 ALANATE-110______________________________________0 3.0 ± 0.5.sup.1,a 2.6 ± 0.2.sup.3,a 2.7 ± 0.1.sup.4,a4 2.6 ± 0.2.sup.1,2,b 2.5 ± 0.1.sup.3,b 2.5 ± 0.1.sup.4,5,b8 2.7 ± 0.2.sup.1,2,c 2.7 ± 0.1.sup.3,c 2.6 ± 0.2.sup.4,5,c12 2.4 ± 0.1.sup.2,d 2.6 ± 0.2.sup.3,d 2.3 ± 0.2.sup.5,d______________________________________
For each line, tow averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
Viscoelasticity was not evaluated for these films as the deformation applied to measure this parameter is three millimeters (3 mm) and according to FIG. 4, the strain at failure is lower than this value.
c) Rate of Bityrosine Formation
The real rate of bityrosine formation produced by irradiation is measured by subtracting the average value obtained at 0 kGy from those obtained from the various amounts of irradiation. Indeed, a signal of fluorescence is perceived at 0 kGy. The initial presence of bityrosine or the contribution of other neighbouring components can cause this signal of fluorescence. This contribution is the consequence of protein dosages with these multiple functional groupings in the vicinity of to the other.
We observed an increase in the formation of bityrosine with an increase in the amount of irradiation for the three caseinates and this, for the two concentrations used.
At 5.0% concentration, the rate of bityrosine formation is significantly higher (P σ 0.05) for calcium caseinate (alanate 380) compared to the two sodium caseinates (alanates 110 and 180) for irradiation of 4, 8 and 12 kGy (see table 8). Moreover, with 12 kGy, the second sodium caseinate (alanate 180) produced significantly more (P σ 0.05) bityrosine than the first (alanate 110).
For 7.5% concentration, sodium caseinate (alanate 110) produced significantly more (P σ 0.05) bityrosine than the caseinates of sodium (alanate 180) and calcium (alanate 380) and this, at levels of 4 and 12 kGy (see table 8 and FIG. 5), whereas at 8 kGy, no significant difference (P>0.05) was perceived between the three caseinates (see table 9).
There exists a significant difference (P σ 0.05) between the two protein concentrations but this difference is not shown for all the levels of irradiation. Indeed, the first sodium caseinate (alanate 110) produced significantly (P σ 0.05) more bityrosine at 7.5% concentration for the 12 kGy level than at 5.0% concentration. The second sodium caseinate (alanate 180) produced significantly (P σ 0.05) more bityrosine at 5.0% concentration with levels of 4 and 8 kGy than at 7.5% concentration. Finally, the calcium caseinate (alanate 380) produced significantly (P σ 0.05) more bityrosine at 5.0% concentration for levels of 4, 8 and 12 kGy compared with 7.5% concentration (see tables 8 and 9).
TABLE 8______________________________________Rate of bityrosine formation according to the amountof irradiation received for alanates 110, 180 and 380at a concentration of 5.0% P/P of proteins.DOSE(kGy) ALANATE-110 ALANATE-180 ALANATE-380______________________________________4 19354 ± 11421.sup.1,a 20730 ± 762.sup.4,a 28552 ± 1621.sup.7,b8 41071 ± 453.sup.2,c 39651 ± 2095.sup.5,c 66803 ± 2391.sup.8,d12 62999 ± 659.sup.3,c 66271 ± 1287.sup.6,f 82504 ± 1650.sup.9,g______________________________________
There is no unit as these rates are measured by the surface under the curves obtained. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 9______________________________________Rate of bityrosine formation according to the amountof irradiation received for alanates 110, 180 and 380at a concentration of 7.5% P/P of proteins.DOSE(kGy) ALANATE-110 ALANATE-180 ALANATE-380______________________________________4 24429 ± 1307.sup.1,a 17067 ± 547.sup.4,h 17192 ± 707.sup.7,b8 38741 ± 599.sup.2,c 35287 ± 1893.sup.5,c 39344 ± 687.sup.8,c12 69305 ± 795.sup.3,d 64735 ± 769.sup.6,c 61076 ± 607.sup.9,f______________________________________
There is no unit as these rates are measured by the surface under the curves obtained. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
d) Tryptophan proportioning
The oxidation of a solution of tryptophan residue by •Oh radicals is directly connected to the loss of intensity of the fluorescence signal. FIG. 6 shows the influence of irradiation on a solution of 500 tryptophan PPM.
There is no regular and continuous signal loss as function of the level of irradiation during dosage of caseinates. Even if a significant difference (P σ 0.05) is sometimes perceived between the levels of irradiation for the three caseinates, in no case is there a continuous fall of the signal. This state is perceived for two concentrations (see tables 10 and 11 and FIG. 6).
TABLE 10______________________________________Tryptophan dosage according to the level ofirradiation received for alanates 110, 180 and 380with a concentration of 5.0% P/P of proteinsDOSE(kGy) ALANATE-110 ALANATE-180 ALANATE-380______________________________________0 775511 ± 3047.sup.1,a 733889 ± 3222.sup.5,b 764770 ± 2693.sup.8,c4 742878 ± 3570.sup.2,d 712041 ± 9816.sup.6,e 793769 ± 1677.sup.9,f8 710587 ± 2122.sup.3,g 741933 ± 2615.sup.5,h 749959 ± 8149.sup.10,h12 712735 ± 7679.sup.3,i 695793 ± 8417.sup.7,j 778002 ± 10064.sup.11,k______________________________________
There is no unit as these rates are measured by the surface under the curves obtained. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 11______________________________________Tryptophan dosage according to the level ofirradiation received for alanates 110, 180 and 380with a concentration of 5.0% P/P of proteinsDOSE(kGy) ALANATE-110 ALANATE-180 ALANATE-380______________________________________0 1056499 ± 5231.sup.1,a 1022490 ± 8765.sup.5,b 128405 ± 22051.sup.8,c4 1021131 ± 8183.sup.2,d 1074262 ± 5076.sup.6,e 1101364 ± 3365.sup.9,f8 1042411 ± 8518.sup.3,g 1040796 ± 1100961 ± 4713.sup.9,h 14792.sup.5,7,g12 988217 ± 7563.sup.4,i 1054722 ± 1108578 ± 13728.sup.6,7,j 14058.sup.8,9,k______________________________________
here is no unit as these rates are measured by the surface under the curves obtained. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
e) Selection of the Protein
The physical chemical behavior of the protein solutions during the irradiation treatment enabled us to select the most adequate protein extract for the manufacture of a film. To accomplish this, we studied: 1. the rheological parameters: resistance until rupture and the strain at failure 2. chemical parameters: rates of bityrosine formation and tryptophan loss.
The results obtained for the F/E ratio for calcium caseinate (alanate 380), with a concentration of 5.0%, are slightly higher than the two sodium caseinates (alanates 110 and 180) for levels (4, 8 and 12 kGy. On the other hand, at a concentration of 7.5%, the F/E ratio for calcium caseinate (alanate 380) is significantly higher (P σ 0.05) than the two sodium caseinates (alanates 110 and 180) at 4, 8 and 12 kGy (see tables 4 and 5 and FIG. 3).
The results of measurements of bityrosine formation showed that with 5.0% concentration, calcium caseinate (alanate 380) showed a significantly higher production of bityrosine (P σ 0.05) than the two sodium caseinates (alanates 110 and 180) at 4, 8 and 12 kGy. With 7.5% concentration, the first sodium caseinate (alanate 110) produced significantly more (P σ 0.05) bityrosine at levels of 4 and 12 kGy, whereas at 8 kGy, the three caseinates produced an equivalent quantity of bityrosine (see tables 8 and 9 and FIG. 5).
During the irradiation of the proteinic solutions, the observation of the solutions enabled us to note that the viscosity of sodium caseinates (alanates 110 and 180) increases with the amount of irradiation. This state is perceptible at the time of handling when the solutions are treated at 8 and 12 kGy. At the other end, the viscosity of calcium caseinate (alanate 380) is quasi unchanged as a function of irradiation levels.
According to tables 6 and 7 and FIG. 4, the protein films formed without a plasticizing agent have a low deformation capacity. Then, the presence of a plasticizing agent becomes essential for obtaining a film with a more adequate deformation capacity.
Therefore, according to the preceding results, we chose calcium caseinate (alanate 380) to continue the tests with a plasticizing agent, that is, glycerol.
The Effect of Glycerol in Calcium Caseinate
In this second part, the influence of glycerol as a plasticizing agent was studied. To this end, the three mechanical properties and the dosages of fluorescence were evaluated for purposes of comparison.
Under certain treatment conditions, it is sometimes difficult if not impossible to obtain films with 5.0% protein and 5.0% glycerol without radiation treatment.
a) The Force at Rupture
FIG. 7 and tables 12 and 13 show that for concentrations of 5.0% and 7.5%, the F/E ratio decreases as glycerol content increases. Then, a lesser force is necessary to rupture the film when glycerol content increases.
At a concentration of 5.0% protein and 0% glycerol, the F/E ratio remains high and stable (16.3 to 17.4) as a function of the level of irradiation. At 1.0% glycerol, the ratio varies between 11.8 and 13.9 for levels of 0 to 12 kGy and these two extreme values are considered significantly different (P δ 0.05) between them. On the other hand, the F/E ratio increases significantly (P δ (0.05) at 15 and 20 kGy to reach 16.3 and 17.2 respectively. At a 2.5% glycerol concentration, the F/E ratio grows significantly (P δ 0.05) with the increase in the level of irradiation. It goes from 5.6 to 12.1 and a maximum is reached at 30 kGy. For 5.0% glycerol concentration the F/E ratio also increases significantly (P δ 0.05) as a function of the level of irradiation. It increases from 2.7 to 4.5 and also reaches its maximum at 30 kGy. (see table 12 and FIG. 7). Under these conditions, irradiation contributes to create a more resistant film.
For a protein concentration of 7.5% with 0% of 2.5% glycerol, there is little variation of the F/E ratio for levels varying between 0 and 12 kGy. Indeed, the ratio varies from 16.3 to 17.4 and 10.4 to 11.2 per 0% and 2.5% of glycerol respectively. On the other hand, at glycerol 2.5%, the F/E ratio undergoes an increase but it is not significant (P>0.05) at levels of 15 and 20 kGy. At 5.0% glycerol, the F/E ratio increases significantly (P δ 0.05) with the increase in the level of irradiation; it increases from 4.3 to 6.3 with a maximum at 30 kGy (see table 13 and FIG. 5).
At 5.0% protein the F/E ratio decreases significantly (P δ 0.05) with the addition of glycerol whatever its concentration (1.0%, 2.5% and 5.0%) and this, for all the tested levels of irradiation. In the presence of 7.5% protein, the same phenomenon is observed for levels between 0 and 20 kGy.
At 5.0% glycerol, we observe a significant increase (P δ 0.05) of F/E with the increase in the protein contents and this, for all levels of irradiation. At glycerol 2.5%, we observe the same phenomenon save for the samples treated at 15 kGy.
TABLE 12______________________________________The F/E ratio according to the level of receivedirradiation and the glycerol contents for alanate 380with a protein concentration of 5.0% P/P. F/E × 100 F/E × 100 F/E × 100 F/E × 100DOSE (N X μm) (N X μm) (N X μm) (N X μm)(kGy) 5.0%/0% 5.0%/1.0% 5.0%/2.5% 5.0%/5.0%______________________________________ 0 16.8 ± 0.9.sup.1,a 12.5 ± 0.3.sup.2,3,b 5.6 ± 02.sup.5,c -- 4 16.3 ± 1.5.sup.1,d 13.9 ± 1.3.sup.3,e 5.9 ± 0.1.sup.5,f 2.7 ± 0.2.sup.10,g 8 17.4 ± 0.5.sup.1,h 12.6 ± 1.1.sup.2,3,i 6.9 ± 0.1.sup.6,j 3.3 ± 0.1.sup.11,12,k12 17.2 ± 1.0.sup.1,l 11.8 ± 0.1.sup.2,m 7.0 ± 0.2.sup.6,n 3.8 ± 0.4.sup.11,13,o15 -- 16.3 ± 0.1.sup.4,p 10.5 ± 0.4.sup.7,q 3.6 ± 0.3.sup.11,12,13,r20 -- 17.2 ± 0.6.sup.4,s 10.1 ± 0.4.sup.8,t 4.0 ± 0.3.sup.13,u30 -- -- 12.1 ± 0.1.sup.9,v 4.5 ± 0.3.sup.14,w40 -- -- 10.7 ± 0.3.sup.7,x 3.2 ± 0.3.sup.12,y______________________________________
The term F/E expresses the ratio of the breaking load versus the thickness of film. The Expression 5.0%/1.0% means 5.0% protein with 1.0% glycerol. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 13______________________________________The F/E ratio according to the level of receivedirradiation and glycerol contents for alanate 380with a protein concentration of 7.5% P/P. F/E × 100 F/E × 100 F/E × 100DOSE (N X μm) (N X μm) (N X μm)(kGy) 7.5%/0% 7.5%/2.5% 7.5%/5.0%______________________________________ 0 17.4 ± 0.4.sup.1,a 11.0 ± 1.0.sup.3,b 4.3 ± 0.2.sup.4,c 4 16.4 ± 0,0.sup.2,d 11.2 ± 0.5.sup.3,e 4.4 ± 0.2.sup.4,f 8 16.3 ± 0.2.sup.2,g 10.4 ± 1.5.sup.3,h 4.6 ± 0.1.sup.4,i12 16.7 ± 0.2.sup.2,j 10.5 ± 0.9.sup.3,k 5.8 ± 0.2.sup.5,l15 -- 12.5 ± 1.4.sup.3,m 5.2 ± 0.2.sup.6,n20 -- 12.1 ± 0.1.sup.3,o 5.7 ± 0.15.sup.5,p30 -- -- 6.3 ± 0.1.sup.740 -- -- 5.9 ± 0.2.sup.5______________________________________
The term F/E expresses the ratio of the breaking load versus the thickness of film. The Expression 7.5%/2.5% means 7.5% protein with 2.5% glycerol. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
b) The Strain at Failure
According to FIG. 8 and tables 14 and 15, the presence of glycerol strongly increases the deforming capacity of films.
At 5.0% protein, the amount of irradiation and the addition of 1.0% glycerol do not bring comparatively important changes to the deforming capacity of films in the absence of glycerol. The deformation varies from 2.2 mm to 2.4 mm and from 2.6 mm to 2.9 mm for 0% and 1.0% glycerol respectively. Whereas in 2.5% and 5.0% glycerol, the deforming capacity increases significantly (P δ 0.05) with the increase in the level of irradiation. The deformation varies from 5.7 mm to 7.4 mm for 2.5% glycerol and from 7.6 mm to 10.8 mm for glycerol 5.0%. A maximum is reached between 20 and 30 kGy for these two concentrations of glycerol (see table 14 and FIG. 9). Therefore, irradiation contributes to improve the deforming capacity of films. The difference between the deformation and the three concentrations of glycerol is considered significant (P δ 0.05) at all levels of irradiation.
For a 7.5% concentration of protein, the presence of 2.5% of glycerol does not bring a significant different (P>0.05) in the deformation as a function of the levels of irradiation (0 to 20 kGy). The deformation varies from 3.8 mm to 4.2 mm between levels of 0 and 20 kGy. On the other hand, the difference in deformation between 0% and 2.5% of glycerol is considered significant (P δ 0.05) for levels 0 to 12 kGy. With the addition of 5.0% of glycerol, the deformation is significantly higher (P δ 0.05) than in the presence of 2.5% or the in absence of glycerol. The deformation values vary from 7.7 mm to 11.6 mm as a function of the levels of irradiation to a maximum value towards 15 to 20 kGy (see table 15 and FIG. 9).
At 2.5% glycerol, the deformation to 5.0% of proteins is significantly higher (P δ 0.05) than at 7.5% of proteins for levels of 0 to 20 kGy (see tables 14 and 15).
For a 5.0% glycerol concentration, there is a significant difference (P δ 0.05) of the deformation between the two protein concentrations. The deformation is higher at protein 7.5% compared to 5.0% for levels of 4, 8, 15, 20 and 40 kGy. It is significantly higher (P δ 0.05) than for levels of 8, 15 and 40 kGy. At 12 and 30 kGy, the deformation with 7.5% protein is lower than that obtained at 5.% (see tables 14 and 15). However, this difference is significantly lower (P δ 0.05) only at 12 kGy.
Therefore, deformation as a function of the level of irradiation is higher in the presence of 5.0% glycerol and this, for the two protein concentrations. The effect of the level of irradiation on deformation is more evident in the presence of 7.5% of proteins and 5.0% of glycerol. In the presence of 2.5% glycerol and 5.0% protein, the deformation undergoes a slight increase as a function of the level amount but it is considered significant (P δ 0.05).
TABLE 14______________________________________Strain at failure as a function of the level of receivedirradiation and glycerol contents for alanate 380at a protein concentration of 5.0% P/P. DEFOR- DEFOR- DEFOR- DEFOR- MATION MATION MATION MATIONDOSE (mm) (mm) (mm) (mm)(kGy) 5.0%/0% 5.0%/1.0% 5.0%/2.5% 5.0%/5.0%______________________________________ 0 2.3 ± 0.1.sup.1,2,a 2.6 ± 0.1.sup.3,a 5.7 ± 0.4.sup.6,b -- 4 2.2 ± 0.1.sup.1,c 2.9 ± 0.1.sup.4,d 6.1 ± 0.2.sup.6,7,e 8.5 ± 04.sup.10,f 8 2.3 ± 0.2.sup.1,2,g 2.8 ± 0.1.sup.3,4,5,h 6.6 ± 0.1.sup.7,8,i 9.5 ± 0.1.sup.11,j12 2.4 ± 0.1.sup.2,k 2.6 ± 0.1.sup.3,5,k 7.0 ± 0.3.sup.8,9,l 10.3 ± 0.3.sup.12,13,m15 -- 2.9 ± 0.2.sup.4,5,n 6.2 ± 0.2.sup.6,7,o 9.6 ± 0.6.sup.11,12,p20 -- 2.9 ± 0.2.sup.4,q 7.3 ± 0.3.sup.9,r 10.8 ± 0.7.sup.13,s30 -- -- 7.4 ± 0.5.sup.9,t 10.7 ± 0.2.sup.13,u40 -- -- 5.9 ± 0.2.sup.6,v 7.6 ± 0.3.sup.14,w______________________________________
The expression 5.0%/1.0% means protein 5.0% with glycerol 1.0%. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 15______________________________________Strain at failure as a function of the amount of receivedirradiation and glycerol contents for alanate 380with a protein concentration of 7.5% P/P. DEFOR- DEFOR- DEFOR- MATION MATION MATIONDOSE (mm) (mm) (mm)(kGy) 7.5%/0% 7.5%/2.5% 7.5%/5.0%______________________________________ 0 2.7 ± 0.1.sup.1,a 4.1 ± 0.4.sup.3,b 7.7 ± 0.2.sup.4,c 4 2.5 ± 0.1.sup.1,2,d 3.8 ± 0.3.sup.3,e 9.4 ± 0.5.sup.5,6,f 8 2.6 ± 0.2.sup.1,2,g 4.0 ± 0.3.sup.3,h 11.0 ± 0.1.sup.7,i12 2.3 ± 0.2.sup.2,j 4.0 ± 0.3.sup.3,k 9.1 ± 0.3.sup.5,l15 -- 3.9 ± 0.4.sup.3,m 11.6 ± 0.6.sup.7,n20 -- 4.2 ± 0.2.sup.3,o 11.2 ± 0.6.sup.7,p30 -- -- 10.0 ± 0.5.sup.640 -- -- 8.3 ± 0.3.sup.4______________________________________
The expression7.5%/2.5% means protein 7.5% with glycerol 2.5%. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
c) Viscoelasticity
A characteristic sought in a film is its elasticity, i.e., a film having a low relaxation coefficient. According to relaxation results, films irradiated with calcium caseinate (alanate 380) are viscoelastic products with a relaxation coefficient varying between 0.57 to 0.69 according to the composition of the films (see table 16 and FIG. 10).
Only films able to deform with more than three millimeters (3.0 mm) can be studied as viscoelasticity is measured following a sustained deformation of 3.0 mm. In the present case, three compositions of mediums were retained, that is, 5.0% protein with 2.5% and 5.0% glycerol and 7.5% proteins with 5.0% glycerol.
For a concentration of 5.0% proteins with 2.5% and 5.0% glycerol, irradiation tends to produce a more elastic film since the relaxation coefficients decrease significantly (P δ 0.05) with the increase in the level of irradiation. The values of coefficients vary from 0.66 to 0.61 and 0.63 to 0.57 for glycerol concentrations of 2.5% and 5.0% respectively. A minimum relaxation coefficient is obtained between 30 and 40 kGy for these two glycerol concentrations (see table 16 and FIG. 10). The difference between the two glycerol concentrations is significant (P δ 0.05) at all levels of irradiation except for levels of 15 and 20 kGy. Thus, the addition of 5.0% glycerol produces a more elastic film with a weaker relaxation coefficient.
With a protein concentration of 7.5% and 5.0% glycerol, irradiation tends to lower significantly (P δ 0.05) the relaxation coefficient except when one irradiates at 8 kGy where a maximum value is reached. The values of coefficients vary from 0.67 to 0.63 according to the amounts of irradiation. Then, irradiation contributes to produce a more elastic film with a minimal value following a treatment located between 20 and 40 kGy (see table 16 and FIG. 10).
At 5.0% glycerol, the relaxation coefficients at 5.0% protein are significantly lower (P δ 0.05) than those obtained 7.5% proteins for all levels of irradiation.
TABLE 16______________________________________Relaxation coefficients as a function to the level of receivedirradiation and glycerol contents for alanate 380 withprotein concentrations of 5.0% P/P and 7.5% P/PDOSE(kGy) 5.0%/2.5% 5.0%/5.0% 7.5%/5.0%______________________________________ 0 0.66 ± 0.01.sup.1,2 -- 0.67 ± 0.01.sup.10 4 0.67 ± 0.00.sup.1,a 0.63 ± 0.00.sup.7,b 0.66 ± 0.01.sup.11,12,c 8 0.66 ± 0.01.sup.2,3,d 0.61 ± 0.01.sup.7,8,e 0.69 ± 0.01.sup.13,f12 0.65 ± 0.01.sup.3,4,g 0.62 ± 0.01.sup.7,8,h 0.66 ± 0.01.sup.10,11,f15 0.64 ± 0.00.sup.4,5,j 0.63 ± 0.01.sup.7,j 0.65 ± 0.01.sup.12,14,k20 0.63 ± 0.01.sup.5,l 0.60 ± 0.02.sup.8,l 0.64 ± 0.01.sup.15,m30 0.61 ± 0.01.sup.6,n 0.57 ± 0.01.sup.9,o 0.64 ± 0.01.sup.15,p40 0.61 ± 0.01.sup.6,q 0.57 ± 0.02.sup.9,r 0.63 ± 0.00.sup.15______________________________________
The expression 5.0%/2.5% means protein 5.0% with glycerol 2.5%. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05). The statistical evaluation with glycerol 5.0% is made only for one concentration of 5.0% and protein 7.5%.
d) Rate of Bityrosine Formation
The average value obtained with 0 kGy was subtracted from those obtained from the various levels of irradiation with the aim of obtaining the real rate of bityrosine formation.
The rate of bityrosine formation increases proportionally with the increase in the level of irradiation for the two protein concentrations (see tables 17 and 18 and FIG. 11). The rate of bityrosine formation increases by 23,000 to 350,000 (in arbitrary units of area) for amounts varying from 4 to 40 kGy for the two protein concentrations.
For a 5.0% protein concentration, the rate of bityrosine formation is significantly higher (P δ 0.05) in the presence of glycerol (1.0%, 2.5% and 5.0%) compared to its absence (0%) for levels of 15 and 20 kGy (see table 17). At 7.5% protein, the presence of glycerol (2.5% and 5.0%) significantly increases (P δ 0.05) the rate of bityrosine formation for levels of 4 to 20 kGy (see table 17 and FIG. 11). Moreover, we note than in the presence of 2.5% glycerol, the rate of bityrosine formation in the sample of protein containing 7.5% doubled compared to the sample containing protein containing 5.0% (43513 vs. 20503) and when this one is irradiated at 4 kGy (see tables 17 and 18). We also note an increase of approximately 10% of the bityrosine content when the protein samples (5.0% and 7.5%) are irradiated at 20 kGy in absence and in the presence of glycerol 2.5%. On the other hand, there is no relation between the rate of bityrosine formation and the protein concentration in the presence of 5.0% glycerol.
As glycerol alone in the buffer does not absorb and does not emit at the of excitation and emission wavelengths used, it seems to favour the formation of bityrosine. There exists a linear relation between the rate of bityrosine formation and the levels of irradiation for the various protein-glycerol mixtures that were tested.
TABLE 17__________________________________________________________________________Rate of bityrosine formation according to the level ofreceived irradiation and glycerol contents for alanate 380with a protein concentration of 5.0% P/P.DOSE(kGy) 5.0%/0% 5.0%/1.0% 5.0%/2.5% 5.0%/5.0%__________________________________________________________________________ 4 28552 ± 1621.sup.1,a 21836 ± 1484.sup.6,bc 20503 ± 941.sup.11,b 23126 ± 1482.sup.18,c 8 66803 ± 2391.sup.2,d 76436 ± 1006.sup.7,e 66439 ± 1805.sup.12,d 81304 ± 2395.sup.19,f12 82504 ± 1650.sup.3,g 79531 ± 1964.sup.8,h 75782 ± 1206.sup.13,i 85465 ± 1392.sup.20,j15 89584 ± 1817.sup.4,k 113309 ± 2249.sup.9,l 134112 ± 1328.sup.14,m 125394 ± 1551.sup.21,n20 129044 ± 931.sup.5,n 146654 ± 1511.sup.10,p 163519 ± 1126.sup.15,q 158853 ± 2892.sup.22,r30 -- -- 254378 ± 1440.sup.16,s 256610 ± 2398.sup.23,s40 -- -- 348299 ± 4022.sup.17,t 336676 ± 2254.sup.24,u__________________________________________________________________________
There is not unit as these rates are measured by the surface under the curves obtained. Expression 5.0%/2.5% means protein 5.0% with glycerol 2.5%. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 18______________________________________Rate of bityrosine formation according to the level ofreceived irradiation and glycerol contents for alanate 380with protein concentration of 7.5% P/P.DOSE(kGy) 7.5%/0% 7.5%/2.5% 7.5%/5.0%______________________________________ 4 17192 ± 1621.sup.1,a 43513 ± 1328.sup.6,b 20803 ± 928.sup.11,e 8 39344 ± 687.sup.2,d 97240 ± 4388.sup.7,e 57961 ± 897.sup.12,f12 61076 ± 607.sup.3,g 103811 ± 1653.sup.8,h 92734 ± 1901.sup.13,i15 955871 ± 1252.sup.d,j 128415 ± 1232.sup.9,k 117110 ± 1398.sup.14,l20 1392491 ± 1697.sup.5,m 184986 ± 1581.sup.10,n 151133 ± 1653.sup.15,o30 -- -- 290277 ± 1848.sup.1640 -- -- 3627561 ± 1564.sup.17______________________________________
There is no unit for these rates are measured by the surface under the curves obtained. Expression 7.5%/2.5% means 7.5% protein with 2.5% glycerol. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
e) Dosage of Tryptophan
In the presence of glycerol, the rate of tryptophan loss due to the irradiation treatment is significant (p δ 0.05), that is, a fall of the fluorescence signal is perceived with the increase in the level of irradiation (see tables 19 and 20 and FIG. 12).
At 5.0% protein concentration, the decrease of the signal is significant (P δ 0.05) in the presence of glycerol (1.0%, 2.5% and 5.0%) compared to its absence for levels varying from 4 to 20 kGy. The signal varies approximately from 760,000 to 560,000 between 0 and 20 kGy and decreases approximately to 470,000 for the level of 40 kGy when the dosages are done on mediums in the presence of glycerol (1.0%, 2.5% and 5.0%). However, there is not regular and continuous signal loss as a function of the level of irradiation to 0% glycerol. The average signal obtained between 0 and 20 kGy is 778,000 for a protein concentration of 5.0%. Even if sometimes a significant different (p δ 0.05) to 0% glycerol is perceived between the levels of irradiation, there is no constant fall of the signal. Thus, the perceived signal with 0% glycerol is significantly higher (p δ 0.05) than the one perceived in the presence of glycerol for levels of irradiation higher or equivalent to 4 kGy (see table 19 and FIG. 12).
With amounts higher or equivalents to 15 kGy, the presence of glycerol favours a reduction in the signal obtained in the 5.0% proteins solutions. This fall of signal seems to be more important with the increase in glycerol content. It becomes a significant (P δ 0.05), however, between 5.0% and 2.5% glycerol for levels of 30 and 40 kGy (see table 19 and FIG. 12).
At 7.5% proteins, the loss of the signal in the presence of glycerol is significant (P δ 0.05) at 12, 15 and 20 kGy in the presence of 2.5% and 5.0% glycerol compared to its absence. In the presence of glycerol (2.5% or 5.0%), the signal varies approximately 1,115,000 to 900,000 between 0 and 20 kGy and decreases up to 814,000 for the level of 40 kGy at 5.0% glycerol. On the other hand, in the absence of glycerol, there is no regular and continuous signal loss during irradiation. An average signal of 1,122,000 is obtained for levels of irradiation of 0 to 20 kGy. Thus, the signal obtained in the absence of glycerol is significantly higher (P δ 0.05) than that obtained in its presence for levels of irradiation higher than 8 kGy (see table 20 and FIG. 12).
For an irradiation level equivalent or higher than 12 kGy, the signal perceived at 7.5% proteins is significantly lower (Pδ0.05) in presence of 5.0% glycerol than 2.5% glycerol (see table 20 and FIG. 12).
TABLE 19__________________________________________________________________________Tryptophan dosage as a function of the level of receivedirradiation and glycerol contents for alanate 380with a protein concentration of 5.0% P/P.DOSE(kGy) 5.0%/0% 5.0%/1.0% 5.0%/2.5% 5.0%/5.0%__________________________________________________________________________ 0 764770 ± 2693.sup.1,a 796315 ± 3894.sup.6,b 782666 ± 23326.sup.10,ab 700887 ± 4245.sup.18,c 4 793769 ± 1677.sup.2,d 710132 ± 2361.sup.7,c 714711 ± 6221.sup.11,e 739892 ± 10315.sup.19,f 8 749959 ± 8149.sup.3,g 677805 ± 7018.sup.8,h 686849 ± 3743.sup.12,h 684373 ± 7521.sup.20,h12 778002 ± 10064.sup.4,i 669722 ± 10182.sup.8,j 623320 ± 4653.sup.13,k 623178 ± 2164.sup.21,k15 814920 ± 2447.sup.5,l 585219 ± 2866.sup.9,m 585219 ± 2866.sup.14,m 583052 ± 1559.sup.22,m20 765954 ± 9612.sup.1,n 579666 ± 7450.sup.9,o 561248 ± 11830.sup.15,p 546316 ± 3320.sup.23,p30 -- -- 531297 ± 5928.sup.16,q 494688 ± 2136.sup.24,r40 471847 ± 4943.sup.17,s 466259 ± 3208.sup.25,t__________________________________________________________________________
There is no unit as these rates are measured by the surface under the curves obtained. The expression 5.0%/2.5% means 5.0% protein with 2.5% glycerol. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
TABLE 20__________________________________________________________________________Tryptophan dosage as a function of the level of receivedirradiation and glycerol contents for alanate 380with a protein concentration of 7.5% P/P.DOSE(kGy)7.5%/0% 7.5%/2.5% 7.5%/5.0%__________________________________________________________________________ 0 1128405 ± 22051.sup.1,a 1140330 ± 12521.sup.4,ab 1179255 ± 31338.sup.9,b 4 1101364 ± 3365.sup.2,c 1146510 ± 20464.sup.4,d 1131341 ± 8699.sup.10,d 8 1100961 ± 4713.sup.2,e 10081601 ± 16486.sup.5,ef 1070098 ± 14308.sup.11,f12 1108578 ± 14058.sup.1,2,m 1006871 ± 7153.sup.6,h 980093 ± 10770.sup.12,i15 1158964 ± 5372.sup.3,j 972919 ± 5338.sup.7,k 935709 ± 8417.sup.13,l20 1133910 ± 21926.sup.1,3,m 934142 ± 7591.sup.8,n 876339 ± 9557.sup.14,o30 -- -- 847660 ± 3469.sup.1540 814091 ± 11282.sup.16__________________________________________________________________________
There is no unit as these rates are measured by the surface under the curves obtained. The expression 7.5%/2.5% means 7.5% protein with 2.5% glycerol. For each line, two averages followed by the same letter are not significantly different between them (P>0.05). For each column, two averages followed by the same figure are not significantly different between them (P>0.05).
Biodegradability
In this section, the results of the biodegradability of a type of film will be presented. The tests were repeated in triplicate with three recoveries.
The results of the first test show that when P. fragi is in contact with film, the bacterial growth is fast and a maximum of population (approximately 107 UFC/ml of medium) is reached after approximately 80 hours of agitation (see table 21 and FIG. 13). The population tends to decrease very slowly as a function of time and this one remained higher than 10 6 UFC/ml after 1127 hours of experimentation. On the other hand, in the absence of film, the population remained appreciably the same at 20 UFC/ml for the first 100 hours. Thereafter, it decreased and remained <5 UFC/ml until the end. In presence of single film, the bacterial population is <5 UFC/ml from beginning to end of the experimentation.
TABLE 21______________________________________Results of test #1 countings of Pseudomonas fragi in thepresence and/or in the absence of a film sample of alanate380 composed of 5.0% P/P proteins and 2.5% P/P glycerolirradiated at 20 kGy. P. fragi P. fragi FILMTIME WITH FILM ONLY ONLY(h) (UFC/ml) (UFC/ml) (UFC/ml)______________________________________ 0 23 ± 12 15 ± 12 <5 4 20 ± 17 -- -- 8 18 ± 12 -- -- 9 -- -- <5 10 53 ± 45 -- -- 21 100 ± 18 -- -- 27 370 ± 120 27 ± 20 <5 53 -- -- <5 54 12 × 10.sup.4 ± 61 × 10.sup.3 -- -- 76 89 × 10.sup.5 ± 18 × 10.sup.5 -- -- 102 12 × 10.sup.6 ± 24 × 10.sup.5 13 ± 13 <5 125 12 × 10.sup.6 ± 23 × 10.sup.5 -- -- 146 10.4 × 10.sup.6 ± 16 × 10.sup.5 -- -- 148 -- <5 <5 267 92 × 10.sup.5 ± 27 × 10.sup.5 -- -- 287 -- <5 <5 293 93 × 10.sup.5 ± 22 × 10.sup.5 -- -- 413 77 × 10.sup.5 ± 24 × 10.sup.5 -- -- 414 -- <5 <5 624 46 × 10.sup.5 ± 26 × 10.sup.5 -- -- 646 -- <5 <51127 36 × 10.sup.5 ± 87 × 10.sup.4 <5 <5______________________________________
In the second test, the bacterial growth is rapid in the presence of film and a maximum (approximately 107 UFC/ml) is reached after approximately 60 hours of agitation (see table 22 and FIG. 14), the maximum population was reached more quickly but the initial population was 70 UFC/ml compared to 20 UFC/ml for the first time. The population only decreased very slightly as a function of time and remains at 106 FC/ml after about a hundred hours of agitation. Thereafter, the population decreased regularly as a function of time to read approximately 10 3 UFC/ml after 1102 hours (see table 22 and FIG. 14). In presence of film only, the bacterial calculation is <5 UFC/ml over the duration of the experimentation.
TABLE 22______________________________________Results of test #2 counting the in presenceand/or absence of a film sample of alanate 380composed of 5.0% P/P proteins and 2.5% P/Pglycerol, irradiation at 20 kGy. P. fragi P. fragi FILMTIME WITH FILM ONLY ONLY(h) (UFC/ml) (UFC/ml) (UFC/ml)______________________________________ 0 67 ± 45 87 ± 27 <5 4 83 ± 22 -- -- 21 7400 ± 5300 -- -- 24 -- 180 ± 44 <5 34 81 × 10.sup.4 ± 62 × 10.sup.4 -- -- 47 48 × 10.sup.5 ± 12 × 10.sup.5 -- -- 53 66 × 10.sup.5 ± 67 × 10.sup.4 -- -- 70 -- -- <5 71 62 × 10.sup.5 ± 14 × 10.sup.5 -- -- 93 64 × 10.sup.5 ± 64 × 10.sup.4 -- -- 96 -- 83 × 10.sup.4 ± 14 × 10.sup.4 --120 -- 91 × 10.sup.4 ± 13 × 10.sup.4 --189 47 × 10.sup.5 ± 10 × 10.sup.5 -- --190 -- -- <5192 -- 80 × 10.sup.4 ± 69 × 10.sup.3720 31 × 10.sup.5 ± 21 × 10.sup.5 -- <5746 -- 43 × 10.sup.3 ± 30 × 10.sup.3 --1102 99 × 10.sup.4 ± 26 × 10.sup.4 800 ± 730 <5______________________________________
For the third test, bacterial growth is very fast in the presence of film and is maximum (approximately 107 UFC/ml) after about sixty hours of agitation. The initial population was approximately 130 UFC/ml and the maximum was reached within a time similar to the second test. In this test, the population also tends to decrease according to time but after 1200 hours of agitation, this population tends to increase slightly thereafter (see table 23 and FIG. 15). In absence of film, the population remains stable (approximately 110 UFC/ml) for first period the 24 hours and increases quickly to 10 6 UFC/ml after a hundred hours of agitation. Then, the population decreases by one logarithmic unit and remains stable for the interval from 500 to 1500 hours. Thereafter, the population falls quickly to 2800 UFC/ml after 1779 hours of agitation (see FIG. 15). In presence of film only, the population is <5 UFC/ml throughout the experiment.
The experiments of biodegradability were stopped after obtaining the stability of the P. fragi population in the mediums in the presence of film and when the population had distinctly decreased, in the mediums in the absence of film (tests 2 and 3). For the three tests, the film was not entirely biodegraded at the time of stopping the experimentation.
Various attempts were made in order to follow the rate of biodegradation of film by P. fragi as a function of time by soluble nitrogen dosage. In no case were we able to could recover film after complete immersion in the mediums without losing a significant quantity of it. Indeed, the film has a tendency to disorganize once immersed in water, so that it loses its initial structure. Then, a recovery by filtration and/or evaporation was not effective to isolate the film from the mediums during the biodegradation tests.
TABLE 23______________________________________Results of test #3 countings of Pseudomonas fragiin the presence and/or absence of a film sample ofalanate 380 composed of 5.0% P/P proteins and 2.5% P/Pglycerol, irradiated at 20 kGy. P. fragi P. fragi FILMTIME WITH FILM ONLY ONLY(h) (UPC/mI) (UFC/ml) (UFC/ml)______________________________________ 0 130 ± 56 130 ± 39 <5 4 170 ± 47 103 ± 29 -- 24 21 × 10.sup.3 ± 2700 88 ± 22 <5 30 85 × 10.sup.3 ± 31 × 10.sup.3 160 ± 18 -- 50 47 × 10.sup.5 ± 14 × 10.sup.5 30 × 10.sup.3 ± 20 × 10.sup.3 <5 73 87 × 10.sup.5 ± 98 × 10.sup.4 75 × 10.sup.4 ± 57 × 10.sup.4 -- 98 78 × 10.sup.5 ± 10 × 10.sup.5 98 × 10.sup.4 ± 59 × 10.sup.4 -- 173 56 × 10.sup.5 ± 85 × 10.sup.4 10 × 10.sup.5 ± 45 × 10.sup.4 <5 291 61 × 10.sup.5 ± 25 × 10.sup.5 83 × 10.sup.4 ± 55 × 10.sup.4 -- 503 38 × 10.sup.5 ± 11 × 10.sup.3 82 × 10.sup.3 ± 23 × 10.sup.3 <5 634 29 × 10.sup.5 ± 33 × 10.sup.4 -- <51083 26 × 10.sup.5 ± 49 × 10.sup.4 -- <51152 -- 10 × 10.sup.4 ± 16 × 10.sup.3 --1465 33 × 10.sup.5 ± 11 × 10.sup.5 82 × 10.sup.3 ± 19 × 10.sup.3 <51779 74 × 10.sup.5 ± 21 × 10.sup.5 2800 ± 480 <5______________________________________
Analysis of Results for the Three Alanates
Of the three caseinates used, calcium caseinate (alanate 380) has a behavior to irradiation which differs from that of the two sodium caseinates (alanates 110 and 180). Various measurements of the rheological and physical chemical properties showed that:
The breaking load (F/E ratio) of calcium caseinate (alanate 380) is higher compared to the two sodium caseinates (alanates 110 and 180). At 5.0% P/P and 7.5% P/P, the calcium caseinate (alanate 380) has a higher F/E ratio than the two sodium caseinates (alanates 110 and 180) for levels of 4, 8 and 12 kGy. However, there is no direct relation between protein concentration and film resistance. Indeed, for a concentration of 5.0% P/P, the F/E ratio is higher than the one at 7.5% P/P for the three caseinates. The only exceptions are for the two sodium caseinates (alanates 110 and 180) irradiated at 4 kGy where the ratio is very slightly lower (see tables 4 and 5). Therefore, all things considered, a film produced with a greater quantity of proteins does not form obligatorily a more resistant film after irradiation.
At 5.0% protein, irradiation up to 12 kGy of the second sodium caseinate (alanate 180) generates a significant reduction (P δ 0.05) in the F/E ratio. This phenomenon is observed for the first sodium caseinate (alanate 110) at a level of 4 kGy only. Irradiation up to 12 kGy of calcium caseinate (alanate 380) does not have a significant effect (P>0.05) on the F/E ratio (see table 4).
In the absence of glycerol, irradiation generates a significant reduction (P δ 0.05) in the F/E ratio for the sodium caseinates (alanate 110) and the calcium caseinates (alanate 380) at a concentration of 7.5%. Irradiation up to 12 kGy does not have a significant effect (P>0.05) on the F/E ratio for the second sodium caseinate (alanate 180) at 7.5% (see table 5).
Thus, irradiation up to 12 kGy does not generate a more resistant film for these three caseinates in the absence of plasticizing agents.
At a 5.0% concentration, the calcium caseinate (alanate 380) produced a rate of bityrosine formation significantly higher (P δ 0.05) than the two sodium caseinates (alanates 110 and 180) when this caseinate is treated at levels of 4, 8 and 12 kGy. On the other hand, at 7.5% protein, the sodium caseinate (alanate 110) formed significantly more (P δ 0.05) bityrosine that the sodium caseinates (alanates 180) and the calcium caseinates (alanate 380) at levels of 4 and 12 kGy. At 8 kGy, the three caseinates formed a similar proportion of bityrosine (see tables 8 and 9).
However, the sodium caseinates (alanate 180) and the calcium caseinates (alanate 380) produced significantly more (P δ 0.05) bityrosine at a 5.0% protein concentration than at 7.5% for levels of 4, 8 and 12 kGy. The sodium caseinate (alanate 110) produced more bityrosine at 5.0% protein than at 7.5% for levels of 8 kGy only (see tables 8 and 9). Then, would it be possible that the 5.0% concentration would represent a zone where the rate of bityrosine formation would be a maximum and that the 7.5% concentration would represent a point of saturation? A much more thorough study should be made to validate this assumption.
The cohesion force of a film, among others, is connected to its polymeric and chemical structure (Kester and Fennema, 1986). The rate of bityrosine formation represents an important factor in the process of polymerization induced by the hydroxyl radicals (Davies, 1987 and Davies et al., 1987a). Thus, at a concentration of 5.0% protein, the calcium caseinate (alanate 380) shows, at the same time, a F/E ratio and a rate of bityrosine formation that is higher than the two sodium caseinates (alanates 110 and 180). On the other hand, such a relation is not observed with a 7.5% protein concentration for the three caseinates.
On the other hand, irradiation up to 12 kGy has little or no significant effect (P>0.05) on the strain at failure of the three caseinates used for the two tested concentrations (see tables 6 and 7).
Likewise, there was no occurrence of a regular and continuous tryptophan loss as a function of the level of irradiation during dosage by fluorescence. This situation was noticed for the three caseinates and at the two concentrations used (see tables 10 and 11). In the absence of glycerol, it is possible that the gamma irradiation generates a proteinic denaturation which exposes the hydrophobic pockets on the surface of the protein. Then, the relative stability of the signal fluorescence which is perceived during the tryptophan dosage, would be more likely explained by a greater quantity of tryptophan having migrated on the surface rather than the formation of new residues by the irradiation.
Influence of Glycerol
a) Analyses of Results with 5.0% Protein
Compared to the results obtained in the absence of glycerol, for a treatment from 0 to 12 kGy, at a concentration of 5.0% protein, the presence of 1.0% glycerol significantly lowers (P δ 0.05) the breaking load, increases the deformation (approximately 0.4 mm) and does not affect the rate of bityrosine formation (see tables 12, 14 and 17). On the other hand, for levels of 15 and 20 kGy, the load breaking shows F/E ratios which are comparable to those obtained in the absence of glycerol for a 0 treatment at 12 kGy. The deformation is increased (approximately 0.6 mm) compared to the results obtained in the absence of glycerol for the amounts varying between 0 and 12 kGy (see tables 12 and 14). The rate of bityrosine formation is significantly higher P δ 0.05) compared to the absence of glycerol for levels of 15 and 20 kGy (see table 17).
At 2.5% and 5.0% glycerol with 5.0% protein, the F/E ratio, the deformation, the viscoelasticity and the rate of bityrosine formation increase significantly (P δ 0.05) with the increase in the level of irradiation (see tables 12, 14, 16 and 17).
In the presence of 2.5% glycerol, irradiation made it possible to increase the F/E ratio by a factor of 2.2 and to increase the deformation by a factor of 1.3, while at 5.0% glycerol, irradiation made it possible to increase the F/E ratio by a factor of 1.6 and the deformation by a factor of 1.4 (see tables 12 and 14). The viscoelasticity of films with 5.0% glycerol is higher than that with 2.5%. However, the handling of films with 5.0% glycerol remains much more difficult (see table 16).
The fact of adding a greater quantity of glycerol (2.5 and 5.0%) in the medium considerably reduced the resistance of film but improves greatly its deforming capacity.
The glycerol does not seem to act like a radicalizing inhibitor. By its presence, it even seems to encourage bityrosine formation as a function of the level of irradiation. Indeed, the presence of glycerol (1.0%, 2.5% or 5.0%) significantly improves (P δ 0.05) the rate of bityrosine formation for levels of irradiation equivalent or higher than 15 kGy for a 5.0% concentration of protein (see table 17). On the other hand, the reasons justifying the beneficial effect that the presence of glycerol produces on the rate of bityrosine formation are not shown.
b) Analysis of Results with 7.5% Protein
In the presence of 2.5% glycerol and of 7.5% proteins, irradiation (0-12 kGy) generates a significant reduction (P δ 0.05) in the F/E ratio, a significant increase (P δ 0.05) in the deforming capacity and the rate of bityrosine formation compared to the results obtained in the absence of glycerol (see tables 13, 15 and 18). Nevertheless, a radiative treatment up to 20 kGy does not have significant consequences (P>0.05) on the F/E ratio and the deformation of films formed with 7.5% protein and 2.5% glycerol (see tables 13 and 14).
At 5.0% glycerol and 7.5% protein, the F/E ratio, the deformation, the viscoelasticity and the rate of bityrosine formation increase significantly (P δ 0.05) with the increase in the level of irradiation (see tables 13, 15 and 18). In the presence of 5.0% glycerol, irradiation made it possible to increase the F/E ratio and the deformation by a factor of 1.5 (see tables 13 and 15).
The presence of glycerol also contributes to greatly reduce the resistance of film but greatly improves its deformation.
In the presence of 5.0% protein, the addition of glycerol does not inhibit the formation of bityrosine. Quite to the contrary, the formation of bityrosine, as a function of the levels of irradiation (4 to 20 kGy), is significantly higher (P δ 0.05) (see table 18).
c) Comparison Between the Two Protein Concentrations
In the presence of 2.5% glycerol, the F/E ratios at 5.0% protein are lower than those at 7.5% for levels of irradiation from 0 to 20 kGy. On the other hand, the deformations at proteins 5.0% are significantly higher (P δ 0.05) than those at 7.5% for same the treatments (see tables 12 to 15). At 5.0% glycerol, the F/E ratios at 5.0% protein are significantly lower (p δ 0.05) than those at 7.5% for levels which vary from 0 to 40 kGy, while the deformations at 7.5% proteins are higher than those at 5.0% for levels of 4, 8, 15, 20 and 40 kGy. At 12 and 30 kGy, the deformations at 7.5% protein are lower than those at 5.0% (see tables 12 to 15). The viscoelasticity of films with 5.0% glycerol is significantly higher (P δ 0.05) with proteins 5.0% than at 7.5% (see table 16).
The addition of 2.5% glycerol with 7.5% protein significantly increases (P δ 0.05) the rate of bityrosine formation between the two protein concentrations except for the 15 kGy level. Nevertheless, there is no direct relation between the protein concentration and the formation of bityrosine. Thus, the rate of bityrosine formation is not proportional to the quantity of proteins present in the medium for the same level of irradiation (see tables 17 and 18).
A maximum F/E ratio is obtained at 30 kGy for the two protein concentrations with 2.5% and/or 5.0% glycerol. The deformation is highest between 20 and 30 kGy in the presence of 5.0% protein and 2.5% or 5.0% glycerol. At 7.5% protein with 5.0% glycerol, the deformation is highest between 15 and 20 kGy. Finally, viscoelasticity is at its maximum between 30 and 40 kGy for the two protein concentrations with 2.5% and/or 5.0% glycerol (see tables 12 to 16). Thus, a level of irradiation between 20 and 30 kGy seems to be an area where the tested mechanical properties are highest for these two concentrations of proteins and glycerol.
The glycerol/protein ratio seems to be an important factor on the influence of irradiation on the mechanical, physical and chemical properties for the two protein concentrations with 2.5% or 5.0% glycerol. Thus, a ratio of 0.5 (2.5% glycerol/5.0% protein) shows the strongest increase in the F/E ratio as a function of the irradiation levels whereas the weakest is perceived for a ratio of 0.33 (2.5% glycerol/7.0% protein). The strongest capacity of deformation during irradiation was noticed for a ratio of 0.67 (5.0% glycerol/7.5% protein) and the weakest was obtained for a ratio of 0.33. Finally, the progression obtained for viscoelasticity is appreciably the same one for the 0.5; 0.67 and 1.0 ratios. Thus, the glycerol/protein ratios located between 0.5 and 0.67 seem to show the strongest variations of the rheological properties to irradiation.
Therefore, a radiation treatment is beneficial for the resistance of a film, its deforming capacity and bityrosine formation for the two protein concentrations with 2.5% or 5.0% glycerol. During the process of polymerization, all the polymeric chains are inter-connected and gathered in a gigantic network. If the number of points of contact is not too high, the network shows an appreciable elastic capacity. This recoverable deformation would be due to the presence of flexible junctions (Wunderlich, 1981). Thus, a period of irradiation or an inadequate quantity of glycerol would concretely affect the structure of the protein network which, inevitably, would deteriorate the rheological properties of the film.
d) Tryptophan Dosage in the Presence of Glycerol
The oxidation of a tryptophan solution by the hydroxyl radicals is directly connected to the loss of intensity of the fluorescence signal (Davies et al., 1987a and see FIG. 6). In absence of glycerol, there is no tryptophan loss during dosages of the irradiated caseinate solutions. At the opposite side, a loss of the signal is perceived when glycerol is present in the treated mediums. At 5.0% protein, the loss of the signal in the presence of glycerol is significant (P δ 0.05) from 4 to 20 kGy whereas at 7.5% protein, it is significant (P δ 0.05) for levels of 12, 15 and 20 kGy (see tables 19 and 20).
The presence of glycerol tends to privilege the native or folded up state of a globular protein rather than a denatured state (Gekko and Timasheff, 1981). Thus, only the tryptophan located on the surface of the protein will be affected during irradiation.
All in all, the loss of intensity of the signal at 40 kGy compared to 0 kGy varies from 30 to 40% for the two protein concentrations.
In the presence of 5.0% proteins and 5.0% glycerol, a better protection against the tryptophan loss is observed compared to 2.5% or 1.0% glycerol, whereas between 2.5% and 1.0% glycerol, the proportion of signal loss as a function of the level of irradiation is roughly the same.
On the other hand, at 7.5% protein, the loss of signal intensity as a function of the level of irradiation in the presence of 5.0% glycerol is proportionally higher than when only 2.5% glycerol is present (see tables 19 and 20). The addition of 2.5% glycerol concentration shows a greater resistance to tryptophan loss compared to a solution containing 5.0% protein levels of irradiation varying from 0 to 20 kGy. At 5.0% glycerol, the reverse situation arises; however, for the 30 and 40 kGy levels, the loss becomes slightly higher with 5.0% protein than 7.5% (see tables 19 and 20).
Essentially, there is no direct relation between the loss of the signal and the glycerol content as a function of the level of irradiation for the two studied protein concentrations. It is difficult to establish a glycerol/protein ratio for which protection against tryptophan loss as a function of the level of irradiation would be maximized. For a 5.0% protein concentration a ratio of 1.0 is most adequate whereas for a 7.5% protein concentration, a ratio of 0.33 is more adequate.
The presence of glycerol strongly modifies the physical and chemical properties of calcium caseinate films (alanate 380). It tends to decrease the force at rupture, it increases the strain at failure, it improves viscoelasticity, it does not inhibit the formation of bityrosine and it protects protein from radiation denaturation.
Biodegradability
Generally, maximum bacterial growth is quickly reached when P. fragi is in the presence of the film. For the three tests, a maximum of approximately 107 UFC/ml is reached within a time of 60 to 80 hours after the removal of the mediums. A downward trend of the population is noticed after the maximum is reached except for the third test, where the population tends to increase after 1200 hours of agitation.
For the last two tests in the absence of film, the bacterial population requires a latency time of approximately 24 hours before starting to grow. A maximum of 106 UFC/ml is reached after about one hundred hours of agitation and in both cases, the population decreases in an obvious way thereafter.
With the single presence of film, the population remained <5 UFC/ml for the duration of the experimentation and on the three tests.
EXAMPLE 8
Other Formulations
Other films containing caseinate were manufactured by taking the same protocols as in the preceding Examples with the flowing modifications. Alanate 380 was solubilized at a rate of 5% P/P in a Tris-HCl buffer 1 mM with pH 8.0. The added plasticizing agents were propylene glycol (PG) and triethylene glycol (TEG) at 0, 2.5% and 5% P/P concentrations. The average flow of irradiation was 1.5 KGy/h for levels of 8, 16, 32, 64, 96 and 128 KGy. Calcium chloride was added after the irradiation at 0, 0.125 and 0.25% P/P concentrations. The best films obtained were made of 5% caseinate/2.5% PG and 5% caseinate/2.5% TEG (amounts lower than 32 KGy), the first having a higher breaking load and the second being more viscoelastic. Calcium seems to increase the cohesion force of film without affecting the strain at failure.
EXAMPLE 9
Additions of Other Components
One can add polysaccharides to calcium caseinate films/plasticizing agents. For example, the addition of carboxymethyl cellulose (CMC) gives a rigid film (total composition 5% alanate 380/2.5% glycerol/0.25% CMC). This film is made more viscoelastic if one adds a plasticizing agent supplement like 2.5% sorbitol. The CMC are added after irradiation to avoid a precipitation. The resistance and viscoelasticity properties of a caseinate film can thus be modified at will by the addition of other components (calcium, polysaccharides and plasticizing agents (polyethylene, propylene and triethylene glycols, glycerol and sorbitol). The best mechanical properties are obtained with ratios of 0.5 to 0.67 plasticizing agent/protein to levels of approximately 30 KGy.
When one adds the PEG as a plasticizing agent, concentrations lower than 1% are preferred to avoid the formation of heterogeneous films.
The addition of CaCl 2 (approximately 0.125% w/w) to the solution with three components (above) increases the formation of bityrosine and the breaking load. The caseinate films are formed at irradiation levels equal or higher than 16 KGy. The maximum force of films is obtained at 64 KGy. With higher amounts, protein degradation seems to overcome the formation of bityrosine. At 64 KGy, the presence of CaCl 2 has little influence on the breaking load in the presence of absence of mannitol or sorbitol.
PEG decreases the breaking load in the presence of CaCl 2 . PEG seems to inhibit the formation of electrostatic bonds and between salts. Sorbitol is the preferred plasticizing agent since it increases viscoelasticity the most.
EXAMPLE 10
Specific Formulation
One of the preferred formulations is 5% alanate 380/2.5% sorbitol/0.25% CMC/0.125% CaCl 2 , combining force of cohesion and viscoelasticity. The amount of optimal irradiation is located between 32 and 64 KGy.
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Ministere d'approvisionnements et services Canada, 1992, Le plan vert du Canada, Les instruments economiques et la protection de l'environnement, No. cat. En 21-119/1992F, Gouvernement du Canada.
Modler, H. W., 1985, Functionnal properties of nonfat dairy ingredients--a review, Modification of products containing casein, J. Dairy Sci., 68, 2195-2205.
Motoki, M.; Aso, H.; Seguro, K. and Nio, N. 1987, " sl -Casein film prepared using transplutaminase, Agric. Biol. Chem., 51, 993-996.
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Yamamoto, O., 1977, Ionizing radiation-induced crosslinking in proteins, dans: Protein crosslinking Biochemical and molecular aspects, Friedman, M. (Ed), Plenum Press, N.Y., 509-547. | The packing and even the excessive packaging of products for human consumption is a current practice in the industrialized countries. As this packaging is made primarily of non-biodegradable polymers, they currently cause environmental problems. These environmental problems are found not only in industrialized countries but also in developing countries. This situation supported the development of various films, more ecological, starting from biodegradable elements containing polysaccharides, proteins and/or lipids. We developed a biodegradable protein film from a casein salt. Of dairy origin, casein is abundant and could even be recovered from unsold milk. The process of polymerization is induced by gamma irradiation. Indeed, the interaction of hydroxyl radicals with tyrosins present in protein creates a covalent bond (bityrosine). The addition of a plasticizing agent is essential in order to produce a more flexible and less friable film. The presence of glycerol does not inhibit the formation of bityrosine. It protects protein from the denaturation caused by irradiation, increases the deforming capacity and decreases the breaking strength of film. The biodegradation tests, carried out in our laboratories, showed that the film produced by gamma irradiation is accessible to the enzymatic attacks from Pseudomonas fragi. | 2 |
This is a continuation of application Ser. No. 07/007,032 filed Jan. 27, 1987 now abandoned.
FIELD OF THE INVENTION
This invention relates to a compact hearing aid of the kind generally referred to as an in-the-ear (or ITE) hearing aid.
BACKGROUND OF THE INVENTION
In-the-ear or ITE hearing aids have been manufactured for some time. Such aids include full concha aids, low profile full concha aids, half concha aids, canal aids, and semi-canal aids. In all cases there exists a need to build smaller hearing aids which will fit more ears. There is also a need to build such hearing aids with better performance and more features.
Traditional custom ITE hearing aids have been constructed by creating a shell which anatomically duplicates the relevant parts of the user's ear canal and concha. A receiver is placed in this shell, and then the open end of the shell is closed with a faceplate subassembly. The faceplate subassembly consists of an arrangement of individual components, typically an amplifier, microphone, volume control, battery compartment and potentiometers for adjusting the hearing aid performance to the user's individual needs. Adjustment or repair of the internal parts requires the faceplate to be cut away from the shell. This is an awkward procedure, and after repair or adjustment, subsequent buffing or polishing is needed to restore the hearing aid to an acceptable cosmetic appearance.
These difficulties have motivated the construction of modular hearing aids in which an electroacoustic module (consisting of a receiver, which is simply a miniature loudspeaker, a microphone, an amplifier, a battery compartment, a volume control and other optional controls) is mated into a faceplate with a matching opening. The module can be inserted into and removed from a faceplate-shell subassembly to make the building and repair of the hearing aid more efficient. However a detrimental consequence of modularity has been an increase in the size of finished hearing aid.
In all existing modular ITE hearing aids, the module contains a battery compartment with a battery compartment lid attached to the module. The size of the lid is determined by the dimensions of the battery and the space required to provide a hinge to fasten the battery lid to the modular insert. The hinged lid is opened frequently to exchange batteries, thus exerting wear and tear on the module. In current modular hearing aids, the module must fit snugly into the faceplate and must be securely attached to the faceplate by a suitable snap or fastening detail. Usually latches or the like are used to provide a secure fastening. Both the hinge and the fastening detail add considerably to the size of the module and thus to the size of the finished aid. As a result, modular ITE hearing aids which are presently available are not suitable for more than 40 to 50 percent of all ears which could be candidates for such hearing aids.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a modular ITE hearing aid in which the battery compartment lid and hinge are removed from the module itself and are placed instead on the faceplate which is attached to a custom or stock shell. The stresses which arise from opening and closing the battery compartment lid are now exerted on the faceplate ring rather than on the modular insert. Consequently the module is not required to be as securely fastened in the faceplate. The space which is saved by not having to provide a hinge on the module, and by not having to provide as strong a fastening in the faceplate for the module, can therefore be used to provide features such as controls while still retaining a very small overall size for the finished aid. Tests have shown that a large percentage of adult ears in North America can be fitted with the modular hearing aid of this invention.
In one of its aspects the present invention provides a hearing aid comprising:
(a) a shell adapted to fit within a user's ear and having an outer rim,
(b) a faceplate fixed to said outer rim and having an opening therein,
(c) an electronic module comprising a microphone, an amplifier connected to said microphone to amplify sound therefrom, a receiver connected to said amplifier to produce sound for said user, and a battery compartment to house a battery for said amplifier, said module being removably fitted within said opening of said faceplate,
(d) said battery compartment being open at its outer end,
(e) a lid for said faceplate and having an inside surface, said inside surface defining a closure for said battery compartment,
(f) and hinge means connected between said lid and said faceplate for said lid to be opened and closed, said lid being aligned for said closure for said battery compartment to close said battery compartment when said lid is closed,
(g) and detent means for retaining said lid in a closed position.
In another aspect the invention provides for a hearing aid comprising a shell adapted to be fitted within a user's ear, and an electronic module containing electronic components and a battery compartment and adapted to be fitted to said shell, the improvement comprising a faceplate adapted to be connected to said shell and to house said module, said faceplate comprising an enlarged plastic plate, an opening in said plate adapted to receive said module, said plate having an upper surface, an annular rim encircling said opening and extending upwardly from said upper surface, and a hinge portion located on the upper edge of said rim, whereby material can be removed from said faceplate without damaging said hinge portion.
Further objects and advantages of the invention will appear from the following description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is an exploded perspective view of a hearing aid according to the present invention with the electronic module removed from the aid and with the lid in open position;
FIG. 2 is a perspective view similar to FIG. 1 but with the electronic module installed in the hearing aid;
FIG. 3 is a perspective view similar to FIG. 2 but with the lid closed;
FIG. 4 is a perspective view of a faceplate used to form the faceplate ring of the invention, before material has been removed therefrom;
FIG. 5 is a top view of a portion of the faceplate of FIG. 4;
FIG. 6 is an exploded sectional view showing a faceplate, shell, and the plastic housing of the electronic module;
FIG. 7 is a sectional view similar to that of FIG. 6 but showing the module housing inserted in the faceplate;
FIG. 8 is a sectional view showing the complete electronic module in the faceplate and shell;
FIG. 9 is another sectional view showing the electronic module in the faceplate and shell;
FIG. 10 is a side view of a conventional battery used in the hearing aid of the invention;
FIG. 11 is an exploded perspective view of the hinge between the lid and faceplate;
FIG. 12 is a top view showing a plastic gauge used to facilitate the assembly of the faceplate of FIG. 4 to the shell;
FIG. 13 is a sectional view along lines 13--13 of FIG. 12;
FIG. 14 is a sectional view along lines 14--14 of FIG. 12;
FIG. 15 is a sectional view along lines 15--15 of FIG. 12;
FIG. 16 is a sectional view along lines 16--16 of FIG. 12; and
FIG. 17 is a view similar to that of FIG. 9 but showing a modification of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Reference is first made to FIGS. 1 to 3, which show a hearing aid 10 comprising a shell 12, a faceplate 14 and a lid 16. The shell 12 can be a stock (i.e. standard) shell or it can be custom molded to fit the customer's ear. The shell 12 includes an aperture 18 in its lower surface for sound from the hearing aid transducer (to be described) to enter the user's ear canal.
The particular hearing aid shown and described is a canal hearing aid for the right ear. An aid for the left ear would be the mirror image of that shown.
The faceplate 14 begins life as a rectangular plate 14a as shown in FIG. 4. As will be described, the plate 14a is glued to the shell 12, and the excess material is then removed leaving the faceplate 14 as shown in FIGS. 1 to 3.
Housed within the faceplate 14 and shell 12 is an electronic module 20. The module 20 comprises a plastic housing 22 which defines a battery compartment 24. The plastic housing 22 also supports a volume control 26 and various electronic components to be described. These components include a receiver 28 which is suspended from the module 20 by a pair of wires 30 and which produces the sound which is transmitted into the user's ear canal.
The lid 16 is connected by a hinge 32 to the faceplate 14 (as will be described in more detail) and includes in its lower surface a circular compartment 34 which forms a closure for the battery compartment 24. The lid 16 further includes an opening 36 through which the volume control 26 may project, and a small opening 37 to allow sound to reach the microphone (to be described) in the module 20. A plastic latch 38 on the lid 16 serves to latch the lid closed (as will be described).
The construction of the hearing aid 10 will now be described in more detail. Firstly, the shell 12 is conventionally molded of a suitable plastic, either in a standard (stock) shape or by using a casting of the user's ear canal. The resultant shell 12 has an upper edge 40 and an interior opening 42.
The faceplate 14 is molded with an integral central annular rim 44 (FIG. 4) which extends upwardly from one surface of the faceplate and encircles an opening 46 in the faceplate. The opening 46 is the same in all faceplates and is designed to receive the module housing 22 with a snap fit. For this purpose the interior wall 48 of the opening 46 includes two shallow recesses 50 therein, one in each end thereof (see FIGS. 1, 4, 6 and 7). The recesses 50 terminate below the upper edge of rim 44, forming upper lateral surfaces or ledges 52 which retain the plastic housing 22. As shown in FIGS. 6 and 7, the plastic housing 22 has outwardly projecting tapered ends 54 which can be forced into the opening 46 and snap into the recesses 50.
The faceplate 14 also includes four sector-shaped lower stops 56 (FIG. 5) which project laterally inwardly from its interior wall 48, adjacent the bottom of the faceplate. The stops 56 limit movement of the module housing 22 into the faceplate opening.
The faceplate 14 also includes four upper posts 58 and four lower posts 60, one at each corner thereof. The posts are used for stacking and handling. For this purpose the upper posts 58 are narrowed and their tips fit into corresponding openings 62 in the lower posts 60.
After the shell 12 has been formed, it is glued or ultrasonically welded to the faceplate 14 as shown in FIG. 6. While different shells may differ in contour, there is only one standardized faceplate 14 which is used for all shells. After the shell and faceplate are secured together, the excess plastic is then removed from the faceplate 14 as shown by dotted lines 14a in FIG. 6, so that the remaining portion of the faceplate and the shell 12 form a smooth contour.
The hearing aid is now ready to receive the module 20. As discussed, module 20 includes a plastic housing 22. Secured to the bottom of housing 22 is a printed circuit board 66. The electronic components of the module 20 (including volume control 26) are all mounted on or connected to the circuit board 66.
The electronic components include a conventional amplifier 68 mounted on the bottom of circuit board 66, a microphone 70 located below the amplifier 68, and an adjustment potentiometer 72 mounted on the top of the circuit board 66. The top of the potentiometer 72 is accessible for adjustment through opening 74 in the housing 22.
The microphone 70 is held in place by an elbow-shaped rubber tube 76 (FIG. 9), which extends through a notch (not shown) in the side of the circuit board 66 and is then wedged into a hole 78 in the bottom of the plastic housing 22. The hole 78 extends upwardly into an opening 79 in the top of housing 22, for sound to reach the microphone.
The battery compartment 24 includes a bottom wall 80 which supports a battery bottom contact spring 82. Spring 82 includes a side tab 84 which extends downwardly to and is soldered to the circuit board 66. Spring 82 contacts the narrowed bottom portion 86 of a conventional battery 88 (FIG. 10).
The battery compartment 24 further includes a curved sidewall 90 located between the battery compartment and the volume control 26. Mounted on the curved sidewall 90 is a battery side contact spring 92. The curvature of the spring 92 is very slightly sharper than that of the upper sidewall 94 of the battery. Thus spring 92 firmly contacts battery sidewall 94. A tab 96 extends downwardly from spring 92 to the circuit board 66.
Before the module 20 is inserted into the faceplate 14, the receiver 28 (the wires 30 of which are also soldered to the circuit board 66) is lowered into the shell 12, so that it faces the aperture 18 in shell 12. The receiver 28 is normally surrounded by a rubber sleeve 98 (FIG. 1) with small rubber stand-offs (not shown) thereon, to provide vibration isolation between the receiver and the wall of the shell 12. The module 20 may then be snapped into the faceplate 14, where it is retained between the recesses 50 and the stops 56 of the faceplate, as described. The module 20 helps to hold the receiver in position in the shell.
Next the lid 16 may be assembled to the faceplate 14. The lid 16 is also a molded plastic piece, shaped to match in outline that of the upper rim 44 of the faceplate 14. One edge of the lid 16 has a slot 100 molded therein (see FIGS. 1, 11). Cylindrical pins 102 extend one from each end of the slot 100 toward each other. The pins 102 and slot 100 together form half of the hinge 32.
The other half of hinge 32 is formed by an upstanding formation 104 molded in the faceplate upper rim 44. The formation 104 contains two slots 106 therein, one at each end thereof, to accommodate the pins 102 in a snap fit. The formation 104 does not extend laterally outwardly beyond the rim 44, so that it is less likely to be damaged when excess material is being removed from faceplate 14. Similarly it does not extend laterally inwardly into the faceplate opening 46, so as not to interfere with the module 20.
The plastic latch 38 of the lid 16 is molded integrally therewith. The latch catches in a recess 110 in the faceplate interior wall 48, to hold the lid closed. A conventional notch 112 (FIG. 3) in the lid allows the user to pry the lid open. The interior battery closure 34 of the lid also includes a recess 113 to accommodate the spring 92.
Because the lid 16 holds the battery 88 in position but does not itself contain any metal contacts, the lid 16 can easily be replaced should it become physically or cosmetically damaged. In addition the entire module 20 can readily be removed, without removing the lid, simply by pulling it out of the faceplate 14. Because the stresses acting in the module 20 are normally small, the snap fit detail (the recesses 50 and projections 52) used to hold it in the faceplate can be of very light construction, so that only a modest force is needed to remove the module.
When the faceplate 14 is being glued or welded to the shell 12, it is important to ensure that the positioning is such that the amplifier 68 and microphone 70, both of which project below the faceplate 14 will not interfere with the inside of the shell 12. For this purpose a plastic gauge 114 is used as shown in FIGS. 12 to 16. The plastic gauge 114 is a transparent molded plastic part having a circumferential outline which is the same as that of the housing 22 of the electronic module 20. The bottom contour 116 of the gauge 114 is shaped to simulate that of the module, including the circuit board 66, amplifier 68 and microphone 70. A plastic pin 118 extends upwardly from the gauge 114 and serves as a handle to allow the gauge to be grasped.
In use, before the faceplate 14 is glued or welded to the shell 12, the gauge 114 is first inserted into the faceplate opening 46. Then the faceplate 14 may be applied to the shell 12 and glued or welded in position. The fabricator may look through the transparent gauge 114 during the assembly process in order better to view the operation. After the fastening process is completed (or before if the faceplate 14 and shell 12 are each held in a jig, as will often be the case), the gauge 114 is removed by pulling on its upwardly projecting pin 118.
While in the embodiment shown, the volume control projects through the lid, if desired the volume may be preset and the volume control (if any) may be covered by the lid. Alternatively a push-button volume control may be used. The lid can cover part of the push-button or twist volume control and can expose part for access by a user.
If it is desired to provide wind noise protection for the hearing aid, then a foam insert (not shown) can be placed in hole 37 in the lid 16. Alternatively, a wind noise hood of standard configuration may be placed on the lid 16, extending part way over the hole 37 from one side thereof to provide protection against wind noise.
If desired, the shape either of the hole 37 in the lid 16 or of the opening 79 in the plastic housing 22 can be modified as desired to provide acoustic emphasis or de-emphasis in specific frequency bands. For example, if desired the hole 37 may be made funnel-shaped, being enlarged at its top and narrowed at its bottom, in order to gather additional sound over a broad frequency range.
Further, if it is desired to make the hearing aid directional, then an additional opening can be provided in lid 16 and a matching opening can be formed in housing 22 so that there will be two sound ports, one front and one rear. From the additional opening in the housing 22, a rubber tube can be directed to an additional port on the microphone 70.
If desired, a thin shelled replica of the bottom contour of the gauge 114 can be molded integrally with the faceplate 14, forming a basket to provide the necessary gauging function and also to help retain the receiver 28 in position. This arrangement is shown in FIG. 17, where primed reference numerals indicate parts corresponding to those of FIGS. 1 to 16. As shown in FIG. 17, the gauge 114' is molded, of as thin plastic as possible, integrally with the faceplate 14. The gauge 114' is molded at the bottom of the faceplate 14, in effect replacing the stops 56, and is contoured to follow approximately the shape of the bottom of the module 20'. The module 20' snaps as before into the recesses 50' in the faceplate. An opening 120 in the bottom of the gauge 114' accommodates and helps to locate the sleeve 98' for the receiver. | A modular hearing aid to fit in the user's ear, having a shell, a faceplate fixed to the shell, and an electronic module removably snapped into the faceplate. The module includes an open-topped battery compartment which is closed by a lid hinged to the faceplate rather than to the module. This eliminates a bulky hinge on the module and allows a smaller snap fastener between the module and faceplate. The volume control on the module projects through an opening in the closed lid. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a division of application Ser. No. 09/892,951, filed Jun. 26, 2001, the filing date of which is hereby claimed under 35 U.S.C. § 120. Application Ser. No. 09/892,951 claims the benefit of U.S. provisional patent application No. 60/244, 481, filed Oct. 30, 2000, which is expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to the field of computing devices with graphical user interfaces. More specifically, this invention relates to providing high-performance message queues and integrating such queues with message queues provided by legacy user interface window managers.
BACKGROUND OF THE INVENTION
[0003] Graphical user interfaces typically employ some form of a window manager to organize and render windows. Window managers commonly utilize a window tree to organize windows, their child windows, and other objects to be displayed within the window such as buttons, menus, etc. To display the windows on a display screen, a window manager parses the window tree and renders the windows and other user interface objects in memory. The memory is then displayed on a video screen. A window manager may also be responsible for “hit-testing” input to identify the window in which window input was made. For instance, when a user moves a mouse cursor over a window and “clicks,” the window manager must determine the window in which the click was made and generate a message to that window.
[0004] In some operating systems, such as Windows® NT from the Microsoft® Corporation of Redmond, Wash., there is a single window manager that threads in all executing processes call into. Because window manager objects are highly interconnected, data synchronization is achieved by taking a system-wide “lock”. Once inside this lock, a thread can quickly modify objects, traverse the window tree, or any other operations without requiring additional locks. As a consequence, this allows only a single thread into the messaging subsystem at a time. This architecture provides several advantages in that many operations require access to many components and also provides a greatly simplified programming model that eliminates most deadlock situations that would arise when using multiple window manager objects.
[0005] Unfortunately, a system-wide lock seriously hampers the communications infrastructure between user interface components on different threads by allowing only a single message to be en-queued or de-queued at a time. Furthermore, such an architecture imposes a heavy performance penalty on component groups that are independent of each other and could otherwise run in parallel on independent threads.
[0006] One solution to these problems is to change from a system-wide (or process-wide) lock to individual object locks that permits only objects affected by a single operation to be synchronized. This solution actually carries a heavier performance penalty, however, because of the number of locks introduced, especially in a world with control composition. Such a solution also greatly complicates the programming model.
[0007] Another solution involves placing a lock on each user interface hierarchy, potentially stored in the root node of the window tree. This gives better granularity than a single, process-wide lock, but imposes many restrictions when performing cross tree operations between inter-related trees. This also does not solve the synchronization problem for non-window user interface components that do not exist in a tree.
[0008] Therefore, in light of the above, there is a need for a method and apparatus for providing high-performance message queues in a user interface environment that does not utilize a system-wide lock but that minimizes the number of locked queues. There is a further need for a method and apparatus for providing high-performance message queues in a user interface environment that can integrate a high-performance non-locking queue with a queue provided by a legacy window manager.
SUMMARY OF THE INVENTION
[0009] The present invention solves the above-problems by providing a method and apparatus for providing and integrating high-performance message queues in a user interface environment. Generally described, the present invention provides high-performance message queues in a user interface environment that can scale when more processors are added. This infrastructure provides the ability for user interface components to run independently of each other in separate “contexts.” In practice, this allows communication between different components at a rate of 10-100 times the number of messages per second than possible in previous solutions.
[0010] More specifically described, the present invention provides contexts that allow independent “worlds” to be created and execute in parallel. A context is created with one or more threads. Each object is created with context affinity, which allows only threads associated with the context to modify the object or process pending messages. Threads associated with another context are unable to modify the object or process pending messages for that context.
[0011] To help achieve scalability and context affinity, both global and thread-local data may be moved into the context. Remaining global data has independent locks that provide synchronized access for multiple contexts. Each context also has multiple message queues that together create a priority queue. There are default queues for “sent” messages and “posted” messages, carry-overs from legacy window managers, and new queues may be added on demand. A queue bridge is also provided for actually processing the messages that may be integrated with a legacy window manager.
[0012] The present invention also provides a method, computer-controlled apparatus, and a computer-readable medium for providing and integrating high-performance message queues in a user interface environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0014] FIG. 1 is a block diagram showing an illustrative operating environment for an actual embodiment of the present invention.
[0015] FIG. 2 is a block diagram showing aspects of an operating system utilized in conjunction with the present invention.
[0016] FIG. 3 is a block diagram illustrating additional aspects of an operating system utilized in conjunction with the present invention.
[0017] FIG. 4 is a block diagram showing an illustrative software architecture for aspects of the present invention.
[0018] FIG. 5 is a block diagram showing an illustrative software architecture for additional aspects of the present invention.
[0019] FIG. 6 is a flow diagram showing an illustrative routine for transmitting a message between user interface objects according to an actual embodiment of the present invention.
[0020] FIG. 7 is a flow diagram showing an illustrative routine for transmitting a message from one user interface component to another user interface component in another context according to an actual embodiment of the present invention.
[0021] FIG. 8 is a flow diagram showing an illustrative routine for atomically adding an object into an s-list according to an actual embodiment of the present invention.
[0022] FIG. 9 is a flow diagram showing an illustrative routine for posting a message according to an actual embodiment of the present invention.
[0023] FIG. 10 is a flow diagram showing an illustrative routine for processing a message queue according to an actual embodiment of the present invention.
[0024] FIG. 11 is a flow diagram showing additional aspects an illustrative routine for processing a message queue according to an actual embodiment of the present invention.
[0025] FIG. 12 is a flow diagram showing an illustrative routine for processing an s-list according to an actual embodiment of the present invention.
[0026] FIG. 13 is a flow diagram showing the operation of a queue bridge for integrating a high-performance message queue with a legacy message queue according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] The present invention is directed to a method and apparatus for providing high-performance message queues and for integrating these queues with message queues provided by legacy window managers. Aspects of the invention may be embodied in a computer executing an operating system capable of providing a graphical user interface.
[0028] As will be described in greater detail below, the present invention provides a reusable, thread-safe message queue that provides “First in, All Out” behavior, allowing individual messages to be en-queued by multiple threads. By creating multiple instances of these low-level queues, a higher-level priority queue can be built for all window manager messages. According to one actual embodiment of the present invention, a low-level queue is provided that does not have synchronization and is designed to be used by a single thread. According to another actual embodiment of the present invention, a low-level queue is provided that has synchronization and is designed to be safely accessed by multiple threads. Because both types of queues expose common application programming interfaces (“APIs”), the single threaded queue can be viewed as an optimized case of the synchronized queue.
[0029] As also will be described in greater detail below, the thread-safe, synchronized queue, is built around “S-Lists.” S-Lists are atomically-created singly linked lists. S-Lists allow multiple threads to en-queue messages into a common queue without taking any “critical section” locks. By not using critical sections or spin-locks, more threads can communicate using shared queues than in previous solutions because the atomic changes to the S-List do not require other threads to sleep on a shared resource. Moreover, because the present invention utilizes atomic operations available in hardware, a node may be safely added to an S-List on a symmetric multi-processing (“SMP”) system in constant-order time. De-queuing is also performed atomically. In this manner, the entire list may be extracted and made available to other threads. The other threads may continue adding messages to be processed.
[0030] Referring now to the figures, in which like numerals represent like elements, an actual embodiment of the present invention will be described. Turning now to FIG. 1 , an illustrative personal computer 20 for implementing aspects of the present invention will be described. The personal computer 20 comprises a conventional personal computer, including a processing unit 21 , a system memory 22 , and a system bus 23 that couples the system memory to the processing unit 21 . The system memory 22 includes a read only memory (“ROM”) 24 and a random access memory (“RAM”) 25 . A basic input/output system 26 (“BIOS”) containing the basic routines that help to transfer information between elements within the personal computer 20 , such as during start-up, is stored in ROM 24 . The personal computer 20 her includes a hard disk drive 27 , a magnetic disk drive 28 , e.g., to read from or write to a removable disk 29 , and an optical disk drive 30 , e.g., for reading a CD-ROM disk 31 or to read from or write to other optical media such as a Digital Versatile Disk (“DVD”).
[0031] The hard disk drive 27 , magnetic disk drive 28 , and optical disk drive 30 are connected to the system bus 23 by a hard disk drive interface 32 , a magnetic disk drive interface 33 , and an optical drive interface 34 , respectively. The drives and their associated computer-readable media provide nonvolatile storage for the personal computer 20 . As described herein, computer-readable media may comprise any available media that can be accessed by the personal computer 20 . By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EPROM, EEPROM, flash memory or other solid-state memory technology, CD-ROM, DVD or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the personal computer 20 .
[0032] A number of program modules may be stored in the drives and RAM 25 , including an operating system 35 , such as Windows® 98, Windows®2000, or Windows® NT from Microsoft® Corporation. As will be described in greater detail below, aspects of the present invention are implemented within the operating system 35 in the actual embodiment of the present invention described herein.
[0033] A user may enter commands and information into the personal computer 20 through input devices such as a keyboard 40 or a mouse 42 . Other input devices (not shown) may include a microphone, touchpad, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 21 through a serial port interface 46 that is coupled to the system bus 23 , but may be connected by other interfaces, such as a game port or a universal serial bus (“USB”). A monitor 47 or other type of display device is also connected to the system bus 23 via a display interface, such as a video adapter 48 . In addition to the monitor, the personal computer 20 may include other peripheral output devices, such as speakers 45 connected through an audio adapter 44 or a printer (not shown).
[0034] As described briefly above, the personal computer 20 may operate in a networked environment using logical connections to one or more remote computers through the Internet 58 . The personal computer 20 may connect to the Internet 58 through a network interface 55 . Alternatively, the personal computer 20 may include a modem 54 and use an Internet Service Provider (“ISP”) 56 to establish communications with the Internet 58 . The modem 54 , which may be internal or external, is connected to the system bus 23 via the serial port interface 46 . It will be appreciated that the network connections shown are illustrative and other means of establishing a communications link between the personal computer 20 and the Internet 58 may be used.
[0035] Referring now to FIG. 2 , additional aspects of the operating system 35 will be described. The operating system 35 comprises a number of components for executing applications 72 and for communicating with the hardware that comprises the personal computer 20 . At the lowest level, the operating system 35 comprises device drivers 60 for communicating with the hardware of the personal computer 20 . The operating system 35 also comprises a virtual machine manager 62 , an installable file system manager 64 , and a configuration manager 66 . Each of these managers may store information regarding the state of the operating system 35 and the hardware of the personal computer 20 in a registry 74 . The operating system 35 also provides a shell 70 , which includes user interface tools. An operating system core 68 is also provided which supplies low-level functionality and hardware interfaces. According to the embodiment of the present invention described herein, aspects of the present invention are implemented in the operating system core 68 . The operating system core 68 is described in greater detail below with respect to FIG. 3 .
[0036] Turning now to FIG. 3 , an illustrative operating system core 68 will be described. As mentioned above, the Windows® operating system from the Microsoft® Corporation provides an illustrative operating environment for the actual embodiment of the present invention described herein. The operating system core 68 of the Windows® operating system comprises three main components: the kernel 70 ; the graphical device interface (“GDI”) 72 ; and the User component 74 . The GDI 72 is a graphical system that draws graphic primitives, manipulates bitmaps, and interacts with device-independent graphics drivers, including those for display and printer output devices. The kernel 70 provides base operating system functionality, including file I/O services, virtual memory management, and task scheduling. When a user wants to start an application, the kernel 70 loads the executable (“EXE”) and dynamically linked library (“DLL”) files for the application. The kernel 70 also provides exception handling, allocates virtual memory, resolves import references, and supports demand paging for the application. As an application runs, the kernel 70 schedules and runs threads of each process owned by an application.
[0037] The User component 74 manages input from a keyboard, mouse, and other input devices and output to the user interface (windows, icons, menus, and so on). The User component 74 also manages interaction with the sound driver, timer, and communications ports. The User component 74 uses an asynchronous input model for all input to the system and applications. As the various input devices generate interrupts, an interrupt handler converts the interrupts to messages and sends the messages to a raw input thread area, which, in turn, passes each message to the appropriate message queue. Each Win32-based thread may have its own message queue.
[0038] In order to manage the output to the user interface, the User component 74 maintains a window manager 76 . The window manager 76 comprises an executable software component for keeping track of visible windows and other user interface objects, and rendering these objects into video memory. Aspects of the present invention may be implemented as a part of the window manager 74 . Also, although the invention is described as implemented within the Windows® operating system, those skilled in the art should appreciate that the present invention may be advantageously implemented within any operating system that utilizes a windowing graphical user interface.
[0039] Referring now to FIG. 4 , additional aspects of the present invention will be described. As shown in FIG. 4 , the present invention provides a new system component for providing message queues 88 A- 88 N to threads 90 A- 90 N executing within an application 80 . According to an embodiment of the invention, the new system component provides separate contexts 84 A- 84 N. Each message queue 88 A- 88 N is associated with a corresponding context 84 A- 84 N. Any thread 90 A- 90 N in a given context 84 A- 84 N can process messages in the context's message queue. Threads 90 A- 90 N can send messages to other threads by utilizing their respecting message queues 88 A- 88 N. Contexts 84 A- 84 N also maintain locks 86 A- 86 N. As will be described in greater detail below, threads 90 A- 90 N within a particular context can send messages to other threads 90 A- 90 N within the same context without utilizing the message queue 88 A- 88 N. Moreover, the message queues 88 A- 88 N associated with each context 84 A- 84 N are implemented as non-locking using “atomic” hardware instructions known to those skilled in the art. Aspects of the present invention for sending messages, posting messages, and processing messages will be described below with respect to FIGS. 6-12 .
[0040] Referring now to FIG. 5 , additional aspects of the present invention will be described. As mentioned briefly above, in addition to providing high-performance message queues, the present invention also provides a method and apparatus for interfacing such queues with legacy window managers. According to the actual embodiment of the invention described herein, a queue bridge 94 is provided between a new window manager 84 having non-locking queues 88 A-N and a legacy window manager 76 , such as the window manager provided in the User component of Windows NT®.
[0041] The queue bridge 94 satisfies all of the requirements of the User component message queue 92 , including: on legacy systems, only GetMessageo, MsgWaitForMultipleObjectsEx( ) and WaitMsg( ) can block the thread until a queue has an available message; once ready, only GetMessage( ) or PeekMessage( ) can be used to remove one message; legacy User component queues for Microsoft Windows®95 or Microsoft Windows® NT/4 require all messages to be processed between calls of MsgWaitForMultipleObjectsEx( ); only the queue on the thread that created the HWND can receive messages for that window; the application must be able to use either ANSI or UNICODE versions of APIs to ensure proper data processing; and all messages must be processed in FIFO nature, for a given mini-queue.
[0042] Later versions of Microsoft Windows® have been modified to expose message pump hooks (“MPH”) which allow a program to modify system API implementations. As known to those skilled in the art, a message pump 85 is a program loop that receives messages from a thread's message queue, translates them, offers them to the dialog manager, informs the Multiple Document Interface (“MDI”) about them, and dispatches them to the application.
[0043] The queue bridge 94 also satisfies the requirements of the window manager having non-locking queues 82 , such as: operations on the queues must not require any locks, other than interlocked operations; any thread inside the context that owns a Visual Gadget may process messages for that Visual Gadget; and multiple threads may try to process messages for a context simultaneously, but all messages must be processed in FIFO nature, for a given queue.
[0044] The queue bridge 94 also provides functionality for extensible idle time processing 83 , including animation processing, such as: objects must be able to update while the user interface is waiting for new messages to process; the user interface must be able to perform multiple animations on different objects simultaneously in one or more threads; new animations may be built and started while the queues are already waiting for new messages; animations must not be blocked waiting for a new message to become available to exit the wait cycle; and the overhead of integrating these continuous animations with the queues must not incur a significant CPU performance penalty. The operation of the queue bridge 94 will be described in greater detail below with reference to FIG. 13 .
[0045] Referring now to FIG. 6 , an illustrative Routine 600 will be described for sending a Visual Gadget event, or message. The Routine 600 begins at block 602 , where the message request is received. Routine 600 continues from block 602 to block 604 , where parameters received with the message request are validated. From block 604 , the Routine 600 continues to block 605 , where the context associated with the current thread is determined. The Routine 600 then continues to block 606 , where a determination is made as to whether the context of the current thread is the same as the context of the thread for which the message is destined. If the contexts are the same, the Routine 600 branches to block 608 , where the queues are bypassed and the message is transmitted from the current thread directly to the destination thread. Sending a message to a component that has the same context (see below) is the highest priority message and can be done bypassing all queues. From block 608 , the Routine 600 continues to block 611 , where it ends.
[0046] If, at block 606 , it is determined that the source and destination contexts are not the same, the Routine 600 continues from block 606 to block 610 , where the SendNL process is called. As will be described in detail below with respect to FIG. 7 , the SendNL process sends a message to a non-locking queue in another context. From block 610 , the Routine 600 continues to block 611 , where it ends.
[0047] Turning now to FIG. 7 , a Routine 700 will be described that illustrates the SendNL process for sending a message to a component that has a different context. Sending a message to a component that has a different context requires the message to be en-queued onto the receiving context's “sent” message queue, with the sending thread blocking until the message has been processed. Once the message has been processed, the message information must be recopied back, since the message processing may fill in “out” arguments for return values. “Sending” a message is higher-level functionality built on top of the message queue.
[0048] The Routine 700 begins at block 702 , where the parameters received with the message are validated. The Routine 702 then continues to block 704 , where a processing function to handle when the message is “de-queued” is identified. The Routine 700 then continues to block 706 where memory is allocated for the message entry and the message entry is filled with the passed parameters. The Routine 700 then continues to block 708 , where an event handle signaling that the message has been processed is added to the message entry. Similarly, at block 710 , an event handle for processing outside messages received while the message is being processed is added to the message entry. At block 712 , the AddMessageEntry routine is called with the message entry. The AddMessageEntry routine atomically adds the message entry to the appropriate message queue and is described below with respect to FIG. 8 .
[0049] Routine 700 continues from block 712 to block 713 , where the receiving context is marked as having data. This process is performed “atomically.” As known to those skilled in the art, hardware instructions can be used to exchange the contents of memory without requiring a critical section lock. For instance, the “CMPXCHG8B” instruction of the Intel 80×86 line of processors accomplishes such a function. Those skilled in the art should appreciate that similar instructions are also available on other hardware platforms.
[0050] From block 713 , the Routine 700 continues to block 714 , where a determination is made as to whether the message has been processed. If the message has not been processed, the Routine 700 branches to block 716 , where the thread waits for a return object and processes outside messages if any become available. From block 716 , the Routine 700 returns to block 714 where an additional determination is made as to whether the message has been processed. If, at block 714 , it is determined that the message has been processed, the Routine 700 continues to block 718 . At block 718 , the processed message information is copied back into the original message request. At block 720 , any allocated memory is de-allocated. The Routine 700 then returns at block 722 .
[0051] Referring now to FIG. 8 , an illustrative Routine 800 will be described for adding a message entry to a queue. The Routine 800 begins at block 802 , where the object is locked so that it cannot be fully destroyed. The Routine 800 then continues to block 804 , where the object is atomically added onto the queue. As briefly described above, according to an embodiment of the invention, the queue is implemented as an S-list. An S-list is a singly-linked list that can add a node, pop a node, or remove all nodes atomically. From block 804 , the Routine 800 continues to block 806 , where it returns.
[0052] Referring now to FIG. 9 , an illustrative Routine 900 will be described for “posting” a message to a queue. Messages posted to a component in any context must be deferred until the next time the application requests processing of messages. Because a specific thread may exit after posting a message, the memory may not be able to be returned to that thread. In this situation, memory is allocated off the process heap, allowing the receiving thread to safely free the memory.
[0053] The Routine 900 begins at block 902 , where the parameters received with the post message request are validated. The Routine 900 then continues to block 904 , where the processing function that should be notified when the message is “de-queued” is identified. At block 906 , memory is allocated for the message entry and the message entry is filled with the appropriate parameters. The Routine 900 then continues to block 908 , where the AddMessageEntry routine is called. The AddMessageEntry routine is described above with reference to FIG. 8 . From block 908 , the Routine 900 continues to block 910 , where the receiving context is atomically marked as having data. The Routine 900 then continues to block 912 , where it ends.
[0054] Referring now to FIG. 10 , an illustrative Routine 1000 will be described for processing a message queue. As mentioned briefly above, only one thread is allowed to process messages at a given time. This is necessary to ensure that all messages are processed in a first-in first-out (“FIFO”) order. When a thread is ready to process messages for a given message queue, because of the limitations of S-Lists, all messages must be de-queued. After the list is de-queued, the singly-linked list must be converted from a stack into a queue, giving the messages first-in, first-out (“FIFO”) ordering. At this point, all entries in the queue may be processed.
[0055] The Routine 1000 begins at block 1002 , where a determination is atomically made as to whether any other thread is currently processing messages. If another thread is processing, the Routine 1000 branches to block 1012 . If no other thread is processing, the Routine 1002 continues to block 1004 , where an indication is atomically made that the current thread is processing the message queue. From block 1004 , the Routine 1000 continues to block 1006 , where a routine for atomically processing the sent message queue is called. Such a routine is described below with respect to FIG. 11 .
[0056] From block 1006 , the Routine 1000 continues to block 1008 , where routine for atomically processing the post message queue is called. Such a routine is described below with respect to FIG. 11 . The Routine 1000 then continues to block 1010 where an indication is made that no thread is currently processing the message queue. The Routine 1000 then ends at block 1012 .
[0057] Referring now to FIG. 11 , an illustrative Routine 1100 will be described for processing the send and post message queues. The Routine 1100 begins at block 1102 , where a determination is made as to whether the S-list is empty. If the S-list is empty, the Routine 1100 branches to block 1110 , where it returns. If the S-list is not empty, the Routine 1100 continues to block 1104 , where the contents of the S-list are extracted atomically. The Routine 1100 then continues to block 1106 , where the list is reversed, to convert the list from a stack into a queue. The Routine 1100 then moves to block 1108 , where the ProcessList routine is called. The ProcessList routine is described below with reference to FIG. 12 .
[0058] Turning now to FIG. 12 , an illustrative Routine 1200 for implementing the ProcessList routine will be described. The Routine 1200 begins at block 1202 , where a determination is made as to whether the S-list is empty. If the S-list is empty, the Routine 1200 branches to block 1216 , where it returns. If the S-list is not empty, the Routine 1200 continues to block 1204 , where the head message entry is extracted from the list. At block 1206 , the message entry is processed. From block 1206 , the Routine 1200 continues to block 1208 , where the context lock is taken. From block 1208 , the Routine 1200 continues to block 1210 , where the object is unlocked. At block 1212 , the context lock is released. At block 1214 , an S-list “add” is atomically performed to return memory to the sender. The Routine 1200 then continues to block 1216 , where it returns.
[0059] Turning now to FIG. 13 , an illustrative Routine 1300 will be described for providing a queue bridge between a window manager utilizing high-performance message queues and a legacy window manager. The Routine 1300 begins at block 1302 , where a determination is made as to whether a message has been received from the high-performance window manager. If a message has been received, the Routine 1300 branches to block 1310 , where all of the messages in the high-performance message manager queue are extracted and processed. This maintains the constraints required by non-locking queues. As described above, to ensure strict FIFO behavior, only one thread at a time within a context may process messages. The Routine 1300 then returns from block 1310 to block 1302 .
[0060] If, at block 1302 , it is determined that no high-performance window manager messages are ready, the Routine 1300 continues to block 1304 . At block 1304 , a determination is made as to whether messages are ready to be processed from the legacy window manager. If no messages are ready to be processed, the Routine 1300 continues to block 1306 , where idle-time processing is performed. In this manner, background components are given an opportunity to update. Additionally, the wait time until the background components will have additional work may be computed.
[0061] If, at block 1304 , it is determined that messages are ready to be processed from the legacy window manager, the Routine 1300 branches to block 1306 , where the next available message is processed. At decision block 1307 , a test is performed to determine whether the operating system has indicated that a message is ready. If the operating system has not indicated that a message is ready, the Routine 1300 returns to block 1306 . If the operating system has indicated that a message is ready, the Routine 1300 returns to block 1302 . This maintains existing queue behavior with legacy applications. The Routine 1300 then continues from block 1308 to block 1302 where additional messages are processed in a similar manner. Block 1308 saves the state and returns to the caller to process the legacy message.
[0062] In light of the above, it should be appreciated by those skilled in the art that the present invention provides a method, apparatus, and computer-readable medium for providing high-performance message queues. It should also be appreciated that the present invention provides a method, apparatus, and computer-readable medium for integrating a high-performance message queue with a legacy message queue. While an actual embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
[0063] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | A method and apparatus is provided for providing and integrating high-performance message queues. “Contexts” are provided that allow independent worlds to be created and execute in parallel. A context is created with one or more threads. Each object is created with context affinity, allowing any thread inside the context to modify the object or process pending messages. Threads in a different context are unable to modify the object or process pending messages for that context. To help achieve scalability and context affinity, both global and thread-local data is often moved into the context. Remaining global data has independent locks, providing synchronized access for multiple contexts. Each context has multiple message queues to create a priority queue. There are default queues for sent messages and posted messages, carry-overs from legacy window managers, with the ability to add new queues on demand. A queue bridge is also provided for actually processing the messages. | 6 |
FIELD OF ART
This invention relates to a device for cleaning cylindrical objects, such as bolts, shafts and pins.
BACKGROUND OF THE INVENTION
Various kinds of bolts and nuts are used for fastening together various parts of a machine, whether it may be a common industrial machine or a machine designed for a specific purpose. When the bolts and nuts are removed to enable the inspection or replacement of any machine part, it is also usual to clean the screw threads of the bolts. The simplest method of cleaning any such bolt is to apply a wire brush or the like to its surface to remove stain or foreign matter therefrom. This kind of work has been done manually. There is also known a device which has been developed exclusively for cleaning a specific type of bolts efficiently.
Boilers, reactors, steam turbines and related equipments in steam or nuclear power plants are periodically inspected, either in accordance with law or voluntarily. The inspection includes not only the disassembling of the machine parts, but also the strict examination of the bolts and nuts. It is, for example, necessary to clean the bolts by removing any foreing matter from their screw threads and polishing them.
There is, however, a limit to the efficiency which can be achieved if the bolts are cleaned manually by means of an ordinary or rotary brush, or the like. The scattering of dust is unavoidable, even if a special cleaning device may be employed. It is necessary to keep any dust from rising, particularly in a nuclear power plant, since it is likely to result in a greater danger of radioactive contamination. Therefore, it is usual to, for example, set up a tent enclosing the place where any such cleaning work is done, and collect any rising dust into a disposal system by a blower. The cleaning work which makes it necessary to set up a tent whenever it is done is, however, far from efficient.
The bolts to be cleaned are removed from the machine parts and carried to the tent. If the bolts to be cleaned are of the type which cannot be brought to the tent, such as bolts embedded in a turbine casing, it is necessary to set up another tent enclosing the place where they exist. Even if a special cleaning device may be available, it is necessary to do any such cleaning work in a tent at the sacrifice of efficiency, as the device has no sealing mechanism that can prevent the scattering of dust.
The present applicant has filed Japanese Patent Application No. 238011/1987 which discloses a device designed for the efficient cleaning of bolts, etc. This device includes a sleeve in which the bolt to be cleaned is placed, and a rotor disposed therein and having a brush. The bolt is held by the rotor and is polished by the brush disposed on the peripheral surface of the rotor.
An arm is pivotally attached to the peripheral surface of the rotor. A centrifugal force acts on the arm when the rotor is rotated, and brings the brush into rubbing contact with the surface of the bolt. The arm forms the free end of the rotor and is, therefore, vibrated considerably when the rotor is rotated at a high speed. The arm forms a center of mass and is, therefore, likely to cause resonance, depending on its length and the rotating speed of the rotor. Its resonance results in a heavy vibration of the entire device. The vibration of the device not only imposes a great burden on a man holding it during a particular cleaning job, but also causes the generation of a large noise and is even likely to result in its own destruction.
If the cleaning device is rotated only in such a direction that the brush is moved in the direction opposite to the lead of a screw thread, the thread not only imparts a greater resistance to the operation of the device, but also causes it to vibrate to a greater extent. Therefore, in case that the brush is continuously contacted to the periphery of the bolt throughout the operation, if the direction of rotation of the brush differs from the lead of the screw thread, the resistance imposes a greater burden on the worker and gives him a greater amount of fatigue, while the vibration is undesirably transmitted to his hands. The continuance work of such operation will not be good for the health of the worker. A still greater burden is imposed on the worker who has to use a larger device for cleaning a larger bolt. When cleaning, for example, an upright embedded bolt, he has to move the device up and down. No efficiency can be expected from any work when he has to support the weight of the device manually.
If the brush is rotatable only in one direction, it always takes the same position when contacting the screw thread and can, therefore, clean only one flank thereof, while leaving the other flank thereof uncleaned.
SUMMARY OF THE INVENTION
It is, therefore, an object of this invention to provide a device which can clean a cylindrical object, such as a bolt, efficiently and is easy to use without vibrating. It is another object of this invention to provide a device which can be held lightly by hand for cleaning a bolt easily and effectively, as its operation can be performed along the screw thread on the bolt.
In order to accomplish the above objects, the cleaning device according to the present invention is characterized in that a device for cleaning a cylindrical object such as bolts comprises a sleeve having an open end, a rotor provided in the sleeve substantially coaxially therewith, the object being placed in the sleeve, a driving device provided on the sleeve for driving the rotor in one or the other direction, a plurality of arms each having a base end supported on the rotor and provided with a brush at its free end, the arms being connected to the outer periphery of the rotor by means of pins and being swingable toward the radial direction, a holding ring provided around the rotor movably in the axial direction of the rotor and having a tapered wall portion in the outer periphery thereof against which the proximal ends of the arms detachably engage, and an exhaust circuit connected to the sleeve, the exhaust circuit comprising a means of suction due to negative pressure and being able to exhaust the air together with dust in the sleeve.
The brushes provided on the arms are brought into rubbing contact with the surface of the bolt by rotating the rotor in which the bolt is inserted. The cleaning operation is performed in the sleeve which forms a enclosed space to the exterior. Further, since one end of each arm is held by the holding ring, the arms do not strongly swing when the rotor rotates at a high speed, which leads to restraint of vibration and noise.
When the driving device drives the rotor to rotate in one or the other direction, the brush moves by the lead of the screw of the bolt, and the brush is mechanically inserted and pulled out using the lead of the screw.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side elevational view indicating operation of the cleaning device embodying this invention;
FIG. 2 is a sectional view taken along the line I--I of FIG. 1; and
FIG. 3 is a fragmentary longitudinal sectional view of the cleaning device for cylindrical objects including bolts which are respectively different in diameter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of this invention is explained hereinafter with the reference to the embodiments shown in Figures.
FIG. 1 is a side elevational view indicating operation of the cleaning device shown in an example of this invention, and FIG. 2 is a sectional view taken along the line I--I of FIG. 1. This embodiment shows a device for cleaning each of a plurality of bolts (A) embedded in a turbine casing.
The bolts (A) are fixed in an equally spaced apart relation from one another. The device is adapted to enclose the entire bolt (A) to be cleaned, and clean and polish its surface.
The device includes a circular cylindrical sleeve 1 and a rotor 2 disposed in the sleeve 1 coaxially therewith. A base block 3 is connected to the upper end of the sleeve 1. Bearings 3a are provided in the base block 3 for supporting the rotor 2 rotatably. A pneumatic motor 4 is mounted on the base block 3 for rotating the rotor 2. The motor 4 has an output shaft which is rotatable at a high speed in either direction when it is supplied with compressed air. The motor 4 has a projecting portion defining a handle 4a to which a hose 4b is connected for supplying compressed air to the motor 4. The handle 4a is also provided with a switch 4c which is used for starting the rotation of the motor 4 in either direction or stopping it. A grip bar 3b is attached to the base block 3. The user of the device can grip it for transporting or adjusting its position relative to the bolt (A) to be cleaned.
The rotor 2 rotated by the motor 4 is a hollow cylinder having an open lower end. Four cleaning mechanisms are connected to the outer peripheral surface of the rotor 2.
Each cleaning mechanism comprises an arm 6 connected to the outer surface of the rotor 2 rotatably by a pin 5 and carries at its lower end a brush 7 which is formed by a multiplicity of filaments of steel wire. The pin 5 lies horizontally and at right angles to the radius of the rotor 2, as shown in FIG. 2, so that the arm 6 may be rotatable in a vertical plane to or away from the longitudinal axis of the rotor 2.
Each arm 6 has a lower end to which an auxiliary arm 6a is rotatably connected by a pin 6b, so that the position of the brush 7 can be adjusted to suit the outside diameter of the bolt (A) to be cleaned. The brush 7 can, therefore, be placed in uniform contact with even a bolt having a considerably small diameter. If the auxiliary arm 6a is, however, connected to the arm 6 in a fixed way instead of being rotatable by the pin 6b, the brush 7 can be pressed against the surface of the bolt (A) more strongly.
A holding ring 8 is provided around the rotor 2 for engaging the upper ends of the arms 6 and thereby holding them against movement. The holding ring 8 is connected around the rotor 2 threadedly as shown at 8a, and is movable along the axis of the rotor 2 if it is turned. The ring 8 has toward its lower end a tapered wall portion 8b having a gradually decreasing outside diameter. The tapered wall portion 8b has an outer surface engaging the inner edge of the upper end of each arm 6. If the ring 8 is moved along the rotor 2, therefore, its tapered wall portion 8b causes the arms 6 to rotate around the pins 5 and thereby alter their positions. The ring 8 can be secured to the rotor 2 by a lock bolt 8c extending through its wall near its upper end.
A ring 9 is fitted in the lower end of the sleeve 1 for maintaining the bolt (A) in axial alignment with the sleeve 1 and also defining a substantially closed space in the sleeve 1. The ring 9 has an inside diameter which is substantially equal to the outside diameter of the bolt (A) to be cleaned. The ring 9 consists of an inner annular portion 9a made of a hard synthetic resin and engaging the bolt (A), and an outer annular portion 9b made of a metal or preferably a synthetic resin and supporting the inner portion 9a. This construction ensures that the ring 9 causes no harm to the screw thread on the bolt (A). The ring 9 enables the coaxial positioning of the sleeve 1 with the bolt (A) and facilitates the insertion of the bolt (A) into the rotor 2. It also enables the smooth operation of the device which is free from any chattering or any interference between the inner surface of the rotor 2 and the outer surface of the bolt (A). The inner portion 9a of the ring 9 has an inside diameter which is slightly larger than the outside diameter of the bolt (A). A flexible hose 10 is connected to the sleeve 1 for collecting any dust that rises therein when the bolt (A) is cleaned. A suction blower 11 is connected to the hose 10.
Referring now to the operation of the device as hereinabove described, the device is so positioned that the bolt (A) to be cleaned may be inserted therein through the ring 9 at its lower end. The ring 9 enables the axial alignment of the sleeve 1 with the bolt (A) and thereby facilitates the insertion of the bolt (A) into the rotor 2.
FIG. 1 shows the bolt (A) and also another bolt (a) having a smaller diameter for the mere sake of explanation. The two arms 6 appearing in FIG. 1 are shown in different positions from each other for the mere sake of explanation. The left arm 6 is in its position suited for cleaning the bolt (A), and the right arm 6 in its position for cleaning the bolt (a). The position of each arm 6 depends on the diameter of the bolt (A) or (a) to be cleaned and is altered by the positional adjustment with use of the holding ring 8. FIG. 1 shows two halves of the ring 8 in different positions from each other for the mere sake of explanation. The left half of the ring 8 is shown in its raised position in which the upper end of the arm 6 engages the tapered wall portion 8b of the ring 8 adjacent to its lower end, so that the arm 6 may stay in its upright position enabling the brush 7 to contact the surface of the bolt (A) effectively. On the other hand, the right half of the ring 8 is shown in its lowered position in which the upper end of the arm 6 engages the tapered wall portion 8b of the ring 8 at its upper end, so that the arm 6 may have its lower end positioned closer to the longitudinal axis of the sleeve 1 enabling the brush 7 to contact the bolt (a) having a smaller diameter effectively.
If compressed air is supplied to the motor 4 to rotate its output shaft, the rotor 2 is rotated to cause the brushes 7 to rotate about the bolt (A) or (a) in rubbing contact with its surface, whereby foreign matter is removed from the bolt (A) or (a) and its surface is polished. It is possible to clean the whole bolt (A) if the bar 3b and the handle 4a are gripped to raise the device gradually. The rotor 2 is rotated at a speed of 600 to 1300 rpm.
The dust which rises when the bolt is cleaned is drawn by the blower 11 and collected through the hose 10 into an appropriate dust collector not shown. The inner portion 9a of the ring 9 has an inside diameter which is slightly larger than the diameter of the bolt (A), as hereinbefore stated. Therefore, the bolt (A) and the ring 9 have therebetween a small clearance through which air can flow into the sleeve 1, when the dust is drawn by the blower 11. No dust flows out through the clearance, since the clearance is small and the air in the sleeve 1 is drawn into the hose 10. The device can finish any cleaning job without causing any leakage of dust and thereby maintain a good working environment. Therefore, the device can overcome, for example, any problem of radioactive contamination that has hitherto been likely to occur during the maintenance and inspection of facilities in a nuclear power station.
The arms 6 are held by the holding ring 8 in their positions suited for the diameter of the bolt (A) or (a) to be cleaned. When the rotor 2 is rotated, the lower end of each arm 6 is radially outwardly moved by a centrifugal force, as it has a greater mass than that of the upper end portion thereof which is rotatably supported by the pin 5. On the other hand, the upper end of each arm 6 is moved radially inwardly and abuts on the tapered wall portion 8b of the holding ring 8, whereby the arm 6 is held in a particular position. Therefore, it is possible to maintain the brushes 7 in appropriate rubbing contact with the surface of the bolt (A) or (a) to be cleaned, if the holding ring 8 is appropriately positioned.
The bolts (A) and (a) are shown more clearly with two brushes 7 in FIG. 3. As is obvious therefrom, each brush 7 engages in the groove defined by the screw thread on the bolt (A) or (a) when it is in its appropriate cleaning position. Therefore, each brush 7 can be moved along the screw thread and groove in intimate contact therewith with the rotation of the rotor 2 if it is made of a relatively hard material, such as steel filaments. In other words, each brush 7 is movable up or down, depending on the direction of rotation of the rotor 2, by turning about the bolt (A) or (a), as if it were a nut. If the switch 4c is used to rotate the output shaft of the motor 4 in one or the other direction, it is possible to move the cleaning device up or down, while the bolt (A) or (a) stays at a standstill.
The screw thread or groove on the bolt (A) or (a) can, thus, be utilized to cause the cleaning device to move up or down automatically by turning about the bolt (A) or (a). Therefore, the user of the device can clean the bolt (A) or (a) along its whole length simply by holding the handle 4a lightly, positioning the device appropriately relative to the bolt, and turning on the switch 4c. The brushes 7 move along the screw thread to clean the bolt (A) or (a) from its upper to its lower end if the rotor 2 is rotated in one direction, and clean it from its lower to its upper end if the rotation of the rotor 2 is reversed. The user does not need to hold the device strongly, but is only required to use a greatly reduced force for doing any cleaning job.
Even if the device may vibrate heavily, its vibration does not exert any adverse effect on the user or cause any hazard to him, insofar as he has only to hold the device lightly.
As the arms 6 are held in position by the ring 8, the device does not make any appreciable vibration even when the rotor 2 is rotated at a high speed, as opposed to the conventional cleaning device which relies solely upon the centrifugal force. Although the arms 6 are rotatably supported on the rotor 2 by the pins 5, the arms 6 are held by the ring 8 at their upper ends throughout any particular cleaning job as if they were integral parts of the rotor 2, and do not make any appreciable vibration or noise.
Although the device has been described as being used for cleaning the bolt (A) or (a) embedded in a turbine casing, the device of this invention is, of course, useful for cleaning any independent bolt, if a jig or the like is used for holding the bolt in a vertical or horizontal position.
The device of this invention can also be used for cleaning any other cylindrical machine elements, such as a pin or shaft. Although the brushes 7 have been described as being made of steel filaments, they can also be formed from any other materials, such as filaments of stainless steel, brass or nylon, if they are suitable for the object to be cleaned.
The brushes 7 can be made of other materials which are sufficiently hard or rigid to enable the cleaning device as a whole to move along the screw thread on the bolt (A) or (a).
Moreover, mechanization can be promoted if a plurality of bolts (A) or (a) to be cleaned are to be disposed beforehand and cleaning device is so designed as to be movable on rails or by any other appropriate means in the direction of the disposed bolts. A still higher degree of efficiency can be expected from such continuous cleaning if a control system is provided for enabling the cleaning device to stop automatically in front of each object to be cleaned.
INDUSTRIAL FEASIBILITY
In the cleaning device according to this invention, a rotor which encloses a cylindrical body in a sleeve enclosing the cylindrical body with space around is disposed, and the brushes are brought into rubbing contact with the surface of the bolt when the rotor is rotated. The operation is easier and more efficient than any conventional manual cleaning. The device also enables the uniform cleaning of all the bolts used for fastening together the parts of a particular machine, and ensures the cleaning work which satisfies the requirements of inspection and maintenance imposed on the machine. The sleeve enclosing the object to be cleaned keeps any dust from scattering and thereby enables the maintenance of a good working environment. The holding ring prevents the arms from being displaced by a centrifugal force, or vibrating, even when the rotor is rotated at a high speed. Therefore, the device is easy to use without making any undesirable vibration or noise, and is free from any fear of being broken as a result of the occurrence of resonance.
The brushes can be moved spirally around the bolt along its screw thread, as if they were nuts. If the rotor is rotated in either direction, the cleaning device can be moved in either direction along the axis of the bolt. Therefore, the device can perform the cleaning of any bolt while moving along its screw thread, only if the user thereof holds the device lightly in its position suited for the bolt. The load to be imposed on the user of the device can be reduced. As it is sufficient for the user to hold the device lightly, he is free from any danger of a hazard due to its vibration. The device can, therefore, be used for a wide range of applications. | A device for cleaning cylindrical objects such as bolts has a sleeve (1) which contains a rotor (2) equipped with a brush (7). A bolt is inserted into the sleeve (1), and the rotor (2) is rotated by a motor (4) to clean the periphery of the bolt. The sleeve (1) is connected to a suction means of negative pressure such as blower (11), and the motor (4) is capable of rotating the rotor (2) in one or the other direction. In the cleaning device a bolt is enclosed in the sleeve (1) and is cleaned with the brush (7) which is driven in contact with the peripheral surface of the bolt by the rotation of the rotor (2). Dust and dirt generated by the cleaning are prevented from leaking out of the sleeve and collected in the suction means of negative pressure. As the rotor (2) rotates in one or the other direction by the motor (4), furthermore, the rotating direction of the brush (7) is set to meet the direction in which the lead of the thread of the bolt advances. | 1 |
BACKGROUND OF THE INVENTION
[0001] Silt fences prevent sediment carried by sheet flow from leaving a construction site and entering natural drainage ways or storm drainage systems by slowing storm water runoff and causing the deposition of sediment at the structure. Silt fencing encourages sheet flow and reduces the potential for development of rills and gullies. Silt fencing should be installed where sheet flow runoff can be stored behind the barrier without damaging the barrier or the submerged area behind the barrier. Silt fencing is generally located at the topographically lowest portions of the site where silt migrates during rain events.
[0002] Visual fence is placed just inside the clearing boundaries to define the limits of clearing. This is necessary to prevent the overclearing of trees, brush, etc., and to visually identify the clearing limits. Many local ordinances require that the visual fence have certain minimum visibility requirements.
[0003] Conventional fence systems are installed by first digging a narrow shallow trench the length that the fence is to be run. The stakes are set into the ground in the trench at a specific distance apart. Typically, a wire backing is attached to the stakes using fasteners. The wire backing lends support and strength to the fence and, in particular, to the fabric. The wire backing extends from down in the trench to above the ground level, generally up to at least a portion of the height of the fence material. The fence material, typically a synthetic fabric or mesh, is attached to the stakes using fasteners such that the lower portion of the fabric overlaps the wire backing. The trench is backfilled to secure the fence in the ground. In use, the silt fence blocks silt runoff while permitting water to pass through the fence mesh.
[0004] By the time the construction is completed to the point where the fence is no longer needed, the fence material has often degraded or is otherwise unusable in another application. However, the fence must still be removed by construction crews and either recycled or dumped in the garbage or landfill.
[0005] Currently, at least one line, and often two lines, of silt fence are separately installed and used to prevent silt runoff and a separate line of visual fence is used to provide a visual indication of tree save or other marked area. Each line must ordinarily be manually installed by workers. Often, wire ties are used to attach the fence to the stakes, with each tie taking time to feed through the fabric, around the stake and twisted off. This results in significant time being required to install and later uninstall these fences, increased waste product as the fences are often unreusable after the first use, and increased cost. It would be desirable to have a single fence which could provide a silt barrier yet also serve as a visual fence. It would also be desirable to have fence system that is easier and take less time to install, while reducing the quantity of fence required.
SUMMARY OF THE INVENTION
[0006] Generally described, the present invention provides in a first exemplary embodiment a novel combination of a silt and visual fence to prevent sedimentation from leaving the limits of construction and the visual impact of a clearing tree save fence to define the limits of project clearing. The silt/visual fence combination reduces the need for two separate material and installation processes and will allow for one product and one installation. More particularly, the present invention provides, in one exemplary embodiment, a silt/visual fence comprising a plurality of stakes, each stake comprising, a generally flat surface having a plurality of holes defined therein and spaced along at least a portion of the flat surface, a strip of fabric, comprising, a lower portion having a first visual indicia associated therewith, an upper portion having a second visual indicia associated therewith distinct from the color of the first portion, the upper and lower portions being connected; and, a plurality of fasteners for fastening the strip of fabric to the plurality of stakes. The fence preferably also includes, where use so requires, a wire grid or mesh backing to provide additional strength and support to the lower portion fabric. For certain applications a wire grid or mesh backing is not required.
[0007] Other features and advantages of the present invention will become apparent upon reading the following detailed description of embodiments of the invention, when taken in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is illustrated in the drawings in which like reference characters designate the same or similar parts throughout the figures of which:
[0009] FIG. 1 is a perspective view of one exemplary embodiment of the present invention.
[0010] FIG. 2 is a detailed view of the stake according to one exemplary embodiment of the present invention.
[0011] FIG. 3 is a top schematic view of a stake with a fastener inserted through the wire back and fabric.
[0012] FIG. 4 is a bottom plan view of a fabric fastener according to one exemplary embodiment of the present invention.
[0013] FIG. 5 is a side view of the fabric fastener of FIG. 4 , shown in position in the fence.
[0014] FIG. 6 is a bottom plan view of a wire back fastener according to one exemplary embodiment of the present invention.
[0015] FIG. 7 is a side view of a fastener inserted into a fence system.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0016] The present invention provides a silt fence to prevent sediment from leaving a site with a visual fence to define the limits of project clearing or a protected tree save area. In one exemplary embodiment a silt fence 10 is shown in FIG. 1 and generally comprises a plurality of stakes 12 and a strip of fabric 14 .
[0017] The stake 12 is preferably formed of a durable generally rigid material, such as, but not limited to, metal, wood, plastic, combinations of the foregoing, and the like. In a preferred embodiment the stake is made of wood or steel. The lower end of the stake 12 preferably, though not mandatorily, terminates in a tapered tip for easier insertion into the ground. The stake 12 preferably has a generally flat portion 16 (although a curved portion, or even a cylindrical shaped stake 12 are contemplated as being within the scope of the present invention). Preferably, though not mandatorily, the stake has a reinforcing portion 18 , which can be formed as an L-shaped or T-shaped (as shown in FIG. 1 ) part of the stake. The flat portion 16 has a series of space apart holes 20 along at least a portion of the length of the flat portion 16 . Optionally, there are a series of tabs or protrusions 22 extending generally outward from the flat portion 16 . In one exemplary embodiment, shown in FIG. 1 , the flat portion 16 has a generally vertical line of holes 20 on both left and right sides and a series of tabs 22 between the sets of holes 20 .
[0018] The fabric 14 can be any suitable fluid porous material which can also retain a substantial portion of sedimentous material, such as, but not limited to, silt, topsoil, rocks, branches, leaves, and the like. In one exemplary embodiment the fabric 14 is made of polypropylene, available commercially from a number of manufacturers. The fabric 14 is preferably made of a first horizontal strip 30 and a second horizontal strip 32 . The first and second strips 30 , 32 are joined together, such as by adhesive, fusing or other technique known in the art, with the seam 33 shown in the drawing. Alternatively, the first and second strips 30 , 32 can be part of a single strip of fabric 14 .
[0019] The first strip 30 is preferably located above the top edge of the second strip 32 . The first strip 30 has a first unique visual indicia associated therewith and the second strip 32 preferably has a second unique visual indicia associated therewith. The visual indicia can be any visually distinctive indicator, such as, but not limited to, color, pattern, words, symbols, combinations of the foregoing, or the like. In one preferred embodiment the first strip 30 has an orange color and the second strip 32 has a black color. Preferably, the fabric itself is made of the colored material; alternatively, the color can be applied to the fabric using any suitable technique.
[0020] In one exemplary embodiment, the fence 10 also includes a wire backing 34 as a support and strength adjunct to the fabric 14 . The wire backing 34 preferably has a curved portion 36 at its lower end so as to conform to the shape of a trench into which the wire backing is maintained, as described in greater detail hereinbelow. The wire backing 34 preferably extends upward from the lower portion of the stake 12 to at least a portion of the stake 12 aboveground when installed. The wire backing 34 is preferably made of metal, plastic or other durable strong material. A primary purpose of the wire backing 34 is to provide additional strength to the fabric 14 when silt accumulates behind the fabric 14 and to resist deformation or ripping of the fabric 14 .
[0021] The fabric 14 is preferably attached to the stake 12 using a number of fasteners 38 . The fastener 38 has a shank 40 which is pushed through the fabric 14 and force fit into one of the holes 20 in the stake 12 (see FIG. 3 ). In one exemplary embodiment the fastener 38 can be either a fabric fastener 42 or a wire backing fastener 44 . The fabric fastener 42 may have a circular head. The wire backing fastener 44 may have a rectangular head. The fasteners 42 or 44 preferably have at least one, and more preferably, a plurality of annular barbs to restrict unintentional removal of the fastener. It is to be understood that other fasteners 38 can be used with the present invention, and may include, but are not limited to, wire or plastic ties or wraps, staples, nails, hook and loop fasteners, screws, clips, combinations of the foregoing or the like. A novel fastener is described in detail herein below.
[0022] By spacing the stakes 12 a desired distance apart (usually mandated by state or local regulation) the fabric 14 can be stretched between the stakes 12 and secured in place using the fasteners 38 . A portion of the fabric 14 is placed in a trench in the ground (as discussed above, this is usually mandated by state or local regulation) and soil placed over that portion to maintain the fabric 14 in place and to prevent silt and other nonfluid runoff from passing under the fabric 14 .
[0023] An advantage of the present invention is that the two color fabric 14 eliminates the need for separate silt and visual fences as are conventionally used; i.e., one black fence and one orange fence. The elimination of one fence reduces time and cost of installation and subsequent removal of the fence once construction has ended. The present invention also reduces landfill impacts or the need to recycle one fence.
[0024] In another aspect of the present invention, a novel fastener is provided for use with the fence system 10 . FIGS. 4 and 5 show an exemplary embodiment of a fabric fastener 50 having a head or cap 52 and a shank 54 . The fabric fastener 50 is preferably made of plastic, but can also be made of metal or other material that preferably can be struck without substantial deformation yet be resistant to weathering. The surface of the cap 52 can be rounded or flat. The cap can be circular in circumference or of other shape. The cap 52 has a plurality of ribs 56 or barbs, teeth, fins or the like that protrude from preferably the back side (i.e., the side with the shank extending therefrom) of the cap 52 . The ribs 56 are preferably arranged is a series of concentric circles (with each rib being straight, curved, jagged, or other shape), as shown in FIGS. 4 and 5 . It is to be understood that other regular or irregular arrangements, e.g., grid, spiral, radial, random and the like, are contemplated as being possible. The ribs 56 can be the same height, or can be of different heights above the back of the cap 52 . A purpose of the ribs 56 are to increase the gripping strength of the fabric fastener 50 to the fabric 32 when installed. When the fabric 32 is installed against the support 12 , the shank 54 , which preferably has a pointed tip 58 and a series of protrusions 60 or threads, passes through the fabric 32 and is retained in one of the holes 20 . The ribs 56 are pushed towards and/or into the fabric 32 and preferably engage the fabric fibers. This multiple-point engagement helps to retain the fabric 32 in place and reduce the tendency to rip during extended use. In one exemplary embodiment it is possible for the ribs 56 to be the result of piercing the front of the cap 52 and creating a protrusion of material extending out of the back of the cap 52 .
[0025] FIG. 6 shows an alternative embodiment of a fastener, namely a wire backing fastener 70 , similar in material construction to the fabric fastener 50 , but preferably having a generally rectangular shaped cap 72 . The surface of the cap 72 can be rounded or flat. The ribs 74 are preferably arranged horizontally in rows so as to improve engagement and retention of the wire 34 . The wire backing fastener 70 has a shank 76 similar to the shank 54 . FIG. 7 shows a wire backing fastener 70 installed in a fence system. The shank 76 of the wire backing fastener 70 is inserted through the hole 20 in the support 12 , with at least one row of ribs 74 being below the wire 34 . Preferably, at least one row of ribs 74 is above the wire 34 . In this manner the ribs assist in supporting the wire 34 and maintaining it in position with respect to the support 12 .
[0026] It is to be understood that the caps 52 and 72 of the fasteners 50 and 70 , respectively, may be constructed with different shapes, such as, but not limited to, circular, rectangular, rhomboid, elliptical, oval, hemispherical, square, wedge, asymmetric or other regular or irregular shape.
[0027] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. It should further be noted that any patents, applications and publications referred to herein are incorporated by reference in their entirety. | A fence for retaining silt and providing a visual marker comprising a plurality of stakes, each stake comprising, a generally flat surface having a plurality of holes defined therein and spaced along at least a portion of the flat surface, a strip of fabric, comprising, a lower portion having a first visual indicia associated therewith, an upper portion having a second visual indicia associated therewith distinct from the color of the first portion, the upper and lower portions being connected; and, a plurality of fasteners for fastening the strip of fabric to the plurality of stakes. The fence preferably also includes a wire grid or mesh backing to provide additional strength and support to the lower portion fabric. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates, generally, to robot operation and training. More specifically, various embodiments relate to the acquisition, organization, and use of task-related information by industrial robots to facilitate performance of tasks in an autonomous manner.
BACKGROUND OF THE INVENTION
[0002] Industrial robots perform a variety of tasks involving the movement and manipulation of physical objects. A typical industrial robot may, for example, have one or more arms, equipped with grippers, that allow the robot to pick up objects at a particular location, transport them to a destination location, and put them down in accordance with particular coordinates, thereby, for example, stacking them or placing them into cardboard boxes present at the destination location.
[0003] Robots may manipulate different types of objects and perform many tasks beyond simply moving them—for example, welding, joining, applying fasteners, etc. As a result, many different “end effectors” have been developed for deployment on robot appendages; some of these end effectors, such as grippers, have utility across a range of tasks, while others, such as weld guns, are designed to perform a single, specialized task. To promote versatility, a commercial robot may accommodate different end effectors. For example, different end effectors may share a common linkage design that permits them to be interchangeably mounted to the cuff or wrist of a robot arm. Accommodating the robot to the end effector operationally is more difficult. Frequently, selection of the end effector for a robot occurs during system integration or assembly and is essentially permanent; the programming necessary to operate the selected end effector is written into the controller code for the robot. In some robots, end effectors may be changed dynamically during operation, but typically this occurs at preprogrammed phases of task execution; that is, the robot controller code signals the need for a new end effector when the code governing the next task expects a replacement. Even dynamic changes in the robot's end effector, in other words, occur in response to robot expectation as it executes tasks or when the robot is outfitted for a new task.
[0004] What is needed, therefore, is a more versatile approach to hot-swapping of end effectors that permits arbitrary replacement by the operator and dynamic accommodation by the robot. The operator, for example, may find during operation that the task being performed by the robot unexpectedly requires finer control than the current set of grippers permits. In such circumstances, the operator will want to replace the existing grippers with a more suitable end effector, but without rewriting the robot's task-execution code.
SUMMARY OF THE INVENTION
[0005] The present invention relates to robots capable of accommodating dynamic replacement of end effectors, and hardware and software associated with the end effectors that facilitate communication with the robot to dynamically load and run software that allows the end effector to be operated without change to the main control program. Such effector-specific programming is herein generically referred to as a “driver.” The driver may be dynamically linked and run during program execution when the corresponding end effector is detected. Typically, the robot controller will store a library of drivers, and load the appropriate driver when a new end effector is detected; this process is referred to herein as “self-configuration.” The controller code itself, however, may issue generic commands not tied to any particular driver but to which appropriate drivers are coded to respond. This avoids the need to make changes at the controller-code level to accommodate different end effectors.
[0006] The term “configuration data” or “configuration information” refers to information identifying or helping to instantiate (e.g., select and parameterize) the proper driver for a particular end effector. Thus, configuration data may be an actual driver, parameters used to tailor a generic driver to a particular end effector, or merely an identifier for the type of driver needed. The term “identifier” or “identification data” refers to information that identifies the end effector and that may be combined with or used to locate appropriate configuration information for the end effector. As explained below, drivers, configuration data and identifiers can be variously distributed among components of a system depending on design priorities and preferences.
[0007] In various embodiments, the end effector is not connected directly to the robot appendage but instead to a “tool plate” that is removably mounted to the distal end of the robot appendage. The tool plate receives the end effector mechanically and may supply power and, in some cases, data signals thereto. Various types and degrees of functionality can be distributed between the end effector and the tool plate, and the latter may accommodate more than one type of end effector. This arrangement facilitates flexible deployment of capabilities as best suited to a particular robot architecture; for example, one component may be “dumb” (e.g., incapable of communication or data processing) and the other “smart” (e.g., capable of communicating with the robot and performing data-processing operations). Thus, one implementation features a “dumb” end effector and a “smart” tool plate. The smart tool plate may detect which of multiple types of connectable end effectors has been attached to it (e.g., based on electrical characteristics or the mechanical configuration of the end effector's connector), reporting this to the robot controller, which loads the appropriate driver. Alternatively, the smart tool plate may accommodate only a single type of end effector, in which case it need only report its own identity to the robot controller, since this is sufficient to determine the proper driver.
[0008] Another implementation features a “smart” end effector and a “dumb” tool plate, in which case the tool plate merely facilitates communication between the end effector's on-board processor or controller and the robot controller; the end effector reports its identity in a wired or wireless fashion to the robot controller. In this configuration, the tool plate may, for example, serve as an adapter between the robot appendage and a mechanically incompatible end effector. As explained below, “reporting” may be active (the “smart” component may initiate communication with the robot controller on its own and send information) or passive (the “smart” component may respond to a polling signal or other communication from the robot controller, which has detected attachment).
[0009] Accordingly, in a first aspect, the invention relates to a robot system with replaceable end effectors. In various embodiments, the robot system includes a robot body; a robot arm connected to the robot body and having a distal end including a first connector; a robot controller for controlling the robot arm and an end effector connected thereto; an end-effector removably connectable to the robot arm, where the end-effector assembly includes (1) an end effector; (2) nonvolatile memory storing data comprising identification information and/or configuration information; (3) a communication interface; (4) a processor; and (5) a second connector removably but securely matable with the first connector for establishing bidirectional communication between the processor and the robot controller via the communication interface. The processor is configured to cause transmission of the data to the robot controller upon mating of the first and second connectors, and the robot controller is adapted to self-configure based on the data and to control movements of the connected end effector based on the self-configuration.
[0010] In various embodiments, the first connector is disposed in a tool plate that is itself disposed at the distal end of the robot arm and removably connected thereto. The end effector is connected to the opposite side of the tool plate. The tool plate includes the nonvolatile memory, the processor and the communication interface. In some implementations, the tool plate is adapted to mate with a single type of end effector and stores the identification and/or configuration information relating thereto. In other implementations, the tool plate may accommodate multiple types of end effectors and store identification and/or configuration information for each end-effector type. Mating of the end effector to the tool plate establishes the end-effector type either mechanically or by means of data exchange. The tool plate, in turn, communicates with the robot controller to provide the identification and/or configuration information thereto.
[0011] As noted, the robot controller self-configures based on the deployed end effector. In some embodiments, the end-effector assembly supplies both identification and configuration information, e.g., a driver that the controller programming uses to operate the end effector. In other embodiments, the end-effector assembly supplies only identification information, and the controller locates the appropriate driver. For example, the controller (or other robot component) may store a series of drivers and a database relating end effectors to corresponding drivers. Once the controller learns the identity of the end effector, it selects and loads the appropriate driver based on the database entry corresponding to the identified end effector (without change to the main control program). If the controller is unable to locate a suitable driver, it may seek the driver remotely, either by communicating with a server acting as a master repository of drivers for end effectors, or by autonomously conducting an Internet search for suitable drivers and, if one is found, downloading and installing it.
[0012] In another aspect, the invention again relates to a robot system with replaceable end effectors. In various embodiments, the robot system includes a robot body; a robot arm connected to the robot body and having a distal end including a first connector; a robot controller for controlling the robot arm and an end effector connected thereto via the first connector; a tool plate removably connectable to the robot arm; and an end effector connected to the tool plate, where the tool plate includes (1) nonvolatile memory storing data comprising at least one of identification information or configuration information; (2) a communication interface; (3) a processor; and (4) a second connector matable with the first connector for establishing bidirectional communication between the processor and the robot controller via the communication interface. The processor is configured to cause transmission of the data to the robot controller upon mating of the first and second connectors, and the robot controller is adapted to self-configure based on the data and to control movements of the connected end effector based on the self-configuration.
[0013] In some embodiments, the data includes both identification information and configuration information. In other embodiments, the data does not include configuration information, and the robot system further comprises a database including records relating end-effector identification information to configuration information for the end effector. The controller is further adapted to query the database using the identification information to obtain the corresponding configuration information and to self-configure based thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing will be more readily understood from the following detailed description of the invention, in particular, when taken in conjunction with the drawings, in which:
[0015] FIG. 1A is a perspective view of a robot in accordance with various embodiments.
[0016] FIG. 1B schematically illustrates internal and external components of the robot shown in FIG. 1A .
[0017] FIGS. 2A and 2B are perspective views of a tool plate in accordance with embodiments of the invention.
[0018] FIGS. 3A and 3B are perspective and plan views, respectively, that show the manner in which a tool plate in accordance herewith may mate with the end of a robot arm.
[0019] FIG. 4 schematically depicts an interoperating system including a robot arm, a tool plate, and a pair of end effectors in accordance with embodiments hereof
DETAILED DESCRIPTION
[0020] Refer first to FIGS. 1A and 1B , which illustrate, respectively, a perspective view of a representative robot 100 and a schematic detailing the various internal operative components. The robot 100 includes at least one robot arm 105 —as shown in FIG. 1B , a robot may have more than one arm—that terminates in one or more end effectors 110 for manipulating objects. The arm 105 has several (e.g., seven) degrees of freedom provided by suitable (and conventional) rotational joints. Each joint desirably employs a series elastic actuator, enabling the robot to sense external forces applied to it, such as, e.g., forces resulting from unexpected collisions. In the embodiment illustrated in FIG. 1A , a parallel-jaw gripper 110 that allows the robot to grasp, lift, and move objects is mounted at the end of the arm 105 ; as explained below, the gripper 110 is just one of many possible end effectors. The robot 100 also has a head-like screen 112 , which may display a pair of eyes or other output reinforcing the robot's orientation to nearby personnel or announcing its state. In some embodiments, the screen 110 can rotate about a vertical access, and nod about a horizontal axis running parallel to the long axis of the screen 110 .
[0021] The robot 100 includes one or more cameras 115 . In FIG. 1A , a camera 115 is shown above the screen 112 . The robot 100 may also include one or more range sensors in the wrist 117 of the appendage 105 , and in some embodiments, one or more sonar sensors detects moving objects in the environment. In addition to these sensors for visually and/or acoustically detecting objects, the robot 100 may include a number of touch-sensitive sensors and mechanical features on the arm 105 that facilitate mechanical interaction with a person (e.g., a trainer). For example, the robot 100 may include a set 118 of knobs and buttons (a “navigator”) that allows the user to respond to information displayed on the screen 112 (e.g., by selecting menu items, switching between training and execution mode) and enter numbers (e.g., to indicate in how many rows and columns objects are to be packed in a box) or text (e.g., passwords or object and task names) via a digital rotary knob.
[0022] The robot 100 described above is, of course, only one of many possible robot embodiments in accordance with the invention, and the various features described above are representative rather than limiting. Various components and features can be modified in manners that will be readily apparent to persons of skill in the art. For example, the robot may, generally, have any number of arms (or, more generally, appendages), and each arm may have any number of degrees of freedom. The links of the arms need not be joined by rotational joints with one degree of freedom (such as, e.g., hinge joints), but may, for example, include ball-and-socket joints that provide two rotational degrees of freedom, or rail systems that facilitate translational motion.
[0023] Robot operation is governed by a robot controller 125 , which monitors and alters robot positions, kinematics, dynamics, and forces; controls joint-level actuators to move the robot and/or its moving parts as directed by the robot controller; and high-level computational functionality that facilitates image-processing, user interaction, etc. The robot controller 125 may generally be implemented in hardware, software, or a combination of both on a general-purpose or special-purpose computer, which includes a bidirectional system bus 128 over which the central processing unit (CPU) 130 , memory 133 , and storage devices 136 communicate with each other as well as with internal or external input/output devices such as the screen 112 , the camera 115 , navigators 118 , wrist cuffs, and any other input devices and/or external sensors. A conventional communication interface 138 facilitates communications over a network, such as the Internet and/or any other land-based or wireless telecommunications network or system. The storage devices 136 store an end-effector database 140 which, as explained in greater detail below, maintains information relevant to the various types of end effectors 110 that may be associated with the robot 100 . The various modules may be programmed in any suitable programming language, including, without limitation, high-level languages such as C, C++, C#, Ada, Basic, Cobra, Fortran, Java, Lisp, Perl, Python, Ruby, or Object Pascal, or low-level assembly languages. The robot controller 125 may be implemented in software, hardware, or a combination.
[0024] The end effector 110 is connected to the robot arm 105 via a tool plate 150 , which may accommodate more than one type of end effector 110 and, in some implementations, more than one end effector at a time. In this way, the tool plate 150 acts as a “universal” connector that is mechanically and electrically connected to the robot 100 via the robot arm 105 , and which receives mechanical and electrical connectors from the end effector 110 . In addition, the tool plate 150 assists the robot controller 125 in locating and installing the appropriate driver for a particular end effector 110 . In various embodiments, the tool plate 150 may alert the robot controller when an end effector has been removed and replaced with a different (but compatible) end effector, providing information that allows the controller 125 to locate, load, and run the appropriate new driver in real time. The tool plate 150 may be one of several differently configured tool plates, each having identical mechanical and electrical connectors for mating with the robot arm 105 but different receptacles for receiving different end effectors. In this way, it is possible to accommodate more end effectors than the number of receptacles a single tool plate could physically support, and also facilitates system extensibility: as new end effectors with different connector configurations are developed, it is not necessary to replace the entire robot 100 or even the robot arm 105 ; rather, the ability to swap tool plates 150 means it is only necessary to design a new tool plate. Features of the tool plate 150 described below provide flexibility in this regard.
[0025] FIGS. 2A and 2B illustrate both faces of a representative tool plate 150 , and FIGS. 3A and 3B depict its attachment to the end of a robot arm. The face 205 includes a recess 210 having a circular perimeter and, at the center of the recess 210 , a raised platform 215 within which are 10 spring-loaded pins (pogo pins) 220 for establishing removable electrical connection to complementary receptacles. A plurality of bores 225 extend through the tool plate 150 and allow bolts to be passed through for secure attachment to the robot arm. In the illustrated embodiment, the effector-facing face 230 includes a raised annular ridge 235 with indentations 240 exposing the bores 225 . In some embodiments, these indentations 240 interlock with complementary extensions into the annular recess on the end effector (not shown) that receives the ridge 235 . A series of bolt holes 245 along the top surface of the ridge 235 allow the end effector to be secured to the tool plate 150 . In the illustrated embodiment, attachment of an end effector to the face 230 results only in a mechanical connection. Electrical signals and power are delivered to the mounted end effector by a pair of electrical connectors (e.g., M8 industrial connectors), which are connected via suitable cables to the end effector. As explained in detail below, the electrical signals and power typically originate with the robot controller and are received by the tool plate 150 via the pin connectors 220 . The tool plate 150 may include circuitry that converts signals and/or power received from the robot into a different form for the end effector mounted thereto.
[0026] With reference to FIGS. 2A and 3A , the tool plate 150 is brought into contact with the end face 305 of the robot arm 105 , and the raised annular ridge 310 on the end face 305 is received within the complementary recess 210 of the tool plate 150 . A series of bolt holes 315 align with the bores 225 through the tool plate, allowing the tool plate 150 to be bolted or otherwise mechanically secured to the robot arm 105 ; in some embodiments, however, a quick-release latch is used instead of bolts. The pin connectors 220 are received in a receptacle 320 as the tool plate 150 and the robot arm 105 assume the mated configuration illustrated in FIG. 3B .
[0027] The operation and key internal components of the tool plate 150 are illustrated in FIG. 4 . The tool plate includes a memory 405 , support circuitry 410 , and a control element 415 that may be a microprocessor, microcontroller, or other suitable component. The capabilities of the control element 415 depend on the functions assigned to the tool plate 150 , as described below. The tool plate mechanically and electrically mates with one or more end effectors 420 , two of which are representatively shown at 420 1 , 420 2 ; that is, the tool plate 150 has two receptacles, one for each of the end effectors 420 , and each containing appropriate features to facilitate mechanical and electrical mating therewith. As noted above, the tool plate 150 may simultaneously accommodate more than one end effector 420 and/or may interchangeably accommodate different types of end effectors. For example, instead of grippers with fingers that close around an object as shown in FIG. 1 , an end effector 420 may include suction grippers or other means of holding or manipulating an object. Alternatively or additionally, the end effector may be a tool (such as a drill, saw, welder, etc.), a measuring device (such as e.g., a scale, gauge, etc.) or other function-implementing device.
[0028] When mated mechanically and electrically with the robot arm 105 , the tool plate 150 receives power and establishes communication with the robot controller 125 (see FIG. 1B ). Typically, this occurs via intermediary hardware such as an interface 425 and a local motor controller 430 . The interface supplies power from the robot to the tool plate 150 and supports bidirectional data communication with the tool plate 150 via, for example, the RS-485 serial communication protocol; the support circuitry 410 of the tool plate 150 contains complementary communication components. The local motor controller 430 receives commands from the robot controller 125 (via, for example, a link-layer protocol such as Ethernet) and actuates motors associated with one or more nearby joints of the robot arm 105 to effect the commands. In the illustrated implementation, the local controller 430 also receives commands from the robot controller 125 that operate the end effectors 420 . It communicates these commands to the tool plate 150 via the interface 425 (using RS-485, for example), and the tool plate 150 issues commands (or provides power) to the addressed end effector via the Digital Out line. The commands are typically low-level commands specific to the end effector. That is, although the tool plate 150 could be configured to accept high-level, generic commands from the robot controller 125 and translate these into effector-specific signals, usually this is not done; rather, in more typical implementations, the robot controller 125 has “self-configured” to deliver effector-specific commands. The manner in which this may be accomplished is explained below. It should also be emphasized that the robot arm 105 may itself include a processor that can perform higher-level tasks. Thus, while the processor 415 may act as a “master” to control communications with the robot arm 125 , it may instead act as a “slave” to a processor in the robot arm (which may, for example, poll the tool plate 150 and transmit data to the robot controller).
[0029] When an end effector 420 is mated with the tool plate 150 , various communications take place whose end result is to provide power to and enable communication between the robot controller 125 and the end effector 420 , but also to enable the robot controller to self-configure in order to operate the end effector. In one representative implementation, the end effector is a “dumb” device with no onboard information to offer the robot controller. The tool plate 150 recognizes the end effector because of the receptacle configuration (e.g., it is designed to accept a single type of end effector), or from its mechanical and/or electrical characteristics, or because the tool plate accommodates only one type of end effector. In the illustrated embodiment, the memory 405 stores an identifier for each of the two possible end effectors 420 1 , 420 2 . When the control element 415 detects attachment of a particular end effector, it communicates the corresponding identifier to the robot controller 125 via the robot arm 105 . The robot controller uses the communicated identifier to locate, in the database 140 (see FIG. 1B ), configuration information for the end effector. The database 140 may contain a library of configuration information (e.g., drivers or pointers to drivers stored elsewhere), and upon selection of the driver information based on the received end-effector identifier, the robot controller 125 self-configures, i.e., loads and installs the proper driver. Because the tool plate 150 can detect both installation and removal of an end effector, these may be “hot swapped” in real time without powering down and re-booting the robot; via the circuitry 410 , the control element 415 will alert the robot controller 125 that a new end effector has been attached, and provide the identifier for the new end effector.
[0030] Detecting attachment of an end effector, either by the tool plate 150 or by the robot controller 125 (if, for example, the end effector is attached directly to a robot arm 105 ), can occur in an active or passive fashion. For example, the end effector or tool plate can initiate communication with the robot controller or the tool plate. Alternatively, the end effector or tool plate can, upon attachment, emit a characteristic signal that is detected by the robot controller polling for that signal. In either case, the robot controller 125 (or, in some implementations, the robot arm 105 ) sends commands to the end effector or the tool plate, which responds with data (I/O or status data, or stored configuration/identification data, depending on the command).
[0031] In some embodiments, the configuration information is stored in the memory 405 of the tool plate 150 , and upon detecting attachment of an end effector, the control element 415 locates the corresponding configuration information in the memory 405 and transmits this to the robot controller 125 . Once again, the configuration information may be the driver itself or a pointer thereto, enabling the robot controller 125 to download the latest version of the driver before self-configuring, or information that enables the robot controller 125 to parameterize a generic driver for the particular end effector. The memory 405 can also store end-effector-specific metrics such as cycle counts and hours of operation, allowing for preventive maintenance such as replacing suction cups when they are near their rated cycle limit.
[0032] In various implementations, any of the receptacles 420 can accommodate more than one type of end effector. In such cases, the end effector may store an identifier that is provided to (or retrieved by) the tool plate 150 upon establishing communication with a newly installed end effector. In this case, the tool plate 150 communicates the identifier to the robot controller 125 or, in some embodiments, uses the identifier to retrieve configuration information from the memory 405 and sends this information to the robot controller 125 . The optimal distribution of information—i.e., whether to store configuration information on the tool plate 150 or in nonvolatile memory on the robot itself—represents a design choice. The more information that is stored on the tool plate 150 , the more generic the robot can be, but the more memory the tool plate 150 will require. Another consideration is the need to update information or programming. For example, if the configuration data is subject to change over time, it may be desirable to store only unchanging information, such as an end-effector identifier, in the memory 405 ; the robot controller 125 can verify, at power-up or when installation of a new robot arm is detected, that it has the most current driver. It is possible, of course, to include functionality on the tool plate 150 enabling it to check for updates to stored configuration information before providing it to the robot, but such capability requires either on-board connectivity or the ability to access the network resources (e.g., via the Internet) through the robot.
[0033] In cases where the end effector is “smart,” i.e., contains its own configuration information, this can be retrieved by the tool plate 150 and provided to the robot controller 125 . It is even possible for the tool plate 150 to communicate wirelessly with end effectors and/or the robot controller 125 using a suitable on-board wireless interface. If, on the other hand, the robot controller 125 is unable to locate a suitable driver, it may search for a driver in a remote (e.g., hosted) repository of drivers or may autonomously conduct an Internet search for the proper driver, installing and testing proper operation and functionality via the tool plate 150 before actually allowing the robot to operate normally.
[0034] As previously noted, the control element 415 of the tool plate 150 may be any suitable microprocessor or microcontroller, depending on the functions that the tool plate is to perform. For example, the control element 415 may be a programmable microcontroller designed expressly for embedded operation, or one or more conventional processors such as the Pentium or Celeron family of processors manufactured by Intel Corporation of Santa Clara, Calif. The memory 405 may store programs and/or data relating to the operations described above. The memory 405 may include random access memory (RAM), read only memory (ROM), and/or FLASH memory residing on commonly available hardware such as one or more application specific integrated circuits (ASIC), field programmable gate arrays (FPGA), electrically erasable programmable read-only memories (EEPROM), programmable read-only memories (PROM), or programmable logic devices (PLD).
[0035] The terms and expressions employed herein are used as terms and expressions of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described or portions thereof. In addition, having described certain embodiments of the invention, it will be apparent to those of ordinary skill in the art that other embodiments incorporating the concepts disclosed herein may be used without departing from the spirit and scope of the invention. In particular, embodiments of the invention need not include all of the features or have all of the advantages described herein. Rather, they may possess any subset or combination of features and advantages. Accordingly, the described embodiments are to be considered in all respects as only illustrative and not restrictive. | Robots capable of accommodating dynamic replacement of end effectors load and run software that allows the end effector to be operated without change to the main control program. The driver may be dynamically linked and run during program execution when the corresponding end effector is detected. Typically, the robot controller will store a library of drivers, and load the appropriate driver when a new end effector is detected. | 1 |
FIELD OF THE INVENTION
This invention generally relates to three-dimensional ultrasound imaging of the human anatomy for the purpose of medical diagnosis. In particular, the invention relates to methods and apparatus for three-dimensional imaging of the human anatomy by detecting the ultrasonic echoes reflected from a scanned volume in a human body.
BACKGROUND OF THE INVENTION
Conventional ultrasound scanners create two-dimensional B-mode images of tissue in which the brightness of a pixel is based on the intensity of the echo return. Alternatively, in a color flow imaging mode, the movement of fluid (e.g., blood) or tissue can be imaged. Measurement of blood flow in the heart and vessels using the Doppler effect is well known. The phase shift of backscattered ultrasound waves may be used to measure the velocity of the backscatterers from tissue or blood. The Doppler shift may be displayed using different colors to represent speed and direction of flow. In power Doppler imaging, the power contained in the returned Doppler signal is displayed. Although the following disclosure refers predominantly to B-mode imaging for the sake of brevity, the present invention applies to any mode of ultrasound imaging.
The basic signal processing chain in the conventional B mode is depicted in FIG. 1. An ultrasound transducer array 2 is activated to transmit an acoustic burst along a scan line. The return RF signals are detected by the transducer elements and then formed into a receive beam by the beamformer 4. The beamformer output data (I/Q or RF) for each scan line is passed through a B-mode processing chain 6 which includes equalization filtering, envelope detection and logarithmic compression. Depending on the scan geometry, up to a few hundred vectors may be used to form a single acoustic image frame. To smooth the temporal transition from one acoustic frame to the next, some acoustic frame averaging 8 may be performed before scan conversion. For a sector scan, compressed images in R-θ format are converted by the scan converter 10 into X-Y format for display. On some systems, frame averaging may be performed on the X-Y data (indicated by dashed block 12) rather than the acoustic frames before scan conversion, and sometimes duplicate video frames may be inserted between acoustic frames in order to achieve a given video display frame rate (typically 30 Hz). The scan-converted frames are passed on to a video processor 14, which basically maps the scan-converted data to a display gray or color map for video display.
System control is centered in a host computer 20, which accepts operator inputs through an operator interface 22 (e.g., keyboard and track-ball) and in turn controls the various subsystems. (In FIG. 1, the system control lines from the host computer to the various subsystems have been omitted for the sake of simplicity.) During imaging, a long sequence of the most recent images are stored and continuously updated automatically in a cine memory 16. Some systems are designed to save the R-θ acoustic images (this data path is indicated by the dashed line in FIG. 1), while other systems store the X-Y video images. The image loop stored in cine memory 16 can be reviewed on the display monitor via track-ball control (interface 22), and a section of the image loop can be selected for hard disk storage. For an ultrasound scanner with free-hand three-dimensional imaging capability, the selected image sequence stored in cine memory 16 is transferred to the host computer 20 for three-dimensional reconstruction. The result is written back into another portion of the cine memory or to scan converter memory, from where it is sent to the display system 18 via video processor 14.
Referring to FIG. 2, the scan converter 10 comprises an acoustic line memory 24 and an XY display memory 26. A separate acoustic line memory (not shown) is provided for color flow acoustic samples.! The B-mode data stored in polar coordinate (R-θ) sector format in acoustic line memory 24 is transformed to appropriately scaled Cartesian coordinate intensity data, which is stored in XY display memory 26. Each image frame out of XY display memory 26 is sent to both the video processor 14 and the cine memory 16.
A multiplicity of successive frames of B-mode data are stored in cine memory 16 on a first-in, first-out basis. The cine memory is like a circular image buffer that runs in the background, continually capturing image data that is displayed in real time to the user. When the user freezes the system (by depressing the FREEZE key on the interface 22), the user has the capability to view image data previously captured in cine memory.
The conventional system has the capability to superimpose graphical symbols on any ultrasound image. The superimposition of graphics on the image frame is accomplished in the video processor 14, which receives the ultrasound image frame from the XY display memory 26 and the graphics data from a graphics display memory 34. The graphics data is processed and input into the graphics display memory 34 by a graphics processor 36, which is synchronized with the other subsystems by the host computer 20.
The host computer 20 comprises a central processing unit (CPU) 28 and a random access memory 30. The CPU 28 has memory for storing routines used in transforming an acquired volume of intensity data into a multiplicity of three-dimensional projection images taken at different angles. The CPU 28 controls the X-Y memory 26 and the cine memory 16 via the system control bus 32. In particular, the CPU 28 controls the flow of data from the acoustic line memory 24 or from the X-Y memory 26 of the scan converter 10 to the video processor 14 and to the cine memory 16, and from the cine memory to the video processor 14 and to the CPU 28 itself. Each frame of imaging data, representing one of a multiplicity of scans or slices through the object being examined, is stored sequentially in the acoustic line memory 24, in the X-Y memory 26 and in the video processor 14. In parallel, image frames from either the acoustic line memory or the X-Y memory are stored in cine memory 16. A stack of frames, representing the scanned object volume, is stored in cine memory 16, forming a data volume.
Two-dimensional ultrasound images are often hard to interpret due to the inability of the observer to visualize the two-dimensional representation of the anatomy being scanned. However, if the ultrasound probe is swept over an area of interest and two-dimensional images are accumulated to form a three-dimensional data volume, the anatomy becomes much easier to visualize for both the trained and untrained observer.
In order to generate three-dimensional images, the CPU 28 can transform a source data volume retrieved from cine memory 16 into an imaging plane data set. The successive transformations may involve a variety of projection techniques such as maximum, minimum, composite, surface or averaged projections made at angular increments, e.g., at 100 intervals, within a range of angles, e.g., +90° to -90°. Each pixel in the projected image includes the transformed data derived by projection onto a given image plane.
In free-hand three-dimensional ultrasound scans, a transducer array (1 D to 1.5 D) is translated in the elevation direction to acquire a substantially parallel set of image planes through the anatomy of interest. These images can be stored in the cine memory and later retrieved by the system computer for three-dimensional reconstruction. If the spacings between image frames are known, then the three-dimensional volume can be reconstructed with the correct aspect ratio between the out-of-plane and scan plane dimensions. If, however, the estimates of the interslice spacing are poor, significant geometric distortion of the three-dimensional object can result.
A conventional ultrasound scanner collects B-mode, color and power Doppler data in a cine memory on a continuous basis. As the probe is swept over an area of the anatomy, using either a free-hand scanning technique or a mechanical probe mover of some sort, a three-dimensional volume is stored in the cine memory. The distance the probe was translated may be determined by a number of techniques. The user can provide an estimate of the distance swept. If the probe is moved at a constant rate by a probe mover, the distance can easily be determined. Alternatively, a position sensor can be attached to the probe to determine the position of each slice. Markers on the anatomy or within the data could also provide the required position information. Yet another way would be to estimate the scan plane displacements directly from the degree of speckle decorrelation between successive image frames. Once the data volume has been acquired, the central processing unit can then provide three-dimensional projections of the data as well as arbitrary slices through the data volume.
Referring to FIG. 3, if the ultrasound probe 2' is swept (arrow 38 indicates a linear sweep) over an area of a body (either by hand or by a probe mover), such that the interslice spacing is known, and the slices 40 are stored in memory, a three-dimensional data volume 42 can be acquired. The data volume can be processed (e.g., using projection onto an imaging plane) to form a three-dimensional view of the area of interest. In addition, the data can be reformatted to produce an individual slice 44 at an arbitrary angle (see FIG. 4), thus allowing the user to get the exact view desired regardless of the anatomy under investigation. Algorithms for producing three-dimensional projections of two-dimensional data are well known, as are techniques for reformatting data to produce arbitrary slices through a data set. The problem that arises is how to display the information such that it is easy for the observer to easily relate the two-dimensional slice to the three-dimensional anatomy.
SUMMARY OF THE INVENTION
The present invention incorporates a user interface designed to allow the operator of an ultrasound imaging system to switch between two-dimensional slices and three-dimensional projections in such a way that it is easy for the operator to visualize the relationship of the two-dimensional slice to the three-dimensional anatomy.
In accordance with a preferred embodiment of the invention, in a "volume rotate" mode, the display screen displays an orientation box along with a three-dimensional projected image generated from a defined data volume. The orientation box provides a visual indication of the shape and orientation of that defined data volume.
Although the orientation box can be used in conjunction with any known technique for projecting three-dimensional images from a data volume at arbitrary angles, in accordance with a preferred technique, voxel data is multiplied by aspect scaling factors, rotated by the desired angle and projected onto an image plane. In accordance with a further aspect of the preferred projection technique, scaling factors are used to ensure that voxels which are one unit apart along the X, Y and Z axes in data space are mapped onto pixels that are at most one unit apart along the X and Y axes on the image plane.
In a "cut plane" mode, a movable polygon representing a selected two-dimensional slice is displayed inside a stationary orientation box. The polygon provides a visual indication of the orientation and position of the slice relative to the defined data volume. The operator may use a track-ball to scroll through the data volume in order to display a desired two-dimensional slice. The polygon is moved inside the orientation box as a function of the track-ball movement to indicate the position of a two-dimensional slice relative to the defined data volume. When the track-ball is stopped, the position of the polygon relative to the orientation box is frozen and the reformatted slice having a corresponding position relative to the defined data volume is displayed.
In a "cut plane rotate" mode, a stationary polygon representing a selected two-dimensional slice is displayed inside a rotatable orientation box. The operator moves a track-ball to rotate the orientation box. The shape of the polygon changes to conform to the changing shape of the two-dimensional slice. When the track-ball is stopped, the orientation of the orientation box relative to the polygon is frozen and the reformatted slice having a position corresponding to the position of the polygon is displayed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the major functional subsystems within a real-time ultrasound imaging system.
FIG. 2 is a block diagram showing means for reconstructing frames comprising successive volumetric projections of pixel intensity data.
FIG. 3 is a diagram depicting a volume of data acquired by linearly scanning an ultrasound probe in a direction perpendicular to the scan plane of the probe.
FIG. 4 is a diagram depicting an individual slice at an arbitrary angle obtained by reformatting the data volume depicted in FIG. 3.
FIG. 5 is a flow chart showing an acquisition and display procedure in accordance with a preferred embodiment of the invention.
FIG. 6 is a diagram depicting a display of a sector scan ultrasound image with graphics indicating a user-defined volume of interest.
FIG. 7 is a diagram depicting a display of a projected ultrasound image made at an arbitrary angle with graphics indicating the orientation of the data volume.
FIG. 8 is a diagram depicting a projection transform procedure in accordance with a preferred embodiment of the invention.
FIG. 9 is a diagram depicting a display of a two-dimensional slice with graphics representing the position and orientation of the slice relative to the data volume.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 5 shows a flow chart of the acquisition and display procedure. The user begins by sweeping the ultrasound probe over an area of interest (step 50). For example, the sweep may be acquired by a free-hand sweep in a linear or rocking motion. Once the data is acquired, the user "freezes" the cine memory (step 52) by depressing the FREEZE key and then selects the range of cine memory frames (slices) to be included in the Z-dimension of the data volume (step 54). The operator accomplishes the latter step by moving a track-ball. As seen in FIG. 6, a Z-dimension select gauge 100 appears on the display screen 18' when the track-ball is moved. The track-ball is then used to control the position of an indicator 102 relative to the gauge 100. The indicator can be moved to a desired left end point and then the left end point is locked by depression of predetermined key on the operator interface. Then the indicator can be moved to a desired right end point and then the right end point is locked by depression of the same predetermined key. This establishes the slices to be included in the data volume. The operator then enters the particular "3D mode" desired, i.e., the "re-slice" mode, by depressing the appropriate key on the interface (step 56).
Upon entering the re-slice mode, the operator must first select the XY-dimension and location of the data volume (step 58). This step is accomplished by manipulating a region of interest box 104 (shown in FIG. 6) which appears in a default position on the display screen 18' in response to depression of the re-slice mode key. The region of interest box 104 can be sized and translated in X and Y to encompass an imaged structure 108 which appears on the sector scan image 106. The region of interest box 104 is translated by moving the track-ball and is sized by operation of a four-sided rocker switch incorporated in the operator interface. For example, the rocker switch is programmed so that the region of interest increases in size in the Y dimension when the switch is moved downward; decreases in size in the Y dimension when the switch is moved upward; increases in size in the X dimension when the switch is moved rightward; and decreases in size in the X dimension when the switch is moved leftward.
After the data volume has been defined, the operator selects (step 60 in FIG. 5) the type of three-dimensional projection desired (minimum or maximum pixel projection, surface, composite, etc.) and presses a render key. The defined data volume is then retrieved from cine memory 16 (see FIG. 2) by the host computer 20. The host computer scans the retrieved data for duplicate frames and discards them (step 62). The host computer then calculates the inter-slice spacing for the data set (step 64). (The inter-slice spacing is assumed to be constant over the length of the data volume.) For example, the inter-slice spacing can be calculated using the adaptive speckle correlation technique disclosed in U.S. patent application Ser. No. 09/045,780 filed on Mar. 20, 1998, the disclosure of which is incorporated by reference herein.
After the inter-slice spacing has been calculated, the system enters a "volume rotate" mode, which is one of three sub-modes included in the so-called "re-slice" mode. Referring to FIG. 2, in the "volume rotate" mode, signals representing a colored (e.g., green) orientation box are generated by the graphics processor 36, arranged in XY format in the graphics display memory 34 and then sent to the video processor 14. The video processor causes a green orientation box to be displayed on display screen (step 66). At the same time the host computer performs the selected projection of the defined data volume based on the calculated inter-slice spacing (step 68). The projected three-dimensional image is sent to the XY display memory 26 and then on to the video processor 14. The projected three-dimensional image is also captured by the cine memory 16. The video processor 14 causes the projected three-dimensional image to be displayed on display screen along with the orientation box. Both the orientation box and the initial projection are oriented with the Z axis pointing into the screen, the Y axis vertical, and the X axis horizontal, i.e., the orientation box appears as a rectangle having X and Y dimensions proportional to the X and Y dimensions of the selected region of interest. The data slices are acquired along the Z axis. This is defined to be the zero angle projection.
In the "volume rotate" mode, the operator can use the track-ball to rotate the orientation box about the X and Y axes. Rotation about the Z axis is performed using a separate rotary knob on the operator interface. The orientation box follows the movement of the track-ball and rotary knob in "real-time" so that the user can orient the box as desired (step 70). The rotational position of each axis is shown on the display panel. When the position is set, the user depresses the "calculate" key (step 72), which causes the system to display a new projection of the three-dimensional data set (step 68) at the orientation indicated by the orientation box. FIG. 7 shows an exemplary projection 112 at an arbitrary angle indicated by the orientation box 110. The orientation box has a marker 114 in the lower front left corner while the back corners of the box are dashed to aid the user in distinguishing the front and back of the box. As an aid to visualization, a box 116 is overlaid on the projection 112 which matches the orientation box 110 and is depth shaded to appear to become darker as the box goes towards the "back" of the data volume. The user may reposition the orientation box 110 with the track-ball and rotary knobs and re-project as many times as desired. In addition, rotations of plus or minus 90° may be made with special keys on the operator interface.
In accordance with one preferred embodiment of the present invention, the rendering of a three-dimensional ultrasound data set is accomplished utilizing an object-order volume visualization technique where each voxel is mapped from the data space to the image space according to a projection matrix. The goal of this rendering method is to efficiently generate two-dimensional images from the three-dimensional data while minimizing artifacts.
The data volume consists of N x by N y by N z data samples, known as voxels, along the X, Y, and Z axes respectively. In the data coordinate system, voxels are assumed to be uniformly spaced one unit apart along each axis, with the origin at the center of the data volume. Since voxels in the actual data volume may not be uniformly spaced, a scaling matrix S A ! is used to account for the aspect ratio of data samples. The data samples may then be rotated by the desired angles about the X, Y, and Z axes, and projected onto the image plane using an orthographic transformation. This process can be written as:
X.sub.d, Y.sub.d, Z.sub.d ! S.sub.A ! R!= x.sub.i, y.sub.i, z.sub.i !
where X d , Y d , Z d ! is the coordinate of a voxel in data space, R! is the desired rotation matrix and x i , y i , z i ! is the image space pixel. The projection transformation S A ! R! maps Z 3 to R 3 (where the coordinates in R space are real numbers and the coordinates in Z space are integers). The z component is discarded and a floor operation (i.e., the real numbers are truncated to integers) is applied to convert R 2 to Z 2 . As this projection transformation is performed, the voxel data is processed in accordance with the selected projection technique. For example, if a maximum pixel projection technique is used, each image space pixel will store only the maximum of the set of voxel data mapped to that image space pixel by the above-described projection transformation. This process is illustrated in FIG. 8, which shows the voxel data 118 being multiplied by aspect scaling (step 120), rotated by the desired angle (step 122) and projected onto the image plane (step 124).
Using the process illustrated in FIG. 8, adjacent data samples do not necessarily project to adjacent pixels on the image plane, leading to blank spots or "holes" in the projected images. To eliminate these holes, two additional scaling steps are introduced into the projection, yielding:
X.sub.d, Y.sub.d, Z.sub.d ! S.sub.A ! R! S.sub.H ! S.sub.H.sup.-1 != x.sub.i, y.sub.i, z.sub.i !
This projection process is then decomposed into two steps:
X.sub.d, Y.sub.d, Z.sub.d ! S.sub.A ! R! S.sub.H != X.sub.t, Y.sub.t, Z.sub.t !
X.sub.t ', Y.sub.t '! S.sub.H.sup.-1 != X.sub.i, Y.sub.i !
In the first step, the data coordinate X d , Y d , Z d ! in Z 3 is mapped to the intermediate coordinate X t , Y t , Z t ! in R 3 . The z component is discarded and a floor operation is used to obtain X t ', Y t '! in Z 2 . In the second step, the inverse scaling operation is performed in two-dimensional image space.
In order to eliminate holes from the image, the scaling matrix S H ! must ensure that neighboring data samples (those that are at most one sample apart along the X, Y and Z axes in the data space) map to neighboring pixels. There are two factors that contribute to holes in the image. The first is attributable to the scaling of the sample points to account for the aspect ratio and the second is due to the rotation of the data samples. The scaling matrix S H ! eliminates the holes by scaling along the X and Y axes of the image.
The scaling factors to account for the aspect ratio are computed using the following equations:
X.sub.as =1.0/|| 1,0,0! R.sup.-1 ! S.sub.A.sup.-1 !||
Y.sub.as =1.0/|| 0,1,0! R.sup.-1 ! S.sub.A.sup.-1 !||
Z.sub.as =1.0
These scaling factors are used to define an intermediate scaling matrix S H '! which is used to compute the rotation scaling factors.
The scaling factors to correct for rotation are determined by projecting each of the four diagonal vectors in a cube, V={ 1,1,1!, -1,1,1!, -1,1,-1!, 1,1,-1!}, onto the image plane and computing the maximum separation distance along the X and Y dimensions independently:
X.sub.rs =1.0/(MAX{|| 1,0,0!· V.sub.i ! S.sub.A ! R! S.sub.H '!!||}∀V.sub.i ε V)
Y.sub.rs =1.0/(MAX{|| 0,1,0!· V.sub.i ! S.sub.A ! r! S.sub.H '!!||}∀V.sub.i ε V)
The final scaling factors used to compute S H ! are the product of the aspect and rotation scaling factors:
X.sub.s =X.sub.as X.sub.rs, Y.sub.s =Y.sub.as Y.sub.rs, Z.sub.s =1.0
These combined scaling factors are used to ensure that voxels which are one unit apart along the X, Y and Z axes in data space are mapped onto pixels that are at most one unit apart along the X and Y axes on the image plane.
If the ultrasound imaging system operator desires to see two-dimensional slices through the data volume at the current X, Y, Z rotation orientation, the operator presses the "display mode"' key (step 74 in FIG. 5) to change from the "volume rotate" mode to the "cut-plane" (reformat) mode. Referring to FIG. 9, the orientation box 110 changes color (e.g., from green to white) and a colored (e.g., green) polygon 126 appears within the orientation box (step 76) at the center of the data volume. The green color signifies that this portion within the box can be moved. The system then produces an initial representation 128 of a two-dimensional slice through the center of the data set at the current orientation (step 78).
The shape of the slice 128 matches the shape of the green polygon 126 in the orientation box 110. The operator may then use the track-ball to scroll through the data set, displaying successive two-dimensional slices of the data set at the selected orientation and position. As the track-ball is moved (step 80), the green polygon in the orientation box moves (step 82) to visually indicate the location of the slice within the data volume and a display panel is updated to show the location of the slice as a percentage of the total volume (i.e., 50% would be the center of the data volume). When the track-ball stops moving, the system checks the status of the "display mode" key (step 84). If the "display mode" key is not depressed, the display is reformatted by the host computer to show the slice through the data volume at the last slice position when the track-ball stopped moving. If the "display mode" key is depressed, the system exits the "cut plane" mode and enters the "cut plane rotate" mode.
In the "cut plane rotate" mode, the green polygon that indicates the location of the slice through the data volume turns white and the orientation box turns green (step 86), indicating that the slice is now fixed and the data volume may rotate relative to the slice. The system then displays the reformatted slice in the manner previously described (step 88). The user may now rotate the orientation box to a new X, Y, Z orientation by moving the track-ball (step 90). As the user does so, the white polygon changes shape to show the shape of the slice. When the orientation is set, the user depresses the "calculate" key (step 92), which causes the system to display a new two-dimensional slice taken at the angle indicated by the angle of the polygon relative to the orientation box. If the "display mode" key is not depressed (step 94), the operator can reorient the data volume. If the "display mode" key is depressed, the system returns to the "volume rotate" mode.
Algorithms for producing three-dimensional projections of two-dimensional data are well known, as are techniques for reformatting data to produce arbitrary slices through a data set. The projected or reformatted data is output by the host computer to the XY display memory 26 (see FIG. 2). The image frame of projected or reformatted data is then sent to the video processor 14 and captured by the cine memory 16. The video processor superimposes the orientation box and other graphical symbols onto the image frame of projected reformatted data for output to the display monitor.
The foregoing preferred embodiments have been disclosed for the purpose of illustration. Variations and modifications of the basic concept of the invention will be readily apparent to persons skilled in the art. For example, graphical symbols other than parallelograms can be used to depict a data volume and graphical symbols other than polygons can be used to depict a slice through a data volume. Nor is the user interface limited to the specific input devices (i.e., track-ball, rocker switch, rotary switch, and keys) disclosed herein. A mouse, a joystick, a lever, a slider or other input device could also be used. All such variations and modifications are intended to be encompassed by the claims set forth hereinafter. | A method and an apparatus for allowing the operator of an ultrasound imaging system to switch between two-dimensional slices and three-dimensional projections in such a way that it is easy for the operator to visualize the relationship of the two-dimensional slice to the three-dimensional anatomy. In a "volume rotate" mode, the display screen displays an orientation box along with a three-dimensional projected image generated from a defined data volume. The orientation box provides a visual indication of the shape and orientation of that defined data volume. In a "cut plane" mode, a movable polygon representing a selected two-dimensional slice is displayed inside a stationary orientation box. The polygon provides a visual indication of the orientation and position of the slice relative to the defined data volume. In a "cut plane rotate" mode, a stationary polygon representing a selected two-dimensional slice is displayed inside a rotatable orientation box. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a joint between two vehicles or vehicle parts such as an articulated bus or a railcar for example.
[0003] 2. Description of the Prior Art
[0004] Joints between two vehicles or vehicle parts, in an articulated bus for example, are notoriously well known. A central joint in the form of a buckle joint is thereby provided, its central axle being arranged in the central longitudinal axis of the vehicle. The vehicle buckles about this axle when threading a curve.
[0005] The shortcoming of the known buckle joints is that the two vehicles or vehicle parts need to be separated by a distance of approximately 1,600 mm on account of the extension of the joint. As the space the joint occupies between the two vehicles or vehicle parts is in principle of limited use only, there is an interest in minimizing the distance between the two vehicles or vehicle parts in order to possibly accommodate another row of seats in the vehicles or vehicle parts.
BRIEF SUMMARY OF THE INVENTION
[0006] The object of the invention is therefore to provide a joint, more specifically a buckle joint, that permits to reduce the distance between the two vehicles or vehicle parts that are joined together by way of said joint as compared to a conventional buckle joint.
[0007] To achieve this object and in accordance with the purpose of the invention, a first variant suggests to provide the joint with at least two joint members that are held apart from the central longitudinal axis of the vehicle and with at least one, preferably two joint arms that is/are carried so as to be capable of rotating about the two joint members. In the simplest case i.e., in an embodiment with two joint members and one joint arm, the joint arm, depending on the direction of the curve, alternatively rotates about the axle of the one or of the other joint member in a way similar to that of a swinging door. It has thereby to be made certain that the respective one of the joint members that is not in operation is fixed.
[0008] In dividing a central buckle joint into two joint members which have one pivot each and are located outside the central longitudinal axis of the vehicle i.e., to the side of the vehicle, the distance between the two vehicles or vehicle parts in the region of the joint is reduced. More specifically, the distance of heretofore 1,600 mm may be reduced to less than 1,100 mm, so that another row of seats may be arranged in one of the vehicles or vehicle parts. Another advantage is that the bellows may be shortened to about half its length due to the reduced distance between the vehicles, which is particularly advantageous with regard to cost since the central frame that serves as a stabilizing element may be dispensed with. Another advantage is that the change in the kinematics that was occasioned by the division into two joint members causes the bellows to be only slightly displaced transversely, which results in an improved durability of the bellows. From a constructional point of view, splitting the prior art central buckle joint into two joint members that are held apart from the central longitudinal axis of the vehicle causes the one or the other joint to be activated depending on the curve the vehicle has to thread. By virtue of the reduced length when traveling around a curve, the bellows bulges less, more particularly downward, because it may be of a more rigid configuration as it is only slightly displaced transversely. Inasmuch, busses with little road clearance (low-platform busses) may also be built with such a joint or bellows.
[0009] Further advantageous embodiments and features of this variant will become apparent in the subordinate claims.
[0010] In a first embodiment with two joint arms, it is for example particularly advantageous that each vehicle or vehicle part be provided with a bearing bracket, each of the bearing brackets receiving a joint arm. Said joint arm is thereby rotatably connected to the bearing bracket. To attach the joint to the vehicle by means of bearing brackets has the advantage that the joint may be inserted between the two vehicles or vehicle parts as an entity so to speak.
[0011] Furthermore, the bearing brackets are advantageously flush on the vehicles or vehicle parts i.e., they are arranged on the same height in an effort to prevent vertical moments from being brought into the vehicles or vehicle parts.
[0012] To minimize the height of the joint as a whole, the two joint arms are arranged, according to another feature, above and beneath the corresponding bearing bracket.
[0013] To prevent the joint from not being activated when the vehicle is traveling in a straight line, the two joint arms are non-rotatably linked to the corresponding bearing bracket in the joint member in the region of their respective pivot. This also means that, when threading a curve, the corresponding joint arms are alternatively rotatably linked to the one or to the other bearing bracket, stopping or locking of the respective one of the joint members depending on the curve that has to be threaded. More specifically and to prevent rotation, at least one bolt is provided for connecting at least one joint member to the respective one of the bearing brackets.
[0014] As the two joint arms are joined together, the bolt must take hold of both the one and the other joint member in order to fixate the one joint in such a manner that it cannot rotate.
[0015] According to another advantageous feature, the one bearing bracket may be linked to the vehicle or vehicle part in such a manner as to be vertically pivotal which permits the vehicle to travel through depressions or drive over hilltops.
[0016] According to a second and third embodiment, the solution in accordance with the invention is that the joint members that are held apart from the central longitudinal axis of the vehicle may be slidably received by the one vehicle or vehicle part across the central longitudinal axis of the vehicle, the two joint arms being connected by their other end to the other vehicle or vehicle part by means of a swivel joint that is arranged in the central longitudinal axis of the vehicle. This clearly shows that the buckling movement is performed in two stages. On the one hand the connection of the joint members to the other vehicle or vehicle part by means of a swivel joint arranged in the central longitudinal axis permits a certain buckling angle, preferably a buckling angle of up to 15°. If the buckling angle needs to be higher, which is for example the case when such a bus must travel around sharp curves, one of the joint members is displaced across the central longitudinal axis of the vehicle, thus enlarging the buckling angle. For, depending on the curve that is threaded, the one joint member, with a vertically oriented axle for example, that holds the one joint arm is caused to move toward the other joint member with the other joint arm. The joint arm hereby oscillates about the corresponding joint member. This means that the distance between the two vehicles or vehicle parts increases on the outer side of the curve, the extent of the increase of said distance between the two vehicles or vehicle parts being dimensioned in function of the capability of the joint member that holds the joint arm of moving toward the other joint arm. How much the distance between the two vehicles or vehicle parts increases additionally depends on the length of the joint arms.
[0017] This buckling in two stages bases on the finding that in 90% of the driving time of an articulated bus the maximum buckling angle to be realized is of only 15°. Merely exceptional cases require greater buckling angles and it was found out that buckling angles never exceed 26°. The angle of 26° also corresponds, by the way, to the maximum buckling angle of a prior art joint.
[0018] It was found that the distance between the two vehicles or vehicle parts can also be reduced from originally 1,600 mm to less than 1,100 mm by virtue of this special construction of the joint. The length of the built-in bellows only amounts to about 800 mm. As a result thereof, another row of seats may be arranged in one of the vehicles or vehicle parts.
[0019] It is well known to provide the region of the joint with a connection that permits the passage from one vehicle to the other. The connection is comprised of an intercar gangway and of a bellows that surrounds both the gangway and the joint in the manner of a tunnel.
[0020] The advantages regarding design and durability of the bellows as they have been described for the first variant apply to these variants as well. More specifically, the bellows is shortened. By virtue of the buckling kinematics, the bellows is displaced in transverse direction but slightly, which positively influences its durability. As the bellows is only slightly displaced transversely, it may be made stiffer so that it bulges less, more particularly in downward direction.
[0021] Further advantageous features of the second and third embodiments will become apparent in the subordinate claims 11 through 24.
[0022] According to a particularly advantageous feature, the respective joint members for joint arms are arranged on a cradle that is movable across the central longitudinal axis of the vehicle. The cradle is thereby advantageously arranged on a bracket guiding device, in this case more specifically on a bracket guiding device provided with a round guiding facility, said bracket guiding device being connected to the one vehicle or vehicle part. The advantage of a such type bracket guiding device with a round guiding facility is that the cradle may be received by the bracket guiding device in such a manner that it may be pivoted vertically, the joint as a whole being, as a result thereof, capable of yielding to nodding movements as they occur for example when such type articulated vehicles travel through a depression or drive over a hilltop.
[0023] A bracket for the swivel joint is provided on the other vehicle or vehicle part, said swivel joint serving to receive the joint arms in such a manner that they are pivotal.
[0024] To attenuate the motion of rotation of the joint arms about the swivel joint, an attenuating device is provided. A such type attenuating device includes at least one attenuator that is connected on the one hand to the joint arm and on the other hand to the vehicle or vehicle part or the bracket. It is the function of such an attenuator, which is preferably realized as a double acting attenuator, to for example prevent the rear vehicle part when the vehicle of concern is a so-called pusher vehicle i.e., a vehicle in which the last rear axle is driven, from swerving to the side when the vehicle is traveling in a straight line. Furthermore, the bracket or the joint arm is advantageously configured in such a manner that the attenuator plunges into the bracket or the joint arm when the joint executes a pivoting movement, the whole buckling angle being thus available.
[0025] According to another feature of the invention, an attenuating member is advantageously provided between cradle and joint arm (second embodiment). Alternatively, an attenuating member may be arranged between the joint arms or, even better, between the cradles (third embodiment). Since, in arranging one respective attenuating member between cradle and joint arm, a total of two such attenuating members is required, the embodiment with one double-acting attenuating member located between the cradles or the joint arms respectively is less expensive. The primary function of said attenuating members or member is to allow the second stage of buckling to only happen when the swivel joint has reached the 15° limit of the buckling angle, which constitutes the first stage. Up to the buckling angle of 15°, the cradles are stopped in their position by the attenuating member or members respectively. Upon reaching the buckling angle of 15°, the attenuating member or members soften; as a result thereof and in function of the curve to be threaded, the respective one of the cradles moves on the bracket guiding device toward the other cradle. Although the attenuating member or members respectively develop a certain, though small attenuating effect at a buckling angle of more than 15° as well, the major part of the attenuation is performed by that attenuator that is active, which depends on the direction of the curve. This is the attenuator that is located on the outer side of the curve.
[0026] As already described herein above, the bracket guiding device may be realized as a round guiding facility so that the cradle, which is received by the round guiding facility, is vertically pivotal. In order to alternatively be capable of yielding to such nodding movements, the bracket on the other vehicle may be designed in such a manner that it is pivotal about a horizontal axle. In such a case, the bracket guiding device for the cradle could also be fixed in vertical direction. Bracket guiding device and bracket may also concurrently form the transverse beam of the vehicle's or the vehicle part's chassis, which permits to spare weight on the one hand and costs on the other.
[0027] In order to be capable of absorbing smaller swaying movements the cradle is advantageously provided with an elastic guide bush for receipt through the round guiding facility.
[0028] According to a second variant, a joint is provided between two vehicles or between two vehicle parts, of an articulated bus or a railcar for example, said joint being provided with a pivot bearing that connects the two vehicles or vehicle parts, said vehicles or vehicle parts slidably receiving said pivot bearing across the longitudinal axis of the vehicles or vehicle parts. In exactly the same manner than with the embodiments of the first variant, this construction permits to realize a short bellows with all of the advantages that have already been described with respect to the first variant and its embodiments. The important point in this variant is again that from a certain buckling angle, namely from a buckling angle of more than 15°, the pivot point is displaced across the central longitudinal axis i.e., toward the outer side of the vehicle or of the vehicle parts respectively. That is to say, up to a buckling angle of 15° the pivot bearing operates like a normal joint and does not change its position in the central longitudinal axis of the vehicle. Not before a buckling angle of more than 15° does said pivot bearing move toward the one or the other outer side of the vehicle, depending on the curve to be threaded.
[0029] In this connection there is more specifically provided that each vehicle or vehicle part be provided with a guidance for the pivot bearing. The guidance may hereby be configured as a bracket that extends across the central longitudinal axis, said pivot bearing being provided on either side with one cradle that is slidably received by the bracket.
[0030] In order to make certain that the pivot bearing is not displaced before a buckling angle of 15° is reached, the bracket is provided with an attenuating device that is connected to the pivot bearing. This clearly shows that the attenuating device is rigid up to a buckling angle of 15° so that the pivot bearing is fixed in its position in the central longitudinal axis of the vehicle, and only softens when the buckling angle exceeds 15° so that the pivot bearing moves outward on the bracket in an effort to provide the required higher buckling angle.
[0031] In order to make certain that a vehicle fitted with such a joint is capable of driving over hilltops and traveling through depressions, there is provided that at least one bracket be arranged on the vehicle or vehicle part in such a manner that it is pivotal about a horizontal axle.
[0032] To limit the buckling angle, a stop is provided between the brackets in spaced relationship from the central longitudinal axis, said stop advantageously providing guiding functions. This means that, by virtue of its construction and more specifically with regard to the design of the stop, said joint is also capable of absorbing swaying movements. To this purpose, the stop is more specifically comprised of two arms, each arm being arranged on a respective one of the brackets and both arms being configured in the shape of a fork and being slidable into one another. Accordingly, when a vehicle fitted with a such type joint is traveling in a straight line, the two arms of the stop are guided one into the other, the outer pair of arms losing contact with each other only when the vehicle travels round a curve while the other pair of arms, namely that pair of arms that is located on the inner side of the curve, is kept in contact and is capable of absorbing swaying movements.
[0033] The subject matter of the invention also is an articulated vehicle such as an articulated bus or a railcar for example, the various vehicle parts of which are linked together by means of a joint, said joint being characterized by one or several features of the two variants or of the embodiments described herein above.
[0034] The two variants of the invention with their embodiments will become apparent from the following detailed description of the invention and accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0035] [0035]FIG. 1 is a top view of the buckle joint of a first embodiment of the first variant in a right-hand bend;
[0036] [0036]FIG. 2 shows the buckle joint according to the illustration of FIG. 1 in a left-hand bend;
[0037] [0037]FIG. 3 is a section taken along the line III-III of FIG. 1;
[0038] [0038]FIG. 4 is a section taken along the line IV-IV of FIG. 1;
[0039] [0039]FIG. 5 is a section taken along the line VI-VI of FIG. 1;
[0040] [0040]FIG. 6 shows how the axle is carried in a sleeve made from a resilient material;
[0041] [0041]FIG. 7 shows a second embodiment of the first variant of the joint in accordance with the invention when the articulated vehicle is traveling in a straight line;
[0042] [0042]FIG. 8 shows the joint of FIG. 7 at a steering angle of 15°;
[0043] [0043]FIG. 9 shows the joint of FIG. 7 at a steering angle of 15° and additionally at an oscillating angle of 11°;
[0044] [0044]FIG. 10 shows a third embodiment of the first variant of a joint when the articulated vehicle is traveling in a straight line;
[0045] [0045]FIG. 11 shows the joint of FIG. 10 at a steering angle of 15°;
[0046] [0046]FIG. 12 shows the joint of FIG. 10 at a steering angle of 15° and at an oscillating angle of 11°;
[0047] [0047]FIG. 13 shows the buckle joint of the first embodiment with two joint members but with only one joint arm;
[0048] [0048]FIG. 14 shows a second variant of a joint, when the vehicle is traveling in a straight line;
[0049] [0049]FIG. 15 shows the second variant of FIG. 14 at a buckling angle of 15°;
[0050] [0050]FIG. 16 shows the second variant at a buckling angle of 26°;
[0051] [0051]FIG. 17 is a section taken along the line XVI-XVI of FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
[0052] As can be seen from FIGS. 1 through 5, the buckle joint of the first embodiment of the first variant, indicated generally at 1 , is comprised of a first bearing bracket 10 and of a second bearing bracket 20 . Bearing bracket 10 is rigidly arranged on the vehicle part 2 , whereas bearing bracket 20 is connected to the other vehicle part 3 in such a manner that it is vertically movable, which is to say that it is connected thereto by horizontally oriented axle 4 . By virtue of this type of connection the vehicle is capable of both traveling through depressions and driving over hilltops. The bearing bracket, which is generally referred to by reference numeral 10 , is provided with a first joint member in the form of axle 11 , to which the one joint arm 12 is pivotally arranged. The second bearing bracket 20 pivotally receives the second joint arm 22 by way of the second joint member in the form of axle 21 , said axle 21 being connected not only to said joint arm 22 but also to joint arm 12 . That is to say, the two joint arms 12 and 22 are joined together through bearing bracket 20 . This furthermore clearly shows that the one bearing bracket is connected to two joint arms and that the other bearing bracket 20 is only connected to one joint arm. With respect to said bearing bracket 20 , the two joint arms are hereby arranged above and beneath said bearing bracket 20 in an effort to minimize the structural height of the joint (FIG. 5).
[0053] To prevent the joint from stretching when the vehicle is traveling in a straight line, the two joint arms 12 , 22 are secured against rotation about their respective axles 11 , 21 . Bolts 17 and 27 (FIG. 4 and FIG. 5) hereby non-rotatably link bearing bracket and joint arm or bearing bracket and the two joint arms 12 , 22 . When, as shown in FIG. 1 for example, the vehicle is traveling around a curve, joint arm 12 is free to rotate about axle 11 , while joint arm 22 is fixed about axle 21 . In a left-hand bend however, as shown in FIG. 2, bearing bracket 10 is rigidly coupled to joint arm 12 . In this case, bolt 27 does not mesh with bearing bracket 20 . Another variant for locking the joint arms is schematically shown in FIG. 2; this Fig. illustrates active or passive hydraulic members 29 that secure the various joint arms 12 , 22 against rotation by blocking the flow of oil, the principle of which has already been described herein above.
[0054] [0054]FIG. 6 shows how the pivot is carried in a sleeve 25 made from a resilient material. The nodding and swaying movements occurring during the ride may be intercepted in accordingly dimensioning the sleeve and in accordingly selecting the material. In such a case, the bearing bracket 20 might be realized as a rigid connection between buckle joint and vehicle.
[0055] The embodiment according to FIG. 13 of the first variant shows a joint arm 12 a and the two joint members 11 a , 21 a . Joint arm 12 a may hereby be pivoted alternatively about the one joint member 11 a or about the other joint member 21 , depending on the curve. It works in a way similar to that of a swinging door with two joints. Active or passive hydraulic members 29 make certain that a respective one of the joint members only is active while threading a curve. When the vehicle travels in a straight line, the two hydraulic members 29 are locked so that the joint does not stretch.
[0056] The joint generally indicated at 100 of the second embodiment of the first variant is located between the front coach 102 and the rear coach 103 , both shown in schematic form. The bracket guiding device 110 , which slidably receives the two cradles 111 and 112 across the longitudinal axis 50 , is linked to front coach 103 . The two joint arms 113 and 114 are linked to the cradles 111 and 112 by means of the joint members 111 a and 112 a that are designed as oscillating joints. Oscillating joint 111 a and 112 a more specifically comprises a vertically oriented axle about which are arranged the joint arms 113 and 114 in such a manner as to be rotatably or pivotally movable. At their other end, the joint arms 113 and 114 are joined together by way of swivel joint 120 . Said swivel joint 120 is a component part of bracket 130 which in turn is arranged on the front coach 102 . Bracket 130 is linked to front coach 102 by way of the joint bearings 135 , 136 that are each provided with a horizontally oriented axle that receives bracket 130 in such a manner that it is vertically movable, the vehicle being thus capable of traveling through depressions or of driving over hilltops. Said pivot bearing 135 , 136 is configured as a metallic rubber bearing so that the connection between the two vehicles is resilient to a certain extent.
[0057] There is furthermore provided an attenuating device 140 with the two attenuators 141 , each of these attenuators being connected to joint arm 113 , 114 on the one hand and to bracket 130 on the other hand. These attenuators 141 are configured as double acting hydraulic cylinders and finally serve to stabilize and stiffen the joint.
[0058] Attenuating members 160 in the form of hydraulic cylinders are furthermore provided, said attenuating members being arranged between cradle 111 , 112 on the one hand and joint arm 113 , 114 on the other hand. The main function of the attenuating members 160 is to keep the cradles 111 , 112 in their outer end position i.e., to prevent them from moving toward each other, up to a buckling angle of 15°. Only after the whole buckling angle of 15° has been utilized by pivoting the joint arms about swivel joint 120 , will the attenuating members 160 become so resilient that the respective one of the cradles moves toward the central longitudinal axis 50 i.e., in the direction of the other cradle, in accordance with the curve to be threaded. The corresponding attenuating member 160 hereby effects a certain small attenuation, although the main attenuation is carried out by the respective one of the attenuators 141 in accordance with the curve that is threaded.
[0059] In the embodiment according to the FIGS. 7 through 9, the bracket guiding device 110 is configured as a purely horizontal guidance for the cradles 111 and 112 . It is therefore necessary, as has already been explained herein above, that the pivot bearings 135 , 136 permit vertical movement.
[0060] The third embodiment of the first variant of the joint according to the FIGS. 10 through 12 among others differs from the second embodiment of the joint according to the FIGS. 7 through 9 in that the bracket guiding device 110 is provided with a round guiding facility for the cradles 111 , 112 so that bracket 130 may be arranged directly on front coach 103 i.e., without using pivot bearings 135 , 136 . Furthermore, in this embodiment, one attenuating member 166 is provided instead of the two attenuating members 160 , said attenuating member 166 being directly arranged between the two cradles 111 , 112 . The function of this attenuating member 166 is the same as that of the attenuating members 160 in the embodiment according to the FIGS. 7 through 9. In the two embodiments, like elements bear the same reference numerals.
[0061] The second variant is described in the FIGS. 13 through 17.
[0062] The joint, which is indicated generally at 200 , is arranged between the vehicle parts 2 and 3 . Said joint 200 has two brackets 210 , 220 , bracket 220 being arranged on the vehicle part 3 in such a manner that it is vertically pivotal about a horizontal axle 230 in an effort to make certain that the vehicle is capable of both driving over hilltops and traveling through depressions. The two brackets 210 , 220 receive the pivot bearing generally referred to by reference numeral 240 . On either side pivot bearing 240 has one respective cradle 241 and 242 , said cradles 241 and 242 being carried in the C-shaped profile of bracket 210 , 220 . Tensile and braking forces between the vehicles are transmitted by way of this pivot bearing.
[0063] The attenuating device 250 has a piston rod 251 and a cylinder 252 , cylinder 252 being fastened to cradle 242 . Attenuating device 250 may hereby be configured as an active or passive hydraulic attenuator. Piston rod 251 of said attenuating device 250 is arranged on the end side of bracket 210 , as can be surveyed from FIG. 16 for example. The arms 226 , 227 have the shape of a fork, a bolt 228 , 229 that joins the two fork elements and engages the matching fork-shaped arms 216 being provided on the front side. When traveling in a straight line (FIG. 14), the arms 216 , 217 and 226 , 227 respectively, which are arranged on the brackets to either side of the central longitudinal axis 50 of the vehicle, are joined together so that swaying movements that occur in this position between the two vehicles may be absorbed by the two arm connections. The pairs of arms hereby also serve as a stop for limiting the buckling angle.
[0064] In the position according to FIG. 15 and at an angle of approximately 15°, the arms 227 , 217 that are located on the inner side of the curve constitute the stop described above when the arms have reached their end position in gliding inside one another. If an angle of more than 15° is required (FIG. 16), the pivot bearing 240 moves in the brackets toward the inner side of the curve. In this case, the attenuating device 250 is soft, thus permitting the pivot bearing 240 to execute such a displacement. The attenuating device is hard up to a buckling angle of 15° in order to make certain that the pivot bearing remains in its position in the central longitudinal axis 50 of the vehicle. | The subject matter of the invention is a joint between two vehicles or vehicle parts such as an articulated bus or a railcar for example, the joint ( 1; 100 ) being provided with at least two joint members ( 11, 12; 11 a, 21 a; 111 a , 112 a ) that are held apart from the central longitudinal axis of the vehicle ( 2, 3; 102, 103 ) and with at least one, preferably two joint arms ( 12 a, 12, 22; 113, 114 ) that is/are carried so as to be capable of rotating about the two joint members. | 1 |
This application is a continuation-in-part of copending Bronstein U.S. patent application Ser. No. 889,823, "Method of Detecting a Substance Using Enzymatically-Induced Decomposition of Dioxetanes", filed July 24, 1986; Bronstein et al U.S. patent application Ser. No. 140,035, "Dioxetanes for Use in Assays", filed Dec. 31, 1987 and Edwards U.S. patent application Ser. No. 140,197, "Synthesis of 1,2-Dioxetanes and Intermediates Therefor", filed Dec. 31, 1987, now abandoned.
FIELD OF THE INVENTION
This invention relates to improved methods of using chemiluminescent compounds, and especially enzymatically cleavable chemiluminescent 1,2-dioxetane compounds. More particularly, this invention relates to the generation and detection of electromagnetic energy released by the decomposition of enzymatically cleavable and chemically cleavable chemiluminescent 1,2-dioxetane compounds used to determine the presence, concentration or structure of substances in a sample, especially an aqueous sample, particularly when such chemiluminescent compounds are used to detect the presence or determine the concentration of chemical or biological substances by art-recognized immunoassay techniques, chemical assays or nucleic acid probe assays, or when they a: used as direct chemical/physical probes for studying the molecular structures or microstructures of various macromolecules: synthetic polymers, proteins, nucleic acids and the like.
BACKGROUND OF THE INVENTION
The decomposition of chemiluminescent chemical compounds to release electromagnetic energy, and especially optically detectable energy--usually luminescence in the form of visible light--is well known and understood. The incorporation of such light emitting reactants in art-recognized immunoassays, chemical assays, nucleic acid probe assays and chemical/physical probe techniques as the means by which the analyte, a substance whose presence, amount or structure is being determined, is actually identified or quantified has assumed increasing importance in recent years, particularly with the advent of enzymatically-cleavable 1,2-dioxetanes; see, for example, the abovementioned copending Bronstein, Bronstein et al and Edwards applications.
SUMMARY OF THE INVENTION
The present invention is based upon the discovery that by using two or more enzymatically cleavable (decomposable) chemiluminescent 1,2-dioxetane compounds, such as those disclosed in the abovementioned copending Bronstein, Bronstein et al and Edwards applications, such compounds being configured, by means of the inclusion of a different light-emitting fluorophore moiety in each molecule, to emit light of a different wavelength from the other(s) upon decomposition [e.g., one such compound can contain a fluorophoric coumarin (benzopyranyl) residue unsubstituted except for a labile ring substituent such as a phosphate ester or acetate ester group, e.g., dispiro(adamantane-2)-3'-(1',2'-dioxetane)-4',2"-(7phosphoryloxy-3"-chromene) sodium salt; see the abovementioned copending Bronstein et al application, the other(s) a labile ring substituent-containing fluorophoric trifluoromethyl-or benzothiazolylbenzopyranyl residue], and each such compound being structured so as to be cleavable by a different enzymatic cleaving means [e.g., one such compound can contain, as mentioned above, a phosphate ester group cleavable by a phosphatase or an acetate ester group cleavable by a carboxylesterase, the other(s) can contain an α-D- or β-D-glucoside group cleavable by a glucose oxidase or a β-D-galactoside group cleavable by a β-galactosidase], light of different wavelengths can be induced simultaneously or sequentially by the decomposition of these differently configured and differently decomposable chemiluminescent compounds. Hence, multi-channel assays can be designed in which different enzymes attached to or associated with two or more different analytes will, by cleaving different enzyme cleavable dioxetane substituents, induce the emission of light of a different wavelength for each analyte being assayed.
Further, the emission of light of different wavelengths by a multiplicity of decomposable chemiluminescent compounds, e.g., in multi-channel assays, can also be accomplished by using one or more enzymatically cleavable chemiluminescent 1,2-dioxetane compounds and one or more chemically or electrochemically cleavable chemiluminescent compounds, such as the chemically cleavable analogs of the enzymatically cleavable 1,2-dioxetanes disclosed in the abovementioned Bronstein, Bronstein et al and Edwards applications which for example contain, instead of an enzyme cleavable group, a chemically cleavable group such as a hydroxyl group, an alkanoyl or aroyl ester group such as an acetoxy group, or an alkyl or aryl silyloxy group such as a t-butyldimethylsilyloxy or t-butyldiphenylsilyloxy group, together with one or more enzymes and one or more chemical cleaving means, each attached to a different substance, e.g., an analyte, to once again induce the emission of light of a different wavelength from each such decomposable chemiluminescent compound, e.g., for each analyte being assayed in a multichannel assay.
It is, therefore, an object of this invention to provide improved methods of using chemiluminescent 1,2-dioxetane compounds, and especially enzymatically cleavable chemiluminescent 1,2-dioxetane compounds.
A further object of this invention is to provide improved methods of inducing the simultaneous generation of light of different wavelengths by decomposing differently configured and differently decomposable chemiluminescent compounds, including chemiluminescent 1,2-dioxetane compounds and, in particular, enzymatically cleavable chemiluminescent 1,2-dioxetane compounds.
A still further object of this invention is to provide multi-channel assays carried out in the presence of at least two differently configured and differently decomposable chemiluminescent compounds, including chemiluminescent 1,2-dioxetane compounds and, in particular, enzymatically cleavable chemiluminescent 1,2-dioxetane compounds, as substrates, each of which compounds emits light of a different wavelength from the other(s) and each of which has a labile substituent cleavable by a different means from the other(s), to detect the presence or determine the concentration, by art-recognized immunoassay, chemical assay and nucleic acid probe assay techniques, of chemical or biological substances, and to elucidate the molecular structures or microstructures of various macromolecules: synthetic polymers, proteins, nucleic acids and the like, by art-recognized direct chemical/physical probe techniques.
These and other objects, as well as the nature, scope and utilization of this invention, will become readily apparent to those skilled in the art from the following description and the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
The enzymatically cleavable chemiluminescent 1,2-dioxetane compounds disclosed and claimed in the abovementioned Bronstein, Bronstein et al and Edwards applications can be represented by the general formula: ##STR1##
In this formula the symbol R 1 represents hydrogen, or a bond when R 2 represents a substituent bound to the dioxetane ring through a spiro linkage, or an organic substituent that does not interfere with the production of light and that satisfies the valence of the dioxetane ring carbon atom to which it is attached to result in a tetravalent dioxetane ring carbon atom, such as an alkyl, aryl, aralkyl, alkaryl, heteroalkyl, heteroaryl, cycloalkyl or cycloheteroalkyl group, e.g., a straight or branched chain alkyl group having from 1 to 7 carbon atoms, inclusive; a straight or branched chain hydroxyalkyl group having from 1 to 7 carbon atoms, inclusive, or an --OR group in which R is a C 1 -C 20 unbranched or branched, unsubstituted or substituted, saturated or unsaturated alkyl, cycloalkyl, cycloalkenyl, aryl, aralkyl or aralkenyl group, any of which may additionally be fused to R 2 such that the emitting fragment contains a lactone ring, a fused ring cycloalkyl, cycloalkenyl, aryl, aralkyl or aralkenyl group, or an N, O or S heteroatom-containing group; or a light-emitting fluorophore-forming fluorescent chromophore group bonded to the dioxetane ring through a single bond or a spiro linkage, i.e., a group capable of absorbing energy to form an excited energy state from which it emits optically detectable energy to return to its original energy state, to which an enzyme-cleavable group is bonded by a bond cleavable by an enzyme to yield an electron-rich moiety bonded to the dioxetane ring, e.g., a bond which, when cleaved, yields an oxygen anion, a sulfur anion or a nitrogen anion, and particularly an amido anion such as a sulfonamido anion. Preferably, R 1 is a methoxy group.
The symbol R 2 represents hydrogen, or a bond when R 1 represents a substituent bound to the dioxetane ring through a spiro linkage, or a light-emitting fluorophore-forming fluorescent chromophore group bonded to the dioxetane ring through a single bond or a spiro linkage, to which an enzyme-cleavable group is bonded by a bond cleavable by an enzyme to yield an electron-rich moiety bonded to the dioxetane ring, e.g., one of the aforementioned bonds which, when cleaved, yields an oxygen, sulfur or nitrogen anion.
The light-emitting fluorophore-forming fluorescent chromophore groups which can be symbolized by R 1 or R 2 can be the residues of the auxiliary fluorophores listed below, unsubstituted or substituted with one or more non-labile substituents such as a branched or straight chain alkyl group having 1 to 20 carbon atoms, inclusive, e.g., methyl, n-butyl or decyl; a branched or straight chain hetercalkyl group having 1I to 7 carbon atoms, inclusive, e.g., methoxy, hydroxyethyl or hydroxypropyl; an aryl group having 1 or 2 rings, e.g., phenyl; a heteroaryl group having 1 or 2 rings, e.g., pyrrolyl or pyrazolyl; a cycloalkyl group having 3 to 7 carbon atoms, inclusive, in the ring, e.g., cyclohexyl; a heterocycloalkyl group having 3 to 6 carbon atoms, inclusive, in the ring, e.g., dioxane; an aralkyl group having 1 or 2 rings, e.g., benzyl; an alkaryl group having 1 or 2 rings, e.g., tolyl; an electron-withdrawing group, such as a perfluoroalkyl group having between 1 and 7 carbon atoms, inclusive, e.g., trifluoromethyl; a halogen; CO 2 H, ZCO 2 H, SO 3 H, NO 2 , ZNO 2 , C.tbd.N, or ZC.tbd.N, where Z is a branched or straight chain alkyl group having 1 to 7 carbon atoms, inclusive, e.g., methyl, or an aryI group having 1 or 2 rings, e.g., phenyl; an electron-donating group, e.g., a branched or straight chain C 1 -C 7 alkoxy group, e.g., methoxy or ethoxy: an aralkoxy group having 1 or 2 rings, e.g., phenoxy; a branched or straight chain C 1 -C 7 alkoxy group, e.g., xethoxy or ethoxy; an aralkoxy group having 1 or 2 rings, e.g., phenoxy; a branched or straight chain C 1 -C 7 hydroxyalkyl group, e.g., hydroxymethyl or hydroxyethyl; a hydroxyaryl group having 1 or 2 rings, e.g., hydroxyphenyl; a branched or straight chain C 1 -C 7 alkyl ester group, e.g., acetate; an aryl ester group having 1 or 2 rings, e.g., benzoate; or a heteroaryl group having 1 or 2 rings, e.g., benzoxazole, benzthiazole, benzimidazole or benztriazole.
The symbols R 1 and R 2 , taken together, can be a fused fluorescent chromophore group bonded to the dioxetane ring through a spiro linkage, e.g., one having the general formula: ##STR2##
In this formula X is ##STR3## --O--, --S-- or --NR 6 where each of R 4 , R 5 and R 6 , independently, is hydrogen, a branched or straight chain alkyl group having 1 to 20 carbon atoms, inclusive, e.g., methyl, n-butyl or decyl, a branched or straight chain heteroalkyl group having 1 to 7 carbon atoms, inclusive, e.g., methoxy, hydroxyethyl or hydroxypropyl; an aryl group having 1 or 2 rings, e.g., phenyl; a heteroaryl group having 1 or 2 rings, e.g., pyrrolyl or pyrazolyl; a cycloalkyl group having 3 to 7 carbon atoms, inclusive, in the ring, e.g., cyclohexyl; a heterocycloalkyl group having 3 to 6 carbon atoms, inclusive, in the ring, e.g., dioxane; an aralkyl group having 1 or 2 rings, e.g., benzyl; an alkaryl group having 1 or 2 rings, e.g., tolyl; or an enzyme-cleavable group as defined above; and each R 6 , independently, can be hydrogen; an electron-withdrawing group, such as a perfluoroalkyl group having between 1 and 7 carbon atoms, inclusive, e.g., trifluoromethyl; a halogen; CO 2 H, ZCO 2 H, SO 3 H, NO 2 , ZNO 2 , C.tbd.N, or ZC.tbd.N, where Z is a branched or straight chain alkyl group having 1 to 7 carbon atoms, inclusive, e.g., methyl, or an aryl group having 1 or 2 rings, e.g., phenyl; an electron-donating group, e.g., a branched or straight chain C 1 -C 7 alkoxy group, e.g., methoxy or ethoxy; an aralkoxy group having 1 or 2 rings, e.g., phenoxy; a branched or straight chain C 1 -C 7 hydroxyalkyl group, e.g., hydroxymethyl or hydroxyethyl; a hydroxyaryl group having 1 or 2 rings, e.g., hydroxyphenyl; a branched or straight chain C 1 -C 7 alkyl ester group, e.g., acetate; or an aryl ester group having 1 or 2 rings, e.g., benzoate; a heteroaryl group having 1 or 2 rings, e.g., benzoxazole, benzthiazole, benzimidazole or benztriazole; or hydrogen or an enzyme-cleavable or chemically cleavable group Z as defined herein, with at least one of R 3 being an enzyme-cleavable group if no other substituent on the dioxetane ring is a fluorophore group having an enzyme-cleavable substituent. Furthermore, all of the R 3 groups together can form a ring which can be substituted or unsubstituted.
The symbol T represents a stablizing group that prevents the dioxetane compound from decomposing before the bond in the labile ring substituent, e.g., the enzyme-cleavable bond in an enzyme-cleavable group, on the light-emitting fluorophore-forming fluorescent chromophore group is intentionally cleaved, such as an unsubstituted or substituted cycloalkyl, aryl, including fused aryl, or heteroaryl group, e.g., an unsubstituted cycloalkyl group having from 6 to 12 ring carbon atoms, inclusive; a substituted cycloalkyl group having from 6 to 12 ring carbon atoms, inclusive, and having one or more substituents which can be an alkyl group having from 1 to 7 carbon atoms, inclusive, or a heteroatom group which can be an alkoxy group having from 1 to 12 carbon atoms, inclusive, such as methoxy or ethoxy, a substituted or unsubstituted aryloxy group, such as phenoxy or carboxyphenoxy, or an alkoxyalkyloxy group, such as methoxyethoxy or polyethyleneoxy, or a cycloalkylidene group bonded to the dioxetane ring through a spiro linkage and having from 6 to 12 carbon atoms, inclusive, or a fused polycycloalkylidene group bonded to the dioxetane ring through a spiro linkage and having two or more fused rings, each having from 5 to 12 carbon atoms, inclusive, e.g., an adamant-2-ylidene group.
One or more of the substituents R 1 , R 2 and T can also include a substituent which enhances the water solubility of the 1,2-dioxetane, such as a carboxylic acid, e.g., acetic acid; sulfonic acid, e.g., methanesulfonic acid or ethanesulfonic acid; or quaternary amino salt group, e.g., ammonium bromide, and at least one of R 1 and R 2 , and preferably R 2 , is one of the above-described light-emitting fluorophore-forming chromophore group containing an enzyme-cleavable group, and preferably an enzyme-cleavable phosphate ester group.
Included among the labile ring substituents which can be positioned on a fluorophore group to make up the fluorophore moieties of this invention are substituents which, as indicated above, are cleaved to yield an anion, e.g., an oxygen anion, a sulfur anion, or a nitrogen anion such as a sulfonamido anion. Such substituents can be chemically cleavable: a hydroxyl group, an alkanoyl or aroyl ester group, or an alkyl or aryl silyloxy group, for example, but preferably are enzymatically cleavable. Enzymatically cleavable substituents include phosphate ester groups represented by the general formula: ##STR4## wherein M+ represents a cation such as alkali metal, e.g., sodium or potassium; ammonium, or a C 1 -C 7 alkyl, aralkyl or aromatic quaternary ammonium cation, N(R 7 ) 4 + in which each R 7 can be alkyl, e.g., methyl or ethyl, aralkyl, e.g., benzyl, or form part of a heterocyclic ring system, e.g., pyridinium. The disodium salt is particularly preferred. Such quaternary ammonium cations can also be connected through one of their quaternizing groups to a polymeric backbone, viz. ##STR5## where n is greater than 1, or can be part of a polyquaternary ammonium salt.
Enzymatically cleavable substituents also include enzyme-cleavable alkanoyloxy groups, e.g., an acetate ester group, or an enzyme-cleavable oxacarboxylate group, 1-phospho-2,3diacylglyceride group, 1-thio-D-glucoside group, adenosine triphosphate analog group, adenosine diphosphate analog group, adenosine monophosphate analog group, adenosine analog group, α-D-galactoside group, β-D-galactoside group, α-D-glucoside group, β-D-glucoside group, α-D-mannoside group, β-d-mannoside group, β-D-fructofuranoside group, β-D-glucosiduronate group, p-toluenesulfonyl-L-arginine ester group or p-toluenesulfonyl-L-arginine amide group.
The improved methods of using chemiluminescent 1,2-dioxetanes of this invention are particularly useful when the dioxetanes are employed as the means of identifying or quantifying several analytes using otherwise art-recognized immunoassays, such as those hitherto employed to detect an enzyme or a member of a specific binding pair, e.g., an antigen-antibody pair or a nucleic acid paired with a probe capable of binding to all or a portion of the nucleic acid. Such assays include immunoassays used to detect a hormone such as β-chorionic gonadotropin (β-HCG), thyroid stimulating hormone (TSH), follicle stimulating hormone (FSH), luteinizing hormone (HLH) or the like, cell surface receptor assays, and nucleic acid probe assays used to detect viruses, e.g., HIV or HTLV III, herpes simplex virus (HSV), human papiloma virus (HPV), and cytomegalovirus (CMV), or bacteria, e.g., E. Coli., and histocompatibility assays; for typical assay protocols see working examples I and II, infra, as well as the abovementioned copending Bronstein and Bronstein et al applications. The improved methods of this invention can also be used in assays for chemical analytes, such as, potassium or sodium ions, or in assays for substances such as inter alia. cholesterol and glucose in which the analytes are caused to decompose, for example using an enzyme such as cholesterol oxidase or glucose oxidase, to form a substance, e.g., hydrogen peroxide, capable in combination with another reagent of causing the chemiluminescent compound to decompose.
As noted above, by using two or more chemiluminescent 1,2-dioxetanes that each emit light of a different wavelength from the others, or by using one or more of these different colored light-emitting chemiluminescent 1,2-dioxetanes with one or more other chemiluminescent compounds which emit light of yet other wavelengths, each of such compounds being structured so as to be decomposable by a different means, this invention enables multichannel assays be designed in which different cleaving means, and especially two or more different enzymes, attached to or associated with two or more different analytes will, by cleaving different cleavable dioxetane substituents, induce the emission of light of a different wavelength for each analyte being assayed.
3-(2'-Spiroadamantane)-4-(7"-acetoxy)benzo-2H-pyran-2'-yl-1,2-dioxetane [dispiro(adamantane-2)-3'-(1', 2'-dioxetane)-4', 2"-(7"-acetoxy-3"-chromene)], ##STR6## for example, when cleaved with a carboxylesterase, will emit light of 450 nm. (blue), 3-(2'-spiroadamantane)-4-(7"-phosphoryloxy-4"-trifluoromethyl)benzo-2H-pyran-2'-yl-1,2-dioxetane, ##STR7## when cleaved with an alkaline phosphatase, will emit light of 480 nm. (cyan, i.e., blue green), and 3-(2'-spiroadamantane)-4-(3" -benzothiazol 2-yl-7"-β-galactosyloxy)benzo-2H-pyran-2'-yl-1,2-dioxetane, ##STR8## when cleaved with β-galactosidase, will emit light of 515 nm. (green). A simultaneous assay for HLH, FSH and β-HCG, or any two of them, can hence be designed using these three chemiluminescent substances, or any two of them, to produce light emissions of a different color for each of the analytes.
Such an assay can, for example, be a simultaneous sandwich two antibody capture enzyme immunoassay in which a serum or urine sample containing a mixture of analytes: HLH, FSH and β-HCG, for example, or any two of them, is added to a coated matrix containing capture antibodies specific for HLH, FSH and β-HCG and incubated. Next, enzyme labeled antibodies: anti HLH labeled with β-galactosidase, anti FSH labeled with alkaline phosphatase and anti β-HCG labeled with acetylesterase, are added, followed by, e.g., a mixture of the aforementioned three chemiluminescent 1,2-dioxetane substrates: the acetoxybenzopyranyl dioxetane cleavable with acetylesterase, the phosphoryloxybenzopyranyl dioxetane cleavable with alkaline phosphatase and the β-galactosyloxybenzopyranyl dioxetane cleavable with β-galactosidase. The resulting light emissions can be detected either with three different monochromators or on black and white photographic film with three different color filters, with the intensity of the light emissions being a function of the various analyte concentrations.
A homogeneous assay using, e.g., these same three chemiluminescent 1,2-dioxetane substrates can be carried out by first adding a mixture of the analytes (Ag 1 , Ag 2 , Ag 3 ) to a mixture of specific Anti Ag 1 , Anti Ag 2 and Anti Ag 3 antibodies and small quantities of each of the three analytes bound to the three different enzymes: Ag 1 -β-galactosidase, Ag 2 -alkaline phosphatase, Ag 3 -acetylesterase, and incubating.
Since in anti Ag 1 Ag 1 -β-galactosidase, Anti Ag 2 Ag 2 -alkaline phosphatase and Anti Ag 3 Ag 3 -acetylesterase complexes the enzyme will be inactivated and hence unable to induce luminescence, only enzyme labeled antigens that are unbound will cleave the substrates to emit light. The emitted light can be detected in the same manner as in the above-described sandwich assay. Since there is a competition between native antigens and enzyme labeled antigens, the intensity of the light emitted will be a function of unbound labeled antigens, and thus will correspond to the concentrations of the analytes measured.
Light of various colors emitted when using the improved methods of this invention to identify or quantify various analytes can also be used to make a permanent record of such emissions on color photographic emulsions as well as on specially sensitized black and white high speed films. And, these improved methods can be used to achieve a matched response by detectors: charged coupled devices (CCD's) or silicor photodiodes, for example, having maximum sensitivity for a color other than blue, e.g., green or red. Further, by using chemiluminescent 1,2dioxetanes together with a light absorbing/light shifting auxiliary fluorophore/light enhancer substance which absorbs light of one wavelength and in turn emits light of a different wavelength, e.g., a phycobiliprotein (phycobiliproteins are naturally-occurring substances in which a fluorophore is bonded to a protein), such as phycocyanine or phycoallocyanine, that will absorb the green light emitted by one such substance that emits light in this region of the spectrum and reemit this light as red light, matched responses by color photographic emulsions that exhibit a poor response to blue light, a better response to green light but the best response to red light can also be achieved.
Besides the phycobiliproteins, other auxiliary fluorophores extraneous to the light-emitting fluorophores produced by the decomposition of the chemiluminescent 1,2-dioxetane compounds used in the method of this invention that will accept energy, especially light, from these light-emitting fluorophores and in turn emit detectable energy, again preferably light, can be used when practicing this invention. Among such auxiliary fluorophores that can be used, alone or in combination, are the following substances whose residues can be present in known chemiluminescent 1,2-dioxetanes, such as those disclosed in the abovementioned copending Bronstein, Bronstein et al and Edwards applications, as fluorescent chromophore groups:
anthracene and anthracene derivatives, e.g., 9,10-diphenylanthracene, 9-methylanthracene, 9-anthracene carboxaldehyde, anthrylalcohols and 9-phenylanthracene;
rhodamine and rhodamine derivatives, e.g., rhodols, tetramethyl rhodamine, tetraethyl rhodamine, diphenyldimethyl rhodamine, diphenyldiethyl rhodamine and dinaphthyl rhodamine;
fluorescein and fluorescein derivatives, e.g., 5-iodoacetamido fluorescein, 6-iodoacetamido fluorescein and fluorescein-5-maleimide;
coumarin and coumarin derivatives, e.g., 7-dialkylamino-4-methylcoumarin, 4-bromomethyl-7-methoxycoumarin and 4-bromomethyl-7-hydroxy coumarin;
erythrosin and erythrosin derivatives, e.g., hydroxy erythrosins, erythrosin-5-iodoacetamide and erythrosin-5-maleimide;
aciridine and aciridine derivatives, e.g., hydroxy aciridines and 9-methyl aciridine;
pyrene and pyrene derivatives, e.g., N-(1-pyrene) iodoacetamide, hydroxy pyrenes and 1-pyrenemethyl iodoacetate;
stilbene and stilbene derivatives, e.g., 6,6'-dibromostilbene and hydroxy stilbenes;
naphthalene and naphthalene derivatives, e.g., 5-dimethylamino naphthalene-1-sulfonic acid and hydroxy naphthalenes;
nitrobenzoxadiazoles and nitrobenzoxadiazole derivatives, e.g., hydroxy nitrobenzoxadiazoles, 4-chloro-7-nitrobenz-2-oxa-1,3-diazole, 2-(7-nitrobenz-2-oxa-1,3-diazol-4-yl) methylaminoacetaldehyde and 6-(7-nitrobenz-2-oxa-1,3-diazol-4-yl-aminohexanoic acid;
quinoline and quinoline derivatives, e.g., 6-hydroxyquinoline and 6-aminoquinoline;
acridine and acridine derivatives, e.g., N-methylacridine and N-phenylacridine;
acidoacridine and acidoacridine derivatives, e.g., 9-methylacidoacridine and hydroxy-9-methylacidoacridine;
carbazole and carbazole derivatives, e.g., N-methylcarbazole and hydroxy-N-methylcarbazole;
fluorescent cyanines, e.g., DCM (a laser dye), hydroxy cyanines, 1,6-diphenyl-1,3,5-hexatriene, 1-(4-dimethyl aminophenyl)-6-phenylhexatriene and the corresponding 1,3-butadienes;
carbocyanines and carbocyanine derivatives, e.g., phenylcarbocyanine and hydroxy carbocyanines;
pyridinium salts, e.g., 4-(4-dialkyldiaminostyryl)N-methyl pyridinium iodate and hydroxy-substituted pyridinium salts;
oxonols; and
resorofins and hydroxy resorofins.
When such auxiliary fluorophores are bonded to a chemiluminescent compound, they are preferably bonded to the portion of the chemiluminescent compound that, upon decomposition, forms a fragment containing the fluorophore portion of the chemiluminescent compound's molecule. In this way energy transfer is enhanced due to the two fluorophores being in close proximity to one another and by beneficial spatial arrangements provided by the rigidity of the microenvironment. Auxiliary fluorophores that are insoluble or partially insoluble in aqueous medium can be solubilized by first grafting them onto solubilizing molecules, e.g., water soluble oligomer or polymer molecules.
And, in all cases, enhancement of the intensity of the light emitted by decomposition of the chemiluminescent 1,2-dioxetane compounds used in the improved methods of this invention carried out in aqueous media can be achieved by the methods disclosed in the aforementioned Voyta et al application.
In order that those skilled in the art can more fully understand this invention, the following examples are set forth. These examples are given solely for purposes of illustration, and should not be considered as expressing limitations unless so set forth in the appended claims. All parts and percentages are by weight, unless otherwise stated.
EXAMPLE I
A dual channel assay for Human Chorionic Gonadotropins (β-chain), β-HCG, and Human Luteinizing Hormones, HLH, is carried out as follows:
MATERIALS
A round nylon membrane (approximately 1 inch in diameter) containing two sets of covalently immobilized capture monoclonal antibodies is used, one set for β-HCG available from Medix Biotech, Anti HCG, Cat. No. H298-01, and the second for HLH also available from Medix Biotech, Anti LH, Cat. No. L461-09. This nylon membrane is stored in a foil pouch until used.
Mouse monoclonal anti β-HCG available from Medix Biotech, Cat. No. H298-12, is conjugated with alkaline phosphatase using the glutaraldehyde coupling procedure [Voller, A., et. al., Bull, World Health Org., 53, 55 (1976)]and used as a detection antibody for β-HCG.
Mouse monoclonal anti HLH available from Medix Biotech, Cat. No. L461-03, is conjugated to carboxylesterase also using the glutaraldehyde coupling procedure referenced above, and used as a detection antibody for HLH.
The substrate buffer solution contains 0.05M carbonate, 1 mM MgCl 2 , 0.1% by weight BSA (pH=0.5) and 3-(2'spiroadamantane)-4-methoxy-4(3'-phosphoryloxy)phenyl-1,2-dioxetane disodium salt, (50 μg/ml), and 3-(2'-spiroadamantane)-4-(3"-benzothiazol-2-yl-7"-β-galactosyloxy)benzo-2H-pyran-2'-yl-1,2-dioxetane, (50 μg/ml) as the chemiluminescent substrates.
The wash buffer contains 0.05M carbonate, 1 mM MgCl 2 and 2% by weight BSA (pH=9.5).
ASSAY PROCEDURE
Five drops of a previously collected urine sample are placed onto the center of the assay membrane and allowed to soak into the membrane. Next, five drops of a solution containing β-HCG and HLH conjugated detection antibodies at a concentration of 0.01 millimolar are added to the assay membrane. The liquid is allowed to soak in for at least one minute. Six drops of the wash buffer are slowly added and allowed to soak in and drain for 30 to 60 seconds. Then, five drops of the buffer solution containing chemiluminescent substrates are added and allowed to soak in for approximately one minute.
The assay membrane is placed in a camera luminometer device equipped with pre-exposed calibration scales for β-HCG and LH.
The chemiluminescent light emission generated as a function of the enzymes, alkaline phosphatase and carboxyl esterase, is imaged through a mask containing two narrow band pass filters (approximately 1 cm in diameter). Kodak Wratten Gelatin Filter No. 115 is used to image green emission from the benzopyranyl 1,2-dioxetane substrate, and Kodak Wratten Filter No. 47B is used to isolate the blue emission from the phenyl dioxetane.
The relative levels of β-HCG and HLH present in the sample are determined by a comparison of the appropriate imaged spot brightness with relevant calibration scales.
EXAMPLE II
A three-channel analysis for Herpes Simplex Virus, (HSV), Cytomegalovirus, (CMV), and Human Papiloma Virus, (HPV) is carried out as follows:
MATERIALS
"Gene Screen Plus", a positively charged nylon membrane (Dupont NEN Products) is used for hybridization.
The following buffers are used for the assay:
HSV DNA PROBE ASSAY
Materials and Buffers
Membrane: Gene Screen Plus membrane.
Buffers: Denaturation Buffer, 0.5 M NaOH
Neutralization Buffer, 0.4 M NaH 2 PO 4 (pH=2.0)
Loading Buffer, 1 part Denaturation Buffer 1 part Neutralization Buffer
Membrane Wetting Buffer 0.4 M Tris (pH=7.5)
______________________________________Membrane Prehybridization BufferSubstance Final Concentration______________________________________0.5 ml 100 × Denhardt's 5 × solution0.5 ml 10% SDS 0.5%2.5 ML 20 × SSPE 5 ×2.0 mg denatured, 200 μg/ml sonicated salmon sperm DNAddH.sub.2 O10 ml______________________________________Membrane Hybridization BufferSubstance Final Concentration______________________________________0.5 ml 100 × Denhardt's solution 5 ×0.5 ml 10% SDS 0.5%2.5 ml 20 × SSPE 5 ×2.0 mg salmon sperm DNA 200 μg/ml2.0 ml 50% Dextran sulfate 10%-- ddH.sub.2 O10 ml______________________________________ Wash Buffer I______________________________________ 1 × SSPE/0.1% SDS 20 ml 20 × SSPE 4 ml 10% SDS 376 ml ddH.sub.2 O 400 ml______________________________________ Wash Buffer II______________________________________ 0.1 × SSPE/0.1% SDS preheated to wash temperature indicated on Technical Data Sheet. 2 ml 20 × SSPE 4 ml 20% SDS 394 ml ddh.sub.2 O 400 ml (heated)______________________________________ Wash Buffer III______________________________________ 0.1 × SSPE/0.1% SDS 2 ml 20 × SSPE 4 ml 10% SDS 394 ml ddH.sub.O 400 ml______________________________________ Wash Buffer IV______________________________________ 3 mM Tris-HC1 (pH 9.5) 0.6 ml 1 M Trizma Base 199.4 ml ddH.sub.2 O 200.0 ml______________________________________ Wash Buffer V______________________________________ 0.1 M Trizma HC1 pH 6.0 100 × Denhart's solution______________________________________
Preparation of 100 X Denhart's solution (for 100 mls)
Polyvinylpyrrolidone (2 g; mol. wt. 40 K; PVP-40) and 2 g ficoll are dissolved at a temperature greater than 65° C. but less than boiling. The solution is cooled to approximately 40° C., 2 g BSA are added and the solution is brought up to the final volume of 100 ml with ddH 2 O, aliquoted and stored at -20° C. BSA is easily denatured and in combination with PVP and ficoll it will not go into solution at all if it is not cooled down to -40° C. Hence, the solution is not heated over 40° C. when thawing for use.
______________________________________Preparation of 20 × SSC solution______________________________________20 × SSC (for 100 ml)3.0 M Sodium Chloride 17.4 g0.3 M Sodium Citrate 8.8 g______________________________________
The volume is brought to 100 ml and the solution filtered through a 0.45 μm nitrocellulose filter and stored at room temperature.
Preparation of 20 X SSPE solution
20 X SSPE pH 7.4 (for 1 liter)
3.6 M NaCI
200 mM Sodium phosphate 23 g dibasic, 5.92g monobasic
20 mM EDTA 7.44 g
These materials are dissolved, adjusted to pH 7.4 with 5N NaOH, brought to a volume of 1 liter and the solution is then filtered through a 0.45 μm nitrocellulose filter.
______________________________________1 × TE______________________________________1 × TE buffer 10 mM Tris (pH 7.) 1 mM EDTA Autoclave______________________________________
The substrate buffer solution contains 0.05M carbonate, 1 mM MgCl 2 , 0.1% by weight BSA (Ph=9.5) and 3-(2'-spiroadamantane)-4-methoxy-4-(3-acetoxy)phenyl-1,2-dioxetane disodium salt (50 mg/ml), 3-(2'-spiroadamantane)-4-(7"-phosphoryloxy-4"-trifluoromethyl)benzo-2H-pyran-2'-yl-1,2-dioxetane, (50 mg/ml) and 3-(2'-spiroadamantane)-4-(3"-benzothiazol-2-yl-7"-β-galactosyloxy)benzo-2H-pyran-2'-yl-1,2-dioxetane (50 mg/ml) as the chemiluminescent substrates.
ASSAY PROCEDURE
Samples (50 μl) containing DNA are denatured by incubation for 10 minutes at room temperature in 200 μl of Denaturation Buffer. Ice cold Neutralization Buffer (250 μl) is then added, and the samples placed on ice.
Nylon membrane is soaked for 15 minutes in Wetting Buffer and then inserted into a vacuum manifold device producing 2 cm diameter spots. Loading Buffer, (200 μl) is then aspirated through each well. The denatured DNA samples are then added to each well and aspirated through the membrane. The manifold is then disassembled and the DNA fixed to the membrane using a UV Transilluminator for 5 minutes. The membrane is then incubated in Prehybridization Buffer at 70° C. for 1 hour.
Dots of membrane from the region to which the sample DNA is applied are punched out and inserted into tubes for the remaining steps of the assay. The following enzyme labeled probes are used: probe for HSV labeled with alkaline phosphatase; probe for HPV labeled with β-galactosidase; probe for CMV labeled with carboxylesterase.
The enzyme labeled probes (50 n of each probe in 200 μl of Hybridization Buffer per tube) are added to each tube and incubated for 2 hours at 70° C. The Hybridization Buffer is removed and 400 μl of Wash Buffer I added and the tubes agitated for 10 minutes at room temperature. Washing is continued by first washing with 400 μl of Wash Buffer II at 50° C. for 30 minutes; then with 400 μl of Wash Buffer III at room temperature for 10 minutes; and then with 200 μl of Wash Buffer IV at room temperature.
The membrane is subsequently rinsed with Wash Buffer V at pH 6.0 and placed on a piece of transparent Mylar polyester film. Then, 200 μl of the Substrate Buffer is added and allowed to soak in.
The assay membrane is placed in a camera luminometer device equipped with pre-exposed calibration scales for HSV, HPV and CMV.
The chemiluminescent light emission generated as a function of the enzymes--alkaline phosphatase, carboxyl esterase and β-galactosidase --is imaged through a mask containing three narrow bandpass Kodak Wrattan gelatin filters (approximately 1 cm in diameter), which isolate the blue emission from the phenyl phosphate dioxetane, the cyan emission from the phosphoryloxytrifluoromethylbenzopyranyl dioxetane and the green emnission from the galactosyloxybenzopyraryl dioxetane, respectively.
The relative levels of HSV, HPV and CMV present in the sample are determined by a comparison of the appropriate image brightness with the relevant calibration scale.
The above discussion of this invention is directed primarily to preferred embodiments and practices thereof. It will be readily apparent to those skilled in the art that further changes and modifications in the actual implementation of the concepts described herein can easily be made without departing from the spirit and scope of the invention as defined by the following claims. | Processes are disclosed in which light of different wavelengths is simultaneously released from two or more enzymatically decomposable chemiluminescent 1,2-dioxetane compounds, said compounds being configured, by means of the inclusion of a different light emitting fluorophore in each of them, to each emit light of said different wavelengths, by decomposing each of said compounds by means of a different enzyme. Such processes can be used in multi-channel assays--immunoassays, chemical assays and nucleic acid probe assays--to detect the presence or determine the concentration of chemical or biological substances, and in multi-channel chemical/physical probe procedures for studying the microstructures of macromolecules. | 2 |
FIELD OF THE INVENTION
The present invention relates to splitting the flow of a spin solution through a spinneret assembly to increase web uniformity at increased flow rates. In particular, the invention relates to an improved apparatus and method for making spunbonded polyolefin sheets wherein the solution flow is split into a plurality of individual streams such that the resulting flashspun plexifilamentary film-fibrils are laid down side by side into a uniform sheet.
BACKGROUND OF THE INVENTION
Many processes are known wherein fibers from a plurality of positions are deposited and intermingled on the surface of a moving collection surface to form a wide nonwoven sheet. For instance, U.S. Pat. No. 3,402,227 (Knee) discloses a plurality of single orifice jets positioned above a receiver and spaced in a line that makes an angle with the direction of receiver movement so that the fiber streams that issue from the jets deposit fibers on discrete areas of the receiver to form ribbons which combine with ribbons formed from other streams along the line.
Several methods are known for directing the fibers from a plurality of positions to various locations across the width of the collection surface. For example, U.S. Pat. No. 3,169,899 (Steuber) discloses the use of curved oscillating baffles for spreading flashspun plexifilamentary strands while oscillating and directing them to a moving collection surface. Processes for flash-spinning plexifilamentary strands from a polymer spin solution are disclosed in U.S. Pat. Nos. 3,081,519 (Blades et al.) and 3,227,794 (Anderson et al.).
An efficient and improved method for depositing fibers onto the surface of a moving collection surface is disclosed in U.S. Pat. No. 3,497,918 (Pollock et al.). In a preferred embodiment of Pollock et al., plexifilamentary strands are flashspun and forwarded in a generally horizontal direction into contact with the surface of a rotating-lobed baffle. The baffle deflects the strand and accompanying expanded solvent gas downward into a generally vertical plane. Simultaneously, the baffle spreads the strands into a wide, thin web and causes the web to oscillate as it descends toward the collection surface. An electrostatic charge is imparted to the web during its descent to the collection surface. The web is then deposited as a wide swath on the surface of the collection surface. To make a wide sheet, numerous flash-spinning units of this type are employed. The units are positioned above the moving collection surface so that the deposited swaths form ribbons which partially overlap and combine to form a multi-layered sheet.
U.S. Pat. No. 4,537,733 (Farago) suggests that a multi-position apparatus of the type described in Pollock et al. be operated with the frequency of oscillation of the fiber streams varying by more than ±5%, but less than ±50% of the average oscillation frequency, in order to eliminate gage bands in the resulting nonwoven sheet. Gage bands do not necessarily produce a visual defect in the flat sheet itself, but are usually noticeable when a large roll is formed from the nonwoven sheet. The method of Farago and the apparatus of Pollock et al. have been modestly successful in reducing gage bands in the commercial production of wide nonwoven sheets prepared from flash-spun plexifilamentary strands. Such sheets are commercially available from E. I. du Pont de Nemours and Company under the trademark Tyvek® spunbonded polyolefin.
However, the utility of the nonwoven sheets could further be enhanced by improvements in sheet uniformity and appearance, particularly with regard to reducing the frequency and size of an undesired effect, referred to herein as "ropiness". Ropiness exhibits itself as agglomerated groups of fibers or fibrils that look like strings on the surface or within an otherwise uniform sheet. Ropes occur when a web becomes twisted or collapses on itself. Ropiness is especially apparent when viewed with a light source provided behind the sheet. Such nonuniformities often measure as much as 30 cm long and 1 cm wide and detract from the utility of the sheet, especially in end-uses that require printing on the sheet. The problems of ropiness and overall sheet quality become worse when the flow rate of the spin solution from individual spin positions is increased. This occurs since handling becomes inherently more difficult with larger and coarser webs. As flow rates are increased, the gas streams conveying the swaths interact more turbulently with each other and cause the uniformity of the resulting sheet to decrease.
Clearly, what is needed is an apparatus and method for economically maintaining or improving the uniformity of a nonwoven sheet as the flow rate of the spin solution from individual spin positions is increased. It is therefore an object of the present invention to provide an apparatus and method for making nonwoven sheets having less ropiness and improved uniformity at relatively high individual spin position flow rates. Other objects and advantages of the present invention will become apparent to those skilled in the art upon reference to the attached drawings and to the detailed description of the invention which hereinafter follows.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided an apparatus and method for splitting the solution flow of a spin mixture used in a standard flash spinning process for making nonwoven sheets. In one aspect, the invention comprises an improvement in a flash-extrusion apparatus of the type for flash-spinning a polymer solution, which apparatus includes a spinneret assembly having a spinning orifice and a let-down chamber for lowering the pressure of the solution upon flow therethrough prior to discharge through the spinning orifice. The improvement comprises a coarse mesh screen positioned within the let-down chamber to split the flow of the solution into a plurality of individual streams prior to discharge through the spinning orifice. Preferably, the apparatus comprises a 4-20 mesh screen that is positioned within the pressure let-down chamber of the general type disclosed in FIG. 2 of U.S. Pat. No. 3,227,794 (Anderson et al.). In this preferred embodiment, each opening in the screen produces an individual web. Since the webs are smaller in total area, they have less tendency to form ropes. The resulting flash-spun plexifilamentary film-fibrils are laid down side by side into a uniform sheet, even as the solution flow rate from individual spin positions is increased. Preferably, the solution flow rate is between 85 to 200 lb/hr.
In yet another aspect, the invention comprises an improved process for the flash spinning of fibrillated plexifilamentary material by the steps of continuously supplying, under pressure into a dissolution zone, a solution of synthetic crystallizable, organic polymer of filament-forming molecular weight and a solvent for the polymer, the concentration of polymer being 2 to 20% by weight of the solution, dissolving the polymer and forming a polymer solution having a temperature of at least the solvent critical temperature minus 45° C. and a pressure above the two-liquid-phase boundary for the solution, forwarding the solution through a transfer zone, passing the solution into a pressure let-down zone for lowering the pressure of the solution to below the two-liquid-phase pressure boundary for the solution, and discharging the solution through a spinneret orifice of restricted size to an area of substantially atmospheric pressure and temperature. The improvement comprises splitting the solution flow into a plurality of individual streams within the let-down zone before the solution is discharged to the area of substantially atmospheric pressure and temperature.
Due to the unique nature of the polymer spin solution used in flash-spinning operations (i.e., a two-phase dispersion), the solution will remain divided after it has passed through the screen and through the orifice. This is surprising since most liquids will not continue to flow as individual streams in a common channel after they have been divided. The two-phase dispersion will "remember the division" because of the large difference in viscosity between the continuous solution phase and the low viscosity solvent phase. Due to the viscosity difference, any obstruction or shear forces in the flow path will lead to the coalescence of the low viscosity phase forming a number of streams that do not get mixed in the downstream flow path. As a result, the divided structure is retained during the flow through the let-down chamber and through the spinneret orifice. The plexifilamentary film-fibrils produced outwardly appear to be large, as in conventional flash spinning, but actually have a fine divided structure that produces uniform webs with less tendency to form ropes or other agglomerates.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood with reference to the following figures:
FIG. 1 is a schematic cross-sectional view of the arrangement of various elements of an apparatus that can be used with the present invention and is similar to FIG. 1 of U.S. Pat. No. 4,148,595 (Bednarz).
FIG. 2 is a cross-sectional view of a nozzle attached to the exit portion of a flash-extrusion spinneret assembly similar to that disclosed in FIG. 5 of U.S. Pat. No. 3,484,899 (Smith).
FIG. 3 is a cross-sectional view of a spinneret assembly having a pressure let-down chamber containing a coarse mesh screen in accordance with the invention.
FIG. 4 is a cross-sectional view of the let-down chamber of FIG. 3 showing the coarse mesh screen in greater detail within the let-down zone.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures, wherein like reference numerals represent like elements, FIG. 1 shows a general flash-extrusion apparatus similar to that disclosed in U.S. Pat. No. 4,148,595 (Bednarz). As shown in Bednarz and in FIG. 1 herein, the apparatus generally includes a spinneret assembly 1, positioned opposite a rotable baffle 8, an aerodynamic shield comprised of members 13, 17 and 18 located below the baffle and including corona discharge needles 14 and target plate 13, and a collection surface 9 below the aerodynamic shield. A more detailed description is found in Bednarz at column 1, line 67 through column 2, line 34 and in U.S. Pat. No. 3,860,369 (Brethauer et al.) at column 3, line 41 through column 4, line 63, the contents of which are incorporated herein.
FIG. 2 is an enlarged cross-sectional view of a portion of the horizontal spinneret assembly similar to that depicted in FIG. 5 of U.S. Pat. No. 3,484,899 (Smith) and described in column 4, lines 57 through 75 of that patent, but differing primarily by the inclusion of an exit insert 63 which has a flared tunnel 62 located therein. The flared tunnel 62 is the subject of U.S. Pat. No. 4,352,650 (Marshall), the contents of which are incorporated herein. A converging pressure let-down chamber 57 is located in the spinneret body 53 of the horizontal spinneret assembly. If one follows from right to left in FIG. 2, thereby following the direction of extrusion in the apparatus, one finds let-down chamber 57 leading through orifice-approach insert 60 to disc 61 which contains orifice 50, then to exit insert 63 containing flared tunnel 62. Inserts 60 and 63 are fastened to spinneret body 53 by means of threads in tapered nose piece 65. Gasket 66 and O-ring 67 prevent leakage.
FIG. 3 shows a simplified view of the spinneret body 53 and the converging let-down chamber 57 of FIG. 2. In this figure, a coarse mesh screen 72, preferably 4-20 mesh, is positioned within the pressure let-down chamber 57, before the spin solution is discharged through the orifice 50. The spin solution enters the spinneret body 53 through constriction 74 and passes to the pressure let-down chamber 57. The flow is split by screen 72 into numerous individual streams. The number of streams produced is directly dependent on the number of openings in the screen. Screen 72 is positioned so that it extends across the entire inner diameter of let-down chamber 57 and so that it is supported on the annular shelf created at the junction point 68 where the let-down chamber 57 begins to converge towards orifice 50. In this manner, all of the spin solution passes through screen 72. It will be understood that the screen may also be supported within the let-down chamber 57 by other securing means (e.g., slots or grooves within the chamber wall). The let-down chamber 57 converges more sharply towards orifice 50 at junction point 69.
As noted above, the invention lies in the recognition that the two-phase dispersion will remain divided after the shear forces created by the screen have been applied. The divided streams flow side by side as separate streams through the remainder of the let-down chamber and through the orifice 50. The polymer is, in effect, surrounded by the solvent as it travels from the screen 72 towards the orifice 50. As noted before, this is caused by the so-called "memory of the dispersion" where the polymer and solvent remain disperse in laminar flow profiles. As the individual streams are extruded through the orifice 50, the "split personality" of the streams continues so that the plexifilamentary strands that are formed lay down side-by-side on the collection surface 9 in a very uniform manner. It is to be noted that no such division will occur with any other type of spinning solution (i.e, when a two-phase dispersion is not present).
FIG. 4 is a cross-sectional view of FIG. 3 showing screen 72 in greater detail within the let-down chamber 57 of spinneret body 53. Screen 72 is supported at junction point 68 within let-down chamber 57. Each opening in screen 72 produces an individual spin solution stream that is extruded downstream through orifice 50.
EXAMPLES
The invention will be further described by reference to the following non-limiting examples. In these examples, swath analysis for ropes and split webs is determined by the following procedure:
(1) A one yard sample of a sheet is laid out on a large inspection table. The top side and bottom side of the sheet are noted. Weights are placed on the sheet to secure the sheet while swath analysis is performed;
(2) On the top side of the sheet, an individual swath is carefully pulled away from the sheet. The swath's appearance is observed and the following characteristics are noted and recorded:
(a) the number of small, medium or large ropes that have collapsed or become twisted yarn bundles;
(b) the number of split webs (i.e., openings in the web larger than 1 inch). It is noted if these are large (i.e, more than 6 inches in length);
(c) the number of folds which are large collapsed but not twisted web structures; and
(d) the number of stringy webs having broken web filaments that are not part of the continuous web;
(3) Another individual swath is carefully pulled away from the others and observed as noted above. This is continued for successive swaths across the sheet until the opposite edge of the sheet is reached. The rest of the sheet is cut off as edge trim; and
(4) The sheet is turned over on the inspection table so that the bottom is exposed. The same analysis as set forth in steps 2 and 3 above is performed on the bottom of the sheet.
EXAMPLE 1
The inventive apparatus of FIG. 3 (i.e., a coarse mesh screen) was used in the standard process of U.S. Pat. No. 4,352,650 (Marshall) to produce a nonwoven sheet having a basis weight of 2.0 oz/yd 2 . The solvent used was trichlorofluoromethane and the polymer was polyethylene. The flow rate of the spin solution was maintained at about 150 lb/hr. In this example, a 12 mesh screen fabricated from 314 stainless steel was positioned in the pressure let-down chamber of the standard apparatus and process of U.S. Pat. No. 3,227,794 (Anderson et al.). A swath analysis was performed to indicate the number of ropes within the resulting nonwoven sheet. AS a comparison, a 2.0 oz/yd 2 nonwoven sheet was also produced using the standard process of Anderson et al., except without the aid of the applicant's inventive screen. Swath widths were about the same for both sheets. The comparison sheet is characterized as the "Prior Art Sheet". The results are summarized in Table I as follows:
TABLE I______________________________________Type of Rope Inventive Sheet Prior Art Sheet______________________________________None or small 48 40Medium 0 11Heavy 0 0Folds 0 16______________________________________
EXAMPLE 2
Example 1 was repeated except that a 3.3 oz/yd 2 nonwoven sheet was made with and without the benefit of the applicant's inventive screen. The results are summarized in Table II and generally indicate that ropes and folds are not as prevalent in higher basis weight sheets.
TABLE II______________________________________Type of Rope Inventive Sheet Prior Art Sheet______________________________________None or small 12 10Medium 3 5Heavy 0 1Folds 0 2______________________________________
The swaths made from the inventive apparatus appeared to be finer and freer from defects than the swaths made from the prior art comparisons, but there was a slight tendency for more split webs to be produced. However, the split webs appeared to be of good quality, the split was only intermittent and the increase did not affect sheet uniformity. The sheets made by the inventive apparatus and method had an overall quality heretofore only attainable when the spin solution was run at flow rates about one half of the flow rate used in the Examples (e.g., 85 lbs/hr). The number of split webs are summarized in Table III for the swaths made in Examples 1 and 2.
TABLE III______________________________________Split Webs w/screen w/o screen w/screen w/o screen (2.0 oz/yd.sup.2) (3.3 oz/yd.sup.2)______________________________________Small 20 36 8 8Medium 24 10 4 4Large 2 6 3 3Extra Large 2 0 0 0______________________________________
An added benefit of the invention is that there is an increase in spinneret assembly life when using the applicant's inventive screen. It has been discovered that the average inventive test assembly life was about 5 days versus the standard commercial assembly life of about 4 days.
Although particular embodiments of the present invention have been described in the foregoing description, it will be understood by those skilled in the art that the invention is capable of numerous modifications, substitutions and rearrangements without departing from the spirit or essential attributes of the invention. Reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | A method for splitting the flow of a spin solution in a standard flash spinning process to increase sheet uniformity at increased flow rates. In one embodiment, the apparatus comprises a coarse mesh screen that is positioned within the pressure let-down zone of the spinneret assembly. The screen divides the solution flow into numerous individual sheet uniformity compared to sheets formed without the screen and at the same flow rate. The method produces nonwoven sheets having less ropiness and improved uniformity at relatively high solution flow rates. | 3 |
BACKGROUND
The present invention is related to a decorative cover for a tombstone. More particularly, the present invention is related to a cover for adorning a tombstone with a decorative symbol or message which does not obscure the information thereon.
Graveside markers have been used throughout most of recorded history. They range from simple markers with no indicia to very large ornate stones with information such as the name of the deceased, birth and death dates, favorite sayings or verses, decorative images and the like. As is well known the marker, also referred to as a tombstone, is not easily altered and certainly not intended to be altered. Alterations require a very elaborate process and typically the only time a grave marker is altered is upon the occasion of the death of a spouse or an individual sharing the stone over common graves.
Loved ones have long felt an emotional desire to adorn gravesites and tombstones with materials indicative of a season or special occasion. There is currently no way to easily adorn a tombstone for such occasions. There are teachings of covers which can contain images yet these obscure the markings on the tombstone which defeats the purpose of the stone. There has been a long felt need for a decorative tombstone cover which can be placed on a tombstone for a special occasion and removed without permanently altering the stone or obscuring the information permanently etched or printed thereon.
SUMMARY
It is an object of the present invention to provide a decorative tombstone cover which can be adorned with images and which does not block the information on the tombstone.
It is another object of the present invention to provide a decorative tombstone cover which has a cinch system to prohibit the cover from being dislodged by wind.
These and other advantages, as will be realized, are provided in a cover for a tombstone having a member made from a flexible material adapted for disposal over the tombstone wherein the member has a cinch. The member also has a front; a top; opposing sides; and a back. At least 50 percent of a height of the tombstone remains uncovered by the member.
Yet another embodiment is provided in a covered tombstone. Provided is a tombstone and a cover. The cover has a front, a top, a strap attached to the front and circumferentially around the tombstone and at least one vertical strap between the strap and the top. At least 50 percent of a height of the tombstone remains uncovered by the member.
Yet another embodiment is provided in a cover for a tombstone. The cover has a member made from a flexible material adapted for disposal over the tombstone wherein the member further comprises a cinch. The member has a front, top, opposing sides a back. A cinch is integral to the member wherein the cinch contracts a portion of the member inward toward the tombstone and wherein the cinch comprises at least one element selected from the group consisting of an elastic element and a clasp.
BRIEF DESCRIPTION OF FIGURES
FIG. 1 is a schematic front perspective view of an embodiment of the present invention.
FIG. 2 is a rear view of an embodiment of the present invention.
FIG. 3 is a partial schematic view of an embodiment of the present invention.
FIG. 4 is a schematic front perspective view of another embodiment of the present invention.
FIG. 5 is a rear view of another embodiment of the present invention.
DETAILED DESCRIPTION
The present invention is directed to a decorative tombstone cover which does not obscure the markings permanently etched therein. More specifically, the present invention is directed to a rectangular standing tombstone. The invention will be described with reference to the figures forming an integral portion of the present disclosure. Throughout the various figures common elements will be numbered accordingly.
An embodiment of the present invention is illustrated in FIG. 1 . In FIG. 1 , the tombstone, 1 , is a typically a monolith type structure such as a rectangle, an arch, or an ornate design. The shape of the tombstone is not particularly limited herein. The tombstone typically has images etched therein or painted thereon to indicate the name of the deceased, birth date, date of death, and other indications commemorating the life of the deceased or some aspect thereof.
The inventive cover, 2 , encases the top portion of the tombstone only. It is most preferred that at least 50 percent of the height of the face of the tombstone remains uncovered as measured from the base, 3 , to the highest covered extent, 4 . More preferably at least 75% of the height of the tombstone remains uncovered and even more preferably at least 80% of the height of the tombstone remains uncovered. If more than 95% of the height of the tombstone remains uncovered there is insufficient contact between the cover and the tombstone thereby making it difficult for the cover to remain in place.
A cinch, 5 , preferably at the lowest extent of the inventive cover, draws in against the tombstone thereby securing the cover by resistance fit. It is preferred that the cover be substantially shaped like the top of the tombstone and bound by five sides including a front, 6 , two sides, 7 , top, 8 , and back, 9 . It is most preferable to include an image on at least the front such as Merry Christmas, Happy Easter, Happy Birthday, or any other message or image suitable for the occasion and desires of the person placing the cover over the tombstone. Messages may also be on the top, sides or back if so desired.
A schematic rear view of the embodiment of FIG. 1 is illustrated in FIG. 2 . In FIG. 2 , the cinch, 5 , comprises an elastic member, 10 , in a recess, 11 , of the back, 9 . The recess allows the cinch to be pulled tight on the tombstone by the elastic member without buckling of the tombstone cover. It is preferred that the cinch, and associated elastic member, completely circle the tombstone but this is not necessary to demonstrate the present invention.
Another embodiment of the present invention is illustrated in partial cutaway schematic view in FIG. 3 . In FIG. 3 the cinch comprises mating clasp which can be fastened together. A band, 14 , preferably an adjustable band, can be pulled tight thereby securing the cover to the tombstone.
Another embodiment of the present invention is illustrated in front perspective schematic view in FIG. 4 . and rear view in FIG. 5 . The cover comprises a top, 40 , and front, 41 , as described above. The sides and back are formed by circumferential straps, 42 , and vertical straps, 43 . With this embodiment the sides and back of the tombstone are not obscured except for the strap portion which is a small percentage of the surface area. It would be apparent that the cover could be rotated such that the front is on the rear of the tombstone and the front has only a circumferential strap there across. The circumferential strap, or vertical straps, may be elastic or they may have an optional clasp, 44 , which is fastened and the strap tightened.
The material of construction is preferably an opaque material which withstands environmental conditions, is flexible and which can be easily printed. A particularly preferred material is canvas due to the cost, availability, ease of printing and simplicity in preparation and particularly canvas which is treated to resist moisture.
The straps are most preferably an elastic strap or a woven strap. Both types are readily available from commercial sources.
The clasp is not particularly limited herein. Particularly preferred clasp include belt and buckle assemblies, snap insert assemblies, hoop and latch (VELCRO™) assemblies and the like.
The present invention is particularly advantageous since it does not interfere with the efforts of a grounds keeper. Flowers and other grave side adornments are prone to being blown about the property and have to be moved for mowing and the like. With the present invention the adornment is removed from the grass and remains on the tombstone thereby eliminating the necessity to relocate the adornment due to dislodgement or ground keeping activities.
The present invention has been described with particular reference to the preferred embodiments without limit thereto. One of skill in the art would readily realize additional embodiments which are not disclosed but which are within the meets and bounds of the invention as more specifically set forth in the claims appended hereto. | A tombstone cover is described for the display of indicia. The cover has a member made from a flexible material adapted for disposal over the tombstone and a cinch. The member also has a front; a top; opposing sides; and a back. At least 50 percent of a height of the tombstone remains uncovered by the member. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel process for producing α, β-unsaturated aldehydes including industrial important fragrances such as citral and sinensal, starting materials for preparing pharmaceutical drugs such as senecioaldehyde, farnesal, and 8-acetoxy-2,6-dimethyl-2,6-octadienal, and the like.
Previously, there is generally known a process which comprises oxidizing allylic alcohols in the presence of an aluminum alkoxide catalyst to obtain the corresponding α, β-unsaturated aldehydes (refer to Organic Reactions, Vol. 6, Chapter 5, U.S. Pat. No. 4,663,488 (1987), and Japanese Patent Laid-open No. SHO 51 (1976)-141,801).
Also there is known a process which comprises reacting formic acid esters of secondary alcohols with cyclohexanone in large excess in the presence of aluminum alkoxide in a large amount under reflux by heating to obtain the corresponding ketones (refer to J. Am. Chem. Soc., Vol. 78, 816 (1956)).
2. Description of the Related Art
Formic acid esters of allylic alcohols can be readily prepared, for example, according to a process which comprises chlorination of double bond, or a process which comprises reacting sodium formate to allyl chlorides obtained by hydrochloric acid-addition reaction of a diene compound such as isoprene, myrcene, and the like (refer to Japanese Patent Laid-open No. SHO 63(1988)-227,546).
The process of preparing α, β-unsaturated aldehydes from formic acid esters of allylic alcohols comprises hydrolyzing the esters to the corresponding allylic type alcohols, and thereafter oxidizing the obtained allylic type alcohols. But this process has a long reaction sequence and therefore has been desired to be simplified.
Furthermore, the successful application of the well-known oxidizing process for formic acid esters in the presence of an aluminum alkoxide catalyst to prepare α, β-unsaturated aldehydes from formic acid esters of allylic type alcohols known as relatively high reactivity is difficult to obtain the objective α, β-unsaturated aldehydes in high yield because of the active side reactions including the self-condensation of produced α, β-unsaturated aldehydes etc. for its severe reaction conditions.
The object of the invention is to provide a process for producing α, β-unsaturated aldehydes, directly and in high yield, from readily available industrial starting materials such as formic acid esters of allylic type alcohols, dissolving the aforementioned problems.
SUMMARY OF THE INVENTION
According to the invention, the above object can be achieved by a process for producing α, β-unsaturated aldehydes of the general formula (I), ##STR1## wherein R 1 and R 2 are independently a hydrogen atom or a lower alkyl group, and R 3 is a hydrogen atom, an alkyl group, an alkenyl group, an alkadienyl group or an alkatrienyl group without having a cumulative double bond, an aralkyl group, an aryl group with or without being substituted at the ring, a hetero-aromatic group; or the aforementioned alkyl group, alkenyl group, alkadienyl group or alkatrienyl group or the alkyl group of aralkyl group being mono-substituted by a lower alkanoyloxy group, an arylcarbonyloxy group, a lower alkoxy group or an aralkyloxy group with or without being substituted at a position on the ring: R 1 and R 3 integrated with their respectively bonding carbon atoms form a 1-cycloalkenyl group with or without being substituted, and R 2 has the same meaning as defined above: or R 2 and R 3 integrated with their respectively bonding carbon atoms form a cycloalkylidene group, and R 1 has the same meaning as defined above, comprising the reaction between formic acid esters of allylic type alcohols of the general formula (II), ##STR2## wherein R 1 , R 2 and R 3 have the same meanings as defined above, and aldehydes of the general formula (III), ##STR3## wherein R 4 , R 5 and R 6 are independently a lower alkyl group, a lower alkenyl group, an allenyl group, an aryl group with or without being substituted at a position on the ring or a hetero-aromatic group; any two groups selected from R 4 , R 5 and R 6 are integrated to form a lower alkylidene group or an alkylene group, and the other group has the same meaning as described above; or R 4 , R 5 and R 6 are integrated with their respectively bonding carbon atoms to form a 1-cycloalkenyl group, an aryl group with or without being substituted with at a position on the ring, or a hetero-aromatic group: in the presence of an aluminum alkoxide in an catalylic amount.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
R 1 , R 2 , R 3 , R 4 , R 5 and R 6 in the above described formulas are described in detail.
R 1 and R 2 are independently a hydrogen atom or a lower alkyl group. Examples of a lower alkyl group include alkyl groups having from one to four carbon atoms, such as a methyl group, an ethyl groups, a n-propyl group, an i-propyl group, a n-butyl group, a sec-butyl group, a t-butyl group and the like. R 3 is a hydrogen atom, an alkyl group, an alkenyl group, an alkadienyl group or an alkatrienyl group without having a cumulative double bond, an aralkyl group with or without being substituted at a position of the ring, an aryl group with or without being substituted at a position of the ring or a hetero-aromatic group; or the aforementioned alkyl group, alkenyl group, alkadienyl group, alkatrienyl group or the alkyl group of aralkyl group being mono-substituted by a lower alkanoyloxy group, an arylcarbonyloxy group, a lower alkoxy group or an aralkyloxy group with or without being substituted at a position on the ring.
The carbon atom number of the alkyl group is not particularly limited, but usually from one to fifteen, preferably from one to four. Examples of the alkyl group include a methyl group, an ethyl group, a n-propyl group, an i-propyl group, a n-butyl group, a sec-butyl group, a t-butyl group and the like.
The carbon atom number of the alkenyl group is not particularly limited, but usually from two to fifteen, preferably from two to six. Examples of the alkenyl group include a vinyl group, an allyl group, a 1-propenyl group, a 4-methyl-3-pentenyl group and the like.
The carbon atom number of the alkadienyl group without having a cumulative double bond is not particularly limited but usually from five to twenty, preferably from six to eleven. Example of the alkadienyl group include a 3-methylene-4-pentenyl group, a 4,8-dimethyl-3,7-nonadienyl group and the like.
The carbon atom number of the alkatrienyl group without having a cumulative double bond is not particularly limited but usually from seven to thirty, preferably from twelve to twenty four. Examples of the alkatrienyl group include an 4,8,12-trimethyl-3,7,11-tridecatrienyl group and the like.
The aryl group is not particularly limited. Examples of the aryl group include a phenyl group and the like. For example, a phenyl group is substituted by one or two or more of substituents at any one of ortho-, meta- or para-position of the phenyl group. Examples of the substituents for the phenyl group include lower alkoxy group such as a methoxy group, a ethoxy group and the like; halogen atoms such as a chlorine atom, a bromine atom, a fluorine atom and an iodine atom; lower alkyl groups such as a methyl group, an ethyl group, a propyl group and the like.
There is no particular limitation for the aralkyl group with or without being substituted. Examples of the aralkyl group include a phenyl lower alkyl group with the alkyl group having usually from one to four cabon atoms, and with or without being substituted a position on the ring, like the aforementioned aryl group; such as a 2-phenylethyl group, a 2-phenylpropyl group, a 3-phenylpropyl group, a 3-p-tolylbutyl group and the like.
Examples of the hetero-aromatic compounds include a furyl group and the like.
As described above, the aforementioned alkyl group, alkenyl group, alkadienyl group or alkatrienyl group, or the alkyl group of the aralkyl group may be mono-substituted by a lower alkanoyloxy group, an arylcarbonyloxy group, a lower alkoxy group or an aralkyl group with or without being substituted at a position on the ring.
Many of the mono-substituent positions of the aforementioned alkyl group, alkenyl group, alkadienyl and alkatrienyl group are at a ω-positon, but may be at a mid position.
Examples of the substituents include lower alkanoyloxy groups having from one to four carbon atoms such as an acetoxy group, a propionyloxy group, a butylyloxy group and the like, and arylcarbonyloxy groups such as a benzoyloxy group, a p-tolyloxy group and the like.
Examples of the lower alkoxy groups as substituents include the ones having from one to four carbon atoms such as a methoxy group, an ethoxy group and the like.
Examples of the aralkyloxy group with or without substituted at a position on the ring include a benzyloxy group, a p-methoxybenzyloxy group and the like.
Also, R 1 , R 2 and R 3 may be in that R 1 and R 3 integrated with their respectively bonding carbon atoms form a 1-cycloalkenyl group with or without being substituted and R 2 has the same meaning as defined above.
Examples of 1-cycloalkenyl group include the ones having from five to seven carbon atoms such as a 1-cyclopentenyl group, a 1-cyclohexenyl group, a 1-cycloheptenyl group and the like.
Examples of the substituents include a methyl group as being R 2 and/or a gem-dimethyl group bonding to any one of saturated carbon atom on the ring.
Further R 1 , R 2 and R 3 may be in that R 2 and R 3 integrated with their respectively bonding carbon atoms form a cycloalkylidene group, and R 1 has the same meaning as above.
Examples of the cycloalkylidene group having from five to seven carbon atoms include a cyclopentylidene group, a cyclohexylidene group, a cycloheptylidene group and the like.
Examples of the formic acid esters of allylic alcohols include allyl formate, crotyl formate, prenyl formate, geranyl formate, neryl formate, farnesyl formate, geranylgeranyl formate, 8-acetoxy-2,6-dimethyl-1-formyloxy-2,6-octadiene, 8-benzyloxy-2,6-dimethyl-1-formyloxy-2,6-octadiene, 6-p-tolyl-2-methyl-1-formyloxy-2-heptene, 2-methyl-6-methylene-1-formyloxy-2,7-octadiene, 1-formyloxy-2-pentene, cinnamyl formate, 6,6-dimethyl-2-methyl-1-cyclohexene-1-yl-methyl formate, 3,3-dimethyl-1-cyclohexene-1-yl-methyl formate, 5,5-dimethyl-1-cyclohexene-1-yl-methyl formate, cyclohexylidenethyl formate.
R 4 , R 5 and R 6 of the general formula (III) are independently a lower alkyl group, a lower alkenyl group, an aryl group with or without being substituted on a position of the ring or a hetero-aromatic group. Among these cases, the following cases are preferred: the case in which all of R 4 , R 5 and R 6 are lower alkyl groups and the case in which one of R 4 , R 5 and R 6 is a lower alkenyl group, an allenyl group, an aryl group with or without being substituted on a position of the ring or a hetero-aromatic group, and another two are lower alkyl groups.
Examples of the lower alkyl groups include the ones having from one to six carbon atoms, preferably from one to five carbon atoms such as a methyl group, an ethyl group, a n-propyl group, an i-propyl group, a t-butyl group, an i-amyl group and the like.
Examples of the lower alkenyl groups include the ones having from two to six carbon atoms such as a vinyl group, an allyl group, 1-propenyl group, a 4-methyl-3-pentenyl group and the like.
Examples of the aryl group with or without being substituted at a position on the ring include a phenyl group, a phenyl group being substituted by one or two or more of substituents which are selected from the group consisting of lower alkoxy groups such as a methoxy group and the like, halogen atoms such as a chlorine atom, a bromine atom, a fluorine atom and an iodine atom, lower alkyl groups such as a methyl group, an ethyl group, a propyl group and the like, at any one of ortho-, meta- or para-position of the ring, and the like.
Examples of the hetero-aromatic group include a furyl group and the like.
Any two groups selected from R 4 , R 5 and R 6 may be integrated to form a lower alkylidene group or a lower alkylene group, and the other group has the same meaning as described above.
Examples of the lower alkylidene groups include the ones having from one to six carbon atoms, preferably from one to four carbon atoms such as a methylidene group and the like.
Examples of the lower alkylene groups include the ones having from four to six carbon atoms such as a tetramethylene group, a pentamethylene group and the like.
The remaining one group of R 4 , R 5 or R 6 that is not integrated may be any group as described above and generally is a lower alkyl group.
R 4 , R 5 and R 6 integrated with their respectively bonding carbon atoms can form a 1-cycloalkenyl group, an aryl group with or without being substituted at a position on the ring or a hetero-aromatic group.
Examples of the 1-cycloalkenyl group include the ones having from five to seven carbon atoms such as a 1-cyclopentenyl group, a cyclohexenyl group and the like.
Examples of the aryl group with or without being substituted at a position on the ring include a phenyl group, a phenyl group substituted by one or two or more of substituents which are selected from the group consisting of lower alkoxy groups such as a methoxy group and the like, halogen atoms such as a chlorine atom, a bromine atom, a fluorine atom, and an iodine atom, lower alkyl groups such as a methyl group, an ethyl group, a propyl group and the like at any one of ortho-, meta- or para-position of the ring, and the like.
Examples of the hetero-aromatic group include a furyl group, particularly 2-furyl group and the like.
Examples of the aldehyde of the general formula (III) include trimethylacetaldehyde, 2,2-dimethyl-4-pentenal, 2,2-dimethylpentane-3,4-dienal, 1-methylcyclohexane-1-carboaldehyde, 2-phenylpropane-2-carboaldehyde, 3-methyl-2-methylene-1-butanal, 1-cyclohexene-1-carboaldehyde, benzaldehyde, tolualdehyde, mesitaldehyde, p-methoxybenzaldehyde, p-chlorobenzaldehyde, m-chlorobenzaldehyde, furfural and the like.
The amount of the aldehyde of the general formula (III) used in the reaction is generally in an amount of one or more equivalents, preferably from 1.1 to 3 equivalents, for an efficient reaction carrying out to the amount of the formic acid ester of allylic alcohol to be oxidized.
Examples of the aluminum alkoxide catalyst used for the reaction include the ones generally used for the Oppenauer oxidation reaction of alcohol, such as aluminum isopropoxide, aluminum t-butoxide, aluminum s-butoxide, aluminum phenoxide and the like. Among these, aluminum isopropoxide is preferable because of the availability.
The amount of the aluminum catalyst used in the reaction is in the range of from 0.1 to 30 mole percent, preferably from 2 to 10 mole percent to the amount of formic acid ester of allylic alcohol.
The temperature of the reaction depending on the reaction period is in the range of from 10° C. to 180° C. However, the preferred temperature of the reaction is in the range of from 20° C. to 50° C. considering the stability of produced α, β-unsaturated aldehydes.
The use of a solvent is not essential for the reaction but may be used in the difficulty of the aluminum alkoxide catalyst dissolution.
Examples of the solvent include hydrocarbons such as toluene, hexane and the like, chlorinated hydrocarbons such as methylene chloride, chloroform and the like, ethers such as tetrahydrofuran, diethyl ether and the like, esters such as ethyl acetate and the like.
The reaction period depending on the amount of the catalyst used and the reaction temperature is in the range of from 30 minutes to 5 hours.
The reaction is quenched by the addition of water, hydrochloric acid, sulfuric acid and the like to the reaction system. After the completion of the reaction, the objective α, β-unsaturated aldehyde is separated and purified from the reaction mixture according to the following manner.
After the extraction of the reaction mixture by the use of an organic solvent selected from the group consisting of toluene, hexane, diethyl ether, methylene chloride, ethyl acetate and the like, the organic layer is separated, washed successively with water and an aqueous solution of sodium carbonate, distilled off the solvent from the solution, and subjected to distillation or column-chromatography for purification.
Further, after quenching the reaction by the addition of a small amount of water, the reaction mixture may be subjected to distillation as such without separation of the organic layer to obtain the objective α, β-unsaturated aldehyde.
EXAMPLES
The present invention is more particularly described by way of examples, which should not be construed as limiting the present invention.
EXAMPLE 1
Preparation of Citral from Geranyl Formate by Using Trimethylacetaldehyde
A dried 100 ml flask was charged and mixed with 18.2 g (100 mmol) of geranyl formate, 17.3 g (200 mmol) of trimethylacetaldehyde, and 642 mg (3 mmol) of aluminum isopropoxide in an atmosphere of nitrogen, followed by agitation at 40° C. for 3 hours.
To the reaction mixture was added 20 ml of 1N hydrochloric acid and 30 ml of toluene, and phase-separated. The resultant organic phase was washed twice with 20 ml of 1N hydrochloric acid respectively, and further washed with 20 ml of water and separated, and washed with 5% sodium carbonate aqueous solution, thereafter distilled off the organic solvent under a reduced pressure, followed by distillation (at a boiling point of 68° C. at 0.3 mmHg) to obtain 13.68 g of citral (at a yield of 90%).
EXAMPLE 2
Preparation of Citral from Furfural by Using Geranyl Formate
According to the same procedure of Example 1, using 19.5 g (200 mmol) of furfural, and 642 mg (3 mmol) of aluminum isopropoxide, 18.2 g (100 mmol) of geranyl formate was oxidized to obtain citral at a yield of 86%.
EXAMPLE 3
Preparation of 8-acetoxy-2,6-dimethyl-2,6-octadienal from 8-acetoxy-2,6-dimethyl-1-formyloxy-2,6-octadiene Using trimethylacetaldehyde
A dried 500 ml flask was charged and mixed with 170.5 g (purity 70.4%, 500 mmol) of 8-acetoxy-2,6-dimethyl-1-formyloxy-2,6-octadiene, 86.9 g (1 mol) of trimethyl acetaldehyde, 3.06 g (15 mmol) of aluminum isopropoxide in an atmosphere of nitrogen, followed by agitation at 40° C. for 2 hours.
After the quenching of reaction by the addition of 2 ml of water, unreacted trimethyl acetaldehyde and by products of formic acid ester of neopentyl alcohol were distilled off under a reduced pressure.
From the residue, the objective 8-acetoxy-2,6-octadienal was obtained by distillation under reduced pressure (boiling point: 120° C. at 1 mmHg) in a yield of 89%.
EXAMPLE 4
Preparation of 8-acetoxy-2,6-dimethyl-2,6-octadienal from 8-acetoxy-2,6-dimethyl-1-formyloxy-2,6-octadiene Using 2,2-dimethyl-1-pentenal
According to the same procedure of Example 3, using 102.3 g (purity 70.7%, 300 mmol) of 8-acetoxy-2,6-dimethyl-1-pentenal, and 1.84 g (90 mmol) of aluminum isopropoxide, 8-acetoxy-2,6-dimethyl-2,6-octadienal was obtained in a yield of 90.9%.
EXAMPLES 5 to 8
According to the same procedure of Example 1, from the following formic acid esters of allylic alcohols, the α, β-unsaturated aldehydes were obtained in the yields as described below.
EXAMPLE 5
Formic Acid Ester of Allylic Alcohol ##STR4##
Yield: 90%
EXAMPLE 6
Formic Acid Ester of Allylic Alcohol ##STR5##
Yield: 85%
EXAMPLE 7
Formic Acid Ester of Allylic Alcohol ##STR6##
Yield: 82%
EXAMPLE 8
Formic Acid Ester of Allylic Alcohol ##STR7##
Yield: 81% | The present invention provides a novel process for producing α,β-unsaturated aldehydes including industrial important fragrances such as citral and sinensal, starting materials for preparing pharmaceutical drugs such as senecioaldehyde, farnesal, 8-acetoxy-2,6-dimethyl-2,6-octadienal and the like, directly and in high yield, from formic acid esters of allylic alcohols in the presence of a catalytic amount of aluminum alkoxide by the oxidation of the corresponding alehyde. | 2 |
This is a continuation of application Ser. No. 08/858,141, filed on Mar. 27, 1992 now abandoned.
FIELD OF THE INVENTION
The present invention relates to chest enclosures for use in producing assisted ventilation of the lungs of a patient when combined with an air oscillator.
BACKGROUND TO THE INVENTION
In medical practice it is frequently necessary to assist the breathing of a patient. Most frequently this is done by intubating the patient and applying periodic positive air pressure through the intubation into the patient's lungs. Intubation is associated with a number of clinical and practical disadvantages.
The alternative to intubation is to use some form of external ventilator apparatus. External ventilator apparatus of the so-called "Cuirass Ventilator" type has a long history. Until recently, such devices have been of limited usefulness. In our British Patent Specification No. 2226959A, we have described chest enclosures for use in producing assisted ventilation which have proved successful in practice. However, we have found that there are a number of aspects in which still further improvement is possible.
First, we have found that there is some tendency for the top surface of the chest enclosure or shell to move downwardly when suction is applied to the enclosure by the oscillator so as to produce a substantial sub-ambient pressure within the enclosure formed by the shell. The top surface of the shell is drawn downwardly against the patient's chest creating pressure on the chest partially blocking its expansion and this reduces the effectiveness of the ventilating action of the air oscillator to a degree.
Secondly, one of the principal advantages of the chest enclosure described in the application referred to above is the speed with which it can be applied to a patient. The chest enclosure described had bands of closed-cell foam extending from its side edges which were to be wrapped around the patient in overlapping relationship and fastened by straps. We have found that it is possible to devise an edge seal for the shell which enables the shell to be applied over a patient and to form a seal sufficient for use whilst the patient is lying supine and still, even without the use of fastening straps, at least as a temporary measure.
Furthermore, we have devised a form of seal for the shell still better adapted to resist the escape of super-ambient pressure from the shell during use.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is provided a chest enclosure for use in producing assisted ventilation of the lungs of a patient comprising a chest covering shell of springy material for fitting over a patient's chest, said shell having side portions for extending over the sides of a patient's body, means for sealing the shell against a patient's body, an air passageway into said enclosure for connection in use to an air oscillator, said enclosure further comprising a support structure comprising a base member to be located beneath a recumbent patient's back, one or more support members rising from said base member, and means for engaging said shell with said support member or members, whereby to restrain bowing of the side portions of the shell in response to sub-ambient pressure within the shell.
The said one or more support members for engagement with the shell may be integral with the said base member
The base member may take the form of a plate which is sufficiently thin that a patient can lie over it without discomfort with portions of the patient overhanging the plate. Suitably the plate is between 3 and 10 mm thickness, e.g. about 5 mm in thickness. It is suitably formed from a rigid plastics material such as perspex.
Preferably, there are at least a pair of support members rising from such a base member, one of said pair being disposed on each side of the patient in use so that the patient lies between the support members and the shell is engaged by both support members of the pair. Preferably, the shell is engaged by the support members at a location toward the top of the shell, e.g. at about the top of a or each side portion of the shell.
Preferably, the height of the top of the shell when the shell is engaged with the support members is user selectable.
The support members may each take the form of a support column having a series of locations along its length at which engagement means on said shell can be engaged with the column.
Preferably, one support member of the or each pair of support members is removable from the base member to allow the base member to be slid underneath the patient with minimal lifting of the patient. The support member can then be replaced on the base member. The support member may be removably located on the base member for instance by a screw-in fitting. However, other forms of connection such as quick release couplings are envisaged.
Preferably, the space between the or each pair of support members is upwardly open so that a patient fitted with a chest enclosure shell can be lowered between the two columns of the pair and the shell can then be engaged with the support members.
The support members may take the form of a columns which are sufficiently flexible to be deflected apart and to spring inwards to grip a shell located between them. They may be provided with a series of tooth formations engagable by a dog or tongue provided on the adjacent portion of the shell. Alternatively, engagement means may be provided on the shell which is protrudable toward the support member to locate therewith. For instance, the support member may be a column and the shell may be provided with a collar which is sliding fit over the column and is provided with an inwardly directed latch member or with an inwardly directed screw to locate against the column.
Instead of a plate the base member may be an evacuatable envelope having an opening for the evacuation of air therefrom and containing a multitude of small particles, such that the envelope is normally flexible and able to be conformed to a patient's body but upon evacuation of the air therefrom becomes stiff.
Preferably, when such a base member is used the side portions can be turned upwards so that they overlap against side portions of the shell. The upturned portions can be attached to the shell so that on evacuation of the envelope to make it stiff the upturned portions become upwardly directed support means which serve to restrain movement of the shell side portions caused by pressure changes within the shell.
In accordance with a second aspect of the invention there is provided a chest enclosure for use in producing assisted ventilation of the lungs of a patient comprising a chest covering shell of springy material for fitting over a patient's chest, said shell having side portions for extending over the sides of a patient's body, an air passageway into said enclosure for connection in use to an air oscillator, said shell having a front edge portion, opposed side edge portions and a rear edge portion, and means for sealing said edge portions against a patient's body, said sealing means including a sealing flap of resilient, flexible, air impermeable material running continuously around said front, side and rear edge portions.
Said flap may for instance be of closed cell synthetic or natural foam rubber. Suitably, such a flap may be of 2 to 5 cm in width and from 3 to 10 mm, e.g. about 5 mm in thickness. It is preferably so arranged that in use it extends from the edge of the shell or from a further sealing member attached to edge of the shell, to contact the patient's body and in such a direction that its free edge is directed away from the interior of the enclosure. By such an arrangement, when there is sub-ambient pressure within the enclosure, external air pressure tends to force the sealing flap more closely against the patient's body to provide a still better seal.
Those portions of the flap extending along the side edge portions of the shell preferably engage against the patient's back.
By the adoption of such a sealing flap, it is possible to arrange that a springy enclosure shell can be fitted over a patient's chest by pulling the sides of the shell somewhat apart and may be allowed to relax to grip the patient such that the flap forms an adequate seal to allow immediate use of the enclosure for ventilation even without the fitting of straps around the patient. Of course, it may be desired to fit straps later to retain the shell on the patient, for instance if the patient is to be moved or is capable of spontaneous movement. Also, it may be necessary to use straps around the patient if the patient's body is not of a normal shape.
In a third aspect, the invention provides a chest enclosure for use in producing assisted ventilation of the lungs of a patient comprising a chest covering shell of springy material for fitting over a patient's chest, said shell having side portions for extending over the sides of the patient's body, an air passageway into said enclosure for connection in use to an air oscillator, said shell having a front edge portion, opposed side edge portions and a rear edge portion, and means for sealing said edge portions against a patient's body, said sealing means including an inwardly directed sealing member of resilient, flexible, air impermeable material running over part or all of said front, rear and side edge portions and so directed as to overlie the surface of a patient's body in use in such a way that super-ambient pressure within said enclosure presses said sealing member more closely against said patient's body.
Such a sealing member may take the form of a sealing flap extending inwardly from the edge of the shell or from a sealing member attached to the edge of the shell. Preferably, the flap runs continuously over the whole of the front, rear and side edge portions of the shell. Its dimensions and composition may be similar to those of the sealing flap described in connection with the second aspect of the invention. However, where the sealing member is a flap, it is angled inwardly so that its free edge is directed toward the interior of the shell to overlie the patient's body within the shell. In traditional cuirass ventilators, there has been no necessity for sealing the shell against super-ambient pressure within the shell. Such ventilators have been employed with air oscillators which produce periods of sub-ambient pressure within the shell followed by relaxation to atmospheric pressure rather than with oscillators which produce periods of super-ambient pressure alternating with sub-ambient pressure.
According to a fourth aspect of the invention there is provided a chest enclosure for use in producing assisted ventilation of the lungs of a patient comprising a chest covering shell for fitting over a patient's chest, said shell having an air passageway to said enclosure for connection in use to an air oscillator, and backing means for location behind the patient in use, the said backing means comprising an evacuatable envelope having an opening for the evacuation of air therefrom and containing a multitude of small particles, such that the envelope is normally flexible and able to be conformed to a patient's body but upon evacuation of air therefrom becomes stiff.
The backing means may function in conjunction with the cuirass shell to create a box-like enclosure enclosing the chest and associated back region of a patient in a substantially air-tight manner. Side regions of the shell are in such an arrangement connected in an adequately air-tight manner to the backing means. However, the backing means may instead act as the base member as described in connection with the first aspect of the invention.
The backing means may include more than one such envelope. The envelopes may be provided separately or connected together.
In use the weight of the patient causes the distortion of the backing means into a shape which exactly fits the patient. Removing the air from the backing causes the small particles to become locked to one another thereby causing the backing means to harden and become stiff. The degree of evacuation of the envelope can be controlled in order to adjust the firmness of the backing means.
The source of the vacuum for evacuating the envelope may be a vacuum pump or a syringe.
The opening in the envelope preferably includes a valve and the degree to which the backing means can be made more resistant to compression may be controlled by operating the valve.
The valve may be a two-way vacuum valve.
The said multitude of small particles may be sand or they may be small particles or beads made of plastics, glass or metal.
Combinations of different kinds of small particles may be used.
As mentioned above, the backing means and the shell may be linked together by fastening means.
Preferably the fastening means are male and female refastenable sealing strips such as male and female hook and loop fabric strips, e.g. Velcro. The sealing strips may run longitudinally down each side of the cuirass shell and backing means. Male and female sealing strips may be provided between the cuirass shell and the straps. Alternatively, straps may be provided which are attached to the backing means and run over portions of the front and rear ends of the cuirass shell.
Straps may be fixed to the cuirass shell and extend under portions of the backing means.
The side portions of the backing means may be turned upwards or be capable of being turned upwards so that they can overlap with side portions of the cuirass shell. Preferably, such upturned side portions of the backing means overlap with portions of the outside of the cuirass shell.
The backing means may be attached to the cuirass shell using fastening means such as clips, clamps or straps and buckles. Any one of the means of attachment described in connection with the first aspect of the invention can also be used to attach the backing means to the shell.
The backing means may further include an upper layer of soft material. This soft layer is intended to make contact with the patient's back in use. The soft material layer is for the insulation and comfort of the patient and may be attached to the envelope by gluing, or if a plastics or rubber material, by welding. Alternatively, the soft material may be integrally formed with the envelope.
The soft material may be a foamed material.
The distance between the walls of the envelope in use is preferably from 1 to 1.5 cms.
Preferably the backing means is substantially rectangular in shape and corresponds generally in size to the open underside of the cuirass shell.
Preferably, the backing means is made from a flexible plastics material or rubber.
The backing means may be provided in a size suitable for use with a correspondingly sized cuirass shell, e.g. sizes suitable for neonatal, paediatric or adult use.
Preferably of course, chest enclosures according to the invention are provided which embody the features of any two or more of the four aspects identified above within a single chest enclosure. In particular, it is preferred that there be a pair of sealing flaps running around the whole of the front, rear and side edge portions of the shell, one being directed such that its free edge faces out from the enclosure in use and the other being directed so that its free edge faces in towards the interior of the enclosure, both overlying the patient's body and sealing there against. By this means, whether the pressure inside the enclosure is above or below ambient, an improved seal is achieved and there is a still further reduced need for the employment of sealing straps. This can enable a chest enclosure according to the most preferred embodiments of the invention to be applied to a patient's body and be in operation at least as fast as the most skilled operator can carry out an intubation.
Preferably, the edge seal of a shell in an enclosure according to the second or the third aspect of the invention comprises a sealing bead of closed cell foam protruding inwardly from the inner face of the shell itself by from 1 to 4 cm, e.g. about 2 cm. From the internal face of the sealing bead there preferably protrudes the sealing flap according to the second aspect of the invention and/or the sealing member required by the third aspect of the invention. Where both are provided, they preferably extend from the sealing bead at an angle to one another which is from about 30° to about 90°. Preferably, the angle included between the two is smaller at the front and rear of the shell and larger at the side edge portions of the shell. At the front and at the rear it is for instance in the region of 30° to 50° and at the sides it is preferably in the region of 70° to 90°.
The shell in each aspect of the invention is preferably constructed from a stiff but resilient plastics material such as perspex or polycarbonate, e.g. of about 0.5 to 4 mm thickness, larger thicknesses in this range being more appropriate for larger shells. Preferably it is transparent. It may be moulded into the required shape but a plane sheet of suitable material can simply be bent to form a U-shaped channel to constitute the shell.
Any of the first, second or third aspects of the invention described above may be used in combination with the backing means of the fourth aspect of the invention.
The invention will be further explained and illustrated by the following description of a preferred embodiment with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a base member with support members for use in accordance with the first aspect of the invention;
FIG. 2 is a front elevation of the base member illustrated in FIG. 1;
FIG. 3 is a front elevation of the shell of a chest enclosure according to the first, second and third aspects of the invention with its sealing member omitted for clarity;
FIG. 4 is a vertical cross-section through one of the mounting brackets of the shell of FIG. 3;
FIG. 5 is a plan view of the mounting bracket of FIG. 4;
FIG. 6 is a side elevation of the chest enclosure of FIG. 3 including the sealing member;
FIG. 7 is an under plan view of the shell of FIG. 6;
FIG. 8 is a section on the line VIII--VIII of FIG. 7;
FIG. 9 is a section on the line IX--IX of FIG. 7;
FIG. 10 is a section on the line X--X of FIG. 7; and
FIG. 11 is a rear elevation of the shell and back support means of an embodiment according to the fourth aspect of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In each of FIGS. 8 to 10, those portions of the enclosure which lie behind the plane of the section have been omitted for clarity.
As shown in FIG. 1, a chest enclosure according to the first aspect of the invention includes a base member in the form of a base plate 10 which is generally rectangular in shape and approximately one third of the way along its length has a transverse row of eight threaded through holes 12 arranged in two groups of four, each group lying adjacent to and extending in from one long edge of the plate 10. A pair of support members in the form of columns 14 are screwed into respective ones of the holes 12 by means of threaded studs 16 (FIG. 2). Each column is circular in cross-section and comprises a first lower plain portion 18 carrying the stud 16 and an upper toothed portion 20 comprising about fifteen frustoconical regions 22 each having an upwardly facing sloping face 24 and a downwardly facing annular face 26 lying parallel to the base plate 10.
The columns are preferably made of a tough fairly stiff but resilient plastics material.
The shell 40 shown in FIG. 3 may be generally conventional except for the provision of a pair of outwardly facing mounting brackets 28 positioned one on each side of the shell toward the top of the shell. Alternatively, the shell can be provided with suitable sealing members such that it is in accordance with the second and third aspects of the invention.
As shown in FIGS. 4 and 5, each mounting bracket defines a vertically extending U-shaped channel 30 having a wedge-shaped dog 32 extending out from the base of the channel and providing a horizontal upper semi-circular surface 34 and a downwardly facing sloping rectangular face 36. Below the level of the dog 32, the shape of channel 30 changes to being rectangular rather than U-shaped.
The manner of use of the enclosure described is as follows. With a patient fitted with the shell and lying on a bed, one of the two columns 14 is unscrewed from the base plate 10 and the base plate is pushed underneath the patient so that the other column 14 lies by the patient's side. The first column 14 is then refitted to the base plate on the other side of the patient. The spacing of the columns 14 is selected such that they press against the mounting brackets 28 and the dog of each mounting bracket locates under one of the annular faces 26 of the frustoconical regions 22 on each column. When vacuum is applied to the air passageways of the shell, external air pressure will tend to push the top of the shell down on to the patient's chest with consequent bowing out of the side of the shell. This will be prevented by the engagement of the mounting brackets 28 with the columns 14.
An alternative manner of use is to first fit the shell 10 pushing the mounting brackets down ratchet-wise between the columns 14 until the patient is lying on the base plate 10.
The columns of the base plate are easily removed if it is necessary to move the patient. Alternatively, the mounting brackets can be released simply by pulling apart the tops of the columns 14.
If desired, the mounting brackets and the formations on the columns 14 may be made such that it is necessary to press the mounting brackets down slightly before they can be released from the columns 14. For instance, an upstanding lug may be formed on the upper surface 34 of the dog 32 and a downwardly facing co-operating lug may be formed on each annular face 26 of the column 14.
The shell illustrated in FIGS. 3 to 7 constitutes a chest enclosure according to the second, third and fourth aspects of the invention. Shell 40 is of springy plastics material having a front edge 42 a side edge 44 and rear edge 46. It comprises a pair of air passageways 48 for connection to a suitable air oscillator, one passageway being provided on each side of the mid line of the shell.
With reference also to parts of FIGS. 8-10 there is a thick sealing bead 50 of closed cell resilient foam which extends around the internal face of the shell around the front, side and rear edges in a continuous strip. The sealing bead 50 is of generally rectangular cross-section having a rounded nose portion 52.
In accordance with the second aspect of the invention, a sealing flap 54 of closed cell foam similar to that used for the sealing bead 50 extends from the sealing bead 50. Flap 54 is of 5 mm thick foam strip about 2 cm wide. More generally, such a flap is suitably from 3 to 10 mm in thickness, and from 1.5 to 4 cm in width, larger figures within these ranges being more appropriate for larger shells. It is attached by one edge face to the outer root portion of the face of the nose portion 52 of the bead 50, e.g. by adhesive, although of course it could be made integral with the bead 50. The flap 54 extends generally at an angle with respect to a perpendicular to the edge of the shell of from about 0° to 10° outwards in the vicinity of the side of the shell to about 0° to 20° inwards in the region of the front of the shell and about 0° to 10° outwards in the region of the rear of the shell. However, when the shell is placed over a patient, the free edge of the flap can be teased outwards to lie on the body of the patient outside of the shell or at least directed towards the outside of the shell so that atmospheric pressure tends to press the flap more tightly against the patient's body.
In accordance with the third aspect of the invention, a second sealing flap 56 extends inwardly from the bead 50. This is attached to the bead 50 along the nose portion thereof spaced inwardly from the flap 54 by approximately 15 mm. Its dimensions are similar to those of the flap 54 but it is directed toward the interior of the shell so that in use it lies on the body of a patient within the shell and is pressed more tightly against the patient's body in response to super atmospheric pressure in the shell. It extends from the bead 50 at an angle to the adjacent part of the shell of about 5° to 20° in the region of the sides (FIG. 8) and front (FIG. 9) of the shell and about 20° to 60° in the region of the back (FIG. 10) of the shell. The angle included between the two sealing flaps is about 45° at the back of the shell about 70° to 90° along the sides of the shell and about 60° along the front of the shell. The entire sealing structure of bead 50 and flaps 54 and 56 can be made as an integrated whole or assembled from separate constituents.
In use, the enclosure may be fitted to a patient by springing apart the sides of the shell and passing the sides of the enclosure over the patient's chest and releasing them so that the sealing flaps 54 and 56 seal on the patient's body. In the region of the sides of the shell, the flaps, particularly the flap 50, seals against the patient's back so that movement of the patient's ribs is not restricted.
The shell may be fitted with mounting brackets so as to bring the enclosure within the first aspect of the invention. Such mounting brackets may be as illustrated or may for instance take the form of collars with an adjustment screw passing through the wall of each collar. Such collars can be fitted over support columns and held in position by tightening of the screws.
The shell may be fitted with straps to enable it to be strapped on to a patient. It may be necessary to employ such straps if the patient has a chest region of abnormal shape or if the patient is to be moved wearing the enclosure but the seal provided by the sealing flaps 54 and 56 should under normal circumstances be sufficient to enable the enclosure to be used even before such straps are fitted.
In accordance with the first and fourth aspects of the invention, a backing means in the form of a pad 58 is provided which is a generally rectangular shaped envelope comprising an upper layer 60 and a lower layer 62. The layer 60 and layer 62 are attached around their edges so as form the envelope with interior space 64. The space 64 contains sand. The pad 58 corresponds generally in shape to a rectangle of a size which is defined by the sides 44, the front 42 and rear 46 edges of the shell 40. Side portions 66 of the pad 58 are turned upwards so that portions of the upper layer 60 can be brought into contact with the outside lower edges of the shell 40. The side portions 66 of pad 58 are attached to the shell 40 by hook and loop fabric strips 68.
The pad 58 has an access tube 70 which connects the space 64 with the surrounding atmosphere. The tube 70 includes a two-way valve 72.
A layer of foam rubber 74 is attached to upper layer 62 of the pad 58 in order to insulate and provide the patient with a degree of comfort.
In use the pad 58 is spread out flat on a surface. The patient is laid face up on the pad 58 and the shell 40 is placed over the patient's chest. The weight of the patient deforms the pad 58 so that it forms an impression of the contours of the patient's back. The shell 40 is then attached to the upturned portions 66 of the pad 58 by way of the strips 68. A vacuum pump (not shown) is connected to pipe 70 and switched on. Tap 72 is opened in order to allow air to be drawn out of the space 64. As the air is drawn out the pad 58 the particles are compressed together so that the pad "hardens" and fixes the impression of the patient's back therein. What results is a hard lower surface 62 and a softer upper surface 60. The shell 40 and the pad 58 both seal against the patient's body in a substantially air-tight manner so as to completely encase the patient's chest and associated back region. The stiffening of the pad 58 causes the upturned side portion connected to the shell 40 to act as support members against any movement of sides of the shell caused by pressure changes inside the shell. The hardened pad 58 therefore provides a relatively rigid support for the shell 40 and assists in the sealing of the shell 40 to the patient whilst maintaining a degree of comfort to the patient.
The pad 58 is made from rubber or a flexible plastics material. The space 64 inside the pad 58 can be filled with sand or small particles or beads of plastics material, glass or metal.
Many modifications and variations of the embodiments of the invention described above are possible within the scope of the invention. | A chest covering shell (4) of springy material for fitting over a patient's chest is coupled to an air oscillator. Changes in air pressure in the shell (40) cause ventilation of the patient. A back plate (10) can be used which has vertically extending supports (14) for engagement with the sides (28) of the shell (40) so as to support them and prevent their flexing during use. The edge of the shell (4) has a seal (50 which runs continuously around the periphery of the shell (40). The seal (50) can include an inwardly directed flap (56) in order to provide an effective seal when positive pressures are applied under the shell (40). A backing pad (58) comprising an evacuatable envelope containing solid particles can be used which is able to support the shell (40) and seal against the patient. The pad (58) can be deformed by the weight of the patient and can be evacuated via air outlet (70) to stiffen the envelope by compression of the particle. | 0 |
BACKGROUND OF THE INVENTION
[0001] The invention is based on a priority patent application EP 08103353.2 which is hereby incorporated by reference.
[0002] The invention is related to an interior rear view mirror which is designed in plastic material and has smooth edges.
[0003] The internal rear view mirror has at least in some transparent areas that allow the installation of illumination elements to shine through.
STATE OF THE ART
[0004] Internal rear view mirror are defined e.g. by the regulations of ECE 324 Regulation 46. An internal rear view mirror has a couple of requirements as the field of vision which must be at least a 20 m wide flat horizontal portion of the road. One of the requirements is related to the passenger security and requests that the edges of the internal rear view mirror must be rounded to a radius not less than 2.5 mm.
[0005] In result of this requirement the internal rear view mirror known in the art often shows designs with a plastic mirror case defining a front opening. The front opening includes the reflecting glass which is fixed by a retaining bezel. The retaining bezel is form of plastic material to fulfill safety requirement and the minimum radius of the regulations.
[0006] The appearance of the internal rear view mirror with the bezel surrounding the reflecting element is not satisfying some design request.
[0007] It is known from EP 07440321 B1 especially from FIGS. 18-21 to design an internal rear view mirror without a retaining bezel. The reflecting element is snapped in the peripheral side walls of the mirror case which forms lips, rounded in the required radius.
[0008] The proposed solution is using a glass mirror to be pressed between the molded side wall lips. The known solution includes a means to illuminate the interior of a vehicle, read lamps and ambient light. The internal rear view mirror is prepared to receipt light module device and the lenses so that light shines through the mirror housing.
[0009] It is also know in the art by DE 3049169 to form a plastic glass for an internal rear view mirror. The plastic glass is snapped into place and is tightly connected to the mirror housing. The plastic glass is coated with a reflecting layer on the inner surface of the mirror.
[0010] A disadvantage is the connection with the tongue and groove joint that needs a precisely molding to connect the mirror housing part with the mirror without a visible slit.
SUMMARY OF THE INVENTION
[0011] The inventive internal rear view mirror consists of mirror housing and a one piece front plastic glass that has at least one side piece. The fully transparent plastic glass is molded in one piece and coated with a reflective layer at least partly.
[0012] The internal rear view mirror according the invention allows a very simple mirror design including only tow main parts: the mirror housing and the front plastic glass without additional parts as lenses or bezels. The transparent plastic glass is combining the function of the mirror glass, the function of the lenses built in the mirror housing in prior art and the mirror housing with smoothed edges.
[0013] With the internal rear view mirror according the invention a light weighted mirror is created. The high flexibility of molded plastic glass allows a lot of different bezel free designs of the internal rear view mirror. The small weight of the interior mirror allows to ease the mirror base structure or to support further functionalities as GPS receiver, wireless connections, etc without dramatically increase of weight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows a plane view of a internal rear view mirror
[0015] FIG. 2 shows a cross section of the internal rear view mirror
[0016] FIG. 3 shows a first embodiment of the invention
[0017] FIG. 4 shows a second embodiment of the invention
[0018] FIG. 5 shows a schematic illumination
[0019] FIG. 6 shows a second schematic illumination
[0020] FIG. 7 a to b show deforming production process
[0021] FIG. 8 shows deforming of a second embodiment
[0022] FIG. 9 shows the side piece structure to form a lens
DETAILED DESCRIPTION OF EMBODIMENTS
[0023] FIG. 1 shows schematically an internal rear view mirror from the front side. A mirror housing 1 is attached to a mirror base 2 which is connected to vehicle's roof or wind screen. The mirror housing 1 has an opening to the interior of the vehicle in which front plastic glass 3 is inserted.
[0024] Behind the front plastic glass 3 in the mirror housing a light module 4 is installed either at the backside or the base side of the mirror housing. The light module 4 is known in prior art and comprises a printed circuit board with bulbs and or LEDs and reflectors. In a preferred embodiment only LEDs are installed that works through the lifetime of the inventional mirror and must not be replaced.
[0025] FIG. 2 is a cross section of the interior mirror of FIG. 1 . The mirror housing 1 and the front plastic glass 3 form a closed cavity in which the electrical and or the electronically elements and circuits are placed. As an example a part of a light module 4 is shown in the cavity. The front plastic glass forms the front plate of the interior mirror and has a side piece 5 forming together an L-form. The edges are smoothed to follow the regulations and design rules. It is possible to have thick front plastic glass with a radius which is much more than the regulations requests. The front plastic glass 3 is one piece closing the front and the base of the internal rear view mirror. The front plastic glass 3 is coated with a reflective layer 6 , normally a metal layer. The L-formed front plastic glass has two functions: to be the mirror for the internal rear view mirror and to be the lens for the interior illumination means. To achieve this function the front plastic glass is formed as a one-piece plastic glass highly transparent and stable. In a further step the plastic glass is coated with metal layer 6 on the front side covering the visible part for passengers looking perpendicular on the surface in direction of arrow 7 . This means that the internal rear view mirror appears without a bezel and fully reflecting. But this means also that the section between the non transparent mirror housing 1 and the front plastic glass 3 remains transparent and emits light if light module in the mirror housing is activated. This edge illumination is sketched with arrows 8 . Also within the side piece 5 light is emitted through the transparent front plastic glass 3 .
[0026] The two main parts of the mirror the housing 1 and the front plastic glass 3 are connect together in a way person skilled in the art would choose. For example a welding or gluing connection is possible.
[0027] FIG. 3 is a second embodiment of the internal rear view mirror. In this example the references describes the same mirror design as in FIG. 2 . The difference is the surface on which the reflective metal layer is coated. In this embodiment the metal layer 6 is on the inner surface of the front plastic glass 3 .
[0028] As a result the mirror housing 1 would be visible at the lower horizontal part of the mirror from the passengers. In this embodiment this problem is solved with a small area of additional reflective coating 6 on the front side.
[0029] In this embodiment the connection between mirror base and mirror housing on the top must achieved in a way not to destroy the metal layer of the reflective coating 6 . Alternative also an additional reflective coating area on the outer surface of the front plastic glass is possible covering the edges of the front side. This solution eases the connection between front plastic glass and mirror housing.
[0030] The thickness of the reflective coatings depends on the material and the color that should achieved. In FIG. 3 edge illumination appears by guiding the light in the reflective element.
[0031] FIG. 4 is another embodiment of the invention comprising two side pieces of the front plastic glass covering the bottom and the top of the internal rear view mirror. The front plastic glass is unshaped. This embodiment is improving the indirect illumination of the internal rear view mirror which could be seen in FIG. 6 with dotted lines.
[0032] FIGS. 5 and 6 shows the appearance of the lighted internal rear view mirror with different areas of illumination A and B mark the read lamp function and C is an ambient light following different designs.
[0033] The front plastic glass is a material transparent for visible wavelengths and able to guide visible light to a certain extend. Light is coupled in and coupled out by special surface structures as ribs and edges. The surface structures are positioned beside the optical plan surface of the front plastic glass which is used as a mirror.
[0034] The process to mould the plastic glass is published in the EP 1412158.
[0035] The process includes the steps of first providing an injection mould machine. The injection molding machine includes a cavity therein, for forming a transparent plastic article simulating the transparency of glass. The mould includes a pressure sensing and regulating apparatus. The mould is thereafter closed and a clear plastic material is injected into the mould through a port. A portion of the mould is used to pressurize the mould material back into the injection port. After the material is partially injected back into the injection port, the mould is held at a predetermined pressure for optimizing optical properties of the plastic material, to provide a clear transparent plastic material which has optical properties similar to glass.
[0036] In the device there is provided a first mould platen and a second mould platen. The first mould platen includes the cavity for production of the final finished part. A second movable piston portion is provided, which includes a cavity, which is adjustable by movement of the piston. The pressure in cavity is adjusted by way of the hydraulic smaller control piston, which is set forth for use in a control system, which hydraulically can compress or adjust the hold position of the moveable portion. A proportional valve may be utilized in the control system for controlling the adjustment of the pressure in the mould cavity. A pressure sensor is utilized to determine the pressure in the cavity, for purposes of the hold pressure in the subject process. After this, the proper pressure is determined and the mould cavity is held at this pressure by way of the control system linked to the proportional valve.
[0037] Referring to the examples of FIGS. 7 a and b and FIG. 8 , there is shown a sample mirror in which various contours of the mirror can be presented as may be desired. This gives options which were hard to create using glass type mirrors or the like. The examples as shown in FIG. 7 b with one side piece 5 can be molded in one process and ejected with a piston contacting the side piece of the plastic glass. The design as shown in FIG. 7 a has a adjacent rim which is molded together with the plastic glass element. The rim is used as a “loosed” part. During the deform process ejectors eject the article via these rims. Afterward the rims are cut off. With a solution like this the appearance of piston stamps on the transparent plastic glass is avoided.
[0038] A design as shown in FIG. 8 shows a drip mould which means that the molding form must include pistons and pins to remove the article form the cavity.
[0039] Preferably, the mould is then held at a pressure of generally from about 900 bar to about 1800 bar preferably from about 1000 to about 1800 bar and preferably from about 1000 to about 1200 bar.
[0040] It has been found that by using these steps, a glass-like transparency can be obtained. Utilizing these steps helps relieve internal tension in the material therefore removing barriers to optical clarity which otherwise might arise.
[0041] Mould temperatures vary depending on the material used. Typically, suitable temperatures are from about 80 to 120 [deg.] C. A most preferred temperature of about 80 [deg.] C. is utilized in the process.
[0042] Typical plastics used in the present invention include optical grade injection moldable material, optical grade polycarbonates, methacrylates or methacrylate modified polycarbonates. Suitable materials are obtainable from General Electric, for instance, plastics sold under the trade designations MAKROLON 2207 and LEXAN LSI are particularly suitable in processes of the present invention. Also, it is necessary to provide optical quality polished mould surfaces to maintain the optical properties of the finished part. The optical surface can be restricted to the plane part of the reflective element. The side piece 5 of the front plastic glass 3 can be designed to appear like frosted glass.
[0043] The surface 5 a as shown in FIG. 7 a is the surface through which illuminating light is emitted. The frosted glass effect achieved by a different structured surface in the molding tool emits a smooth light.
[0044] To provide read lamps the lenses of this read lamps A and B are also molded directly by structuring the tool. Therefore a Fresnel lens can be produced in the same molding step. FIG. 9 shows an embodiment of the front plastic glass seen from the bottom side of the mirror. The surface 5 a of the front plastic glass 3 includes lenses 16 and a structure 17 out-coupling of light. The surface 5 a is in this embodiment not fully transparent.
[0045] Subsequent heat treatments of the part which may occur due to protective or reflective coatings which may be applied do not detrimentally affect or degrade the mirrors of the present invention. This is due to the step of maintaining the part under the pressures specified at molding temperature. Generally, dwell times at temperature are from about 0.1 to 60 seconds. Typical dwell times at temperature are from about 10 to 50 seconds, with preferred dwell times being from about 18 to 25 seconds.
[0046] Because the plastic is allowed to harden at an elevated temperature and pressure, subsequent treatments requiring heat, such as adding reflective coatings, do not adversely affect the optical properties of the plastic.
Legend
[0000]
1 Mirror Housing
2 Mirror Base
3 Reflective Element
4 Light Module
5 Side Piece of Reflective Element
6 Reflective Coating
7 Pane View
8 Edge Illumination
A, B Read Light
C Ambient Light
Rim
10 Piston
11 Second Plastic Glass
12 Inter glass Space
13 Electrochromatic Material
14 Fixing and Isolating Mean
Lens
Surface Structure
LED | The invention is related to a rear view mirror formed by a plastic glass structure and mirror housing. The plastic glass allows smooth edges and a bezel free appearance of the mirror. The plastic glass allows in addition to shine through the mirror body to create different types of illumination in the passenger's cabin. | 1 |
PRIORITY INFORMATION
This application is a continuation of U.S. patent application Ser. No. 11/276,542, filed Mar. 4, 2006, the contents of which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to directed dialog speech recognition systems and more specifically to a system and method for directing a dialog in an interactive speech recognition system and for permitting skipping of menus in a menu hierarchy for users familiar with the interactive speech recognition system.
2. Introduction
Directed dialog speech recognition systems are implemented for automation of customer care applications, as well as other customer applications. A typical directed dialog speech recognition system may replace an older touch tone interactive voice response (IVR) system or a live attendant. Directed dialog speech recognition systems respond to individual words or phrases defined in a grammar. The individual words or phrases are usually prompted in a menu. The system may also prompt a user for yes/no answers to questions, as well as form-filling information, such as, for example, credit card numbers. Calls may also be routed by the system to attendants or alternate destinations.
Other than providing an ability to speak words rather than use touch tones, conventional directed dialog speech recognition systems provide little in terms of user interface improvement over touch tone menu systems. A system which offers many options may have a hierarchical menu structure, such that novice users may be walked through a long list of options in a conceptual manner. However, expert system users may become frustrated when forced to walk through the long list of options.
SUMMARY OF THE INVENTION
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth herein.
In a first aspect of the invention, a method for managing an interactive speech recognition system is provided. Whether a voice input relates to expected input, at least partially, of any one of a group of menus different from a current menu is determined. If the voice input relates to the expected input, at least partially, of any one of the group of menus different from the current menu, skipping to the one of the group of menus is performed. The group of menus different from the current menu include menus at multiple hierarchical levels.
In a second aspect of the invention, a processing device is provided. The processing device includes an electronic storage component, and at least one processor operatively connected to the electronic storage component. The at least one processor is arranged to determine whether a voice input relates to expected input, at least partially, of any one of a group of menus different from a current menu, and if the voice input relates, at least partially, to the expected input of any one of the plurality of menus different from a current menu, skip to the one of the group of menus different from the current menu. The group of menus different from the current menu include menus at multiple hierarchical levels.
In a third aspect of the invention, a machine-readable medium that has instructions recorded therein for at least one processor is provided. The machine-readable medium includes instructions for determining whether a voice relates to expected input, at least partially, of any one of a group of menus different from a current menu, and instructions for skipping to the one of the group of menus different from the current menu if the voice input is determined to relate, at least partially, to the expected input of any one of the group of menus different from the current menu. The group of menus different from the current menu include menus at multiple hierarchical levels.
In a fourth aspect of the invention, a processing device is provided. The processing device includes means for determining whether a voice input relates to expected input, at least partially, of any one of a group of menus different from a current menu, and means for skipping to the one of the group of menus different from the current menu if the voice input relates to the expected input, at least partially, of any one of the group of menus different from the current menu. The group of menus different from the current menu include menus at multiple hierarchical levels.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 illustrates an exemplary directed dialog speech recognition system consistent with principles of the invention;
FIG. 2 illustrates an exemplary processing device that may be used to implement one or more components of the exemplary system shown in FIG. 1 ;
FIG. 3 illustrates a hierarchical menu for an exemplary directed dialog speech recognition system; and
FIG. 4 is a flowchart that illustrates an exemplary process that may be used in implementations consistent with the principles of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Various embodiments of the invention are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the invention.
Exemplary Directed Dialog Speech Recognition System
FIG. 1 is a functional block diagram of an exemplary directed dialog speech recognition system 100 consistent with the principles of the invention. Directed dialog speech recognition system 100 may include an automatic speech recognition (ASR) module 102 , a dialog management (DM) module 106 , a spoken language generation (SLG) module 108 , and a text-to-speech (TTS) module 110 .
ASR module 102 may analyze speech input and may provide a transcription of the speech input as output. DM module 106 may receive the transcribed input, may apply a grammar to the transcribed input to analyze a word or group of words that are included in the transcribed input, may determine to which one of a group of menus the speech input is directed, may process the received input and may determine an action, such as, for example, providing a spoken response, based on the input. SLG module 108 may generate a transcription of one or more words in response to the action provided by DM module 106 . TTS module 110 may receive the transcription as input and may provide generated audible speech as output based on the transcribed speech.
Thus, the modules of system 100 may recognize speech input, such as speech utterances, may transcribe the speech input, may match the transcribed speech to a grammar, may determine an appropriate response to the speech input, may generate text of the appropriate response and from that text, generate audible “speech” from system 100 , which the user then hears. Those of ordinary skill in the art will understand the programming languages and means for generating and training ASR module 102 or any of the other modules in the directed dialog speech recognition system. Further, the modules of system 100 may operate independent of a full dialog system.
FIG. 1 is an exemplary spoken dialog speech recognition system. Other spoken dialog speech recognition systems may include other types of modules and may have different quantities of various modules.
Exemplary System
FIG. 2 illustrates an exemplary processing system 200 in which one or more of the modules of system 100 may be implemented. Thus, system 100 may include at least one processing system, such as, for example, exemplary processing system 200 . Processing device 200 may include a bus 210 , a processor 220 , a memory 230 , a read only memory (ROM) 240 , a storage device 250 , an input device 260 , an output device 270 , and a communication interface 280 . Bus 210 may permit communication among the components of processing device 200 .
Processor 220 may include at least one conventional processor or microprocessor that interprets and executes instructions. Memory 230 may be a random access memory (RAM) or another type of dynamic storage device that stores information and instructions for execution by processor 220 . Memory 230 may also store temporary variables or other intermediate information used during execution of instructions by processor 220 . ROM 240 may include a conventional ROM device or another type of static storage device that stores static information and instructions for processor 220 . Storage device 250 may include any type of media, such as, for example, magnetic or optical recording media and its corresponding drive.
Input device 260 may include one or more conventional mechanisms that permit a user to input information to system 200 , such as a keyboard, a mouse, a pen, a voice recognition device, a microphone, a headset, etc. Output device 270 may include one or more conventional mechanisms that output information to the user, including a display, a printer, one or more speakers, a headset, or a medium, such as a memory, or a magnetic or optical disk and a corresponding disk drive. Communication interface 280 may include any transceiver-like mechanism that enables processing device 200 to communicate via a network. For example, communication interface 280 may include a modem, or an Ethernet interface for communicating via a local area network (LAN). Alternatively, communication interface 280 may include other mechanisms for communicating with other devices and/or systems via wired, wireless or optical connections.
Processing device 200 may perform such functions in response to processor 220 executing sequences of instructions contained in a computer-readable medium, such as, for example, memory 230 , a magnetic disk, or an optical disk. Such instructions may be read into memory 230 from another computer-readable medium, such as storage device 250 , or from a separate device via communication interface 280 .
Processing device 200 may be, for example, a personal computer (PC), or any other type of processing device capable of processing textual data. In alternative implementations, such as, for example, a distributed processing implementation, a group of processing devices 200 may communicate with one another via a network such that various processors may perform operations pertaining to different aspects of the particular implementation.
In some implementations consistent with the principles of the invention, processing device 200 may receive input via, for example, a wired or wireless telephone line connection and may provide output via the telephone line connection.
Directed Dialog Speech Recognition
A directed dialog speech recognition system may replace a live attendant or a touch tone interactive voice response (IVR) system. Directed dialog systems may respond to individual words or phrases, defined in a grammar. The individual words or phrases may be prompted in a menu, such as, for example, a menu for an express delivery customer application.
FIG. 3 illustrates a hierarchical menu for an exemplary directed dialog speech recognition system that implements an express delivery customer application. First, a user may hear “what do you wish to do, please say ‘send package’, ‘track package’, or ‘check account’” with respect to main menu 302 .
If the user responds with “send package”, then the application may proceed to menu 304 and may generate speech for the user asking the user “international or domestic”. If the user responds with “domestic”, the application may proceed to menu 306 and may generate speech for the user asking “overnight, next day, or ground”. If, at menu 304 , the user responds with “international”, the application may proceed to menu 308 and may generate speech for the user asking “overnight, next day, or ground”.
If, at menu 302 , the user responds with “track package”, the application may proceed to menu 310 , and if, at menu 302 , the user responds with “check account”, the application may proceed to menu 312 .
The hierarchical menu structure of FIG. 3 is exemplary. The application may include other prompts or questions for the user, such as, for example, yes/no questions and form-filling questions, such as, for example, “please say your credit card number”.
In implementations consistent with the principles of the invention, a single grammar may be used to recognize responses that may apply to any menu in the hierarchical menu structure. In an alternate implementation, some menus or groups of menus may have a slightly different grammar. Non-overlapping key phrases may be chosen for each of the menus in the hierarchy. In one implementation, progressive elaborations of a phrase may be used. For example, the exemplary express delivery customer application may use progressive elaborations of the phrase “send package”, such as, “send domestic package”, “send international package”, “send domestic package overnight”, “send domestic package next day”, “send domestic package ground”, “send international package overnight”, “send international package next day”, and “send international package ground”. In other implementations, direct phrases may be used instead of progressive elaborations of a phrase. Thus, in implementations consistent with the principles of the invention, the user may be prompted for a subset of responses, such as responses that apply to a current menu, although the user may reply with a response that may apply to any of the menus. Further, the user may respond with a portion of a key phrase. For example, using the exemplary express delivery customer application, a user may respond with “overnight” and the application may prompt the user for additional information, such as, “do you want to send an overnight package international or domestic”.
Implementations consistent with the principles of the invention may permit users to skip menu prompting by, for example, responding to a prompt with a key phrase associated with another menu. For example, with reference to FIG. 3 , if the user responds to a prompt associated with menu 302 with “send domestic package overnight”, the application may perform an action associated with sending an overnight domestic package. If the user responds to the prompt associated with menu 302 by saying “send international package”, the application may skip to menu 308 and may prompt the user with generated speech saying “overnight, next day, ground”.
Implementations consistent with the principles of the invention may provide a tutorial to a user who is determined to be a non-expert. In such implementations, the user's behavior may be recorded. In one implementation, if the user is determined to not have used a keyword or key phrase associated with a menu other than the current menu, then the user may be considered a non-expert. In another implementation, the application may keep a dynamic record of menu traversal in real time and may provide a tutorial based upon the path traversed. For example, if the dynamic record of menu traversal indicates that the user traversed menus inefficiently, such as, traversing menus and then backtracking to another menu before reaching a final menu, or traversing menus very slowly, then the user may be considered a non-expert and the system may provide a tutorial. For example, a user, who the application considers to be a non-expert user, sending an overnight international package may receive a tutorial of “next time, say ‘send international package overnight’ after the first prompt”. A user who the application considers to be an expert user may not be presented with a tutorial.
In other implementations consistent with the principles of the invention, the system may accommodate a corrected phrase. For example, if the user says a phrase, such as, for example, “oh no, I meant to say check account”, or “no, I want check my account”, the system may recognize a keyword or phrase, for example, “check account”, and may skip to the proper menu or take appropriate action (i.e., present the user's account balance).
Exemplary Process
FIG. 4 is a flowchart of an exemplary process that may be used in implementations consistent with the principles of the invention. The process may begin by DM module 106 informing SLG module 108 to send text, corresponding to a prompt, to TTS module 110 , which may perform a text-to-speech operation to generate a speech prompt, such as, for example, “what do you want to do”, to a user (act 402 ). The user may hear the prompt and may verbally respond to the prompt. The verbal response may be converted to text by ASR module 102 and the text passed to DM module 106 (act 404 ).
DM module 106 may receive the text of the user's response and may determine whether the response matches a keyword or key phrase associated with the current menu (act 406 ). If the response is determined to match a keyword or key phrase associated with the current menu, then DM module 106 may process the response (act 408 ). Processing the response may include performing a final action, such as, for example, providing account information for an account, providing tracking information for a package, etc. Next, DM module 106 may determine whether the user's request is completed, i.e., whether a final action was performed (act 410 ). If the user's request is not completed, the DM module 106 may determine which menu is next (act 412 ) and may perform acts 402 - 0410 again.
If, at act 410 , DM module 106 determines that the user's request is completed, then DM module 106 may determine whether the user is an expert user (act 420 ). In one implementation, this may be performed by determining whether a skip was performed based on user input. In another implementation, this may be performed by tracking and recording which of the menus DM module 106 traverses based on the user's input and may further track a length of time spent within each menu. Based on recorded tracking information, DM module 106 may determine whether the user traversed a particular track and then backtracked, whether the user spent an unusual amount of time in a menu, such as, for example, 5 minutes or some other suitable time limit, or whether the user caused a skip based on input before proceeding. DM module 106 may then determine that the user is an expert user if the user did not backtrack, did not spend an unusual amount of time in a menu, and caused a skip. If DM module 106 determines that the user is not an expert (a non-expert), then DM module 106 may inform SLG module 108 to send text to TTS module 110 to provide a tutorial to the user (act 422 ). For, example, if DM module 106 determines that the user should receive a tutorial based on sending a next day international package, the DM module 106 may inform SLG module 108 to generate appropriate text to TTS module 110 , which may generate a verbal tutorial for the user. The tutorial may be of a form such as, for example, “next time you wish to” <perform action> “simply say” <keyword> or <key phrase>.
If, at act 406 , DM module 106 determines that the response is not a response for the current menu, the DM module 106 may determine whether the input includes a keyword or key phrase for another one of the menus or a final action (act 414 ). If DM module 106 determines that the input does include a keyword or key phrase for another one of the menus or a final action, the DM module 106 may perform a skip to the other menu or may prepare to perform the final action (act 416 ). DM module may then perform act 408 .
If, at act 414 , DM module 106 determines that the input does not match a keyword or key phrase of any menu, then DM module 106 , in cooperation with SLG module 108 and TTS module 110 , may prompt and receive from the user more information (act 418 ). For example, the user may be prompted with “do you wish to send a package”, do you wish to check your account”, etc. After receiving additional information, DM module 106 may then determine whether the additional information can be used to match the response to one of the menus (act 416 ).
CONCLUSION
The above-described embodiments are exemplary and are not limiting with respect to the scope of the invention. Embodiments within the scope of the present invention may also include computer-readable media for carrying or having computer-executable instructions or data structures stored thereon. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code means in the form of computer-executable instructions or data structures. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or combination thereof) to a computer, the computer properly views the connection as a computer-readable medium. Thus, any such connection is properly termed a computer-readable medium. Combinations of the above should also be included within the scope of the computer-readable media.
Computer-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. Computer-executable instructions also include program modules that are executed by computers in stand-alone or network environments. Generally, program modules include routines, programs, objects, components, and data structures, etc. that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of the program code means for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described in such steps.
Those of skill in the art will appreciate that other embodiments of the invention may be practiced in network computing environments with many types of computer system configurations, including personal computers, hand-held devices, multi-processor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, and the like. Embodiments may also be practiced in distributed computing environments where tasks are performed by local and remote processing devices that are linked (either by hardwired links, wireless links, or by a combination thereof) through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
Although the above description may contain specific details, they should not be construed as limiting the claims in any way. Other configurations of the described embodiments of the invention are part of the scope of this invention. For example, a natural speech module may be used in implementations instead of a TTS module. In such a system, the natural speech module may play a recorded announcement to a user. Further, in other implementations, hardwired logic may be used instead of processors, or one or more application specific integrated circuits (ASICs) may be used in implementations consistent with the principles of the invention. In addition, implementations consistent with the principles of the invention may have more or fewer acts than as described, or may implement acts in a different order than as shown. Accordingly, the appended claims and their legal equivalents should only define the invention, rather than any specific examples given. | A method and a processing device for managing an interactive speech recognition system is provided. Whether a voice input relates to expected input, at least partially, of any one of a group of menus different from a current menu is determined. If the voice input relates to the expected input, at least partially, of any one of the group of menus different from the current menu, skipping to the one of the group of menus is performed. The group of menus is different from the current menu include menus at multiple hierarchical levels. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns an element to cover the connectors connecting the poles of the elements forming electric accumulators.
2. General State of the Art
As it is known, electric accumulators consist of a plurality of elements which are connected with each other in series by means of connectors which realize the electric connection between poles belonging to adjacent elements.
Said connectors, which essentially consist of a bar made of lead provided with holes at its extremity which match the corresponding poles of the elements, are protected by covering elements which essentially consist of hollow lids made of plastic or insulating material which are removably coupled by pressure or a snap with the connectors themselves.
The connectors are realized in different lengths and, consequently, the battery manufacturers must keep in stock covering elements presenting different lengths, each one suited to couple with a connector of the corresponding length.
It is understood that this fact implies the necessity of keeping large supplies of covering elements in stock and, therefore, to bear the relative costs.
SUMMARY OF THE INVENTION
In the attempt of overcoming such an inconvenience, covering elements have been developed, consisting of two extremity elements longitudinally sliding in relation to a central body to which they are coupled. In this way, the same covering element can be applied, within a restricted range of lengths, to connectors presenting different lengths.
Such a solution, if on one hand it reduces the amount of sizes of the covering elements to be kept in stock, on the other hand it requires the construction of a larger number of moulds since, for each covering element, it is necessary to realize at least one mould for the construction of the extremity elements and one mould for the construction of the central body to which said extremity elements are coupled.
Moreover, since said covering elements consist of more parts co-operating with one another, these must be joined together before applying the covering element to the corresponding connector and this fact means additional working times for the operators, as compared with the time which is strictly necessary to apply the covers to the connectors.
It is with the purpose of overcoming such inconveniences that the present invention is disclosed.
In particular, one purpose of the invention is to obtain an element to cover the connectors for the connection of the poles of the accumulators, which can be applied to connectors having lengths differing from one another.
Another purpose is for said covering element to be composed of only one element.
Another purpose is for said covering element, after the assembling to the relative connector, to unmistakably indicate the position of the positive pole and of the negative pole.
Not the last purpose is for said covering element to permit the reading of electric measurements on the poles, without removing it.
The described purposes are achieved by the realisation of an element to cover the connectors connecting the poles of the elements of an electric accumulator which, in accordance with the main claim comprises a hollow body suited to receive the body of one of said connectors, said hollow body presenting its extremities suited to match the corresponding extremities of the body of said connector one being connected with the positive pole and the other with the negative pole of adjacent elements belonging to said accumulator and is characterized in that at least one part of said hollow body presents a shaped profile suited to realize an elastically flexible structure which allows the variation of the length of said covering element, whenever said covering element is strained by an axial force, said variation of length being suited to allow the coupling of the same covering element with connectors presenting lengths differing from one another.
According to one preferred embodiment, the essentially central area of the hollow body of said covering element presents an undulated profile having an essentially sinusoidal development which defines a bellows structure presenting a high degree of axial elastic flexibility.
Advantageously, the covering element according to the invention can quickly be applied to the corresponding connector since it is obtained in a single piece.
With as much advantage, the covering element according to the invention reduces the amount of the size variations of the covering elements to be kept in stock.
BRIEF DESCRIPTION OF THE DRAWINGS
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific example, 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 and from the drawings, wherein:
FIG. 1 shows in an axonometric exploded representation the covering element according to the invention suited to be coupled with the connector for the connection of the poles of the elements of an underlying accumulator;
FIG. 2 shows the covering element of FIG. 1 applied to the corresponding connector, the latter being connected with the poles of the accumulator;
FIG. 3 shows the detail of the covering element according to the invention in a top view;
FIG. 4 shows the covering element of FIG. 3 in a longitudinal section, coupled with the corresponding connector;
FIG. 5 shows the covering element according to the invention seen from below;
FIG. 6 shows the covering element according to the invention in a top view and extended;
FIG. 7 shows a top view of a different embodiment of the covering element according to the invention;
FIG. 8 shows the cutaway lateral view of the different embodiment of the covering element represented in FIG. 7;
FIG. 9 shows the different embodiment of the covering element according to the invention represented in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As can be observed in FIG. 1, the covering element according to the invention, indicated as a whole with 1, is applied to a connector 2 which presents two circular annular holes 21 and 22 which match the positive pole 31 and the negative pole 32 respectively, of two adjacent elements of an electric accumulator, indicated as a whole with 3, which, in this way are connected in series.
Obviously, the connector 2 can also connect in series elements belonging to accumulators differing from one another.
Said connector 2, once it has been coupled with the poles 31 and 32, is welded to them and then covered, as can be observed in FIG. 2, by applying to it the covering element 1.
As can be observed in FIG. 3, the covering element 1 comprises a body 10 which presents a first extremity 11 and a second extremity 12 placed opposite to each other which, as can be observed in FIG. 5, have profiles 14 and 15 respectively, presenting the shape essentially of an arch of a circle which allow them to match the corresponding profile of the extremities 24 and 25 of said connector 2.
It can also be observed that said covering element 1 is essentially hollow and lodges inside the body 20 of said connector 2, against which it laterally contrasts by means of the lateral centering projections 16. Moreover, the body 10 of said covering element 1 also presents, as can be observed in FIG. 4, retaining tabs 140 facing the interior and arranging themselves under the connector 2 so as to ensure the stability of the coupling. Said tabs 140 are arranged at an angle 240 of 45° in relation to the axis of said covering element.
The body 10 of said covering element presents a shaped profile having an essentially sinusoidal undulated development which defines a bellows structure 17 which gives to the covering element characteristics of axial elastic flexibility, whenever it subjected to tensile axial stresses 18.
Such a flexibility facilitates the application of the covering element to the connector 2 and also permits its application to other connectors which are longer than connector 2. In fact, by applying to the covering element 1 a tensile axial stress 18, it essentially acquires the configuration represented in FIG. 6 which permits to apply it to connectors which are longer than the connector 2 represented in FIG. 1.
Moreover, after the extension and the application to the connector, the elastic return of the bellows 17 causes the cover to be securely locked to the connector, said locking being further improved by the insertion of the tabs 140 under the connector.
It can be observed that one of the extremities of said covering element, in this case the second extremity 12, has the external configuration 120 of an acute angle facing away from the covering element and an arrow symbol 122 is impressed on it which stands for the direction of the current which, conventionally, goes from the positive pole to the negative pole. If, conventionally, it is decided to always connect the second extremity 12, shaped as an acute angle 120, to the negative pole 32 of the element of the accumulator, the positions of all of the positive and negative protected by the application of the covering element.
The second extremity 11, as can be observed in the FIGS. 3 and 6, presents a curved shape and is provided with an area 110 for receiving a symbol, a mark or similar.
Said covering element presents, in correspondence with said second extremity 12, a hole 121 which permits the insertion of the terminal of an electric measurement gauge for monitoring the voltage or the intensity of the current. It is pointed out that in a different embodiment, there may be eventually two holes on the covering element, one in correspondence with each extremity, being, however, a single hole fully sufficient, since the other terminal of the measuring gauge is inserted in the corresponding single hole of the other covering element arranged on the connector of the adjacent element.
According to a different embodiment represented in the FIGS. 7, 8 and 9, the covering element according to the invention, indicated as a whole with 201, presents both the first extremity 212 and the second extremity 211 having the shape of a curved inner profile 215 and 214, respectively. Even in such a different embodiment, said second extremity 211 is provided with an area 210 for receiving a symbol, a mark or similar, while the first extremity 212 presents a profile 222 in the shape of an acute angle on its upper surface 220. Such a profile is comprised inside the curved profile of said first extremity 212, on the upper surface 220 of which it is obtained and oriented along the axis 300 of the element itself.
On such an upper surface 220, is also impressed an arrow 400 pointed in the same direction as the acute angle 222.
On the basis of what has been said, it is understood that the covering element, in whichever different embodiment it is constructed, reaches all the proposed purposes.
First of all, the purpose of making possible for the same covering element to be coupled to connectors presenting different lengths has been achieved. This is done by exploiting the flexibility due to the particular configuration with which the body of the covering element is obtained.
Moreover, the particular shape of one of the extremities of the covering element makes it possible to unmistakably recognize the polarity of the pole of the accumulator arranged in correspondence with said extremity.
Moreover, since the covering element according to the invention is obtained in a single component, the number of items to be kept in stock is reduced to the minimum as compared with covering elements manufactured with several pieces and equivalent with it. In this way, the assembling operations to be performed before applying the cover to the connectors, are also eliminated.
During the construction, the covering element according to the invention may undergo modifications consisting, for instance, of a different shape of the profile of its extremities and of the bellows which realizes its flexibility.
However, it is to be understood that all said variations and other possible ones fall within the scope and spirit of the invention. | The invention discloses an element (1; 201) to cover the connectors (2) connecting the poles (31, 32) of the elements of an electric accumulator (3) and consists of a hollow body (10) which receives the body (20) of one of said connectors (2). At least one part of said hollow body (10) presents a shaped profile (17) suited to realize an elastically flexible structure which allows the variation of the length of said covering element (1), whenever it is strained by an axial force (18). Said variation of length allows the coupling of the same covering element (1; 201) with connectors (2) presenting lengths differing from one another. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process and apparatus for producing finished wood sheets from rough cut wood and particularly to producing wood panels for use in making multi-layer wood products.
The invention relates to a method and a device for the production of wood sheets from cut wood. Wood sheets in this context are to be understood as relatively thin wood panels which are thicker than 2 to 3 mm and which are processed into high-grade products made up of one or more layers, such as, for example, natural wood panels made up of several layers, glue binders, glued laminated wood, window ledges, solid wood panels and the like.
2. Description of the Prior Art
According to the prior art, such wood sheets are generally produced in that the cut wood is firstly dried to a relatively low degree of humidity and that the cut wood planks are then sawn by means of bandsaws and the like into the individual wood sheets. Such a method has several disadvantages. On the one hand, the quality of the wood sheets produced in this way leaves something to be desired, since the wood sheets in the sawing process easily fray or become ragged, particularly in the region of knots and edges, with this occurring all the more, the drier the cut wood is which is to be cut. This results in a relatively high proportion of damaged goods.
A further disadvantage of the known method is to be seen in the relatively poor yield, i.e. the proportion of waste is relatively high. This lies in the fact that waste occurs on each cut by the saw, corresponding to the thickness of the saw cut. If, for example, wood sheets are produced with a thickness of 4 mm and if the saw cut width is 2.5 mm, then a wastage of approximately 40% of the cut wood material already results from this.
A further disadvantage in the method according to the prior art is to be seen in that in the production of the wood sheets, a relatively large amount of energy is consumed. The reason for this is that owing to the relatively wide cutting slit of the saw cut, a large amount of material has to be machined off.
On the other hand, it is known to produce wood sheets in a cutting device by means of a sawdust-free cutting process such as is described in PCT application No. WO 88/00517 entitled "Process and Device for Cutting Up Tree Trunks into Wood Products Without Shavings", incorporated herein by reference. In the sawdust-free process, a tree trunk or rough cut wood plank is axially guided against a knife which separates a sideboard laterally from the tree trunk. The results which have been able to be achieved hereby to date are, however, likewise not very satisfactory. On the one hand, the yield here is increased by avoiding the saw cut, but on the other hand in this method a so-called residual sheet occurs, i.e. after cutting off the maximum number of wood sheets which an be cut from the cut wood plank with the required nominal thickness, a remainder is left behind, which has a smaller thickness than the nominal thickness of the wood sheets which are to be produced, and is therefore unable to be used further, in any case not in the respective continuation of production.
Furthermore, the quality of the wood sheets thus produced leaves much to be desired, especially since the individual wood sheets leave the cutting device in a greatly warped state, which derives form the fact that the wood sheets cut off from the cut wood plank are carried away obliquely to their original direction of transportation. In the known cutting device, consequently, the problem is posed, which has not been solved to date, of restoring such warped wood sheets into their non-warped, level or flat state at a justifiable expense.
The invention is therefore based on the problem of indicating a method which provides high-grade wood sheets at a justifiable expense, in which at the same time a maximum yield is to be achieved and, moreoever, the necessary expenditure of energy is to be kept as low as possible. Furthermore, a device is to be created, which satisfies the above-mentioned conditions.
SUMMARY OF THE INVENTION
This problem is solved according to the invention substantially in that the cut wood is cut into the individual wood sheets in a sawdust-free manner, that the wood sheets are then dried and that according to requirements, one or more sides of the dried wood sheets are then subsequently worked in particular by grinding, wherein the method steps are preferably carried out continuously, so that the individual wood sheets run through the entire installation automatically and continuously.
Although the wood sheets are subject to warping after sawdust-free cutting, as in the prior art, the sheets are straightened during drying wherein the sheets are pressed between opposed carpets of wire mesh within the drying apparatus.
In a preferred further development of the inventon, a further method step can be added before the method step of sawdust-free cutting, which further method step makes possible an optimization of the cut, such that no residual sheets arise. This method step, which is added in front, may consist of the fact that the the cut wood is preconditioned as regards humidity, to achieve a uniform initial humidity before the method step of cutting; in particular it is pre-died, whereby a humidity of the cut wood of approximately 40 to 60% is aimed for, preferably approximately 50%, adapted to the respective type of wood.
Alternatively, or in addition, this method step which is added in front, may consist of the fact that the humidity of the cut wood which is fed to the cutting station is measured and the cutting parameters, such as in particular the contact pressure in the region of the cutting blade and or the cutting thickness are controlled according to the measured humidity. Tolerances which would otherwise lead to the occurrence of residual sheets, can be balanced out in this way.
The combination, according to the invention, of sawdust-free cutting/drying/subsequent working by machining including, if necessary, the method step preceding cutting, leads to the following advantages:
Wood sheets of the highest quality are produced. The visible surfaces of the panel sheets treated by grinding have a high surface quality, since fraying in the region of knots as in the case of the prior art do not even occur at all here in this extent and, in addition, are largely eliminated through the grinding process. Since the cut wood is not, as in the known prior art, dried down to a low degree of humidity before processing, the wood remains intact in the knot regions during cutting.
The energy required for the production of the wood sheets is less than in the prior art. Whereas in the prior art with every cut, wood is machined in the width of the saw cut, in the case of the method according to the invention, owing to the grinding process, material is merely removed in the width of a fraction of a millimeter; in the cutting device itself, no material is machined. The total of the expenditure of energy necessary for cutting and for subsequent later treatment (grinding) is less than the expenditure of energy required during sawing.
Owing to the sawdust-free cutting of the wood sheets, practically no waste occurs in the cutting device. Since in the subsequent processing of the cut wood sheets likewise only a comparatively small amount of waste occurs, the method according to the invention produces an excellent yield. This is further improved in that an optimization of the cut is possible, such that even the so-called residual sheets, which have the same tolerances as the other wood sheets and are therefore able to be used further just as the latter, can remain in the production cycle; or, in other words, residual sheets can be completely avoided in the method according to the invention.
In the case of the method according to the invention, the material used is consequently decisively reduced compared with conventional methods; thus, approximately 50% to 80% less waste occurs, so that a correspondingly higher yield of the starting material results.
The method according to the invention permits a production of sheets which is substantially more protective to the wood than conventional methods. Thus, for example, the drying and processing tears which otherwise occur in particular in the knot regions are largely eliminated or respectively are not present.
By the method according to the invention, in which the wood sheets are dried following cutting, particularly uniform drying results are achieved to down to approximately 6% wood humidity and even less. In the conventional technology, in which the wood is dried before cutting or respectively sawing, a further processing of the material with such a low wood humidity is no longer possible in practice or is only possible under certain conditions, i.e. with corresponding losses of quality. The drying of the wood sheets after the cutting of the cut wood planks additionally has the advantage that in the drying process less energy is consumed, since on the one hand the waste occurring in the case of the prior art during sawing, such as sawdust and residual sheets are not also dried in the process and, moreover, the thinner material, which is already cut, is easier to dry than the substantially thicker starting material.
A further crucial advantage of the drying process added after the cutting process lies in that in the temperature-controlled drying process, in which drying is carried out at a temperature in the order of approximately 160°, the warping of the wood sheets which occurred in the cutting process, can be reversed again, so that completely flat, non-warped panel sheets leave the drier. Only under this condition are economically suitable uses produced for the method, known per se, of producing the wood sheets by means of cutting with a blade.
A further feature of the invention is based on the knowledge that in the sawdust-free cutting of the cut wood by means of cutting blades, one of the two side faces of the wood sheets, namely that on the cutting side, has a lesser surface quality than the other, since on this side fibres are obviously destroyed on the surface in the cutting station, which causes these sides, hereinafter named "open" sheet sides, to have small tears and the like, which reduce the surface quality of this open sheet side. According to a further method step according to the invention, the wood sheets are therefore marked following the cutting process as regards their underside facing the cutting blade and/or their upper side facing away from the cutting blade, for example by a visual marking, so that up to the final processing of the wood sheets to be the end product it can be established which side of the wood sheet is the open sheet side and which is the closed sheet side. Since this marking can disappear in the subsequent working process, the marking can be repeated if necessary following the subsequent working process. The marking which is applied to the wood sheets makes it possible to ensure that in the end product the visible surface or respectively surfaces are always formed by the closed sheet sides. Through this, a uniform quality of the end products can be ensured.
The subsequent working device, which is arranged after the drying device, preferably comprises components which may be connected in individually for the selective subsequent working of the side faces of the wood sheets, running at a maximum of four parallel to the direction of advance. Such components are preferably formed from high speed grinding machines, in which, however, in particular the narrow sides of the wood sheets are alternatively also equalized and may be processed by high speed milling units. If required, also, several components may be connected in series. The components may serve for grinding, planing, milling and, if applicable, also for profiling the wood sheets, for example to remove the edges. The individual connectability of the individual components ensures that only those sides of the wood sheets are subsequently treated in which this is necessary from a technical point of view; for example, in a multi-layered board, the surfaces of the wood sheets lying on the inside of course do not have to be ground, or only under particular conditions. The entire processing in the region of the subsequent working is adapted to the later use of the wood sheets, i.e. the processing machines are designed such that different faces or respectively edges may not be processed, or else may be processed several times within one passage, depending on the setting.
Further advantageous features of the invention will emerge from the remaining sub-claims in connection with the following description, in which several example embodiments of the invention are illustrated in further detail with the aid of the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of a device operating by a method according to the inventon, for the production of wood sheets from cut wood,
FIG. 2 shows a diagrammatic side view of the sorting apparatus of the device according to claim 1, and
FIG. 3 shows a plan view onto a portion of a further form of embodiment of a device according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIG. 1, in the case of the example embodiment described here, the cut goods, in the form of cut wood, e.g. square timbers, boards, planks 2 etc. is firstly predried or respectively preconditioned in a conditioning apparatus 4, in which the planks 2 are arranged so as to be stationary. The conditioning apparatus 4 may be a cut wood drier, which as the possibility that in certain areas within the cut wood drier, the wood humidity can be raised somewhat, according to requirements, for example by spraying or introducing vapour. The conditioning apparatus 4 sees to it that the planks leaving the conditioning apparatus have a very uniform initial humidity, whereby particularly good and accurate cutting results are achieved. The wood humidity of the planks 2 leaving the conditioning apparatus is approximately 50%.
After the wood planks are conditioned, they are separated and passed to the cutting apparatus, which is designated as a whole by the reference number 6, in which the aligned wood planks are carried past one or more cutting stations 8, arranged in series. Each times the plank is carried past a cutting station, in each case one wood sheet 10 is cut off, whereby the planks 2 are carried in a circuit (indicated by the dotted line 12) within the cutting apparats 6 until the plank has been cut up completely into the individual wood sheets. The cutting apparatus 6 as such is substantially prior art and therefore requires no further explanation. To minimize or completely avoid a residual sheet, the cutting process can be dynamically controlled to produce a whole number of sheets from the remaining rough cut sheet. Thus, after each cut, the remaining thickness of a rough cut plank is measured and the thickness of the nest sheet to be cut is controlled accordingly. For example, assume a rough cut plank having a thickness of 56 mm is to be cut into 7 sheets, each 8 mm thick. If, after the first cut, the thickness of the remaining plank is more than 48 mm, the next sheet will be cut to have a thickness of, e.g. 8.1 mm.
From the cutting apparatus 6, the wood sheets 10, which have been cut off from the planks 2, are automatically transported onto a conveyor 14, on which they are conveyed, arranged parallel adjacent to each other, to a drying apparatus 16 and through the latter. At the outlet of the cutting apparatus 6, a marking apparatus 18 is arranged, which marks the upwardly-pointing side of the wood sheets 10 leaving the cutting apparatus 6. This upwardly-pointing side is the closed side of the board sheet, which is suitable for later use as the visible face.
The uniformly dimensioned, marked wood sheets 10, arranged lying adjacent to each other, then run continuously through the drying apparatus 16, which is constructed as a tunnel drier. This tunnel drier is equipped with a temperature control, which makes possible an exact temperature setting in the drier. The wood sheets 10 leaving the drying apparatus are dried very uniformly to wood humidities up to approximately 6%.
In the case of the example embodiment according to FIG. 1, the speed at which the wood sheets 10 run through the tunnel drier is 2.5 m per minute, in which, for example in the case of sheets of pine with a thickness of 8 mm, the drying temperature is approximately 165° C. The volume of the drier is approximately 1000 m 3 and the amount of exhaust air here is approximately 15000 m 3 per hour. The tunnel drier, viewed in the conveying direction of the wood sheets, is divided into several, for example three, temperature zones. The wood sheets which are to be dried may be arranged inside the tunnel driver 16 lying one above the other in one or several levels.
The wood sheets 10 leaving the drying apparatus 16 then run through a cooling- or respectively, air-conditioning apparatus 20, in which the cooling of the wood sheets is accelerated, in order to have available for further processing in the subsequent working apparatus 24 the optimum material temperature for this.
Furthermore, after the cooling apparatus 20, a humidity-measuring station 22 is provided, in which the drying data of the wood sheets 10 are measured, in order to be able to monitor and control the orderly operation of the drying apparatus 16. For this purpose, the data measured in the humidity-measuring station 22 are fed to a data pick-up and memory apparatus 23, from which the data can be printed out on request, or else can be further used for a temperature control of the drying apparatus 16. From the drying apparatus 16 or respectively the humidity-measuring station 22, the dried wood sheets 10, the warping of which was reversed through the heat treatment in the drying apparatus 16 and which are therefore completely flat, are passed via suitable conveying means to the subsequent working apparatus 24. In the case of the example embodiment described, this subsequent working apparatus 24 comprises high speed grinding machines, working a maximum of four sides, which make possible a continuous further working of the dried sheets with speeds of advance of up to 150 m per minute. The individual units of the high speed grinding machines, known per se, are able to be connected in individually, so that always only those sides of the wood sheets are worked, for which such a subsequent working is necessary, taking into account the later purpose of use. In the subsequent working apparatus 24, the wood sheets are processed to closes of tolerances in the order of a total 1/10 mm. As already mentioned above, for example for working the edges of the wood sheets, high speed milling units may be used, which operate in combination with high speed grinding machines for the working of the upper and lower faces of the wood sheets.
After the wood sheets ar processed in the subsequent working apparatus 24, the wood sheets, which if necessary are marked once again in the further marking station 18' arranged after the subsequent working apparatus 24, are passed to a sorting apparatus, designated as a whole by the reference number 26, in which the wood sheets are classified according to their quality and are passed to corresponding different transport paths. The structure of the sorting apparatus 26 can be seen from FIG. 2. The wood sheets 10 coming from the subsequent working apparatus 24 are firstly fed continuously to a sorting line 28, in which they are classified as regards their quality, for example according to three classes of quality A, B and C. This classification may take place automatically or by personnel trained accordingly. The individual wood sheets 10 are displaced in depth according to the quality class allocated to them, whereby for example, one may proceed such that the wood sheets of quality class A, i.e. the highest quality class, are not displaced, the wood sheets of quality class B and C are displaced to the rearm, whereby the good sheets of quality class C are displaced deeper than those of quality class B. At the end of the sorting line 28, light barrier apparatus 30 are provided, which scan the respective positions of the wood sheets 10 running through beneath them, and hereby pick up if required record the classification of the respective wood sheets 10.
Following the sorting line 28, the wood sheets 10 are transferred to a revolving elevator 32, feeds the individual wood sheets 10 according to their respective quality class to different sorting sections 34, 36, 38. Associated with the sorting sections 34, 36, 38 in each case are corresponding flaps 40, which are controlled via a control apparatus 42 connected with the light barrier apparatus 30. The control apparatus 42 causes the flaps 40 of the respective sorting section, associated with the respective quality class, to be actuated with a corresponding delay, depending upon the determined quality class of the individual wood sheets 10. Furthermore, beneath the further processing sections 34 to 38, an additional further processing section 44 is provided, which is selectively likewise able to be controlled, whereby the wood sheets deposited hereon can be fed directly to a further processing machine, for example a continuously operating side glueing press or the like. On the other hand, the wood sheets fed to the further processing sections 34 to 38 are stacked in the stacking stations 36, in which a counting apparatus, not shown in detail, is present, which counts the wood sheets deposited on the stack and initiates the passing of a complete stack to a further elevator 38, which feeds the stack 50 of wood sheets to a conveying apparatus 52, which transports the individual stacks to the final stack sites 54, where the wood sheets are stacked up, sorted according to their quality class. The previously sorted and stacked wooden sheets are then passed on with the aid of suitable transport apparatus to further processing lines, such as, for example, a fully automatic press line.
FIG. 3 shows an alternative form of embodiment of a device according to the invention, in the region of the cutting apparatus and also the unit arranged before the latter. In the case of this example embodiment, before the cutting apparatus 6 in the conveying path of the planks which are to be fed to this cutting apparatus, a measuring station 60 is arranged, which measures the humidity of the cut wood planks and generates a corresponding electrical output signal. This electrical output signal is fed to a control apparatus 62, which as a function of the measured humidity controls one or more cutting parameters of the cutting apparatus 6; the contact pressure of the planks which are to be cut against the cutting blades, or the cutting thickness, particularly come into consideration as suitable cutting parameters. In this way, the tolerances which result from differing wood humidities, can be eliminated, whereby the desired optimization of the cut can be achieved without the occurrence of residual sheets.
In the example embodiment described above, the method steps will run continuously. Alternatively, however, they could also be carried out with a suitable intermediate storage between particular method steps, with subsequent loading.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims. | A method for the production of finished wood sheets from rough cut wood includes the steps of conditioning the rough cut wood, as necessary, to obtain a predetermined moisture content equivalent to a humidity of 50%. The conditioned rough cut wood is cut into predetermined dimensions using a sawdust-free process and then immediately dried to obtain a low moisture content. The dried wood is further treated using a grinding process to eliminate rough edges of the finished sheet. | 1 |
REFERENCE TO PROVISIONAL APPLICATION
This application is based on and hereby refers to U.S. Provisional Patent Application Ser. No. 60/702,133, filed Jul. 25, 2005, having the same title as appears above, the entire contents of which application are incorporated herein by this reference.
FIELD OF THE INVENTION
This invention relates to fittings and associated systems for securing objects to elongated tracks and more particularly, but not exclusively, to anchoring assemblies designed to fix positions of passenger seats within an aircraft or other vehicle.
BACKGROUND OF THE INVENTION
Aircraft and certain other vessels configured for transporting passengers typically include elongated tracks bolted or otherwise connected to their floors. These tracks conventionally contain channels formed by a lower, generally horizontal wall and spaced side walls extending upward therefrom. Integral with the side walls may be inwardly-extending flanges spaced from, but generally parallel with, the lower wall. Formed periodically in the flanges may be crescent-shaped cut-outs, creating generally circular receptacles spaced longitudinally within the elongated track.
U.S. Pat. No. 5,337,979 to Bales, et al., whose contents are incorporated herein in their entirety by this reference, illustrates and discusses examples of such elongated tracks. Also disclosed in the Bales patent are fittings for these tracks. The fittings include fingers adapted to slide along the lower walls of the tracks. Rear boss portions formed with the fingers include plungers biased toward the lower surfaces of the tracks and adapted to be received by the receptacles.
U.S. Pat. No. 5,823,727 to Lee, whose contents also are incorporated herein in their entirety by reference, addresses additional fittings for elongated tracks. According to the Lee patent, fittings with bell-shaped bases may be teamed with abutting “buttons” having inwardly-flared areas to prevent the fittings from moving longitudinally within the tracks. Washers and lock nuts also may be used to retain the positions of the fittings for later attachment of an object.
Yet another anchoring fitting for an aircraft seat is detailed in U.S. Pat. No. 6,260,813 to Whitcomb. The fitting slides along the channeled tracks of the aircraft, with a separate locking pin remote from the fitting employed to fix the position of the seat. The contents of the Whitcomb patent too are incorporated herein in their entirety by reference.
SUMMARY OF THE INVENTION
The present invention provides alternate fitting systems and assemblies for use principally, but not necessarily exclusively, for aircraft seats. The systems are designed to supply positive adjustable positioning of a seat or other object, actuated with a single turn (or less) of a single tool. They additionally are adapted for use with the conventional channeled tracks described in the preceding section.
Beneficially included as part of the systems is a base frame positioned for movement within the track. The base frame also functions as mounting structure both for linkages to an associated seat and for internal components of a fitting assembly. To help fulfill this latter role, the frame may include horizontally- and vertically-oriented openings.
Positioned in a vertically-oriented opening of the base frame of a preferred embodiment of the invention is a rod. The rod is designed to travel vertically within the frame. It also supports an associated plunger, which similarly travels vertically within the frame and is designed to engage a track. The plunger additionally may have flanges and pins, with the former helping reduce vertical motion (rattle) of the fixed seat or other object and the latter providing positive locking against fore and aft movement of the fixed object.
Fitting assemblies of the present invention further may include cams and cam followers. A cam follower may be attached to the rod through one or a series of disc springs and transmit vertical force from a cam to the rod and plunger, ultimately supplying clamping force against the track. This clamping force reduces the vertical motion, or rattle, of the seat or other object mentioned in the preceding paragraph.
In these embodiments, the cam may be positioned through a horizontally-oriented opening in the base frame so as to translate rotational force into the more linear, vertical force applied to the cam follower. Flat areas of the cam permit positive stops for locking purposes. By protruding out the side of the base frame, further, motion of the cam may be actuated by a tool likewise positioned to the side of the base frame. Allowing side access to the actuation mechanism is often beneficial, as typically fewer space constraints exist to the side of the base frame than above or below it.
Other components of exemplary assemblies of the invention may be coil springs and caps. Positioning a coil spring between the base frame and rod provides upward bias to the rod and plunger, ensuring they are fully retracted when the assembly is unlocked (i.e. as for movement of the associated object). A cap, finally, may be attached to an upper section of the rod and employed to encapsulate the remainder of the fitting assembly. Such a cap additionally may function to limit the axial and rotational travel of the cam and, if desired, provide positive indication of whether the assembly is locked or unlocked.
In operation, a tool (such as but not necessarily limited to an Allen wrench) may be used to rotate the cam and, depending on the rotation direction, either depress or retract the plunger. When the plunger is retracted, the cap is in its uppermost position (as an indicator that the assembly is unlocked), and the assembly does not prohibit movement of the base frame and attached object. By contrast, when the plunger is depressed, it engages the track and thereby inhibits movement of the frame and object. When the plunger is fully depressed, the cap is in its lowermost position (indicating the assembly is locked), with the coil and disc springs compressed.
It thus is an optional, non-exclusive object of the present invention to provide improved fitting systems and assemblies.
It is also an optional, non-exclusive object of the present invention to provide fitting systems and assemblies especially adapted for use with aircraft seats.
It is another optional, non-exclusive object of the present invention to provide fitting systems and assemblies requiring no more than a single turn of a single tool to positively adjust (and lock) the position of an article.
It is a further optional, non-exclusive object of the present invention to provide fitting systems and assemblies in which depressible plungers interact with features of elongated flooring tracks to lock an article in position longitudinally.
It is, moreover, an optional, non-exclusive object of the present invention to permit the actuation tool to engage a cam through the side of the base frame.
It is yet another optional, non-exclusive object of the present invention to provide fitting systems and assemblies which provide visual indication of whether an associated object is, or is not, locked in place in a track.
Other objects, features, and advantages of the present invention will be apparent to those skilled in the relevant field with reference to the remaining text and drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary pair of tracks to which fitting assemblies of the present invention may be attached.
FIG. 2 is a cut-away view of a portion of a track of FIG. 1 .
FIG. 3 is a side elevational view of components of a fitting assembly of the present invention, to which components of a vehicle seat are attached, shown in an unlocked position.
FIG. 4 is a side elevational view of the components of FIG. 3 shown in a locked position.
FIG. 5 is a cut-away view of a portion of a base frame of FIGS. 3-4 .
FIG. 6 is a view of a rod of FIGS. 3-4 .
FIG. 7 is a view of a plunger of FIGS. 3-4 .
FIG. 8 is a view of a cam of FIGS. 3-4 .
FIG. 9 is a view of a cam follower of FIGS. 3-4 .
FIG. 10 is a view of a disc spring of FIGS. 3-4 .
FIG. 11 is a view of a cap of FIGS. 3-4 .
FIG. 12 is a cut-away view of components of FIGS. 3-4 shown in the unlocked position of FIG. 3 .
FIG. 13 is a cut-away view of components of FIGS. 3-4 shown in the locked position of FIG. 4 .
DETAILED DESCRIPTION
Illustrated in FIG. 1 is an example of a pair of tracks 10 useful in connection with the present invention. Such tracks 10 are shown mounted in parallel paths to floor F of an aircraft, other vehicle, or other device or object. As detailed in FIG. 1 , each track 10 may comprise lower wall 14 , side walls 18 extending upward therefrom, and a flange 22 extending inward from each side wall 18 . Track 10 thus forms an elongated channel 26 .
Also depicted in FIGS. 1-2 are crescent-shaped cut-outs 30 spaced along each flange 22 . Spacing of these cut-outs 30 is matched along each flange 22 of a track 30 so that, for example, a cut-out 30 A of a flange 22 A is opposite a cut-out 30 B of flange 22 B. By matching spacing of cut-outs 30 in this manner, each pair of opposed cut-outs 30 A and 30 B forms a generally circular receptacle into channel 26 of a corresponding track 10 .
FIGS. 3-5 illustrate base frame 34 of a preferred assembly 38 (see FIGS. 12-13 ) of the present invention. In use base frame 34 is proximate a track 10 and functions to connect article frame 42 of a seat or other article to track 10 . Article frame 42 may be attached to base frame 34 in any suitable way.
Proximate at least one end 46 (and preferably both ends 46 and 50 ) of preferred base frame 34 is a vertically-oriented opening 54 and a horizontally-oriented opening 58 . Opening 54 is designed to receive rod 62 (see FIG. 6 ) and certain other components of assembly 38 , while opening 58 allows access to feature 66 of cam 70 (see FIG. 8 ).
FIGS. 6-13 show various other components of exemplary assembly 38 . Detailed in FIG. 6 is rod 62 , which may travel vertically within opening 54 of base frame 34 . Attached to upper end 74 of rod 62 is cap 78 (see FIG. 11 ), while attached to lower end 82 of the rod 62 is plunger 86 (see FIG. 7 ). Plunger 86 and track 10 operate to limit downward travel of rod 62 , while cam follower 90 ( FIG. 9 ) and one or more disc springs 94 ( FIG. 10 ) limit upward travel of the rod 62 .
Plunger 86 beneficially includes shear pins 98 and flanges 102 . When extended downward, plunger 86 engages a pair of matched cut-outs 30 of track 10 . Shear pins 98 cooperate with cut-outs 30 of track 10 to prevent forward or aft (i.e. longitudinal) movement of article frame 42 . Flanges 102 , by contrast, provide surfaces which may be clamped against flanges 22 of track 10 , thus inhibiting vertical movement of article frame 42 relative to the track 10 . This latter inhibition reduces the likelihood that article frame 42 will rattle in use.
FIG. 11 illustrates an example of cap 78 of the present invention. Cap 78 attaches to upper end 74 of rod 62 . Preferred assemblies 38 connect cap 78 and rod 62 using a snap-hook arrangement, although those skilled in the relevant art will recognize that other attachment mechanisms may be employed instead. Cap 78 may perform multiple functions as part of assembly 38 , including encapsulating other components of the assembly 38 and protecting them from damage. Because of its configuration, cap 78 additionally may limit upward travel and impede rotational travel of rod 62 . Finally, because cap 78 may be (i) visible above base frame 34 when assembly 38 is not locked into track 10 and (ii) not visible above frame 34 when assembly 38 is locked into track 10 , the cap 78 functions as a visible indicator of the operational status of assembly 38 .
Cam 70 appears in FIG. 8 . Cam 70 is positioned within opening 58 of base frame 34 to that feature 66 is accessible externally of the base frame 34 . Although feature 66 is illustrated as comprising a six-sided recess (thus readily receiving a hexagonal Allen wrench or similar tool), it need not necessarily be configured in this manner. Preferably, however, feature 66 is structured so that merely a single turn (or less) of a single tool is necessary to effect change of operational status of assembly 38 .
Curved lobe 106 of cam 70 cooperates with cam follower 90 to translate rotational force provided by the tool into linear force on the cam follower 90 . When cam 70 is rotated fully, flat section 110 of cam 70 abuts flat surface 114 of cam follower 90 , providing a positive stop for the locked position of assembly 38 . One or more compressible disc springs 94 may, if desired, be interposed between cam follower 90 and rod 62 to permit application of clamping force while allowing relative movement between the two components. Coil spring 118 , finally, may circumscribe rod 62 within larger diameter portion 122 of vertically-oriented opening 54 . Spring 118 biases rod 62 and plunger 86 upward, away from track 10 , to ensure their full retraction when assembly 38 is unlocked.
FIG. 12 illustrates assembly 38 in this unlocked position. As shown, plunger 86 is located above flanges 22 of track 10 and thus neither extends into channel 26 nor engages cut-outs 30 . Cap 78 protrudes above base frame 34 , and coil spring 118 biases rod 62 upward so that surface 114 of cam follower 90 abuts curved lobe 106 of cam 70 .
FIG. 13 , by contrast, depicts assembly 38 in its locked position. Rotating cam 70 depresses rod 62 and plunger 86 so that shear pins 98 enter channel 26 and engage cut-outs 30 . This rotation also compresses both coil spring 118 and disc springs 94 , the latter compression assisting in clamping flanges 102 of plunger 86 against flanges 22 of track 10 . When rotation is complete, flat section 110 of cam 70 abuts flat surface 114 of cam follower 90 , providing a positive stopping position discernable by the person handling the tool.
The foregoing is provided for purposes of illustrating, explaining, and describing exemplary embodiments and certain benefits of the present invention. Modifications and adaptations to the illustrated and described embodiments will be apparent to those skilled in the relevant art and may be made without departing from the scope or spirit of the invention. | Fitting systems and assemblies are detailed. The assemblies are designed principally (although not necessarily exclusively) for use with aircraft seats and supply positive adjustable positioning of a seat or other object, typically actuated with a single turn (or less) of a single tool. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 11/674,343, filed 13 Feb. 2007, which under the provisions of 35 U.S.C. §119, claims the benefit of Canadian Application No. 2,577,734 filed 9 Feb. 2007.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electrical isolation connector for interconnecting adjacent conductive components such as tubular drill rods of a drilling system used in drilling bore holes in earth formations.
2. Description of Related Art
Modern drilling techniques employ an increasing number of sensors in downhole tools to determine downhole conditions and parameters such as pressure, spatial orientation, temperature, gamma ray count etc. that are encountered during drilling. These sensors are usually employed in a process called ‘measurement while drilling’ (MWD). The data from such sensors are either transferred to a telemetry device, and thence up-hole to the surface, or are recorded in a memory device by ‘logging’.
The oil and gas industry presently has a choice of telemetry methods:
Wireline (cable between downhole transmitter and surface receiver) Mud Pulse (downhole transmitter creates pressure waves in the drilling fluid that are detected at the surface) Electromagnetic (EM—downhole transmitter creates very low frequency EM waves in the formation adjacent to the well that are detected at the surface) Acoustic (downhole transmitter creates acoustic waves in drill pipe that travel to and are detected at the surface)
In EM telemetry systems, the downhole carrier signal is produced by applying an alternating electric current across an electrically isolated (nonconductive) portion of the drill string. The required isolation is provided by a mechanically strong gap in a portion of drill string (called a ‘sub’) in order to maintain the torsional, bending etc. properties required for the drilling process. The EM signal originating across the gap is subsequently detected on the surface by, in general, measuring the induced electric potential difference between the drill rig and a grounding rod located in the earth some distance away.
Nonconductive materials forming the isolation section of the gap sub typically have inherently less strength and ductility than the conductive steel materials of the drill pipe, giving rise to complex designs that are necessary to complement the structural strength of drill pipe.
As described by several patent publications, many types of electrical isolation arrangements exist for the purpose of signal transmission in a drill string. Although these systems electrically isolate and seal while being subjected to drilling loads, they generally do so with a complicated multi-component design that thus becomes a relatively expensive device. Examples of such complicated and expensive designs are disclosed in U.S. Pat. Nos. 6,158,532 and 6,050,353 assigned to Ryan Energy Technologies, Inc. (Calgary, Calif.) whereby many separate components of the assembly are shown to be necessary in order to resist axial, bending and torsion forces.
U.S. Pat. No. 2,885,224 to Campbell et al. discloses an insulated meter connecting pipe joint that does not have connecting ends of a male and female conductive component that overlap with each other. The lack of overlap results in a lower strength of the Campbell et al. joint compared to a joint having overlapping connecting ends; this non-overlap would result in the joint taught by Campbell et al. to be unsuitable for drilling operations.
It is also common knowledge in the oil and gas industry that a two-part epoxy-filled gap between coarse threads can be used to resist both axial and bending loads. Reverse torsion, which would tend to uncouple the joint, can be resisted by the insertion of dielectric pins into carefully fashioned slots. Since epoxy does not adequately seal against drilling pressures of typically 20,000 psi, additional components must be included to provide an elastomeric seal, again leading to mechanical complexity and added cost.
SUMMARY OF THE INVENTION
Gap sub assemblies in directional drilling service are subjected to severe and repetitive axial, bending and torsional loads. Existing designs incorporate many parts that are designed to independently resist each force, giving rise to complex and costly mechanical arrangements. It is an object of the present invention to overcome in as simple a manner as possible the complex and difficult issues faced by existing gap sub designs.
According to one aspect of the invention there is provided a gap sub assembly having overlapping connecting ends for improved strength of the assembly, enabling the assembly to be used in downhole operations. Such a gap sub assembly can comprise: a female conductive component having a connecting end; a male conductive component having a connecting end inserted into the connecting end of the female conductive component; and an electrical isolator component comprising a substantially dielectric and annular body located between the male and female conductive components. The annular body is located between the male and female conductive components such that the conductive components are mechanically coupled together but electrically isolated from each other at their connecting ends. At least one of the male and female conductive components has a cavity in a surface of its connecting end. The annular body has a barrier portion protruding into each cavity of the male and female components to impede at least the rotation of the conductive component relative to the body. The material of the electrical isolator component can be a thermoplastic. Also, the isolator component can be located between the male and female conductive components such that a drilling fluid seal is established at the connecting ends of the male and female conductive components.
According to another aspect of the invention there is provided a gap sub assembly comprising a female conductive component having a connecting end, a male conductive component having a connecting end inserted into the connecting end of the female conductive component, whereby the connecting ends of the male and female conductive components matingly overlap with each other, at least one of the male and female conductive components having a cavity in a surface of its connecting end, and an electrical isolator component comprising a substantially dielectric and annular body located between the connecting ends of the male and female conductive components such that the conductive components are mechanically coupled together but electrically isolated from each other at their connecting ends, the annular body having a barrier portion protruding into the cavity of at least one of the connecting ends of the male and female components to impede at least the rotation of the conductive component relative to the annular body.
This particular aspect of the invention is patentable over, for example, U.S. Pat. No. 2,885,224 to Campbell et al., wherein it is defined that the connecting ends of the male and female components matingly overlap with each other. In another aspect of the invention, the barriers protrude from an annular outer surface, and not from the end of the annular body as taught in Campbell et al. In yet another aspect of the invention, the isolator component has a thread pattern that conforms to the thread pattern of the connecting ends of the male and female conductive components. This aspect too is patentably distinct from Campbell et al., which does not disclose threaded connecting ends.
The annular body can be located between and around threaded connecting ends of the male and female conductive components in which case the barrier portion is positioned relative to the corresponding conductive component to resist rotation thereof relative to the electrical isolator component. Alternatively, the annular portion can be located between and around smooth connecting ends of the male and female conductive components.
The cavity can be a groove extending generally parallel to an axis of the conductive component and into the threaded connecting end thereof, in which case the barrier portion protrudes into the groove thereby providing resistance against rotation of the conductive component relative to the electrical isolator component.
The cavity can be a curved groove extending at an angle the axis of the conductive component and into the threaded connecting end thereof in which case the barrier portion protrudes into the groove thereby providing resistance against rotation and axial translation of the conductive component relative to the electrical isolator component.
The barrier portion can protrude from the annular portion and extend across the annular portion at a generally acute angle relative to the axis of the annular portion thereby providing resistance against both rotation and axial translation of the corresponding conductive component relative to the electrical isolator component.
Both the male and female conductive components can comprise at least one cavity in the surface of their respective connecting ends, in which case the electrical isolator component comprises at least two barrier portions, namely a first barrier portion that protrudes into a corresponding cavity in the male conductive component, and a second barrier portion that protrudes into a corresponding cavity in the female conductive component.
At least one of the male and female conductive components can comprise multiple spaced cavities and the electrical isolator component can comprise multiple barrier portions that protrude into the cavities.
According to another aspect of the invention, there is provided an electrical isolator component for a gap sub assembly, comprising a substantially dielectric and annular body located between male and female conductive components of the gap sub assembly such that the conductive components are mechanically coupled together but electrically isolated from each other, the body having a barrier portion protruding into a corresponding cavity of the male or female component to impede at least the rotation of the conductive component relative to the body.
According to yet another aspect of the invention, there is provided a method of electrically isolating male and female conductive components in a gap sub assembly comprising:
providing a cavity on a surface of at least one of the conductive components of the gap sub assembly;
inserting a connecting end of the male conductive component into a connecting end of the female conductive component;
softening a substantially plastic dielectric material and injecting the softened dielectric material in between the connecting ends of the male and female conductive components to form a substantially annular body and into the cavity to from a barrier portion protruding from the body;
hardening the dielectric material to form an electrical isolator component comprising the body with barrier portion that mechanically couples the conductive components together, electrically isolates the conductive components from each other and impedes movement of the conductive component having the cavity relative to the electrical isolator component.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings illustrate the principles of the present invention and exemplary embodiments thereof:
FIG. 1 is a cross-sectional view of a three-part gap sub assembly according to one embodiment of the invention and comprising male and female threaded conductive components separated by an electrical isolation component made of a dielectric material.
FIG. 2 is a detailed cross-sectional view of the dielectric component after injection into a gap between equidistant coarse threads of the male and female threaded components.
FIG. 3 is a perspective view of the male threaded conductive component having an anti-rotation groove fashioned into the threads.
FIG. 4 is a perspective view of the dielectric component having an anti-rotational barrier produced by an elongated groove machined into the threads of the female threaded conductive component.
FIG. 5 is a perspective view showing one anti-rotation segment shearing away from the remainder of the barrier.
FIG. 6 is a perspective view of a male threaded conductive component having multiple grooves for producing multiple anti-rotation barriers in the dielectric component according to an alternative embodiment.
FIG. 7 is a perspective view of a smooth core cavity (no threads) of a male conductive component having an elongated groove according to an alternative embodiment.
FIG. 8 is a perspective view of the smooth core cavity of FIG. 7 modified to have a curved and elongated groove.
FIG. 9 is a perspective view of a male threaded conductive component according to an alternative embodiment having an anti-rotation forming means fashioned as a reverse thread overlapping the original thread.
FIG. 10 is a perspective view of a male conductive component according to another alternative embodiment having an anti-rotation forming means provided by drill holes in the surfaces of both the male and female conductive components.
FIG. 11 is a perspective view of a smooth core cavity (no threads) male conductive component according to yet another alternative embodiment and having an anti-rotation forming means provided by dimples in the cavity surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to one embodiment of the invention, an electrical isolator component for an EM gap sub assembly provides both electrical isolation and an anti-rotation means between two connected conductive components of the gap sub assembly and optionally also provides a fluid seal between the interior and exterior of the gap sub assembly. The gap sub assembly can be used to form an electrical isolation in a drill string, across which a voltage is applied to generate a carrier signal for an electromagnetic (EM) telemetry system. In the embodiments shown in FIGS. 1 to 6 , the electrical isolator component comprises a dielectric material that fills a cavity between rounded, coarse (as would be understood to those skilled in the art), tapered threads of male and female threaded conductive components of the assembly. A high-pressure seal is formed by injecting nonporous dielectric material at high pressure into the interstitial cavity between male and female jointed sections proximate to the threaded portions. The preferred embodiment is manufactured by fixing the conductive components in an injection molding machine and injecting a high temperature, high strength thermoplastic into the equidistant cavity formed between the threads. A suitably high temperature is required in the molding process in order that the injectant remains able to beneficially flow and completely fill the cavity between the male and female components. Once filled, a holding pressure (typically ˜20,000 psi) is maintained until the thermoplastic solidifies. In certain oil and gas drilling applications this procedure forms a tight seal against penetration of potentially conductive drilling fluids into the gap sub assembly, as well as prevents the adjacent conductive components of the gap sub assembly from rotating relative to each other.
Anti-rotation, i.e. torsion resistance, is provided by means which require parts of the dielectric material to shear in order to disassemble the threaded section under torsion loading. In the embodiments shown in FIGS. 3 to 8 , such means are provided by an elongated barrier of dielectric material protruding from the electrical isolator component and formed by elongated “grooves” or “slots” in the surfaces of one or both of the male and female conductive components. FIGS. 9 to 11 show alternative anti-rotation means, namely embossments on the electrical isolator component formed by drill holes, dimples, and a reverse thread in one or both conductive components. Such grooves, slots, holes, dimples and reverse threads are generally referred herein to as “barrier forming cavities”. While specific examples of anti-rotation means are shown in these figures, other means that utilize the direct shearing of an interstitial dielectric material to resist rotation are within the scope of this invention; such means can include barriers formed by the machining cavities of various geometries into the surfaces of one or both of the conductive gap sub components.
Although the embodiments are described herein are in the context of oil and gas drilling applications, a connector having sealing and anti-rotation means can be used in other applications within the scope of the invention, such as surface oil and gas pipelines, water or food conveying pipes, chemical plant pipelines etc.
Referring to FIGS. 1 to 5 , and according to a first embodiment, a gap sub assembly 1 comprises three major parts, namely male and female threaded conductive components 10 and 12 , and an electrical isolator component 11 made of a thin dielectric material (hereinafter “dielectric component”). The conductive components 10 and 12 are comprised of a nonmagnetic, high strength, stainless steel alloy, having box 13 and pin 14 connections on either end to allow for direct attachment to a drill collar section of the bottom hole assembly (BHA) of a typical drill string (not shown). Male conductive component 10 has a tapered and rounded coarse male threaded end while female conductive component 12 has a matching female threaded end. In this embodiment, the dielectric component 11 is a thermoplastic material injected under high pressure into the interstitial space between the equidistant male and female threads of the conductive components 10 , 12 . The injected thermoplastic fills barrier forming cavities in the conductive components to form the anti-rotation barriers, and between the conductive component threads to electrically isolate the conductive components 10 , 12 from each other. Suitable thermoplastics include polyethylethylketone (PEEK), polyetherimide (PEI), and polyetherketone (PEK) which exhibit good high temperature properties.
The method of forming the dielectric component 11 by injecting thermoplastic material in between the threads of the conductive components 10 and 12 will now be described.
First, the gap sub assembly 1 is assembled by loosely screwing the threaded ends of the male and female conductive components 10 , 12 together in an axially symmetric arrangement.
Then, the threaded connecting ends of two conductive components 10 , 12 are fixed in a mold of an injection molding machine (not shown) such that the tapered threads overlap but do not touch. Such injection molding machine and its use to inject thermoplastic material into a mold is well known the art and thus are not described in detail here. The mold is designed to accommodate the dimensions of the loosely screwed together gap sub assembly 1 in a manner that the thermoplastic injected by the injection molding machine is constrained to fill the gaps in between the threads.
Then, the thermoplastic material is injected in a softened form (“injectant”) into an equidistant gap 20 formed between the threads of the conductive components 10 , 12 , into the barrier forming cavities (e.g. groove 30 shown in FIG. 3 ) of the conductive components 10 , 12 , and into the annular channels 21 , 22 at each end of the gap 20 . The mold temperature, thermoplastic temperature, flow rate, and pressure required to beneficially flow the injectant and completely fill these spaces are selected in the manner as known in the art. Once filled, a holding pressure (typically ˜20,000 psi) is maintained until the thermoplastic injectant solidifies and the dielectric component 11 is formed.
After the thermoplastic material solidifies and become mechanically rigid or set, formation the dielectric component 11 is complete and the conductive components 10 , 12 can be removed from the injection molding machine. The dielectric component 11 now firmly holds the two conductive components 10 , 12 together mechanically, yet separates the components 10 , 12 electrically. The dielectric component 11 also provides an effective drilling fluid barrier between the inside and outside of the gap sub assembly 1 .
FIG. 2 provides a closer view of the dielectric component ( 11 of FIG. 1 ) after injection into the gap between generally equidistant coarse threads 20 . The dielectric component 11 is generally annular, having an annular outer end 21 , an annular inner end 22 , and an annular undulating interconnect portion interconnecting the outer and inner ends 21 , 22 . The dielectric component 11 also has a pair of anti-rotation barriers that are not shown in this figure but is shown in FIGS. 4 and 5 and discussed below. The outer and inner end ends 21 , 22 are respectively exposed on the outer and inner surfaces of the gap sub assembly 1 of with sufficient distance between the conductive components ( 10 , 12 of FIG. 1 ) to provide the electrical isolation necessary for an EM telemetry sub to function.
As is well known in the art, the tapered coarse threads in this application efficiently carry both axial and bending loads, and the interlock between the threads provides added mechanical integrity should the dielectric component be compromised for any reason. The dielectric component provides an arrangement that is self-sealing since the dielectric material is nonporous, free from cracks or other defects that could cause leakage, and was injected and allowed to set under high pressure. As a result, drilling fluids cannot penetrate through the dielectric material ( 11 of FIG. 1 ) and cannot seep along the boundary between the dielectric component and the surfaces of the clean conductive components ( 10 , 12 of FIG. 1 ). Thus no additional components are necessary to seal this assembly.
Referring to FIG. 1 , without the anti-rotation feature provided by the dielectric component 11 , reverse torsion tending to uncouple the coarse threads would be resisted only by the bonding strength between the dielectric material and the surfaces of the conductive components 10 , 12 , which tends to be of insufficient strength to carry the drilling loads normally encountered.
In the embodiment shown in FIG. 3 and referring to FIG. 1 , torsion resistance is achieved by a pair of elongated barriers which are formed by injecting dielectric material into grooves in the surfaces of the male and female components 10 , 12 . A groove 30 in the male threaded component 10 prevents the dielectric component 11 from rotating with respect to the male conductive component 10 . A similar groove in the female threaded component 12 (not shown) prevents the dielectric component 11 from rotating with respect to the female conductive component 12 . As is obvious to one skilled in the art, grooves in both the male and female conductive components 10 , 12 are necessary to adequately resist torsion with there being no need for the grooves to be proximately aligned.
As shown in FIG. 4 and referring to FIGS. 1 and 3 , each barrier 40 extends longitudinally along the interconnect portion of the dielectric component 11 . The barrier 40 shown in FIG. 4 has been formed by injecting dielectric material into the groove (similar to 30 but not shown) in the female conductive component 12 . Segments of the barrier 40 are shaded in this figure to better illustrate the portions of dielectric material that must be sheared in order to decouple the connection between the male and female conductive components 10 , 12 . These segments are herein referred to as anti-rotation segments. In this embodiment, the first barrier 40 provides shear resistance against the female threads, and a second barrier (not shown) is provided which provides shear resistance against the male threads. In an alternative embodiment, only a single barrier is provided, proximate to either the male or female threads, providing some torsion resistance. However, it is clear that having a barrier preventing rotation of both male and female threads with respect to the dielectric material provides better torsion resistance than a single barrier. This is because the threads which do not have a barrier will be easier to unscrew than the threads which incorporate a barrier.
FIG. 5 illustrates what must happen for the female threads to uncouple from the dielectric component 11 . All segments 50 must shear away from the remainder of the dielectric material simultaneously (for clarity, only one sheared segment 51 is shown). The crosshatched pattern 52 shows the ‘shear area’ of one anti-rotation segment 51 . Varying the depth of the groove ( 30 of FIG. 3 ) will affect the shear area of each segment. The torsion resistance of each individual segment is determined by multiplying the shear area with the shear strength of the dielectric material and the moment arm, or distance from the center axis, as the following equation denotes:
T i =A i SD i
where:
T i is the torsion resistance of an individual anti-rotation segment, A i is the area of dielectric material loaded in pure shear, S is the shear strength of the dielectric material, and D i is the segment moment arm or distance from the center axis.
Referring to FIG. 6 and according to another embodiment, the male threaded conductive component 10 has multiple anti-rotation grooves 60 that create a dielectric component having multiple barriers (not shown) against the male threads. Multiple barriers provide additional shear resistance over a single barrier. In this embodiment, corresponding grooves are found in the female threaded component 12 to provide multiple barriers against the female threads, but are not shown. Torsion resistance between the dielectric component 11 (referring to FIG. 1 ) and the male component 10 (or the dielectric component 11 and the female component 12 ) is determined by the sum of the resistances provided by each individual segment, as follows:
T
M
or
T
F
=
∑
1
N
slot
∑
1
N
seg
T
i
=
∑
1
N
slot
∑
1
N
seg
A
i
SD
i
where:
T M is the torsion resistance between dielectric component and male conductive component T F is the torsion resistance between dielectric component and female conductive component N seg is the number of anti-rotation segments per slot N slot is the number of slots in male or female conductive component
Since rotation of the dielectric component 11 with respect to either of the conductive components 10 , 12 would constitute decoupling of the joint, torsion resistance for the entire joint is the lesser of T M or T F .
As illustrated, the torsion resistance provided by this embodiment is a function of geometry and the shear strength of the material. With the formulae presented and routine empirical testing to confirm material properties, the quantity of anti-rotation segments required to produce any desirable safety margin is easily determined by one skilled in the art.
Referring to FIG. 7 and according to another embodiment, a male conductive component 70 has a smooth bore cavity surface (no threads) having multiple milled straight grooves 71 . These grooves 71 create a dielectric component having multiple elongated straight barriers (not shown). Similar straight grooves are found in a female (non-threaded) conductive component that creates multiple barriers to rotational movement in the dielectric component (not shown) with respect to the female conductive component. The barriers themselves provide torsion resistance, illustrating that a thread form is not required to provide torsion resistance. In FIGS. 1 to 6 , the thread form is present to resist axial and bending loads, and does not contribute to torsion resistance.
Referring to FIG. 8 and illustrating another embodiment, a smooth cavity surface is shown that has multiple milled curved grooves 80 that extend at an angle to the axis of the male conductive component 81 . The grooves 80 create a dielectric component (not shown) having curved and angled barriers that provide both axial and torsion resistance against the male conductive component 81 . Similar curved grooves are found in the female conductive component (not shown) that serve to create a dielectric component having curved and angled barriers (not shown) that provide both axial and torsion resistance against the female conductive component.
Referring to FIG. 9 and illustrating a further embodiment, the threaded surface of the male conductive component 90 is provided with curved grooves that are fashioned as a reverse thread 91 overlapping the original thread. A similar reverse thread is found in the threaded surface of the complementary female conductive component (not shown). The grooves in both conductive components create curved barriers in a dielectric component (not shown). The torsion resistance provided by these barriers can be adjusted by adjusting the characteristics of the grooves, e.g. the pitch and the number of thread starts and thread profiles.
As can be seen in the embodiments illustrated in FIGS. 7 to 9 , the male and female conductive components ( 10 and 12 of FIG. 1 ) can be provided with grooves of any reasonable size, shape, and path to create a dielectric component ( 11 of FIG. 1 ) having the exact axial and torsional resistance desired.
Referring to FIG. 10 and illustrating another embodiment, holes 100 are drilled into the surfaces of both male and female conductive components ( 10 and 12 of FIG. 1 ). Although a male conductive component having a smooth bore cavity is shown in this figure, similar holes can be provided in threaded conductive components. Drill holes 100 serve as molds for creating multiple barriers in the dielectric component (not shown). The hatched regions 101 indicate shear areas of the barriers, and the ‘hidden’ lines 100 illustrate that material remains in the holes after shearing. Although multiple rows of drill holes are shown in this figure, a different number and layout of holes can be provided within the scope of the invention.
Referring to FIG. 11 and illustrating yet another embodiment, dimples 110 are provided in the surfaces of both male and female conductive components ( 10 and 12 of FIG. 1 ). Although a male conductive component 111 having a smooth bore cavity is shown in this figure, similar dimples 110 can be provided in threaded conductive components. Dimples serve as molds for creating multiple barriers in the dielectric component (not shown). Such dimples can be fashioned into the material by forms of plastic deformation (e.g. pressed or impacted) or material removal (e.g. grinding, milling, sanding, etc.). Although multiple rows of dimples are shown in this figure a different number and layout of dimples is inferred to be within the scope of the invention.
While FIGS. 10 and 11 illustrate drill holes 100 and dimples 110 for creating torsion resistance barriers in the dielectric component ( 11 of FIG. 1 ), recessed portions of other realizable patterns or shapes could be used to create barriers that would be suitable for providing suitable torsion resistance.
While the present invention has been described herein by the preferred embodiments, it will be understood by those skilled in the art that various consistent and now obvious changes may be made and added to the invention. The changes and alternatives are considered within the spirit and scope of the present invention. | A gap sub assembly can be used to form an electrical isolation in a drill string, across which a voltage is applied to generate a carrier signal for an electromagnetic (EM) telemetry system. The assembly comprises two conductive generally cylindrical components fashioned with a matching set of male and female rounded coarse threads, held such that a relatively uniform interstitial space is formed in the overlap space between them. The third component is a substantially dielectric electrical isolator component placed into the gap between the threads that effectively electrically isolates the two conductive components. Injecting the dielectric material under high pressure forms a tight bond resistant to the ingress of conductive drilling fluids (liquids, gases or foam), thus forming a high pressure insulating seal. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an implantable infusion system, of the type having a neutral pressure medication supply container for liquid medication to be delivered to the patient, the supply container being devised so that its volume changes according to the amount of medication it contains, and a pump for pumping medication from the supply container, via a catheter, to the patient's body, the supply container and the pump being arranged inside an enclosure to which the catheter is connectable at the output of the pump.
2. Description of the Prior Art
In implantable systems of the above general type, the outlet valve is a key component for patient safety and dispensing accuracy. During the estimated service life of the infusion system, assuring compliance with the exceptionally stringent demands made on sealing ability of the valve is very difficult.
One known solution for preventing delivery of excessive doses of medication to the patient if a fault appears in the system is to maintain a negative pressure of e.g. about 700 mbars absolute, in relation to the surroundings, in the insulin container, see e.g. U.S. Pat. No. 4,191,181. A leaking outlet valve in such a system causes a flow into the container because of the lower pressure therein, but no medication flows out into the patient's body.
In implanted infusion systems, the use of higher concentrations of the active substance in the drug to be administered is desirable so that the size of the implant can be reduced and/or the interval between refills prolonged. This makes even greater demands on the sealing ability of the valve, since the emitted flow is correspondingly smaller.
Thus, a constant pressure difference of, typically, 300 mbars across the outlet valve prevails in the above described known infusion system. Even a very slight valve leakage, e.g. on the order of a fraction of a Kl/hour, thus induces a continuous retrograde flow through the valve. The pump operates intermittently with, typically, μl/6 min. at this flow and with 1 μl/10 sec. at a bolus flow, and a minimum flow can amount to 1 μl/10 to 30 minutes. Valve leakage causes a major or minor relative fault in these programmed flows, depending on the magnitude of programmed flow and the magnitude of valve leakage. The relative effect of a given valve leakage increases when the concentration of medication in the fluid increases. Thus valve leakage causes varying deviations in the intended flow which can be considerable and can affect the therapy.
When there is valve leakage, body fluid and/or blood are thus sucked inwardly through the catheter tip when the pump is inactive between each pulse discharge because of the negative pressure in the medication container. Depending on the magnitude of the leakage and the time elapsing between each pulse discharge, the distance that the body fluid penetrates into the catheter varies. For a catheter used in practice, this distance could, typically, amount to 15 mm/μl very likely this will lead to catheter blockage after a time because of the aggregation of proteins, formation of fibrin, etc. Catheter blockage is currently the biggest problem in implantable infusion systems. Further the infusion system probably must be replaced if body fluid penetrates all the way into the pump and medication container.
In addition, the safety system, which is based on a negative pressure in the medication container, could be made inoperative in certain situations. When the medication container is, e.g., overfilled with fluid or air, causing it to bottom out inside the enclosure, a pressure of about 1 bar develops in the container. In the case of active overfilling caused by incorrect handling, a much higher pressure can develop in the container. When valve leakage is considerable or a valve becomes inoperative, body fluid can be sucked into the medication container and the container bottoms out, with pressure in the container then amounting to about 1 bar. In the event of leakage in the outer enclosure directly into the medication container, body fluid is sucked inwardly until the container bottoms out, and the pressure reaches about 1 bar. If, in addition, the container, which is often devised as a bellows container, sticks in an intermediate position, the container pressure can amount, in certain circumstances, to about 1 bar.
If the ambient pressure then drops, which could happen during an air flight, on a trip to a high altitude location, etc., while the refill septum or outlet valve is leaking, unchecked amounts of infusion fluid could leak into the patient with very harmful effects as a result. In these instances, the occurrence of only relatively slight mechanical pressure on the implanted system could cause medication leakage. At altitudes above 3,000 m, the pressure in the container further exceeds the ambient pressure and then leakage from the container would always be a risk. The container pressure also rises when the temperature of the implanted system is higher than intended (37 degrees Celsius), causing an attendant safety hazard. The volume pumped is also affected by both the temperature of the implant and the ambient pressure. The differential pressure across the container's outlet valve governs the degree to which the valve opens, and the freon pressure is temperature-dependent.
Another disadvantage of the known "negative pressure system" is the fact that the pressure difference between the container and the surroundings, i.e. typically 300 mbars, must be overcome by the pump at each pump stroke. A pressure of 300 mbars corresponds to a force of about 0.1N on the valve. This accounts for about 15% of the pump's energy consumption. Pump pressure must also be high enough to overcome the sealing force of the valve and lift the valve during the expulsion phase. In contemporary systems, the sealing force corresponds to a pressure difference of about 1 bar. The energy consumption for the valve opening corresponds to about 50-60% of the energy consumption of the valve.
New pumping principles, such as pumps devised with silicon/micromechanics and employing piezoelectric or thermal activation, electro-osmotic pumps, EHD pumps, etc., which are capable of supplying stipulated fluid flows, are of interest in the future development of implantable infusion systems. A characteristic shared by many of these pumps is that they are only able to achieve a very low static pressure, typically from 1 mbar up to a few tens of mbars. Thus they cannot be used in the above-described negative pressure systems.
Another problem with known negative pressure systems is due to the circumstance that the pressure in the pump chamber drops sharply and chamber fluid starts *cavitating if the piston's retraction force, at the end of a piston stroke, exceeds a given value when the pump chamber is refilled. Cavitation develops in the pump chamber when the retraction force exceeds about 0.2N at a pressure of 700 mbars in the container and when the retraction force exceeds 0.3N at 1,000 mbars with the pumps used. Cavitation in medication fluid should be avoided when the fluid contains delicate molecules which could then be damaged, e.g. be denatured, aggregated, acquire changed biological properties, become adhered to surfaces in the fluid path, thereby affecting the valve function or causing a blockage in the catheter. Insulin is a substance made of such sensitive molecules. In order to minimize the risk of piston "hangup" caused by the capillary force in the airfluid interface, if air should cross the gap between the piston and the container wall moreover there is a requirement that the pumps in question must be capable of pumping air-water mixtures) or for other reasons, such as friction or adherence to the valve surface, the pumps in question must develop a retraction force of about 0.25N, which is the highest value during a retraction operation with increasing force. Thus fluid in the pump chamber cavitates during the latter part of the pump's return. In a similar manner, fluid pressure drops behind the piston, i.e on the pump's inlet side, because of mass forces in the fluid and flow resistance in the inlet tube at the actual pump stroke.
The negative pressure in the medication container also subjects the septum, through which the container is refilled with medication at regular intervals, to a negative pressure of about 300 mbars. Small amounts of body fluid leak through the septum into the container when the injection cannula is introduced and/or withdrawn when medication is refilled. During the filling operation, which first involves evacuation of the container to a pressure of about 60 mbars, followed by sucking in fluid, there is risk that air could simultaneously be sucked into the container if any part of the filling equipment, such as taps, couplings etc., were to start leaking. The presence of air in the medication container is often extremely unsuitable, even hazardous, especially in systems intended for the infusion of insulin. Ascertaining when there is less than 3 ml of air in the medication container after filling is currently not possible. In the course of time, moreover, the number of cannula punctures made in the refill septum will become considerable, typically a hundred or more, and an absolutely leak-proof septum cannot be guaranteed, especially if a number of cannula punctures are adjacent to each other. Because of the pressure difference, leakage of body fluid or free gas in the implant pocket into the container is always a risk during the 4 to 6 weeks which elapse between refills. Even small amounts of body fluid in the medication container can affect the medication, produce precipitations, block filters, have an adverse effect on pump and valve function and contribute to catheter blockage.
There are also types of valve constructions in which the sealing washer is not attached to the valve's metal part, so fluid on the pump's outlet side could be sucked in behind the sealing washer because of the pressure difference between the outlet sides of the pump chamber and of the pump. The sealing washer will then bulge into the pump chamber, causing a drop in the volume pumped in each pump stroke, sometimes by as much as 25-35%, or a certain amount of body fluid could be sucked into the catheter after every pump stroke, typically a distance of 3-4 mm into the catheter. This accelerates blockage of the catheter tip.
The above-described problems can be solved to some degree by "positive pressure systems", i.e. infusion systems with a positive pressure in the medication container in relation to ambient pressure, the positive pressure serving as a driving force for pumping out medication, see e.g. European Patent 0,387,439. A disadvantage of such positive pressure systems, however, is that leakage of disastrously large amounts of medication into the patient in the event of valve leakage, enclosure leakage, septum leakage, when medication containers are refilled etc. is a major risk with these systems.
So-called "neutral pressure systems" eliminate the above discussed problems of "negative pressure systems" and are not associated with any of the risks of "positive pressure systems". Such neutral pressure systems are known from British Specification 2,131,496 and U.S. Pat. No. 4,511,355. Such neutral pressure systems ensure that the pressure in the medication container is essentially the same as the pressure at the catheter tip and the atmospheric pressure, irrespective of the atmospheric pressure and the temperature of the implant. In British Specification 2,131,498 an implantable infusion system is disclosed which has openings in the enclosure so that the space inside it, but outside the medication container, is in communication with the implant's surroundings in the patient. The pressure in this space inside the enclosure, which accordingly acts on the medication container, is therefore the same as pressure outside the implant. The structure shown in this publication, however, cannot be used for, e.g., infusing insulin. If the container were to break, the consequences to the patient would be devastating. An implantable infusion system is described in U.S. Pat. No. 4,511,355 in which a part of the enclosure consists of a membrane made from a hydrophobic material, permeable to gas, which ensures that essentially the same pressure prevails inside the enclosure as outside it. Body fluids, as well as cells and bacteria, are, however, prevented from passing the membrane. The disadvantage of this design is that a simple sealing defect could be very harmful to the patient.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a new, implantable, neutral pressure infusion system with greatly improved patient safety and in which body fluid is unable to penetrate into the enclosure of the implant.
The above object is achieved in accordance with the principles of the present invention in an implantable infusion system having a neutral pressure medication supply container for liquid medication to be delivered to a patient, the supply container being devised so that its volume changes according to the amount of medication contained therein, and a pump for pumping medication from the supply container, via a catheter, to the patient's body. The supply container and the pump are contained inside an enclosure, to which the catheter is connectable at the output of the pump. The system includes a closed space, at least partially contained within the enclosure, in which the supply container is disposed and in which pressure which is essentially equal to atmospheric pressure prevails. The closed space is devised so as to be capable of changing its volume to a corresponding degree when the volume of the supply container changes, so that the pressure is maintained substantially unchanged.
With the system according to the invention, valve leakage is eliminated if the valve should not be leakproof, and delivery of the intended flow is assured. The most likely main cause of catheter blockage, viz. suction and aggregation of proteins etc., is also eliminated. The system according to the invention is completely insensitive to ambient pressure and implant temperature, as well as to the presence of air in the medication container. The critical importance of the valve as a component is greatly reduced, the risk of valve leakage is eliminated and the pumped chamber volume becomes independent of ambient pressure and implant temperature, with increased patient safety as a result. The energy consumption of the infusion system is also reduced, thereby increasing the life of the implant or alternatively of the energy source, which makes a reduction of the volume and weight of the battery possible and, accordingly, the volume and weight of the implant. With the infusion system according to the invention, the energy consumption of the pump and, thus, of the implant, is reduced by about 30% which increases the life of the implant by about 30% or, alternatively, reduces the volume and weight of the battery, and accordingly of the implant, to a corresponding degree. A lower required valve force also reduces wear on and plastic deformation of the sealing surface, which increases the life of the valve and counteracts any change in the pumped chamber volume over time. The infusion system according to the invention also makes it possible to use the new low pressure pumping principles, discussed above, in the infusion system, since the pressure difference between the medication container and surroundings is always very small, irrespective of ambient pressure and temperature. The infusion system according to the invention completely eliminates cavitation in the pump, thereby reducing damage to the pump fluid. Moreover, deposits on the valve and other surfaces in contact with the fluid are reduced without the need to reduce the force of piston retraction, i.e. the margin relative to piston "hangup" can be kept unchanged. Further, the penetration of body fluid, air or any other gas through the refill septum is eliminated by the infusion system according to the invention throughout its service life. The above-described cause of a loss in pumped volume and the attendant cause of catheter blockage due to bulging of the valve sealing washer are eliminated by the infusion system according to the invention.
With the infusion system according to the invention, a pressure difference essentially equal to zero is assured across the outlet valve and across the refill septum, and no fluid or air can then leak in during pump operation or container refilling at any time during the service life of the system, even if the valve and/or refill septum are no longer completely leak-proof because of wear. The service life of the infusion system and its ability to keep its specifications within narrow limits throughout the service life of the system increase considerably. Additionally there is no risk of medication leakage, since the container and surroundings are at the same pressure.
In an embodiment of the system according to the invention, a part of the lateral wall of the enclosure is covered by an elastic membrane with low stiffness, which is radially expandable and contractible in order to keep the volume of the enclosed space outside the container constant when the volume of the supply container changes. The upper part of the enclosure is connected to the bottom by at least two bridges to give the enclosure the required mechanical stability. The advantage of this design is that the enclosure becomes insensitive to common forms of mechanical pressure imposed on the implanted system, such as a tight belt, pressure on the abdomen etc. In addition, any increase in the thickness of the implant, which could occur in previously described versions when the supply container is full, is also completed avoided.
According to another embodiment of the system of the invention, the enclosed space encompasses an expansion chamber connected to the chamber inside the enclosure (housing) in which the supply container is arranged. The expansion chamber is arranged to change its volume in the same way as the supply container. The expansion chamber is connected to the chamber inside the enclosure by a flexible tube. The expansion chamber can be arranged inside the peritoneum or in the abdominal wall. The advantage of arranging the expansion chamber in the peritoneum is that the tip of the catheter and expansion chamber will then be close to each other and accordingly exposed to the same pressure, irrespective of variations in external pressure and tension in the patient's abdominal musculature. This also makes the system insensitive to external mechanical pressure, since the expansion chamber then lies inside the muscle bed, and organs in the abdominal cavity are soft. Thus a local mechanical pressure would cause practically no pressure difference between the catheter tip and the expansion chamber. Leakage of fluid through the catheter would therefore be impossible, and entrances through the skin would not be needed. Moreover, the expansion chamber does not expand and contract inside body tissue, but instead does so inside a body cavity. The tube can have different lengths, and preferably the tube is comparatively long and tunneled laterally through the tissue before entering the peritoneum, since this reduces the risk of any infection in the implant pocket spreading and causing peritonitis. The advantage of placing the expansion chamber in the abdominal wall is that the implantation procedure is simpler with fewer risks of complications.
In the procedure for placing the expansion chamber in the abdominal wall, the expansion chamber is preferably provided with a port, closed with a septum. The supply container can thereby be refilled without the use of positive pressure. When a syringe containing fresh medication is mounted on a cannula arranged in the refill port and an empty syringe is arranged in the port of the expansion chamber, medication can be sucked into the supply-container by withdrawing the piston in the empty syringe connected to the expansion chamber. This reduces the risk of medication leakage during refilling.
In other embodiments of the system according to the invention, the supply container must be refilled by applying a small positive pressure to the syringe connected to the refill port. According to another advantageous embodiment of the system of the invention, the refill port of the supply container is equipped with a cannula sensor which detects correct insertion of the cannula for refilling the supply container. This eliminates the risk of medication being injected into the patient during the refilling procedure if the physician injects at the wrong site, the cannula fails to puncture the septum of the refill port, or the cannula slips out of the septum during the refilling procedure. The cannula sensor can detect whether the cannula really is in the refill port during the entire refilling operation.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of a first embodiment of an infusion system constructed in accordance with the principles of the present invention showing the supply container partially emptied.
FIG. 2 shows the same sectional view as in FIG. 1, but with a filled supply container.
FIG. 3 is a top view of the infusion system as shown in FIGS. 1 and 2, shown in a slightly reduced size.
FIG. 4 is an enlarged sectional view of the refill port in the infusion system of the invention in the embodiment shown in FIGS. 1-3, with a cannula sensor.
FIG. 5 is a side sectional view of a second embodiment of an infusion system constructed in accordance with the principles of the present invention.
FIG. 6 is a top view of the second embodiment of the infusion system shown in FIG. 5.
FIG. 7 is a side sectional view of a third embodiment of an infusion system constructed in accordance with the principles of the present invention.
FIG. 8 is a side sectional view of a fourth embodiment of an infusion system constructed in accordance with the principles of the present invention.
FIG. 9 is a side sectional view of a further version of the embodiment of FIG. 8, illustrating a filling procedure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 3 show a first embodiment of the infusion system according to the invention, implanted in the abdominal wall 8 of a patient. The infusion system has a supply container 6 for medication, e.g. an insulin container devised as a bellows container. The supply container 6 is completely diffusion-proof and preferably made of metal. A pump 10 is arranged to pump medication from the container 6 to the catheter 12, which opens into the patient's peritoneum 14. The supply container 6 is further connected to a refill port 16 equipped with a leak-proof rubber septum. The container 6, the pump 10, and the requisite electronics (which are known and therefore not shown) for control and communication, and the battery for powering the operation of the system are enclosed in a leak-proof enclosure (housing)1. The pump 10, the electronics and battery are situated in the hermetically sealed chamber 19 of the enclose 1. The enclosure 1 is preferably made of titanium and has an opening 2, preferably circular, in the bottom. The opening is covered by an elastic membrane 3 with low stiffness. The membrane 3 can appropriately be made of a polymer with good mechanical properties, poor water diffusion and good biocompatibility. The membrane 3 can be provided with bellows folds 4 to reduce the stiffness and the stress on the material when the membrane moves. The membrane can be a laminate of a plurality of layers with differing mechanical, physical and biological properties. One of the layers can consist of a metallic coating to reduce the diffusion of fluid and gas. Alternatively, the membrane 3 can be made of thin sheet metal with bellows folds and/or corrugation, so that sufficient elasticity is achieved.
The enclosure 1 with the membrane 3 should be diffusionproof. This provides double protection against leakage of medication into the patient's body. If a leak were to occur in the supply container 6, the enclosure 1 with the membrane 3 then prevents medication from leaking into the patient.
The space 5 inside the enclosure in which the supply container 6 is arranged can be filled with a gas at atmospheric pressure and with large molecules to reduce the diffusion of gas. The space can alternatively be filled with a liquid, e.g. water or a liquid with a high molecular weight and appropriate chemical and physical properties in order to prevent outward diffusion. The liquid can be isotonic for reducing or eliminating diffusion. One such appropriate liquid is a physiologically compatible sodium chloride (saline) solution.
In the embodiment of FIGS. 1-3, the pressure in the space 5, the supply container 6 and the abdominal cavity is essentially the same and equal to the atmospheric pressure when the bellows of the supply container 6 and the membrane 3 are properly designed.
When the supply container 6 collapses as it empties of medication, the space 5 decreases to a corresponding degree by bulging the membrane 3 inwardly such that the pressure is maintained constant. When the medication container 6 expands during refilling, the membrane also expands, so that the space 5 becomes larger, and the pressure is maintained constant.
Thus, the membrane 3 bulges inwardly when the container 6 is nearly empty, whereupon soft body tissue in the abdominal wall 8 might also bulge inwardly, possibly with a slight negative pressure, i.e. up to about 10 mbars, developing in the container 6 as a result. Since a medication container 6 in service empties very slowly, the inward bulge of the membrane 3 will fill with extracellular liquid, and no negative-pressure will therefore develop in the tissue in practice.
When the medication container 6 is refilled, the membrane 3 reverses its bulge (see FIG. 2) and a slight positive pressure, i.e. up to about 10 mbars, could develop in the supply container 6 and persist for some time, i.e. a few hours or a day. In practice, these minor pressure differences, of maximally ±10 mbars for a limited period of time, are of no importance.
When the supply container is full, a mechanical pressure on the implant could generate positive pressure in the container which in certain circumstances could be a shortcoming. A pressure force of 30N on the top of the implant in the currently used design of implanted equipments corresponds to a positive pressure in the supply container of about 60 mbars. Such a mechanical pressure for a long period of time is highly unlikely and would be painful to the patient and need not be feared in normal conditions.
After emptying of the supply container 6, the refilling of medication in the embodiment according to FIGS. 1-3 must be performed by the application of weak positive pressure to the syringe, containing fresh medication, connected to the refill port 16, i.e. pressure is cautiously applied to the syringe piston. There is a risk that medication is then injected into the patient, if the physician injects at the wrong site and the cannula has not punctured the septum of the refill port 16 or the cannula slips out of the septum. These risks can be eliminated if a cannula sensor 18 or 20 is arranged to detect whether the cannula actually is inside the refill port 16 throughout the entire refilling operation.
FIG. 4 shows the cannula sensor 18, only schematically indicated in FIG. 1, in greater detail. Thus, FIG. 4 shows a cannula sensor with a disc-shaped permanent magnet 22 suspended by a spring 24 inside the refill port 16. The magnet 22 is magnetized perpendicularly to the disc plane and is hermetically sealed inside an enclosure 26 made of, e.g., pure titanium. The spring device 24 can suitably be devised as a pure titanium or titanium alloy coil spring, the spring 24 keeping the magnetic disc 22 a short distance above the bottom of the port 16.
A gauge 28, which senses when the magnet 22 is approaching, is arranged below the bottom of the port 16. The gauge 28 can be a magnetoresistive gauge in the form of a Hall-plate connected, by lines 30, to an electronic detection circuit (not shown),
When the cannula 32 penetrates the septum 34, the magnetic disc 22 with its enclosure 26 serves as a stop for the cannula 32 and the combination of the disc 22, and the enclosure 26 is pressed towards the bottom of the port 16 and activates the gauge 28. Telemetry equipment can be used to ascertain that the disc 22 remains depressed throughout the whole refilling operation, thereby confirming that the cannula 32 has been in the right position the entire time.
Other types of gauges are conceivable in the cannula sensor as well, e.g. piezoelectric gauges.
FIGS. 5 and 6 respectively show cross-sections from the side and from above of a second embodiment of the infusion system according to the invention. This embodiment generally resembles the embodiment according to FIGS. 1-3 with the difference that a part of the lateral wall of the enclosure consists of an elastic membrane 40 which expands and contracts radially in order to change the volume of the space 5. The membrane 40 extends around most of the implant's periphery and is attached to the rigid upper section 42 and the bottom section 44 of the enclosure, possibly by bellows folds 46.
The upper section 42 and the bottom section 44 are suitably made of titanium and connected to each other by at least two rigid bridges 48 to give the construction the required mechanical stability.
The embodiment according to FIGS. 5 and 6 functions in the same way as the embodiment in FIGS. 1-3. The advantage of the former construction is that it is insensitive to natural mechanical pressures to which the implant is subjected, such as pressure from a tight belt and pressure on the abdomen. Moreover, the slight increase in implant thickness which possibly can occur when the supply container 6 in the embodiment shown in FIGS. 1-3 is full is avoided.
In the embodiment according to FIG. 7, the space 5, in which the supply container 6 is arranged, is connected to an expansion chamber 50 by a flexible tube 52, essentially atmospheric pressure also prevailing in the expansion chamber. The expansion chamber 50 is expandable and contractible and is placed in the peritoneum 14.
The expansion chamber 50 can have the same volume as the medication container 6, and its resistance to expansion and contraction is low. An appropriate material for the expansion chamber 50 can be a polymer or a laminate of a plurality of polymers with appropriate mechanical, physical and biological properties, possibly with a metallization to impede diffusion. The expansion chamber 50 can alternatively be made of thin sheet metal, e.g. pure titanium or titanium alloy.
In the embodiment shown in FIG. 7, the tube 52 is relatively short, but it can be longer and tunneled laterally through the tissue before entering the peritoneum 14. The use of a long tube 52 reduces the risk of any infection in the implant pocket spreading and causing peritonitis.
The tube 52 is diffusion-proof. The tube 52 can thus be, e.g., metallized. The tube 52 can be a composite tube with a polyethylene interior and a silicone rubber exterior and can be reinforced with an embedded metal helix, by fiber reinforcement or the like to prevent tube kinking.
The inlet the abdominal cavity can be provided with a Dacron® cuff (not shown) or the like for attachment and sealing.
The expansion chamber 50 and the space 5 can be filled with air or some other gas, appropriately a gas with large molecules to reduce diffusion, or a liquid, such as water, or a liquid with a high molecular weight and appropriate physical chemical properties, such as an isotonic liquid, to prevent diffusion.
The advantage of this embodiment is that the expansion chamber 50 and the catheter tip are both inside the peritoneum 14, relatively close to each other, and are therefore subjected to the same pressures, irrespective of variations in external pressure and irrespective of tension in the patient's abdominal musculature. This embodiment of the infusion system according to the invention is also insensitive to external mechanical pressure, since the expansion chamber 50 lies inside the muscle bed, and organs in the abdominal cavity are soft. Even in instances of a local mechanical pressure, there is almost no pressure difference between the catheter tip and the expansion chamber 50. There is accordingly no leakage of fluid through the catheter 12. Other advantages are that patient skin entrances are unnecessary and expansion and contraction to achieve the required changes in volume occur in a body cavity, not in body tissue.
A weak positive pressure must be applied to the refill syringe when the supply container 6 is filled, which can have shortcomings as discussed above. These shortcomings can be eliminated, however by providing a cannula sensor of the kind described above in conjunction with FIG. 4.
FIG. 8 shows yet another embodiment of the infusion system according to the invention, with an expansion chamber 54 implanted in the abdominal wall 8 alongside the infuser. The expansion chamber 54 appropriately has a relatively large area in the plane of the abdominal wall 8 so its thickness and changes in thickness will be as small as possible. The connecting conduit 56 is easily flexible and has the same properties as the connecting conduit 52 in the embodiment according to FIG. 7. In other respects, this embodiment works in the same way as the embodiment shown in FIG. 7, i.e. when the volume of the supply container 6 changes during the emptying or filling of medication, the volume of the expansion chamber 54 changes to a corresponding degree, so that a neutral pressure is maintained in the whole closed space.
The advantage of the embodiment of FIG. 8 compared to the embodiment shown in FIG. 7 is that the implantation procedure is simpler and the risk of complications is reduced. The embodiment of FIG. 8, however, has greater sensitivity to local mechanical pressure on the patient.
Also in this embodiment, the supply container 6 is refilled with a weak positive pressure applied to the refill syringe and to minimize the risks to the patient a cannula sensor of the above-described kind can also be utilized in this case.
FIG. 9 shows a refinement of the embodiment in FIG. 8 in which the expansion chamber 58 is equipped with a port 60 covered by a septum 62 in the same way as the refill port 16 of the infuser itself. The port 60 is equipped with a strap 64, serving as a cannula stop, to prevent the cannula 66 from being inserted too far and damaging the opposite wall 68 of the expansion chamber 58. Moreover, the upper part of the expansion chamber 58 is provided with a shield 70 made of a harder, thicker material, such as titanium sheet or a polymer material, to prevent damage to the expansion chamber if an incorrect puncture is applied with the cannula 66.
In this embodiment, the supply container 6 can be refilled without the use of positive pressure. In refilling, any residual insulin is first removed with a syringe and cannula through the septum 34. A syringe with fresh insulin is then attached to the same cannula. An empty syringe 72 is inserted through the septum 62 of the expansion chamber 58, and insulin is drawn into the container 6 when the piston 74 of the syringe 72 is retracted. In this manner, the risk of medication leakage is completely eliminated, and no cannula sensor is needed in the refill port 16.
Once the correct amount of medication has been sucked into the supply container 6, the cannula in the refill septum 34 is removed, and the contents of expansion chamber 58 (air, gas, liquid) sucked out by the syringe 72 are transferred to the expansion chamber 58 in order to restore neutral pressure before the cannula 66 is withdrawn from the septum 62.
In other respects, the embodiment according to FIG. 9 works in the same way as the embodiment according to FIG. 8.
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventor to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of his contribution to the art. | An implantable infusion system has a neutral pressure medication supply container for liquid medication to be delivered to the patient, the supply container being devised so that its volume changes according to the amount of medication it contains, and a pump for pumping medication from the supply container, via a catheter, to the patient's body. The supply container and the pump are arranged inside an enclosure to which the catheter is connectable at the output of the pump. A closed space, at least partly contained inside the enclosure, in which the supply container is arranged, and in which essentially atmospheric pressure prevails, is arranged to change its volume to a corresponding degree when the volume of the supply container changes, so that the pressure is kept essentially unchanged. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates generally to cosmetic oil components and, more particularly, to an improved process for the production of, for example, Guerbet alcohols and dialkyl cyclohexanes which does not require heavy metal catalysts for the condensation reaction and which combines improved selectivity with a higher reaction rate.
PRIOR ART
[0002] Guerbet alcohols are primary alcohols branched in the 2-position which are obtained by condensation of linear fatty alcohols. The products are mainly used as oil components for the production of cosmetic emulsions. They are generally produced from fatty alcohols which, initially, self-condense under the effect of strong bases and heavy metal compounds, for example copper or zinc oxide. It is assumed that, under the reaction conditions, the alcohol is first dehydrogenated to the aldehyde which enters into an aldol condensation with itself, after which the condensation product is hydrogenated to the alcohol. A corresponding overview can be found, for example, in Angew. Chem. 64, 212 (1952). Dialkyl cyclohexanes are similarly produced by double condensation of fatty alcohols with cyclohexanol in the presence of heavy metals.
[0003] However, a disadvantage is that, after the reaction, the heavy metal catalysts have to be removed in order to meet legal requirements and to ensure that they do not cause any irritation in the subsequent application. The heavy metal catalysts are generally removed by washing and subsequent distillation which involves considerable product losses. Another disadvantage is that the reaction times are very long and the selectivities are unsatisfactory.
DESCRIPTION OF THE INVENTION
[0004] The present invention relates to a process for the production of branched alcohols and/or hydrocarbons, in which carbonyl compounds are condensed in the presence of acids or bases and the resulting α,β-unsaturated condensation products are subsequently hydrogenated.
[0005] It has surprisingly been found that branched alcohols or branched hydrocarbons can be obtained by the process according to the invention without the use of heavy metal catalysts in the condensation reaction, both improved selectivities and higher reaction rates being obtained.
[0006] Carbonyl compounds
[0007] Suitable carbonyl compounds are, above all, aldehydes, ketones and mixtures thereof. Suitable aldehydes are, for example, fatty aldehydes which preferably correspond to formula (I):
R 1 CHO (I)
[0008] in which R 1 is a linear or branched alkyl group containing 6 to 12 and more particularly 8 to 10 carbon atoms. Typical examples are hexanol, octanol, 2-ethylhexanal, decanol, dodecanol and mixtures thereof. Also suitable are fatty ketones, preferably those corresponding to formula (II):
R 2 COR 3 (II)
[0009] in which R 2 and R 3 independently of one another represent linear or branched C 6-12 alkyl groups. Typical examples are dihexyl ketone, dioctyl ketone, di-2-ethylhexyl ketone, didecyl ketone or didoceyl ketone. Cyclic ketones, preferably cyclohexanone, may also be used.
[0010] Condensation
[0011] The condensation reaction may be carried out in known manner, i.e. the carbonyl compounds are initially introduced into the reactor together with the acids or bases and then heated to temperatures of 20 to 250° C. and preferably to temperatures of 200 to 240° C. The reaction may be carried out in the absence of pressure or under pressures of up to 30 bar and preferably up to 5 bar. Suitable catalysts are, in particular, alkali metal bases such as, for example, alkali metal hydroxides or alkali metal carbonates. The catalysts may be used in quantities of 1 to 10 mol-% and are preferably used in quantities of 3 to 5 mol-%, based on the carbonyl compounds. In order to displace the reaction equilibrium onto the product side, it is always advisable continuously to distil off the water of condensation.
[0012] Hydrogenation
[0013] The hydrogenation of the unsaturated aldehydes or ketones formed as the intermediate product may be carried out using typical hydrogenation catalysts, preferably based on nickel, copper and/or zinc. The hydrogenation is normally carried out at temperatures of 20 to 350° C. and preferably at temperatures of 50 to 250° C. and under pressures of 1 to 300 bar and preferably under pressures of 20 to 250 bar. The reaction products may then be purified by distillation.
EXAMPLES
Example 1
[0014] In a stirred reactor consisting of a flask, heating mushroom, water separator, reflux condenser and nitrogen inlet, 1 g (0.015 mol) of potassium hydroxide was added to 500 g (3.2 mol) of decanal (99% by weight) at 20° C., followed by heating to 210° C. The water formed during the reaction was continuously distilled off. After 3 hours, the reaction was terminated, the reaction mixture was cooled to 20° C. and the potassium hydroxide precipitated was filtered off. The resulting clear liquid contained 90% by weight of α,β-unsaturated aldehyde, 4% by weight trimers, 2% by weight esters and 4% by weight unreacted starting aldehyde. The reaction mixture was transferred to an autoclave and hydrogenated for 3 hours at 230° C./250 bar in the presence of a nickel catalyst until there was no further uptake of hydrogen. 90% by weight of the hydrogenation product consisted of 2-octyl dodecanol, 6% by weight of decanol and 4% by weight of trimers. After distillation, the 2-octyl dodecanol was obtained in a purity of 95.7% by weight.
Example 2
[0015] As in Example 1, 500 g (3.9 mol) of octanal were condensed in the presence of 1.2 g (0.02 mol) of potassium hydroxide. The resulting product contained 88% by weight of α,β-unsaturated aldehyde, 6% by weight of trimers, 2% by weight of waters and 4% by weight of unreacted octanal. After hydrogenation, a mixture of 88% by weight of 2-hexyl decanol, 6% by weight of octanol and 6% by weight of trimers was obtained. After distillation, the 2-hexyl decanol was obtained in a purity of 93.6% by weight.
Example 3
[0016] As in Example 1, 650 g (5.0 mol) of 2-ethyl hexanal and 245 g (2.5 mol) of cyclohexanone were condensed in the presence of 40 g of 45% by weight aqueous potassium hydroxide solution. After 2 hours, the reaction temperature of 240° C. was reached, the end point being indicated by the end of the separation of water. The product was washed with hot water until neutral and dried with sodium sulfate. According to GC analysis, a mixture of 85.4% by weight of disubstituted product, 8.2% by weight of monosubstituted product, 1.3% by weight of 2-ethyl hexanal, 0.3% by weight of cyclohexanone and 4.8% by weight of polymers was present. 500 g of the mixture were hydrogenated for 14 hours at 245° C./20 bar in the presence of 14 g of a nickel catalyst until there was no further uptake of hydrogen. Wet-chemical analysis of the product revealed an acid value of <0.1, an iodine value of 0.4 and a hydroxyl value of 1. GC analysis showed the composition to be 85.4% by weight 2,6-di-(2-ethylhexyl)-cyclohexane, 8.2% by weight 2-(2-ethylhexyl)-cyclohexane, 1.3% by weight 2-ethyl hexane, 0.3% by weight cyclohexane and 4.8% by weight oligomers. The unreacted starting materials were removed by distillation. | Processes for producing branched compounds are described wherein a carbonyl compound is condensed in the presence of a catalyst selected from the group consisting of acids and bases, to form an α,β-unsaturated condensation product; and the α,β-unsaturated condensation product is hydrogenated. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of Korean Patent Application No. 10-2009-0071755 filed on Aug. 4, 2009, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an inkjet head and a method of manufacturing the same, and more particularly, to an inkjet head that can improve printing quality and a method of manufacturing the same.
[0004] 2. Description of the Related Art
[0005] In general, an inkjet head converts an electric signal into a physical force so that ink droplets are ejected through small nozzles.
[0006] In recent years, piezoelectric inkjet heads have been used in industrial inkjet printers. For example, a circuit pattern is directly formed by spraying ink prepared by melting metals such as gold or silver onto a printed circuit board (PCB). A piezoelectric inkjet head is also used for industrial graphics, and is used in the manufacturing of a liquid crystal display (LCD) and an organic light emitting diode (OLED).
[0007] In general, an inlet and an outlet through which ink is introduced and ejected in a cartridge, a reservoir storing the ink being introduced, and chambers through which a driving force of an actuator by which the ink in the reservoir is moved to nozzles are provided in an inkjet head of an inkjet printer.
[0008] A liquid inside chambers of the inkjet head according to the related art generates driving waves when an actuator being mounted adjacent to the chambers generates vibrations. These driving waves become pressure waves travelling toward a manifold through a restrictor, and the pressure waves are then transmitted to the manifold.
[0009] The transmitted pressure waves cause the inkjet head according to the related art to undergo crosstalk that adversely affects neighboring nozzles. As a result, an unstable meniscus motion is observed, causing unstable droplet ejection and serving as noise in the eigenfrequency of an actuator of an adjacent ink chamber, thereby deteriorating printing quality.
SUMMARY OF THE INVENTION
[0010] An aspect of the present invention provides an inkjet head and a method of manufacturing the same that can prevent crosstalk adversely affecting other nozzles due to driving waves generated when an actuator vibrates.
[0011] According to an aspect of the present invention, there is provided a an inkjet head including: a manifold storing ink being injected from the outside; ink chambers receiving the ink from the manifold to eject the ink to the outside through nozzles; and a restrictor connecting the manifold and the ink chambers to each other and providing a plurality of interconnection paths.
[0012] The interconnection paths may each have a cylindrical shape.
[0013] The interconnection paths may be arranged symmetrically, relative to each other.
[0014] The ink chambers and the manifold may be provided diagonally opposite each other, and the restrictor may extend diagonally from the ink chambers.
[0015] The amount of ink being ejected through the interconnection paths of the restrictor may be twice as much as the amount of ink being ejected through the nozzle.
[0016] The interconnection paths each may have a diameter of 50 μm or less.
[0017] According to another aspect of the present invention, there is provided a method of manufacturing an inkjet head, the method including: providing a flow path plate having ink chambers therein; forming a manifold, storing ink being injected from the outside, and a plurality of interconnection paths, connecting the ink chamber and the manifold, in a nozzle plate; and forming a restrictor including a plurality of interconnection paths by bonding the flow path plate and the nozzle plate to each other.
[0018] The plurality of interconnection paths may be formed at the same time by an etching process.
[0019] The nozzle plate may be formed by bonding an intermediate plate having the manifold and the restrictor formed therein, and a lower plate having nozzles formed therein so as to be connected to the ink chambers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0021] FIG. 1 is a schematic perspective view illustrating an inkjet head according to an exemplary embodiment of the present invention;
[0022] FIG. 2 is a cross-sectional view illustrating the inkjet head of FIG. 1 ;
[0023] FIGS. 3A through 3E are schematic partial perspective views illustrating the restrictors of inkjet heads according to various embodiments of the present invention;
[0024] FIG. 4 is a cross-sectional view illustrating a method of manufacturing an inkjet head according to an exemplary embodiment of the present invention;
[0025] FIG. 5 is a schematic cross-sectional view illustrating an inkjet head according to another exemplary embodiment of the present invention; and
[0026] FIG. 6 is a schematic cross-sectional view illustrating an inkjet head according to another exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] An inkjet head and a method of manufacturing the same according to exemplary embodiments of the invention will be described in detail with reference to FIGS. 1 through 6 . Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[0028] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0029] FIG. 1 is a schematic perspective view illustrating an inkjet head according to an exemplary embodiment of the invention. FIG. 2 is a cross-sectional view illustrating the inkjet head of FIG. 1 .
[0030] Referring to FIGS. 1 and 2 , an inkjet head according to this embodiment includes a flow path plate 110 , an intermediate plate 120 , a lower plate 130 , piezoelectric actuators 140 and a restrictor 150 .
[0031] The flow path plate 110 includes a plurality of ink chambers 112 at regular intervals and has an ink introduction hole 116 through which ink is introduced. Here, the ink introduction hole 116 is directly connected with a manifold 122 . The manifold 122 supplies ink to the ink chambers 112 via a restrictor 124 (in the direction of the arrow of FIG. 1 ).
[0032] Here, the manifold 122 may be one large space to which the plurality of ink chambers 112 are connected. However, the invention is not limited thereto. A plurality of manifolds 122 may be formed to correspond to the individual ink chambers 112 .
[0033] Similarly, one ink introduction hole 116 may be formed to correspond to one manifold 122 . When the plurality of manifolds 122 are formed, a plurality of ink introduction holes 116 may be formed to correspond to the individual manifolds 122 .
[0034] The ink chambers 112 are provided in the flow path plate 110 at positions located under piezoelectric actuators 140 . Here, a portion of the flow path plate 110 that forms the ceiling of the ink chambers 112 serves as a vibration plate 114 .
[0035] Therefore, when a driving signal is applied to the piezoelectric actuators 140 in order to eject ink, the piezoelectric actuators 140 and the vibration plate 114 thereunder are deformed to reduce the volumes of the ink chambers 112 .
[0036] The reduction in the volumes of the ink chambers 112 increases the pressure inside the ink chambers 112 , so that ink inside the ink chambers 112 is ejected to the outside through dampers 126 and nozzles 132 .
[0037] Electrodes electrically connected to each other may be formed on upper and lower surfaces of each of the piezoelectric actuators 140 . The electrodes may be formed of Lead Zirconate Titanate (PZT) ceramics, which is one of piezoelectric materials.
[0038] The intermediate plate 120 may include the manifold 122 having a large length extending in a longitudinal direction and the dampers 126 connecting the nozzles 132 and the ink chambers 112 .
[0039] The manifold 122 receives ink through the ink introduction hole 116 and supplies the ink to the ink chambers 112 . The manifold 122 and the ink chambers 112 are connected with each other through the restrictor 124 .
[0040] The dampers 126 receive the ink ejected from the ink chambers 112 through the piezoelectric actuators 140 and eject the received ink to the outside through the nozzles 132 .
[0041] The dampers 126 may have a multi-stage configuration by which the amount of ink ejected from the ink chambers 112 and the amount of ink ejected through the nozzles 132 can be controlled.
[0042] Here, the dampers 126 are optional. When the dampers 126 are removed, the inkjet head may only include the flow path plate 110 and the lower plate 130 .
[0043] The lower plate 130 corresponds to the ink chambers 112 and includes the nozzles 132 through which the ink passing through the dampers 126 is ejected to the outside. The lower plate 130 is bonded to the bottom of the intermediate plate 120 .
[0044] The ink moving through a flow path formed inside the inkjet head is sprayed as ink droplets through the nozzles 132 .
[0045] Here, silicon substrates being widely used for semiconductor integrated circuits may be used for the flow path plate 110 , the intermediate plate 120 , and the lower plate 130 . The intermediate plate 120 and the lower plate 130 may be bonded to each other, which construction may be referred to as a nozzle plate.
[0046] The restrictor 150 connects the ink chambers 112 and the manifold 122 to each other and includes a plurality of interconnection paths 152 . Here, the restrictor 150 may extend from the bottom of the ink chambers 112 . However, the location at which the restrictor may be formed is not limited thereto.
[0047] Here, the restrictor 150 serves as a passage through which the ink, stored in the manifold 122 , moves toward the ink chambers 112 . In order to realize appropriate droplet ejection, the amount of ink being ejected through the interconnection paths 152 may be twice as much as the amount of ink being ejected through the nozzles 132 . Specifically, the interconnection paths 152 each may have a diameter of 50 μm or less.
[0048] Therefore, in this embodiment, the restrictor 150 having the interconnection paths 152 with the diameter of 50 μm or less can increase high frequency characteristics while maintaining droplet ejection performance.
[0049] FIGS. 3A through 3E are partial perspective views illustrating the restrictors of inkjet heads according to various embodiments of the invention.
[0050] Referring to FIGS. 3A through 3E , the restrictor 150 has the plurality of interconnection paths 152 . As shown in FIG. 3A , the interconnection paths 152 may be arranged in contact with each other.
[0051] As shown in FIG. 3B , the plurality of interconnection paths 152 may be located symmetrically, relative to each other. Alternatively, as shown in FIG. 3C , the plurality of interconnection paths 152 may be localized at one side of the intermediate plate 120 .
[0052] As shown in FIGS. 3D and 3E , there may be two interconnection paths 152 . The locations of the interconnection paths 152 may vary according to the designers' intentions in consideration of cancellation of pressure waves.
[0053] Here, a lower surface of the intermediate plate 120 which corresponds to the space of the ink chambers 112 is only illustrated in FIGS. 3A through 3E .
[0054] As shown in FIGS. 3A through 3E , the restrictor 150 may have a circular shape in cross section. However, the restrictor 150 may have various shapes, such as rectangular and polygonal shapes, which are suitable for cancelling pressure waves.
[0055] If the restrictor 150 is a single large passage having a large diameter, when the actuators 140 , mounted adjacent to the ink chambers 112 , vibrate, the liquid inside the ink chambers 112 generates driving waves. These driving waves may become pressure waves travelling toward the manifold by the restrictor 150 , which may then be transmitted to the manifold. This force may cause crosstalk affecting the neighboring nozzles 132 .
[0056] However, the inkjet head according to this embodiment has the restrictor 150 that connects the manifold 122 and the ink chambers 112 to each other and includes the plurality of interconnection paths 152 . Therefore, when the actuators vibrate, pressure waves, generated from the inside of the ink chambers 112 , may be cancelled to thereby prevent crosstalk.
[0057] Furthermore, the inkjet head according to this embodiment has the plurality of interconnection paths 152 each having a diameter of 50 μm or less, thereby filtering out dust that may enter the ink chambers 112 from the manifold 122 . Therefore, in this embodiment, these problems can be solved to thereby improve high frequency ejection characteristics and increase printing quality.
[0058] FIG. 4 is a cross-sectional view illustrating a method of manufacturing an inkjet head according to an exemplary embodiment of the invention.
[0059] Referring to FIG. 4 , according to a method of manufacturing an inkjet head according to this embodiment, the flow path plate 110 , the intermediate plate 120 and the lower plate 130 are provided.
[0060] Here, the intermediate plate 120 and the lower plate 130 may be bonded to each other, which construction may be referred to as a nozzle plate.
[0061] The ink chambers 112 , the manifold 122 , the dampers 126 and the nozzles 132 may be formed in the flow path plate 110 , the intermediate plate 120 and the lower plate 130 , respectively.
[0062] Here, the plurality of interconnection paths 152 may be formed at the same time by an etching process. The restrictor 150 having the plurality of interconnection paths 152 may be formed at the same time as the interconnection paths 152 are formed. Therefore, the restrictor 150 may be manufactured with ease without forming additional separate structures, thereby reducing the time required for manufacturing the same.
[0063] Here, the flow path plate 110 , the intermediate plate 120 and the lower plate 130 may be bonded together to thereby form a single body. Specifically, the intermediate plate 120 is bonded to the bottom of the flow path plate 110 , and the lower plate 130 is bonded to the bottom of the intermediate plate 120 .
[0064] Therefore, according to the method of manufacturing an inkjet head according to this embodiment, the restrictor 150 that connects the manifold 122 and the ink chambers 112 to each other and has the plurality of interconnection paths 152 can be manufactured with ease.
[0065] FIG. 5 is a schematic sectional view illustrating an inkjet head according to another exemplary embodiment of the invention.
[0066] Referring to FIG. 5 , an inkjet head includes the flow path plate 110 , the intermediate plate 120 , the lower plate 130 , the piezoelectric actuators 140 and a restrictor 250 .
[0067] The flow path plate 110 , the intermediate plate 120 , the lower plate 130 and the piezoelectric actuators 140 according to this embodiment are substantially the same as those of the embodiment, described with reference to FIGS. 1 and 2 . Thus, a detailed description thereof will be omitted.
[0068] The restrictor 250 connects the ink chambers 112 and the manifold 122 and includes a plurality of interconnection paths 252 . Here, the manifold 122 may be provided diagonally opposite the ink chambers 112 .
[0069] Therefore, as shown in FIG. 5 , the restrictor 250 may be located at the side of the ink chambers 112 in the inkjet head in order to connect the manifold 122 and the ink chambers 112 .
[0070] FIG. 6 is a schematic sectional view illustrating an inkjet head according to another exemplary embodiment of the invention.
[0071] Referring to FIG. 6 , an inkjet head according to this embodiment includes the flow path plate 110 , the intermediate plate 120 , the lower plate 130 , the piezoelectric actuators 140 , and a restrictor 350 .
[0072] The flow path plate 110 , the intermediate plate 120 , the lower plate 130 and the piezoelectric actuators 140 according to this embodiment are substantially the same as those of the embodiment, described with reference to FIGS. 1 and 2 . Thus, a detailed description thereof will be omitted.
[0073] The restrictor 350 connects the ink chambers 112 and the manifold 122 and includes a plurality of interconnection paths 352 . Here, the manifold 122 is located diagonally opposite the ink chambers 112 .
[0074] Therefore, as shown in FIG. 6 , the restrictor 350 may extend diagonally from the ink chambers 112 in the inkjet head in order to connect the manifold 122 and the ink chambers 112 .
[0075] Therefore, the inkjet head according to this embodiment has the restrictors 250 and 350 that connect the manifold 122 and the ink chambers 112 and include the plurality of interconnection paths 252 and the plurality of interconnection paths 352 , respectively, to cancel pressure waves generated from the inside of the ink chambers 112 when the actuators vibrate, thereby preventing crosstalk.
[0076] As set forth above, according to exemplary embodiments of the invention, an inkjet head and a method of manufacturing the same include a restrictor that connects a manifold and ink chambers and has a plurality of interconnection paths, thereby cancelling pressure waves generated from the inside of the ink chambers when actuators vibrate.
[0077] Furthermore, the inkjet head and the method of manufacturing the same can filter dust that may enter the ink chambers from the manifold since interconnection paths have a small diameter.
[0078] While the present invention has been shown and described in connection with the exemplary embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims. | An inkjet head according to an aspect of the invention may include: a manifold storing ink being injected from the outside; ink chambers receiving the ink from the manifold to eject the ink to the outside through nozzles; and a restrictor connecting the manifold and the ink chambers to each other and providing a plurality of interconnection paths. | 1 |
RELATED APPLICATIONS
The present application is a 371 of PCT/SE2008/051377 filed Nov. 28, 2008 and claims priority under 35 U.S.C. §119 to U.S. Application Ser. No. 60/991,338 filed Nov. 30, 2007.
FIELD OF THE INVENTION
The present invention relates to the field of IgE-mediated allergy, particularly occupational asthma such as baker's asthma. More specifically the invention relates to the identification of a novel wheat allergen and the use thereof in therapy and diagnosis. The invention also relates to methods for diagnosis and treatment of IgE-mediated allergy in mammals.
BACKGROUND
Allergens from wheat ( Triticum aestivum ) can cause three distinct IgE-mediated allergies, respiratory allergy by inhalation of wheat flour, food allergy by ingestion of wheat products and wheat pollen allergy which belongs to the group of grass pollen allergies. Allergic sensitization to wheat flour components is one of the most frequent causes of occupational asthma and approximately 1-10% of bakery workers are affected, therefore it is called baker's asthma. These bakery workers develop IgE antibodies against wheat flour allergens and flour-induced asthma and/or rhinitis. Support for the assumption that baker's asthma is a true occupational disease comes from the finding that the prevalence of sensitization to bakery-associated allergens is approximately tenfold higher in flour-exposed persons as compared to control populations without flour exposure. Furthermore, it has been possible to establish threshold values for wheat flour which are known to cause bronchial asthma in sensitized persons. A first systematic investigation on flour allergy was carried out already in 1933 by Baggoe. Other early reports focused on the description of cases of baker's asthma followed by mechanistic studies demonstrating the importance of IgE-mediated mechanisms in baker's asthma. Thereafter several attempts were made to characterize the disease-eliciting flour allergens by immunochemical methods, RAST technology, immunoblotting and recently by molecular cloning techniques.
Triticum aestivum is an important member of the grass family. Up to 40% of all allergic individuals carry serum IgE antibodies reacting with grass pollen allergens. Several studies have reported cross-reactivity between wheat flour and grass pollen due to common IgE epitopes in wheat flour and grass pollen proteins. Cross-reactivity between grass pollen allergens and wheat seed allergens has been described and there is evidence that patients suffering from bakers' asthma and IgE-mediated food allergy to wheat may recognize different allergens which may be used for the differential diagnosis of baker's asthma, food allergy flour to wheat and grass pollen allergy. However, the great majority of the soluble wheat flour allergens has not yet been identified. Today, only a few wheat flour allergens have been identified and characterized and they include the members of the alpha amylase inhibitor family, acyl-CoA oxidase, peroxidase, fructore-biphosphate aldolase and recently thioredoxins.
Diagnosis based on wheat flour extract does not discriminate between patients suffering from respiratory allergy or food allergy to wheat. Therefore precise diagnosis still relies on specific inhalation challenge in case of respiratory allergy to wheat flour and double-blind placebo-controlled food challenge (DBPCFC) in case of suspected food allergy and the question is open whether it is possible to identify allergens that can be used for selective diagnosis and treatment of the various wheat induced manifestations of allergy such as baker's asthma, food allergy and pollinosis. Thus there is a need to identify novel wheat allergens and to establish methods and diagnostic tests to specifically identify patients suffering from IgE-mediated allergy, such as respiratory allergy, e.g. baker's asthma, in order to discriminate them from patients suffering from food allergy and/or pollen allergy. Furthermore there is a need to use such novel wheat allergens for use in the treatment of IgE-mediated allergy. The present invention addresses these needs by providing novel wheat allergens and the use thereof in therapy and diagnosis. Furthermore the present invention provides the use of known peptides and proteins in therapy and diagnosis. Some of these peptides are known from Gennaro S. D. et al, Biological Chemistry, April 2005, 386:383-389; UNIPROT accession number P82977; UNIPROT accession number Q6W8Q2; U.S. Pat. No. 7,214,786 and US2006/0107345.
SUMMARY OF THE INVENTION
As stated above the few wheat flour allergens that have been identified and characterized include members of the alpha amylase inhibitor family, acyl-CoA oxidase, peroxidase, fructore-biphosphate aldolase and thioredoxins. So far no allergens have been identified that can be used for selective diagnosis and treatment of various wheat induced manifestations of allergy such as baker's asthma, food allergy and pollinosis. This led the present inventors to look for additional, not yet identified wheat allergens.
The present invention meets at least partly needs of prior art by providing novel wheat allergens and methods for diagnosis and treatment of IgE-mediated allergy in mammals.
In a first aspect the invention relates to polypeptides representing novel wheat allergens isolated from wheat or recombinantly produced and fragments or variants thereof sharing epitopes for antibodies. The isolated polypeptides comprise an amino acid sequence of clone #10, #112, or #126.
In a second aspect the invention relates to nucleic acids encoding the polypeptides of the invention, the nucleic acids having the nucleotide sequence of clone #10, #112, or #126.
In another aspect the invention relates to a polypeptide having clone identity #10, #38, #112, or #126 for use in therapy or diagnosis, preferably therapy and diagnosis of IgE-mediated allergy, such as respiratory allergy to wheat flour, e.g. baker's asthma. Furthermore the invention relates to an isolated polypeptide comprising the amino acid sequence of clone #37 for use in therapy or diagnosis, preferably therapy and diagnosis of IgE-mediated allergy, such as respiratory allergy to wheat flour, e.g. baker's asthma.
In still another aspect the invention provides a pharmaceutical composition comprising a polypeptide having clone identity #10, #38, #112, #126 or #37 or a hypoallergenic form thereof modified to abrogate or attenuate its IgE-binding response, and optionally pharmaceutically acceptable excipients, carriers, buffers and/or diluents. The hypoallergenic form of a polypeptide having clone identity #10, #38, #112, #126 or #37 may be modified by fragmentation, truncation or tandemerization of the molecule, deletion of internal segments, domain rearrangement, substitution of amino acid residues, disruption of disulfide bridges.
In a further aspect the invention relates to an allergen composition “spiked” with a polypeptide having clone identity #10, #38, #112, #126 or #37. Such an allergen composition may be an allergen extract or a mixture of purified or recombinant allergen components having no or a low content of the polypeptide of the invention, wherein the polypeptide is added in order to bind IgE from patients whose IgE would not bind or bind poorly to the other allergen components in the composition. This aspect of the invention also relates to a method for producing such a composition, which method comprises the step of adding a polypeptide having clone identity #10, #38, #112, #126 or #37 to an allergen composition, such as an allergen extract (optionally spiked with other components) or a mixture of purified native or recombinant allergen components.
In a further aspect the invention relates to an allergen composition obtainable by the above method.
The invention further relates to a method for in vitro diagnosis of IgE-mediated allergy comprising the steps of bringing a body fluid sample, such as a blood, plasma or serum sample, from a mammal suspected of having IgE-mediated allergy such as respiratory allergy to wheat flour, e.g. baker's asthma, in contact with the polypeptide having clone identity #10, #38, #112, #126 or #37, and detecting the presence, in the sample, of IgE antibodies that bind specifically to the polypeptides of the invention. The presence of such antibodies specifically binding to the polypeptide having clone identity #10, #38, #112, #126 or #37 is indicative of IgE-mediated allergy. One embodiment of such a method comprises carrying out the method by micro-array analysis.
In a further aspect the invention provides a diagnostic kit for performing the method of in vitro diagnosis of IgE-mediated allergy, such as respiratory allergy to wheat flour, e.g. baker's asthma, said kit comprising a polypeptide having clone identity #10, #38, #112, #126 or #37, and means for detecting the IgE binding to said polypeptide, such as a solid support, e.g. a nitrocellulose membrane or a microarray having a polypeptide with clone identity #10, #38, #112, #126 or #37 bound thereto.
In still a further aspect the invention provides a method for treatment of an IgE-mediated allergy in a mammal, such as respiratory allergy, e.g. baker's asthma. In one embodiment the method comprises administering to an individual susceptible to such a treatment a polypeptide having clone identity #10, #38, #112, #126 or #37 or a fragment or a variant thereof sharing epitopes for antibodies. In another embodiment the method comprises administering to an individual susceptible to such a treatment a pharmaceutical composition according to a previous aspect.
DEFINITIONS
TABLE A
Definition of clones
Clone
Nucleic acid sequence
Amino acid sequence
#10
SEQ ID NO: 1
SEQ ID NO: 2
#37
SEQ ID NO: 3
SEQ ID NO: 4
#38
SEQ ID NO: 5
SEQ ID NO: 6
#112
SEQ ID NO: 7
SEQ ID NO: 8
#126
SEQ ID NO: 9
SEQ ID NO: 10
Variants and fragments of a polypeptide of the invention should be construed as meaning proteins or peptides with a length of at least 10 amino acids, more preferably at least 25, even more preferably at least 50 or 75 amino acid residues and a sequence identity to said polypeptide of at least 50%, preferably over 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98% or 99%.
A modified polypeptide should in the context of the present invention be construed as meaning a polypeptide that has been chemically or genetically modified to change its immunological properties, e.g. as exemplified in relation to the immunotherapy aspect of the invention.
Variants and fragments of a polypeptide sharing epitopes for antibodies with said polypeptide should be construed as being those fragments and variants whose binding of IgE antibodies from a serum sample from a representative patient sensitized with the polypeptide of the invention can be significantly inhibited by the polypeptide. Such an inhibition assay may e.g. be performed according to the protocol disclosed in Example 4.
A hypoallergenic modified polypeptide or variant or fragment of a polypeptide should be construed as being a modified polypeptide or variant or fragment of a polypeptide that is not capable of binding IgE antibodies reactive to said polypeptide from a serum sample of a representative polypeptide-sensitized patient, as determined e.g. by the protocol according to Example 1 or which displays no or significantly reduced biological allergen activity, as determined by a cellular activation assay such as the basophil histamine release assay.
BRIEF DESCRIPTION OF TABLES AND FIGURES
Table I shows the demographic, clinical and serological characteristics of patients suffering from bakers' asthma.
Table II shows the demographic, clinical and serological characteristics of patients suffering from food allergy to wheat (F1-F4) and grass pollen allergy (G1-G4).
Table III shows the percentage amino acid sequence identities between the clone 10-derived allergen and homologous proteins, wherein proteins numbered 1-30 are the following: 1. gi|122065237 ( Triticum aestivum ), 2. gi|66356278 ( Triticum aestivum ), 3. gi|124122 ( Hordeum vulgare subsp. vulgare ), 4. gi|48093360 ( Zea diploperennis ), 5. gi|48093418 ( Tripsacum dactyloides ), 6. gi|75994161 ( Zea mays subsp. parviglumis ), 7. gi|58396945 ( Oryza sativa [japonica cultivar-group]), 8. gi|115649132 ( Strongylocentrotus purpuratus ), 9. gi|37904392 ( Brachypodium distachyon ), 10. gi|26224744 ( Citrus×paradise ), 11. gi|224447 ( Vicia faba ), 12. gi|124395862 ( Paramecium tetraurelia ), 13. gi|50262213 ( Cucurbita maxima ), 14. gi|547743 ( Nicotiana sylvestris ), 15. gi|54610713 ( Lumbricus terrestris ), 16. gi|169491 ( Solanum tuberosum ), 17. gi|218290 ( Nicotiana glauca×Nicotiana langsdorffii ), 18. gi|124121 ( Vigna angularis ), 19. gi|603890 ( Sambucus nigra ), 20. gi|14718445 ( Ipomoea batatas ), 21. gi|114950 ( Momordica charantia ), 22. gi|109138554 ( Fagopyrism esculentum ), 23. gi|18404883 ( Arabidopsis thaliana ), 24. gi|27734408 ( Canavalia lineate ), 25. gi|37901103 ( Hevea brasiliensis ), 26. gi|92874842 ( Medicago truncatula ), 27. gi|13959383 ( Linum usitatissimum ), 28. gi|22759723 ( Zinnia elegans ), 29. gi|37359345 ( Vitis vinifera ) and 30. gi|6453287 ( Amaranthus hypochondriacus ).
Table IV shows clinical data for baker's asthma patients of Example 2.
Table V shows clinical data for food and grass pollen allergic patients of Example 2.
Table VI shows PCR primers used for amplification of cDNAs for clones #10, #38, #112, #123 #126 and #37.
Table VII. Demographic, clinical and serological characteristics of patients suffering from baker's asthma
Table VIII. Demographic, clinical and serological characteristics of patients suffering from grass pollen allergy
Table IX. Demographic, clinical and serological characteristics of patients suffering from food allergy to wheat
FIG. 1 illustrates the nucleotide and deduced amino acid sequence of the clone 10-derived allergen (SEQ ID NO: 1). Coding and non-coding region are in upper and lower case letters, respectively, the start (ATG) and stop codons are underlined. Amino acids of the potato inhibitor I family signature are printed with grey background. Left hand numbers are for the nucleotides and right hand numbers for the amino acids. The sequence has been submitted to the GenBank under the accession number (EU051824).
FIG. 2 illustrates the characterization of purified serine proteinase inhibitor-like allergen. A, Coomassie brilliant blue-stained SDS-PAGE containing purified clone 10-derived allergen. A molecular weight marker (kDa) is shown on the left side. B, Mass spectrometry (MS) of the purified clone 10-derived allergen. The mass/charge ratio is shown on the x-axis and the intensity is displayed on the y-axis as a percentage of the most intensive signal obtained in the investigated mass range. C, Far-ultraviolet circular dichroism (CD) analysis of the purified clone 10-derived allergen. The spectra are expressed as mean residue ellipticities (θ) (y-axis), recorded at 25° C. (bold line), 95° C. (regular line) and 25° C. after cooling (dotted line) at given wave lengths (x-axis).
FIG. 3 illustrates the IgE reactivity of patients suffering from bakers' asthma, grass pollen allergy and food allergy. Purified clone 10-derived allergen, HSA, rPhl p 1, rPhl p 5, rPhl p 7, rPhl p 12, wheat pollen extract and wheat seed extract were dotted onto nitrocellulose membrane strips and incubated with sera from 22 bakers' asthma patients (1-22), four grass pollen allergic patients sera (G1-04), four sera from patients suffering from food allergy to wheat (F1-F4), one non-allergic individual (NC) and buffer without addition of serum (B). Bound IgE antibodies were detected with 125 I-labelled anti-human IgE antibodies and visualized by autoradiography.
FIG. 4 is a box plot representation of IgG subclass reactivities to clone 10-derived allergen. IgG 1-4 subclass reactivities to the clone 10-derived allergen were determined by ELISA for patients suffering from bakers' asthma (n=22) and are displayed as box plots where 50% of the values are within the boxes and non-outliers between the bars. The lines within the boxes indicates the median values, circles are outliers and asterisks extreme values.
FIG. 5 illustrates the allergenic activity of the clone 10-derived allergen. RBL cells were loaded with serum IgE from three bakers' asthma patients (#2, #4, #12) or with serum of a non-allergic patient (NC) and then challenged with recombinant clone 10-derived allergen or timothy grass pollen allergen rPhl p 1. The mean β-hexosaminidase releases are shown on the y-axis as percentages of total release after subtraction of percentages for spontaneous release.
FIG. 6 shows the expression of the serine proteinase inhibitor-like allergen in seeds during seed maturation. Nitrocellulose-blotted wheat extract from immature (day 7, 10, 15, 20, 25, 30, 35) and mature (M) wheat seeds were probed with rabbit antibodies specific for the clone 10-derived allergen, and for control purposes, with the corresponding pre-immune serum. Molecular weights are indicated on the left side in kilo Dalton (kDa).
FIG. 7 shows the identification of the clone 10-derived allergen in wheat pollen and seed extracts. Nitrocellulose blotted extracts were probed with rabbit antibodies specific for the clone 10-derived allergen (20), antibodies specific for wheat profilin (I #123), for a mite allergen (NC) or with buffer without addition of rabbit antibodies (B). The corresponding pre-immune sera are referred as P #10 and P #123 respectively. Bound IgG antibodies were detected with 125 I-labelled donkey anti-rabbit antibodies and visualized by autoradiography. Molecular weight markers (in kDa) are indicated on the left.
FIG. 8 illustrates the detection of the serine proteinase inhibitor-like allergen in extracts from wheat seeds, rice, maize, bean and potato. A, Coomassie blue-stained gel containing extracts from wheat (W), rice (R) and maize (M), common bean (B) and potato (P). B, Nitrocellulose blotted extracts were exposed to rabbit pre-immune serum and C, rabbit antibodies specific for the clone 10-derived allergen. Molecular masses (kDa) are indicated on the left side.
FIG. 9 shows the localization of clone 10-derived allergen by transmission immunogold electron microscopy in a wheat seed. A and B, Cross section of a wheat grain at low (A) and high (B) magnification. A shows fruit and seed coat (C), aleuron layer (AL) and the beginning of the starchy endosperm (SE). The rectangle in A indicates an area comparable to the area shown in B, i.e. border between aleuron layer and starchy endosperm. The rectangles in B indicate areas shown in high magnification in C, D and E, F, respectively. C and D, Detail of a wheat seed aleurone cell probed with rabbit anti-clone 10 derived Ig (C) or preimmune Ig (D). E and F, High magnification micrograph of the starchy endosperm after immunogold localization of wheat protein 10 with rabbit anti-clone 10 derived Ig (E) or preimmune Ig (F). Bound rabbit antibodies were detected with a gold-conjugated goat anti-rabbit Ig antiserum (gold particles=black dots). Arrows point to colloidal gold particles. The bars represent: A, 20 μm; B, 5 μm; C—F, 0.5 μm. AG, aleuron grain; AL, aleuron layer; C, multilayered fruit and seed coat; CY, cytoplasmic materials; L, lipid body; M, mitochondrion; SE, starchy endosperm; SG, starch grain; W, cell wall.
FIG. 10 . IgE Dot Blot of patients suffering from baker's asthma.
FIG. 11 . IgE Dot Blot of patients suffering from food allergy to wheat and grass pollen allergy.
FIG. 12 . Allergen microarray. A, Application scheme of micro-arrayed proteins and wheat pollen extract. Recombinant wheat proteins are designated as: 10, 37, 38, 112, 123, 126; WP: wheat pollen extract; recombinant timothy grass pollen allergens: Phl p 1, Phl p 5, Phl p 7 and Phl p 12. Numbers in the box at the bottom indicate position markers. B and C, Images of microarrays after incubation with serum and detection of IgE-reactive spots with fluorophore-conjugated anti-IgE antibodies. B, Image after incubation with serum from a non allergic individual. C, Images after incubation with serum from a representative patient suffering from baker's asthma (1: B4), wheat induced food allergy (2: F26), grass pollen allergy (3: G16). Dots on the bottom of the slides indicate position markers which are purified IgE antibodies detected with fluorophore-conjugated anti-IgE antibodies.
FIG. 13 . Prevalence of IgE reactivity to wheat seed proteins, wheat pollen extract and grass pollen allergens. Percentages of patients with IgE reactivity are shown for baker's asthma (A) (n=23), food allergy to wheat (B) (n=38) and grass pollen allergy (C) (n=17) at the y-axis. The x-axis shows the tested recombinant wheat proteins #10, #37, #38, #112, #123 and #126, wheat pollen extract, recombinant grass pollen allergens Phl p 1, Phl p 5, Phl p 7 and Phl p 12, a “Wheat Mix” comprising all recombinant wheat proteins, wheat flour and timothy grass CAP used to measure IgE reactivity.
DETAILED DESCRIPTION OF THE INVENTION
The examples below illustrate the present invention with the isolation and use of the polypeptide of the invention. The examples are only illustrative and should not be considered as limiting the invention, which is defined by the scope of the appended claims. Clone #123 mentioned in the Examples is profilin, known from e.g. U.S. Pat. No. 7,214,786.
EXAMPLE 1
The Novel Wheat Allergen Clone #10
Example 1 shows the identification and characterization of a novel wheat seed allergen, clone #10, belonging to the potato inhibitor family, a family of serine protease inhibitors, which together with other protease inhibitors are referred to as pathogenesis related proteins (PR), family PR6. Clone #10 is the first allergen identified and described for the PR6 family. Furthermore Example 1 shows the expression and purification of a recombinant clone 10-derived allergen.
Clone #10 was specifically recognized by serum IgE from patients with baker's asthma but showed no IgE reactivity when tested with sera from patients suffering from food allergy to wheat, celiac disease or grass pollen allergy. Therefore the clone 10-derived allergen together with other wheat allergens may be used to establish diagnostic tests which allow to specifically identify patients suffering from IgE-mediated baker's asthma and to discriminate these patients from allergic patients with food or pollen allergy.
Techniques
Biological Materials, Patients' Sera and Antibodies
Wheat seeds from Triticum aestivum cv. Michael were obtained from the Österreichische Agentur für Gesundheit and Ernährungssicherheit GmbH and planted in a glasshouse. Immature seeds were harvested 7, 10, 15, 20, 25, 30 and 35 days after the onset of pollination directly into liquid nitrogen and stored at −80° C. until use. Wheat pollen was obtained from Allergon (Välinge, Sweden). Rice, maize, beans and potatoes were bought at a local market. Recombinant Phl p 1, Phl p 5, Phl p 7 and Phl p 12 were purchased from BIOMAY (Vienna, Austria) and human serum albumin (HSA) from Behring (Marburg, Germany). Sera were obtained from 22 patients suffering from bakers' asthma. Baker's asthma was diagnosed on the basis of a positive case history, IgE specific for wheat and rye flour by CAP-FEIA System (Phadia, Uppsala, Sweden) and included specific inhalation challenge tests for confirmation of a clinically relevant sensitization (1). Demographic, clinical and serological data of these patients are summarized in Table I. In addition, serum from a non-allergic individual, sera from 4 patients suffering from food allergy to wheat and 4 grass pollen allergic patients without baker's asthma but serum IgE reactivity to wheat and rye flour were included in the experiments (Table II). Sera from grass pollen allergic patients had been analyzed for total serum IgE levels and IgE specific timothy grass pollen by CAP-FEIA System (Phadia) and patients with food allergy to wheat have been characterized as described previously (2). The specificity of the clone 10-derived allergen for baker's asthma was confirmed by testing additional 20 sera from celiac disease patients, 119 food allergic patients, 23 sera from grass pollen allergic patients and 25 baker's asthma patients by chip analysis (Constantin et al, unpublished).
Specific rabbit antibodies against the clone 10-derived allergen were raised by immunization of a rabbit in monthly intervals with purified clone 10-derived allergen (200 μg per injection) using once Freud's complete adjuvant and twice IFA (Charles River, Kisslegg, Germany). Pre-immune serum was obtained from the rabbit before immunization. For control purposes, a rabbit immune serum specific for a house dust mite allergen and rabbit antiserum specific for wheat profilin were used.
Construction of a λgt11 cDNA Library from Wheat Seeds
Total RNA was extracted according to Yeh (3) from wheat seeds, harvested twenty five days after the onset of pollination, and stored at −80° C. Then the RNA pellet was dissolved in guanidinium isothiocyanate buffer (4M guanidinium isothiocyanate, 0.83% v/v 3M sodium acetate, pH 6, 11 mM β-mercaptoethanol) and purified by cesium chloride density gradient ultracentrifugation (4). Poly-A + RNA was isolated by oligo-dT cellulose affinity chromatography (Nucleo Trap mRNA; Machery-Nagel) and double stranded cDNA was synthesized with a cDNA synthesis kit (cDNA synthesis System; Roche Diagnostics, Mannheim, Germany). After methylation with EcoRI methylase (New England Biolabs, Beverly, Mass.), EcoRI linkers (New England Biolabs) were added to the cDNA. Linkered cDNA was digested with EcoRI (Roche Diagnostics). Digested linkers were removed with a Nick column (Pharmacia Biotech, Uppsala, Sweden) and the cDNA was ligated into λgt11 arms (Stratagene, La Jolla, Calif., USA). The ligation product was packed in vitro (Gigapack III Gold Cloning Kit, Stratagene) resulting in a λgt11 expression cDNA library with 2.43×10 6 PFU.
Isolation and Characterization of IgE-Reactive Clones from a Wheat Seed cDNA Library
E. coli Y1090 were infected with 7×10 5 PFU of recombinant phages and immunoscreened with serum IgE of four patients (#1, #2, #4, #12) suffering from bakers' asthma as described (5). Fifteen IgE-reactive phage clones were selected for further re-cloning and their DNA was PCR-amplified using Platinum PCR Supermix (Invitrogen, Life Technologies) with λgt11 primers and sequenced (MWG, Ebersberg, Germany). The obtained sequences were compared with sequences submitted to the GenBank database at the National Center for Biotechnology Information (NCBI). Multiple sequence alignment was performed using the GenBank database at the NCBI. For amino acid sequence identities the Clustal W multiple alignment tool was used. A motif search was carried out with the PROSITE tool of the ExPASy proteomics server, for amino acid composition the ProtParam tool of ExPASy was used. Solvent accessibility and secondary structure prediction was calculated using the PROT software from the Columbia University Bioinformatics Center. A phylogenetic tree was reconstructed based on the amino acid sequence of the clone 10-derived allergen and homologous proteins using the “Multiple Alignment and Phylogenetic Tree Reconstruction” software provided by the Max Planck Institute for Molecular Genetics.
Expression and Purification of the Clone 10-Derived Recombinant Allergen
The coding region of the clone 10 cDNA was amplified by PCR using the following primer pair: forward 5′-CATATGAGCCCTGTGGTGAAGAAGCCGGAGGGA-3′ and reverse, 5′- GAATTC TTAGTGATGGTGATGGTGATGGCCGACCCTGGGGAC-3′ (MWG). The PCR product contained NdeI (italics), EcoRI (underlined) restriction sites and a hexahistidine tag-encoding sequence (bold). The PCR product was subcloned into an AccepTor Vector (Novagen, Madison, Wis.) and sequenced again (MWG). Then the insert was cut out of the AccepTor Vector with NdeI and EcoRI (Roche Diagnostics), gel-purified (Promega, Madison, Wis., USA) and subcloned into the expression plasmid pET 17b (Novagen). The DNA sequence was confirmed by sequencing both DNA strands (Microsynth, Balgach, CH). The pET 17b-clone 10 construct was transformed into E. coli BL21 (DE3) (Stratagene) and grown in Luria Broth (17) medium containing 100 mg/l ampicillin at 37° C. to an OD (600 nm) of 0.8-1. Protein expression was induced by addition of isopropyl β-D-thiogalactopyranoside (IPTG) to a final concentration of 0.5 mM and growing the bacteria for additional 3 h. Bacteria were harvested by centrifugation and—homogenized in 25 mM imidazole, pH 7.5, 0.1% (v/v) Triton X-100 with an Ultraturrax (IKA, Stauffen, Germany). DNA was digested by addition of DNase I, stirred for additional 10 min at 20° C., the reaction was stopped with 200 μl of 5M NaCl and then centrifuged at 4° C. (6000×g, 20 min). The majority of the clone 10-derived allergen was found in the insoluble fraction of the bacterial extract. Clone 10-derived allergen was purified from the inclusion body-containing pellet under denaturing conditions using Ni-NTA resin affinity columns according to the QIAexpressionist handbook (QIAGEN, Hilden, Germany). Fractions containing the recombinant allergen were pooled and dialyzed against 10 mM NaH 2 PO 4 pH 7.5. The protein concentration was determined with a Micro BCA Protein Assay Kit (Pierce, Rockford, Ill.).
ELISA
Clone 10-derived allergen was dissolved in PBS at a concentration of 5 μg/ml and coated on ELISA plates (Nunc Maxisorb, Roskilde, Denkmark). After blocking with 1% (w/v) BSA in PBS, 0.05% (v/v) Tween 20 (PBST), plates were incubated with sera diluted 1:50 in PBST, 0.5% (w/v) BSA for measurement of IgG 1 , IgG 2 , IgG 3 and IgG 4 as described (6). Bound antibodies were detected by incubating first with monoclonal mouse anti-human IgG subclass antibodies (BD Biosciences, Franklin Lakes, N.J.) diluted 1:1000 in PBST, 0.5% (w/v) BSA, and then with a horseradish-peroxidase-coupled sheep anti-mouse antiserum (GE Healthcare, Little Chalfont, UK) diluted 1:2000 in PBST, 0.5% (w/v) BSA as previously described (2). All determinations were performed as duplicates, and results are expressed as mean values.
Protein Extracts, SDS-PAGE and Immunoblots
SDS-protein extracts from mature and immature wheat seeds, rice ( Oryza sativa ), maize ( Zea mays ), common bean ( Phaseolus vulgaris ) and potato ( Solanum tuberosum ) were prepared by homogenization of 3 grams of tissue in 32 ml of sample buffer (6) and subsequent boiling for 10 minutes. In order to remove insoluble particles, the extracts were centrifuged at 10,000×g for 10 min at 4° C. and the supernatants were stored in aliquots at −20° C. In addition a PBS-protein extract from wheat seeds was prepared as previously described (2). Triticum aestivum pollen (500 mg) were extracted at 4° C. over night in 5 ml PBS, 2 mM EDTA, 1 mM PMSF. After centrifugation for 1 h at 13,000×g 4° C., the protein concentration of the supernatant was determined with Micro BCA Protein Assay Kit (Pierce) and aliquots were stored at −20° C. until use. Equal amounts of SDS-protein extracts were separated by 14% preparative SDS-polyacrylamide gels (7). A protein molecular weight marker (Rainbow Marker, GE Healthcare; Precision Plus Protein Standard, BioRad, Herkules, Calif.; Page Ruler Pre-stained Protein Ladder, Fermentas, Burlington, Ontario) was used as a standard. After electrophoretic separation, proteins were either stained with Coomassie brilliant blue or blotted onto nitrocellulose membranes (Schleich 85 Schuell, Dassel, Germany) (8). Membranes were blocked in buffer A (50 mM sodium phosphate buffer, pH 7.4, 0.5% w/v BSA, 0.5% v/v Tween-20, 0.05% w/v NaN 3 ) twice for 10 min and once for 30 min and incubated overnight at 4° C. with a rabbit antiserum specific for the clone 10-derived allergen, the corresponding pre-immune serum, and for control purposes, with a rabbit antiserum specific for an unrelated antigen or buffer alone. Rabbit sera were diluted 1:50,000 in buffer A. Bound antibodies were detected with 1:2000 in buffer A diluted 125 I-labelled anti-rabbit antibodies from donkey (GE Healthcare) for 2 h at room temperature and visualized to Kodak XOMAT films with intensifying screens (Kodak, Heidelberg, Germany) at −70° C.
For IgE dot blot experiments, 100 ng of recombinant clone 10-derived allergen and recombinant grass pollen allergens, Phl p 1, Phl p 5, Phl p 7 and Phl p 12, as well as 3 μg of wheat pollen extract and 2 μg of mature wheat seed PBS-extract were dotted onto a nitrocellulose membrane. The nitrocellulose strips were blocked with buffer A and exposed to patients sera at a 1:10 dilution in buffer A over night at 4° C. Bound IgE antibodies were detected with 125 I-labelled anti-human IgE antibodies (RAST RIA, Demeditec Diagnostics, Germany) diluted 1:20 in buffer A over night at room temperature and visualized by autoradiography using Kodak XOMAT films with intensifying screens (Kodak) at −70° C.
MS and CD Analysis of Recombinant Clone 10
Laser desorption mass spectra were acquired in a linear mode with a TOF Compact MALDI II instrument (Kratos, Manchester, UK; piCHEM, Research and Development, Graz, Austria). Samples were dissolved in 10% acetonitrile (0.1% trifluoroacetic acid), and α-cyano-4 hydroxycinnamic acid (dissolved in 60% acetonitrile, 0.1% trifluoroacetic acid) was used as a matrix. For sample preparation a 1/1 mixture of protein and matrix solution was deposited onto the target and air-dried.
CD measurements were performed with purified clone 10-derived allergen (in H 2 O) at a protein concentration of 0.1 mg/ml on a Jasco J-810 spectropolarimeter (Tokyo, Japan) using a 0.2 cm path length rectangular quarz cuvette. Far-UV CD spectra were recorded from 190 nm to 260 nm with 0.5 nm resolution at a scan speed of 50 nm/min and resulted from the average of three scans. Results are expressed as the mean residue ellipticity (θ) at a given wavelength. Temperature scans were performed according to a step-scan procedure, where the sample was heated from 25° C. to 95° C. with a heat rate of 2° C./min and cooled back to 25° C. at the same rate. Every 5° C. continuous wavelength spectra were recorded with the specified parameters. In addition, temperature scans were recorded at 215 nm with a step resolution of 0.5° C. Results are expressed as the molar mean residue ellipticity (θ MRE ) at a given wavelength. The final spectra were corrected by subtracting the corresponding baseline spectrum obtained under identical conditions. The secondary structure content of clone 10-derived allergen was calculated using the secondary structure estimation program CDSSTR (9).
Human Rat Basophil Leukaemia (huRBL) Assay
For the quantification of IgE Ab-mediated, immediate-type reactions, huRBL cell mediator release assays were performed. RBL cells (clone RBL-703/21) transfected with the human FcεRI (10) were cultured in RPMI 1640 supplemented with 5% FCS, 4 mM L-Glutamine, and 1 mg/ml G418 sulfate. Cells were harvested after incubation with Trypsin/EDTA, washed, re-suspended in culture medium, and the cell concentration was adjusted to 2×10 6 cells/ml. Fifty μl aliquots of the cell solution were added to the wells of a 96-well flat-bottom microplate (cell density/well was 1×10 5 cells). Human sera were diluted 1:10 in culture medium, added to the cells and incubated overnight at 37° C., 7% CO 2 , 95% relative humidity. Medium was removed and the plates were washed 3 times with 200 μl/well of Tyrode's buffer+0.1% BSA. For IgE cross-linking, 100 μl of clone 10-derived allergen or rPhl p 1, (0.3 μg/ml), diluted in Tyrodes's buffer containing 50% D 2 O and 0.1% (w/v) BSA were added to the cells. For spontaneous release, Tyrodes' buffer without protein was added to the wells. Total release was determined by addition of Tyrode's buffer containing 10% Triton X-100. After incubation at 37° C., 7% CO 2 , 95% relative humidity for 1 hour cells were harvested by centrifugation and 50 μl supernatant was transferred to a new plate, and 50 μl assay solution (0.1M Citric Acid or Sodium Citrate, pH 4.5 and 160 μM 4-methyl umbelliferyl-N-acetyl-β-D-glucosaminide) per well was added. After another one hour incubation the reaction was stopped by adding 100 μl glycine buffer (0.2M glycine, 0.2% NaCl, pH 10.7) to each well. Fluorescence was measured at λ ex : 360/λ em : 465 in a fluorescence microplate reader. Spontaneous release was determined from control wells that had not been lysed by Triton X-100. Specific release was calculated using the formula: (sample-spontaneous/total-spontaneous)×100.
Immunogold Electron Microscopy
Dry grains of wheat were cut into small pieces (cubes of approximately 0.5 mm size) using a sharp razor blade. In order to preserve the dry state of the cells, the cubes were anhydrously fixed in acrolein vapor for 5 days at room temperature. They were transferred at room temperature for 1 day to dimethoxypropane (DMP) for removing any residual water and embedded into Lowicryl K4M resin using ascending series of DMP:ethanol and ethanol:monomeric Lowicryl K4 M as intermediate stages. Polymerization was performed at −35° C.
Ultrathin sections were cut from both peripheral and central grain tissues and placed on silver grids for immunolabeling procedures.
Labelling for clone 10-derived allergen was performed in a moist chamber at room temperature (PBS buffer+1% (w/v) BSA, pH 7.4, Tris buffer+1% (w/v) BSA, pH 8.2) as follows: 1.5% (w/v) BSA in PBS buffer, 15 minutes; 2. rabbit anti-wheat protein 10 antibodies and pre-immune antibodies, diluted 1:35 in PBS buffer, 2 hours; 3. PBS buffer, 5 minutes, Tris buffer, 2×5 minutes; 4. goat anti-rabbit IgG antibodies coupled to colloidal gold particles of 10 nm size (BioCell, Plano, Wetzlar, Germany), diluted 1:20 in Tris buffer; 5. Tris buffer, 1×5 minutes, distilled water, 2×5 minutes.
Sections were stained using uranyl acetate (5 minutes) and lead citrate (10 seconds).
Samples were analyzed in a transmission electron microscope EM 410 (FEI, Eindhoven, The Netherlands).
Results
Isolation and Characterization of a Wheat cDNA Coding for a Serine Proteinase Inhibitor-Like Allergen
A wheat seed cDNA expression library was screened with IgE antibodies from four patients suffering from bakers' asthma. The open reading frame of the cDNA of the IgE-reactive clone 10 contained 262 nucleotides coding for a 84 amino acids polypeptide ( FIG. 1 ). A molecular mass of 9.4 kDa and an isoelectric point (pI) of 6.08 was calculated according to the deduced amino acid sequence for the clone 10-derived allergen. The analysis of amino acid composition showed a high content of valin residues (15.5%) and absence of cysteine residues. According to computer-aided secondary structure analysis the clone 10-derived allergen consists mainly of random coils and beta-sheets and one alpha-helical domain. According to solvent accessibility calculations almost 80% of the amino acids are solvent exposed. A search for sequence motifs revealed the presence of one potential casein kinase II phosphorylation site (amino acid 32), two N-terminal myristoylation sites (amino acids 11, 55) and a potato inhibitor I family signature ( FIG. 1 : amino acids 25-36 are boxed). A comparison of the clone 10-derived amino acid sequence with sequences deposited in the NCBI database showed that the allergen is almost identical to a Triticum aestivum subtilisin-chymotrypsin inhibitor WSCI precursor (accession no. gi|122065237) and to T. aestivum WSCI proteinase inhibitor (accession no. gi|66356278) and exhibits significant sequence homologies with a group of serine proteinase inhibitors occurring in plants and animals. These serine proteinase inhibitors constitute a family designated potato inhibitors I and are characterized by a typical consensus sequence pattern which is conserved in each of the proteins. The serine proteinase inhibitors belonging to the potato inhibitor I family are small proteins of 60-90 amino acids lacking disulphide bonds and contain only a single inhibitory site. The sequences of wheat serine proteinase inhibitors show a significant degree of sequence conservation to proteinase inhibitors of other monocotyledonic plants like barley ( Hordeum vulgare ), maize ( Zea mays, Zea diploperennis ), gamma grass ( Tripsacum dactyloides ) and rice ( Oryza sativa ), dicotyledonic plants and worms (Table III). Table III displays the percentages of sequence identities between each of the serine proteinase inhibitors.
Expression, Purification and Physicochemical Characterization of the Serine Proteinase Inhibitor-Like Allergen
The clone 10-derived allergen was expressed in E. coli BL21 (DE3) with a C-terminal hexahistidine tag. Approximately 25 mg/L liquid culture of serine proteinase inhibitor-like allergen could be purified by nickel chromatography ( FIG. 2A ). MALDI-TOF analysis of purified recombinant protein 10 resulted in a mass peak of 9970.8 Da ( FIG. 2B ). The far-UV CD spectrum of purified recombinant clone 10-derived allergen ( FIG. 2C ) indicates that the protein is folded and contains a considerable amount of β-sheets and a low α-helical content. The spectrum is characterized by a minimum at 204 nm and a maximum at 190 nm. Secondary structure analysis using the program CDSSTR with the reference dataset 7 yielded 8% α-helix, 23% β-sheets, 14% β-turns and 53% random coils. The NRMSD value of 0.033 demonstrated a good fit between the calculated and the experimentally derived spectra. Upon heating to 95° C. a slight shift of the minimum of the CD spectrum (from 204 nm to 201 nm) was observed, indicating a partial denaturation of the protein. Upon cooling to 25° C. the protein refolded ( FIG. 2C ). However, the minimum at 204 nm was lower than before heating, which suggests a rearrangement of the β-sheets. In summary, the spectra observed during the temperature scan point to a high thermal stability of the clone 10-derived allergen.
Recombinant Clone 10-Derived Allergen is a New Serine Proteinase Inhibitor-Like Allergen from Wheat
Purified clone 10-derived allergen was tested for IgE reactivity using sera from patients suffering from bakers' asthma, grass pollen allergy and food allergy to wheat by dot blot analysis ( FIG. 3 ). The recombinant clone 10-derived allergen reacted with IgE-antibodies from 3 (#1, #4, #12) out of 22 patients suffering from bakers' asthma (13.6%). Patient #1 who had only low IgE levels specific for the major wheat allergen, alpha amylase inhibitor, showed strong IgE reactivity to the serine proteinase inhibitor-like allergen. Interestingly, the clone 10-derived allergen was exclusively recognized by IgE antibodies from patients with baker's asthma but not by patients suffering from IgE-mediated food allergy to wheat or patients suffering from grass pollen allergy. Several sera from each of the three patients groups showed IgE reactivity to recombinant timothy grass pollen allergens due to co-sensitization to grass pollen. The specific IgE reactivity of the clone 10-derived allergen by baker's asthma patients was confirmed in a chip analysis using additional 20 sera from celiac disease patients, 119 food allergic patients, 23 sera from grass pollen allergic patients and 25 baker's asthma patients (Constantin et al, unpublished, data not shown).
The analysis of IgG subclass reactivities to the clone 10-derived allergen in the group of baker's asthma patients showed the presence allergen-specific IgG 1 and to a lower extent of allergen-specific IgG 4 levels both indicative of a Th 2 response whereas no relevant IgG 2 and IgG 3 reactivity specific for the clone 10-derived allergen was detected ( FIG. 4 ).
To study the allergic activity of IgE antibodies specific for the serine proteinase inhibitor-like allergen RBL cells expressing the human FcεRI were loaded with serum IgE from patients with and without specific IgE antibodies and subsequently exposed to the allergen ( FIG. 5 ). RBL cells loaded with serum IgE from patient #1 showed the strongest degranulation upon allergen exposure (51% of total β-hexosaminidase release). A lower degranulation was obtained with RBL cells that had been loaded with IgE from patients #4 and #12 (22% and 19%, respectively) which corresponded with the intensity of IgE recognition in the dotblots ( FIG. 3 ). Almost no degranulation was observed when RBL cells were loaded with serum from a non-allergic person ( FIG. 5 : NC). The major timothy grass pollen allergen rPhl p 1 induced strong degranulation in RBL cells loaded with serum IgE from patient #12 and mild degranulation when RBL cells were loaded with sera from patients #1 and #4 ( FIG. 5 ). In fact, patients #1, #4 and #12 suffered also from grass pollen allergy (Table I).
The Serine Proteinase Inhibitor-Like Allergen Accumulates in Wheat Seeds During Maturation
Rabbit antibodies, specific for clone 10-derived allergen, were used to investigate the expression of the protein during wheat seed maturation ( FIG. 6 ). Nitrocellulose sheets containing extracts from wheat seeds collected at different time points of seed maturation were probed with specific rabbit antibodies and the pre-immune Ig. The clone 10-specific antibodies reacted with a protein of 40 kDa, representing a tetramer of the serine proteinase inhibitor-like allergens ( FIG. 6 ) (11). The expression of the protein became detectable in 15 days old seeds and continued to increase during further maturation of seeds ( FIG. 6 ). No immunoreactivity was found when the blots were incubated with the pre-immune Ig from the same rabbit ( FIG. 6 ).
The Serine Proteinase Inhibitor-like Allergen is Preferentially Detected in Wheat Seeds.
When we compared pollen and seeds, we found that the serine proteinase inhibitor-like allergen is preferentially expressed in seeds ( FIG. 7 ) whereas only a weak signal was obtained at approximately 65 kDa in wheat pollen extract. The panallergen profilin was detected with rabbit anti-wheat seed profilin antibodies in wheat seeds and pollen ( FIG. 7 : #123). No reactivity was found with pre-immune Ig ( FIG. 7 ).
Next we used the serine proteinase inhibitor-like allergen-specific antibodies to search for cross-reactive structures in rice, maize, common bean and potato for which homologous proteins have been described with a sequence identity of 50% (bean), 49% (maize, rice) and 33% (potato) (Table III).
The serine proteinase inhibitor-like allergen was detected again as tetramer in wheat seeds, a band of approximately 23 kDa was detected in rice but no reactivity was found in maize, common bean or potato ( FIG. 8C ) although comparable amounts of each extract had been subjected to SDS-PAGE ( FIG. 8A ). No reactivity was observed when the blots were incubated with the pre-immune Ig ( FIG. 8B ).
Localization of the Serine Proteinase Inhibitor-like Allergen in the Aleurone Layer and Between Starch Granules of a Wheat Grain by Immunogold Electron Microscopy
FIG. 9A shows an ultra-thin section through a wheat grain at low magnification in the transmission electron microscope. Three major morphological components of the grain are visible: an outward multi-layered fruit and seed coat (C), the aleuron layer (AL) and the beginning of the voluminous interior of the grain, the starchy endosperm (SE). The rectangle marks an area comparable to the area shown in B. FIG. 9B displays the border between an aleuron cell and the adjoining starchy endosperm at higher magnification. The aleuron cell is filled with aleuron grains (AG) (protein vacuoles) which are surrounded by small lipid vesicles (L). Both components are embedded in the cytoplasmic matrix of the cell. The starchy endosperm consists of starch granules with variable size, closely packed just leaving small interspaces of amorphous cytoplasmatic material. The rectangles indicate areas shown in high magnification in C, D and E, F, respectively. FIG. 9C shows the localization of clone 10-derived allergen in an aleuron cell using Abs raised against wheat protein 10. Gold particles (arrows) indicate the presence of wheat protein 10 predominantly in the cytoplasmatic matrix between cell organelles but also in the peripheral parts of the lipid vesicles (L). In the starch region, wheat protein 10 is associated with the amorphous cytoplasmatic material (CY) in between the starch granules (SG) ( FIG. 9E ). Control experiments with preimmune Abs showed a very low degree of non-specific labelling ( FIGS. 9 , D and F).
EXAMPLE 2
Expression and Purification of Recombinant Allergens
Example 2 shows the identification and characterization of six IgE reactive wheat seed allergens named clones #10, #37, #38, #112, #123 and #126. Furthermore Example 2 shows a method for expression and purification of recombinant allergens of said clones.
Biological Materials, Patients' Sera Wheat seeds from Triticum aestivum cv. Michael were obtained from the Österreichische Agentur für Gesundheit and Ernährungssicherheit GmbH and planted in a glasshouse. Immature seeds were harvested directly into liquid nitrogen after a period of 25 days until pollination started and stored at −80° C. until use. Sera were obtained from 24 patients suffering from bakers' asthma (Table IV). Baker's asthma was diagnosed on the basis of case history, total serum IgE levels, IgE specific for wheat and rye by CAP-FEIA System (Phadia, Uppsala, Sweden) and after specific inhalation challenge tests (1) ( FIG. 10 ). Serum from grass pollen allergic patients had been analyzed for total serum IgE levels and IgE specific timothy grass pollen by CAP-FEIA System (Phadia) and food allergic patients to wheat have been characterized as described previously (2) ( FIG. 11 ). Clinical data of these patients are summarized in table V. For control purposes serum from a non-allergic individual was included in the experiments.
Construction of a λgt11 cDNA Library from Wheat Seeds
Total RNA was extracted from wheat seeds stored at −80° C. according to Yeh [3]. Then the RNA pellet was dissolved in guanidinium isothiocyanate buffer (4M guanidinium isothiocyanate, 0.83% v/v 3M sodium acetate, pH 6, 0.11M β-mercaptoethanol) and purified by a cesium chloride density gradient ultracentrifugation. Poly-A + RNA was isolated by oligo-dT cellulose affinity chromatography (Nucleo Trap mRNA; Machery-Nagel) and double stranded cDNA was synthesized via a cDNA synthesis kit (cDNA synthesis System; Roche Diagnostics, Mannheim, Germany). After methylation with EcoRI methylase (New England Biolabs, Beverly, Mass.), EcoRI linkers (New England Biolabs) were added to the cDNA. Linkered cDNA was digested with EcoRI (Roche Diagnostics). Digested linkers were removed with a Nick column (Pharmacia Biotech, Uppsala, Sweden) and the cDNA was ligated into λgt11 arms (Stratagene, La Jolla, Calif., USA). The ligation product was packed in vitro (Gigapack III Gold Cloning Kit, Stratagene) resulting in a λgt11 expression cDNA library with 2.43×10 6 PFU (plaque forming units).
Isolation and Characterization of IgE-reactive Clones from a Wheat Seed cDNA Library
E. coli Y1090 were infected with 7×10 5 PFU of recombinant phages and immunoscreened with serum IgE of four patients (#1, #2, #5, #13) suffering from bakers' asthma as described [5]. Six IgE-reactive phage clones were selected for further re-cloning and their DNA was PCR-amplified using Platinum PCR Supermix (Invitrogen, Life Technologies) with λgt11 primers and sequenced (MWG, Ebersberg, Germany). The obtained sequences were compared with sequences submitted to the GenBank database at the National Center for Biotechnology Information (NCBI).
Expression and Purification of Recombinant Allergens
The coding region of the clones were amplified by PCR using primers listed in table VI. The PCR products were subcloned into an AccepTor Vector (Novagen, Madison, Wis.) and sequenced again (MWG). Then the insert containing AccepTor Vectors were digested with NdeI and EcoRI (Roche Diagnostics), the inserts were gel-purified (Promega, Madison, Wis., USA) and subcloned into the expression plasmid pET 17b (Novagen). The DNA sequences were confirmed by sequencing both DNA strands (Microsynth, Balgach, CH). The pET 17b-insert constructs were transformed into E. coli BL21 (DE3) (Stratagene) and grown in Luria Broth (LB) medium containing 100 mg/l ampicillin at 37° C. to an OD (600 nm) of 0.8-1. Protein expression was induced by addition of isopropyl β-D-thiogalactopyranoside (IPTG) to a final concentration of 0.5 mM and growing the bacteria for additional 3 h. Then bacteria were harvested by centrifugation and homogenized in 25 mM imidazole, pH 7.5, 0.1% (v/v) Triton X-100 with an Ultraturrax (IKA, Stauffen, Germany). DNA was digested by addition of DNase I, stirred for additional 10 min at 20° C., stopped with 200 μl of 5M NaCl and then centrifuged at 4° C. (6000g, 20 min). Clone 10-derived allergen was purified from the inclusion body-containing pellet under denaturing conditions over Ni-NTA resin affinity columns according to the QIAexpressionist handbook, protocol 17 (QIAGEN, Hilden, Germany). Fractions containing the recombinant allergen were pooled and dialyzed against 10 mM NaH2PO4 pH 7.5. Recombinant proteins #37, #38, #112, #123 and #126 were purified from the pellet of the bacterial cell lysate under native conditions over Ni-NTA resin affinity columns according to the QIAexpressionist handbook, protocol 12 (QIAGEN). Fractions containing the recombinant proteins were pooled and dialyzed against 10 mM NaH2PO4 pH 7.5. Protein samples were analyzed for purity on a 14% SDS-PAGE gel and visualized by Coomassie brilliant blue staining. The protein concentrations were determined with Micro BCA Protein Assay Kit (Pierce, Rockford, Ill.).
EXAMPLE 3
Allergen Array
Example 3 shows an allergen micro-array revealing that recombinant wheat seed allergens, prepared as described in example 2, are specifically recognized by serum IgE from baker's asthma patients but not from patients with food allergy to wheat or grass pollen allergy. Hence the recombinant allergens are specific for respiratory allergy to wheat flour. Moreover Example 3 shows the use of timothy grass pollen marker allergens phl p 1 and Phl p 5 and wheat pollen in the array for improvement of in vitro diagnosis of respiratory allergy.
Techniques
Patients and Sera
Sera were obtained from Spanish patients suffering from baker's asthma (B1-B23), Austrian (F1-F26) and German patients (F27-F38) suffering from wheat induced food allergy and Austrian patients (G1-017) suffering from grass pollen allergy. Patients were selected according to a positive case history, specific inhalation challenge tests for confirmation of a clinically relevant sensitization in case of baker's asthma (1) and double blind placebo controlled food challenge (DBPCFC) in infant patients with food allergy to wheat. Serum from all patients has been analyzed for total serum IgE levels and IgE specific for wheat flour and timothy grass pollen by the CAP-FEIA System (Phadia, Uppsala, Sweden). Demographic, clinical and serological data of these patients are summarized in Table VII, VIII and IX. For control purposes, sera from healthy individuals were included in all experiments.
Biological Materials
Recombinant wheat proteins #10, #37, #38, #112, #123 and #126 derived from a cDNA library by screening with sera from baker's asthma patients were expressed in E. coli and purified as described (12). Wheat pollen were purchased from Allergon (Vällinge, Sweden) and recombinant Phl p 1, Phl p 5, Phl p 7, Phl p 12 from BIOMAY (Vienna, Austria).
Protein Extract
Triticum aestivum pollen (500 mg) was extracted at 4° C. over night in 5 ml PBS, 2 mM EDTA, 1 mM PMSF. After centrifugation for 1 h at 13,000×g 4° C., the protein concentration of the supernatant was determined with Micro BCA Protein Assay Kit (Pierce, Rockford, Ill.) and aliquots were stored at −20° C. until use.
Allergen Microarray Analysis
Wheat pollen extract, 1-1.5 ng/spot, recombinant and purified wheat proteins and recombinant grass pollen allergens, 0.1-0.15 ng/spot, were spotted with a Nano Plotter NP2 (Gesellschaft für Silizium-Mikrosysteme mbH, GroBerkmannsdorf, Germany) on nitrocellulose membranes that were attached to microscope glass slides as described (13). Purified human IgE was used as a position marker (14). The spotted microarrays were pre-washed with 30 μl assaybuffer (weak phosphate buffer, pH 7.5) and incubated with 30 μl undiluted sera from allergic patients or controls. After washing with 30 μl assaybuffer bound IgE antibodies were detected with 20 μl fluorophore-conjugated anti-IgE antibody and fluorescence intensities (FI) were measured at a wavelength of 635 nm (GenePix 4000B fran Axon). The cut off level was set to FI=300 based on values obtained with human serum albumin.
Results
Description of Patients
We analyzed patients suffering from baker's asthma, wheat-induced food allergy or grass pollen allergy. The group of baker's asthma patients consisted of 23 persons (4 females, 19 males: mean age 39 years, range 22-60 years) with occupational exposure to wheat flour. Ninety-one percent of the baker's asthma patients suffered from asthma due to inhalation of wheat flour and 94% complained about symptoms of rhinoconjunctivitis. A sensitization to other respiratory allergen sources (e.g., cat, cockroach, dog, grass pollen, horse, house dust mites, moulds and/or olive pollen) was found in 70% of the baker's asthma patients and 48% of the patients suffered from grass pollen allergy (Table VII). Interestingly, none of the baker's asthma patients exhibited allergy to food and symptoms were confined to respiratory manifestations.
The group of patients suffering from wheat-induced food allergy comprised 38 individuals (25 females, 13 males: mean age 13 years, range 0.5-65 years) (Table VIII). Again we found that 71% are sensitized to other respiratory allergen sources (e.g., birch pollen, grass pollen, house dust mites and mugwort pollen) and 58% were also sensitized to food allergens (e.g., carrot, cow's milk, hazelnut, hen's egg, malt, nuts, orange, plum, rice, soybean, celery, seafood, shrimps and/or spices) (Table VIII). IgE-mediated sensitization to grass pollen was found in 55% of these patients. The symptoms of these patients varied from respiratory symptoms (e.g., asthma, bronchitis, cough, conjunctivitis, dyspnea, nasal congestion, rhinorrhoe, rhinoconjunctivitis) to gastrointestinal symptoms (e.g., abdominal pain, diarrhoea, flatulence, sore throat and vomiting) and cutaneous symptoms (e.g., eczema, pruritus and urticaria) (Table VIII).
The group of grass pollen allergic patients consisted of 17 patients (5 females, 12 males: mean age 13 years, range 0.5-65 years). Seventy one percent of these patients suffered also from allergy to other respiratory allergen sources (e.g., birch pollen, cat, dog, house dust mites, rabbit and mugwort pollen) (Table IX). According to serology 65% exhibited IgE reactivity to wheat flour and 23% contained IgE against other food allergens. However, only one patient suffered from urticaria and no symptoms of food allergy could be recorded for these patients. Respiratory symptoms such as asthma, conjunctivitis, dyspnea, rhinoconjunctivitis and rhinitis dominated in the grass pollen allergic patients.
Composition of the Allergen Array
Six recombinant wheat seed allergens designated as #10, #37, #38, #112, #123 and #126 were spotted onto nitrocellulose-coated glass slides ( FIG. 12 , A). The recombinant wheat proteins were expressed in Escherichia coli based on cDNAs which had been isolated from a wheat seed cDNA library with sera from baker's asthma patients as described (15). According to homology with sequences deposited in the NCBI database the wheat allergens can be described as follows: #10 has a 96% homology to a Triticum aestivum subtilisin-chymotrypsin inhibitor WSCI precursor (accession no. gi|122065237), #37 is a T. aestivum thioredoxin H (accession no. gi|27461140), #38 is a T. aestivum glutathione transferase (accession no. gi|20067419), #112 has a 99% homology with a T. aestivum 1-Cys-peroxyredoxine (accession no. gi|34539782), #123 has a 96% homology with T. aestivum profilin (accession no. gi|1346803) and #126 has a 69% homology with Hordeum vulgare dehydrin 11 (accession no. gi|4105101).
In addition to the recombinant wheat allergens, wheat pollen extract, recombinant timothy grass pollen allergens (rPhl p 1, rPhl p 5, rPhl p 7 and rPhl p 12) (16-19) and IgE were also spotted onto the slides ( FIG. 12 , A). Representative images of allergen microarrays after incubation with sera are shown in FIG. 12 , B-C. On the chip probed with serum from a non-allergic person showed no reactivity with any allergen could be detected and only the spotted IgE markers were detected with the anti-IgE conjugate ( FIG. 12 , B). Figures in 12, C show representative images of microarray chips incubated with sera from a baker's asthma patient (1), a patient suffering from wheat-induced food allergy (2) and a grass pollen allergic patient (3). The baker's asthma patient (1: Table I: B4) shows strong IgE reactivity to recombinant wheat allergens #10 and weak reactivities to #126 and #112. For the food allergic patient (2: Table VIII: F26) strong IgE binding to recombinant profilin from wheat #123 and timothy grass pollen rPhl p 12 and weak binding to wheat pollen extract and rPhl p 1 was observed. The image of the chip from a grass pollen allergic patient (3: G16) shows strong signals to rPhl p 5 and rPhl p 12 and weaker signals with wheat profilin #123, wheat pollen extract and rPhl p 1.
Identification of Wheat Seed Allergens Specifically Recognized by IgE Antibodies from Baker's Asthma Patients
Ninety one percent of the baker's asthma patients were positive in the wheat flour CAP (Table VII). Using spotted wheat allergens the IgE reactivity profile for 62% of the baker's asthma patients could be established. Allergens #126 (30%), #10 (26%), #123 (22%) and #122 (17%) were the most frequently detected components whereas #37 and #38 reacted only with 4% of the sera ( FIG. 13 , A). Interestingly, the two patients who were negative in the wheat flour CAP (B5, B18: Table VII) reacted with allergen #126. Forty eight percent of the baker's asthma patients showed IgE reactivity to timothy grass pollen extract and each of these patients was also diagnosed with a combination of spotted rPhl p 1 and rPhl p 5. Recombinant Phl p 12 (35%) was always stronger and more often recognized than wheat profilin #123 (22%). The cross-reactive pollen allergen rPhl p 7 reacted with 13% of the sera.
Recombinant Wheat Seed Allergens Recognized by Baker's Asthma Patients are not Targets for IgE Antibodies of Patients Suffering from Wheat-Induced Food Allergy
All patients with food allergy to wheat were positive in the wheat flour CAP but the recombinant wheat proteins were hardly recognized (5%) ( FIG. 13 , B). The two patients who were positive to cross-reactive timothy grass pollen profilin, had also a positive signal to wheat profilin #123 in the microarray. Fifty five percent of patients with wheat induced food allergy showed IgE reactivity in the Phleum CAP but just 18% were positive to wheat pollen extract on the chip and 26% in the combination of spotted rPhl p 1 and rPhl p 5. Spotted rPhl p 1 and rPhl p 5 alone were recognized by 18% and 16% of the sera respectively, the cross-reactive allergens rPhl p 7 and rPhl p 12 reacted with 13% and 26% of the sera.
rPhl p 1 and rPhl p 5 are Diagnostic Marker Allergens for Grass Pollen Allergy Whereas Profilin is Recognized by Baker's Asthma and Wheat Food Allergic Patients
Sixty-five percent of grass pollen allergic patients were positive in the wheat flour CAP. Out of the recombinant wheat proteins tested in the microarray, only recombinant wheat protein #123 was recognized by 23.5% of the patients ( FIG. 13 , C). Each of these patients were also positive to cross-reactive timothy grass pollen profilin rPhl p 12. But rPhl p 12 was always stronger and more often (35%) recognized than #123. All patients suffering from grass pollen allergy were positive on the timothy grass pollen CAP and in the combination of spotted rPhl p 1 and rPhl p 5. Recombinant Phl p 1 alone was more often recognized (94%) than rPhl p 5 (88%) by patients with grass pollen allergy. Wheat pollen extract reacted with 82% of the sera and cross-reactive rPhl p 7 with 29%.
All grass pollen allergic patients and baker's asthma patients with grass pollen allergy were positive in the combination of rPhl p 1 and rPhl p 5 in the microarray and in the Phleum CAP ( FIG. 13 , A; C). These findings are in agreement with previously published data showing that grass pollen allergy can be diagnosed by IgE reactivity to rPhl p 1 and rPhl p 5 (20, 21). However, among patients with wheat induced food allergy only 26% reacted with rPhl p 1 and rPhl p 5 in the microarray, but more than twice as many (55%) were positive in the Phleum CAP ( FIG. 13 , B). Furthermore, those patients reacting with grass pollen extract in the CAP system and with timothy grass pollen profilin (rPhl p 12) in the microarray were also positive to wheat profilin (22) due to cross-reactivity of plant profilins (23). Nevertheless, frequency and intensity of IgE recognition was always stronger to rPhl p 12 than to wheat profilin (22).
EXAMPLE 4
The analyte is immobilized to a solid support, such as ImmunoCAP (Phadia, Uppsala, Sweden). Serum samples from at least three representative human patients sensitized to the allergen and showing IgE reactivity to that allergen are incubated for 3 h at room temperature with the allergen at a final concentration of 100 μg/mL and, in parallel as negative controls, with buffer alone and the non-allergenic maltose binding protein (MBP) of E. coli . The samples are then analysed for IgE binding to ImmunoCAP (Phadia, Uppsala, Sweden) tests carrying immobilized analyte to study whether preincubation with allergen specifically inhibits or significantly lowers IgE binding.
TABLE I
Demographic, clinical and serological characteristics of patients suffering from bakers' asthma
IgE conc. kUA/l
occupational
fungal
SPT to grass
total IgE
Patients
Age
Sex
Asthma
exposure
Wheat
Rye
Soybean
α-Amylase
pollen
kU/l
PC20
mg/ml
1
35
m
+
+
74.2
20.7
n.d.
0.63
+
163
+
0.29
2
29
m
+
+
18
7.9
6.1
1.5
+
271
+
2
3
36
m
+
+
1.66
1.24
<0.35
<0.35
−
353
+
0.31
4
39
m
+
+
25.8
15.6
1.36
18.6
+
1387
+
0.25
5
54
m
+
+
<0.35
<0.35
<0.35
3.21
−
30.1
n.d.
6
35
m
+
+
24.3
39.6
5.73
2.29
+
416
+
0.25
7
28
m
+
+
2.58
3.77
<0.35
5.39
+
248
+
0.25
8
27
m
+
+
7.86
7.4
3.19
32.2
+
1773
+
0.47
9
24
m
−
+
2.35
2.32
1.62
n.d.
+
204
+
0.09
10
60
m
+
+
3.44
4.08
<0.35
1.15
+
73.3
+
0.44
11
22
m
+
+
3
2
<0.35
<0.35
−
2509
+
3.38
12
26
m
+
+
>100
>100
10.7
7.63
+
321
+
0.5
13
54
m
+
+
2.48
0.6
0.71
<0.35
−
480
+
0.12
14
60
m
+
+
31.8
31.1
n.d.
<0.35
+
629
+
0.15
15
27
m
+
+
5.06
n.d.
n.d.
<0.35
+
278
+
0.079
16
42
f
+
+
3.71
2.71
1.69
<0.35
+
271
+
0.187
17
54
m
+
+
1.68
1.13
<0.35
<0.35
−
79.2
+
16
18
59
m
+
+
<0.35
<0.35
<0.35
5
−
673
+
0.23
19
26
m
+
+
74.6
58.4
<0.35
<0.35
+
17.7
+
1.16
20
43
m
+
+
13.8
26.9
0.77
<0.35
+
538
+
0.25
21
34
f
+
+
2.05
1
<0.35
<0.35
+
n.d.
+
0.5
22
41
f
+
+
1.77
0.75
<0.35
<0.35
+
23.4
+
0.23
m: male, f: female,
+: positive, −: negative,
n.d.: not done,
kUA/l—kilounit antigen per liter,
SPT: skin prick test,
PC20: Methacholine inhalation challenge
TABLE II
Demographic, clinical and serological characteristics of patients
suffering from food allergy to wheat and grass pollen allergy
IgE conc.
kUA/l
total
Patients
Age
Sex
RC
AD
Asthma
Wheat
Rye
IgE kU/l
F1
34
f
−
+
+
18.6
13.4
>2000
F2
34
m
+
−
−
3.1
3.08
155
F3
24
f
−
+
−
1.3
n.d.
336
F4
15
f
−
+
−
5.91
5.3
915
G1
45
m
+
−
+
1.76
2
175
G2
39
m
+
−
+
11.1
10.3
401
G3
55
f
−
−
−
3.16
1
157
G4
54
m
+
−
+
n.d.
n.d.
1528
F: food allergy, G: grass pollen allergy,
m: male, f: female,
RC: rhinoconjunctivitis,
AD: atopic dermatitis,
+: positive, −: negative,
n.d.: not done,
kUA/l—kilounit antigen per liter
TABLE III
Percentage amino acid sequence identities
Clone #10
# 1
# 2
# 3
# 4
# 5
# 6
# 7
# 8
# 9
# 10
# 11
# 12
# 13
# 14
# 15
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
Clone #10
100
98
94
85
54
49
49
52
43
43
35
50
43
41
32
35
# 1
100
97
88
55
50
50
53
44
44
35
50
44
41
32
36
# 2
100
84
52
48
47
50
44
43
33
46
41
40
30
35
# 3
100
55
50
50
53
44
44
38
50
44
43
30
40
# 4
100
88
97
76
35
62
33
50
41
40
27
47
# 5
100
87
73
37
63
33
50
40
40
30
44
# 6
100
73
34
50
38
48
48
40
29
45
# 7
100
36
59
38
46
48
38
38
55
# 8
100
32
41
37
48
48
34
47
# 9
100
30
43
35
34
30
39
# 10
100
43
40
52
40
34
# 11
100
37
46
41
45
# 12
100
35
37
48
# 13
100
37
38
# 14
100
35
# 15
100
# 16
# 17
# 18
# 19
# 20
# 21
# 22
# 23
# 24
# 25
# 26
# 27
# 28
# 29
# 30
# 16
# 17
# 18
# 19
# 20
# 21
# 22
# 23
# 24
# 25
# 26
# 27
# 28
# 29
# 30
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
Clone #10
33
32
34
31
38
35
38
32
48
31
30
30
34
35
28
# 1
33
32
34
31
38
35
38
32
48
31
30
30
34
35
28
# 2
33
30
32
31
37
35
34
30
43
28
31
28
32
35
27
# 3
29
30
32
31
35
35
37
34
43
32
34
31
35
35
30
# 4
31
37
37
38
38
42
33
41
44
32
34
30
32
38
30
# 5
30
38
45
41
41
45
34
42
44
32
37
33
34
38
25
# 6
33
36
45
38
40
44
33
41
43
34
35
38
32
38
30
# 7
29
35
35
33
33
33
38
33
40
30
30
27
35
38
27
# 8
34
34
37
38
32
40
35
34
38
28
35
37
34
38
37
# 9
28
28
28
28
30
33
28
28
33
28
28
23
31
31
24
# 10
39
39
31
46
42
54
49
54
48
51
54
57
68
58
51
# 11
35
40
69
43
48
41
37
40
79
38
37
30
38
38
33
# 12
41
37
34
31
31
34
34
35
40
35
32
34
34
34
32
# 13
37
35
41
44
40
40
41
38
47
44
43
35
41
44
37
# 14
58
68
25
38
38
39
38
42
40
37
41
37
43
39
38
# 15
26
31
38
31
34
41
37
36
49
34
37
31
38
32
35
# 16
100
57
27
32
41
42
43
42
35
34
41
38
48
43
38
# 17
100
25
40
42
41
37
44
38
38
44
37
44
42
35
# 18
100
34
47
39
38
40
80
38
34
31
37
38
31
# 19
100
37
58
58
50
48
47
52
53
52
57
42
# 20
100
41
39
35
47
35
34
37
43
42
35
# 21
100
50
55
44
47
57
48
58
59
50
# 22
100
49
40
49
47
55
53
43
55
# 23
100
43
52
50
49
58
51
51
# 24
100
41
40
33
38
40
35
# 25
100
44
50
40
58
45
# 26
100
53
59
58
47
# 27
100
58
47
80
# 28
100
59
81
# 29
100
45
# 30
100
TABLE IV
Bakers' asthma patients
PC20: Methacholine inhalation challange
m: male, f: female, +: positive, −: negative, n.d.: not done
TABLE V
Food and grass pollen allergic patients
IgE conc.
Age at blood
kUA/l
Patient group
donation
Sex
RC
AD
Asthma
Wheat
Rye
total IgE
Food allergic 1
32
m
+
−
−
3.1
3.08
155
Food allergic 2
34
f
−
−
+
18.6
n.d.
>2000
Food allergic 3
24
f
−
+
−
1.3
n.d.
336
Food allergic 4
15
f
−
+
−
5.91
5.3
915
Grasspollen allergic 1
45
m
+
−
+
n.d.
n.d.
n.d.
Grasspollen allergic 2
39
m
+
−
+
n.d.
n.d.
401
Grasspollen allergic 3
55
f
−
−
−
n.d.
n.d.
n.d.
Grasspollen allergic 4
54
m
+
−
+
n.d.
n.d.
1528
m: male, f: female,
+: positive, −: negative,
n.d.: not done
TABLE VI
PCR Primers used for the amplification of cDNAs
Primer
Sequence
10 fwd
5′ CAT ATG AGC CCT GTG GTG AAG AAG CCG
GAG GGA 3′
10 rev
5′ GAATTC TTA GTG ATG GTG ATG GTG ATG GCC
GAC CCT GGG GAC 3′
37 fwd
5′ CAT ATG GCC GCC GAG GAG GGA GCC GTG
ATA 3′
37 rev
5′ GAATTC TTA GTG ATG GTG ATG GTG ATG GGC
AGA TGC AGA ACC 3′
38 fwd
5′ CAT ATG GCG GGC GAG AAG GGC CTG GTG
CTG 3′
38 rev
5′ GAATTC TTA GTG ATG GTG ATG GTG ATG CTC
GAT GCC GTA CTT 3′
112 fwd
5′ CAT ATG CCG GGC CTC ACC ATC GGC GAC
ACC GTC 3′
112 rev
5′ GAATTC TTA GTG ATG GTG ATG GTG ATG GAC
CTT GGT GAA GCG 3′
123 fwd
5′ CAT ATG TCG TGG CAG ACG TAC GTC GAC
GAC 3′
123 rev
5′ GAATTC TTA GTG ATG GTG ATG GTG ATG GAA
ACC CTG CTC GAC 3′
126 fwd
5′ CAT ATG GCG GAC TAC GGT GGA GAG TAC
GGG 3′
126 rev
5′ GAATTC TTA GTG ATG GTG ATG GTG GTG TCC
AGG GAG CTT 3′
fwd: forward; rev: reverse;
Nde I restriction sites are shown in italic letters, Eco RI restriction sites are underlined, hexahistidine-tags are shown in bold letters
TABLE VII
Demographic, clinical and serological characteristics of patients suffering from baker's asthma
Wheat flour
Phleum pratense
Total
Years
Other
PC20
SIC
Patient
Sex
Age
IgE kUA/l
IgE kUA/l
IgE kU/l
Job
exp.
Symptoms
allergies
mg/ml
wheat mg/ml
B1
m
35
74.2
5.25
163
Confectioner
20
A, RC
g
0.29
0.039
B2
m
29
18
53.5
271
Confectioner
12
A, RC
g
2
n.d.
B3
m
36
1.66
<0.35
353
Baker
8
A, RC
n.k.
0.31
n.d.
B4
m
39
25.8
0.73
1367
Baker-Confectioner
20
A, RC, U
g
0.25
n.d.
B5
m
54
<0.35
<0.35
30.1
Baker
42
RC, A
n.k.
n.d.
n.d.
B6
m
35
24.3
4.67
416
Baker
12
RC, A
g
0.25
n.d.
B7
m
28
2.56
<0.35
246
Baker
14
A, RC
c, d, h, hdm
0.25
n.d.
B8
m
27
7.86
>100
1773
Baker
26
A, RC
n.k.
0.47
0.625
B9
m
24
2.35
>100
204
Baker
18
RC
c, d, g, h, hdm
0.09
n.d.
B10
m
60
3.44
<0.35
73.3
Confectioner
46
A, RC
hdm, m
0.44
n.d.
B11
m
22
3
<0.35
2509
Baker
5
A, RC, U
n.k.
3.36
0.0015
B12
m
26
>100
>100
321
Baker-Confectioner
5
A, RC
g
0.5
n.d.
B13
m
54
2.48
<0.35
480
Confectioner
25
A, RC
n.k.
0.12
n.d.
B14
m
60
31.8
<0.35
629
Baker
13
A
c, cr, d
0.15
0.002
B15
m
27
5.06
42.2
278
Confectioner
10
A, RC
c, cr, d, g
0.079
0.078
B16
f
42
3.71
2.15
271
Pizza
12
A, RC, U
g
0.187
0.625
B17
m
54
1.68
<0.35
79.2
Confectioner
38
A
hdm
16
n.d.
B18
m
59
<0.35
<0.35
673
Baker-Confectioner
22
A, RC
n.k.
0.23
n.d.
B19
m
26
74.6
57.4
17.7
Confectioner
18
A, RC
g
1.16
0.15
B20
m
43
13.8
11
538
Baker
19
A
g, o
0.25
EAR
B21
f
34
2.05
<0.35
229
Confectioner
2
A
hdm, o
0.5
DAR
B22
f
41
1.77
<0.35
23.4
Cook/pastry maker
1
A
o
0.23
EAR
B23
f
53
0.41
<0.35
469
Homemaker
n.k.
n.k.
n.k.
n.d.
n.d.
m: male, f: female,
kUA/l: kilounit antigen per liter,
n.k.: not known,
A: Asthma, RC: Rhinoconjunctivitis, U: Urticaria,
c: cat, cr: cockroach, d: dog, g: grass pollen, h: horse, hdm: house dust mite, m: molds, o: olive pollen,
PC20: Methochaline inhalation challenge (positive if <16 mg/ml),
SIC: specific inhalation challenge,
EAR: early athmatic response, DAR: dual asthmatic response, LAR: late asthmatic response,
n.d.: not done
TABLE VIII
Demographic, clinical and serological characteristics of patients suffering from food
Wheat flour
Phleum pratense
Patient
Sex
Age
IgE kUA/l
IgE kUA/l
Total IgE kU/l
Symptoms
DBPCFC
Other allergies
F1
f
56
0.74
<0.35
820
U
n.d.
s
F2
f
50
0.78
<0.35
275
Ab, CJ, Di, P
n.d.
hdm
F3
f
49
>100
0.65
1794
no symtoms-diet
n.d.
g, hdm, n, sh
F4
f
72
5.99
<0.35
325
E, D, P
n.d.
he, n, s
F5
f
11
2.15
3.28
11
A, C, Ri
n.d.
g, n, s, o
F6
f
40
1.9
<0.35
19.3
C, CJ, S
n.d.
n.k.
F7
m
11
0.92
1.21
118
n.k.
n.d.
g, n, s
F8
m
24
5.76
<0.35
111
C, CJ, N, R
n.d.
n.k.
F9
f
21
1.22
25.8
94.6
C, N, P, R
n.d.
g
F10
f
5
1.93
34.3
453
RC
n.d.
a, b, cm, g, n
F11
f
29
1.55
10.4
101
De, Ri
n.d.
c, b, g, p
F12
f
45
5.72
1.12
30.1
A, C, D, blisters on tongue
n.d.
g, n, s, r
F13
m
7
2.8
>100
<2000
B, RC
n.d.
a, b, g
F14
f
1
0.81
n.d.
46.3
n.k.
n.d.
cm, he
F15
f
28
1.27
>100
616
n.k.
n.d.
a, cm, g, l, m
F16
m
50
7.57
22.6
450
A, C, D, N, RC
n.d.
b, g
F17
f
51
3.97
5.12
44.1
Di, F
n.d.
f, g, n
F18
f
43
1.03
58.3
338
C
n.d.
b, g, h, n, s
F19
f
19
20.5
<0.35
949
A, C, D, R
n.d.
n.k.
F20
f
57
17.6
<0.35
174
n.k.
n.d.
n.k.
F21
m
12
0.81
1.47
769
A, RC
n.d.
he, g, w
F22
f
55
2.11
<0.35
152
no symtoms-diet
n.d.
n, sea
F23
m
43
4.24
2.41
207
n.k.
n.d.
n.k.
F24
f
33
1.65
<0.35
253
n.k.
n.d.
n.k.
F25
m
51
1.64
>100
45
n.k.
n.d.
n.k.
F26
m
27
6.11
67.7
974
C, CJ, D, Ri, in the past A
n.d.
ca, he, g, ce, sp
F27
f
9
6.47
>100
1233.5
E, Ri
+
n.k.
F28
m
0.5
7.39
<0.35
65.2
E, U, Wheezing
+
n.k.
F29
f
1
33.5
<0.35
201
Redness, itching
+
cm, he
F30
f
1
10
n.d.
25.5
U, itching
+
cm, he, s
F31
m
1
18.6
n.d.
1343
U
+
s
F32
m
1
35.1
0.83
325
U, Ri, itching
+
g, s
F33
f
1
4.27
<0.35
38.4
U, Ri, Redness
+
n.k.
F34
f
0.5
21.3
<0.35
1511
U
+
cm
F35
f
1
5.21
n.d.
1718
AD, G, U
+
cm
F36
m
1
61.4
0.69
876
Redness, itching
+
g, cm
F37
m
1
52
0.38
254
Ri, U
+
cm, he, g
F38
f
0.5
94.4
1.9
1524
De, Ri,
open challenge, +
n.k.
m: male, f: female,
n.k.: not known,
n.d.: not done,
kUA/l: kilounit antigen per liter,
A: Asthma, Ab: Abdominaigia, B: Bronchitis, C: Cough, CJ: Conjunctivitis, D: Dyspnea, De: Dermatitis, Di: Diahmoe, E: Eczema, F: Flatulence, G: Gastro-intestinal symptoms, N: Nasal congestion, P: Pruritus, R: Rhinorrhoe, RC: Rhinoconjunctivitis, Ri: Rhinitis, S: Sore throat, U: Urticaria, V: Vertigo, Vo: Vomiting,
DBPCFC: double blind placebo controlled food challenge,
a: artsmisia, b: birch pollen, o: oat, ca: caroites, cm: cows milk, f: formaldehyd, g: grass pollen, h: hazelnut, he: hens egg, hdm: house dust mite, l: latex, m: malt, n: nuts, o: orange, p: plum, r: rice, s: soybean, ce: celery, sea: seafood, sh: shrimps, sp: spices, w: wesp
TABLE IX
Demographic, clinical and serological characteristics of patients suffering from grass
Phleum pratense
Wheat flour
Patient
Sex
Age
IgE kUA/l
IgE kUA/l
Total IgE kU/l
Symptoms
Other allergies
G1
m
22
37.8
1.13
529
D, RC, U
c, b, d, hdm, s
G2
m
30
44.6
0.52
290
D, RC
b, a, hdm, d
G3
f
25
59.8
<0.35
1004
RC
b, d, hdm, h, ce
G4
m
n.k.
25.9
3.62
140
RC
a, b
G5
f
22
37.2
<0.35
566
R
b, c, hdm
G6
f
22
22.4
<0.35
77.4
RC
hdm, r
G7
m
24
30.8
<0.35
60.8
n.k.
n.k.
G8
m
35
9.92
<0.35
88.8
D
b
G9
m
36
20.7
0.45
128
R
ap, b, hdm
G10
f
22
>100
4.13
>5000
RC
b, c, hdm, rye
G11
m
41
49.3
4.01
>2000
A, CJ
a, b, c, hdm
G12
m
37
n.d.
1.11
243
n.k.
n.k.
G13
m
28
39.3
1.06
144
RC
b, a
G14
f
27
>100
<0.35
260
A, RC
n.k.
G15
m
39
>100
11.1
401
n.k.
n.k.
G16
m
54
>100
9.93
1528
A, CJ
n.k.
G17
m
45
n.d.
1.76
175
RC
d, hdm, s, p
m: male, f: female,
n.k.: not known,
n.d.: not done,
kUA/l: kilounit antigen per liter,
A: Asthma, CJ: Conjunctivitis, D: Dyspnea, RC: Rhinoconjunctivitis, R: Rhinitis, U: Urticaria,
a: artemisia, ap: apple, b: birch pollen, c: cat, d: dog, h: hazelnut, hdm: house dust mite, r: rabbit, s: soybean, ce: celery, p: potato
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5. Breiteneder, H., K. Pettenburger, A. Bito, R. Valenta, D. Kraft, H. Rumpold, O, Scheiner, and M. Breitenbach. 1989. The gene coding for the major birch pollen allergen Betv 1, is highly homologous to a pea disease resistance response gene. Embo J 8:1935-1938.
6. Stern, D. A., J. Riedler, D. Nowak, C. Braun-Fahrlander, I. Swoboda, N. Balic, K. W. Chen, S. Vrtala, H. Gronlund, M. van Hage, R. Valenta, S. Spitzauer, E. Von Mutius, and D. Vercelli. 2007. Exposure to a farming environment has allergen-specific protective effects on TH2-dependent isotype switching in response to common inhalants. J Allergy Clin Immunol 119:351-358.
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10. Kaul, S., D. Luttkopf, B. Kastner, L. Vogel, G. Holtz, S. Vieths, and A. Hoffmann. 2007. Mediator release assays based on human or murine immunoglobulin E in allergen standardization. Clin Exp Allergy 37:141-150.
11. Richardson, M., and L. Cossins. 1974. Chymotryptic inhibitor I from potatoes: the amino acid sequences of subunits B, C, and D. FEBS Lett 45:11-13.
12. Vrtala S, Fischer S, Grote M, Vangelista L, Pastore A, Sperr W R, et al. 1999. Molecular, immunological, and structural characterization of Phl p 6, a major allergen and P-particle-associated protein from Timothy grass ( Phleum pratense ) pollen. J Immunol 163:5489-96.
13. Nystrand M. 2006. A multiplexed immunoassay for the rapid detection of specific IgE in allergy diagnosis. IVDT 2006:61.
14. Nilsson K, Bennich H, Johansson S G, Ponten J. 1970. Established immunoglobulin producing myeloma (IgE) and lymphoblastoid (IgG) cell lines from an IgE myeloma patient. Clin Exp Immunol 7:477-89.
15. Constantin C, Quirce S, Grote M, Touraev A, Swoboda I, Stoecklinger A, et al. Molecular and immunological characterization of a wheat serine proteinase-inhibitor as a novel allergen in baker's asthma. Unpublished.
16. Laffer S, Valenta R, Vrtala S, Susani M, van Ree R, Kraft D, et al. 1994. Complementary DNA cloning of the major allergen Phl p I from timothy grass ( Phleum pratense ); recombinant Phl p I inhibits IgE binding to group I allergens from eight different grass species. J Allergy Clin Immunol 94:689-98.
17. Vrtala S, Sperr W R, Reimitzer I, van Ree R, Laffer S, Muller W D, et al. 1993. cDNA cloning of a major allergen from timothy grass ( Phleum pratense ) pollen; characterization of the recombinant Phl pV allergen. J Immunol 151:4773-81.
18. Niederberger V, Hayek B, Vrtala S, Laffer S, Twardosz A, Vangelista L, et al. 1999, Calcium-dependent immunoglobulin E recognition of the apo- and calcium-bound form of a cross-reactive two EF-hand timothy grass pollen allergen, Phl p 7 . Faseb J 13:843-56.
19. Valenta R, Ball T, Vrtala S, Duchene M, Kraft D, Scheiner 0.1994. cDNA cloning and expression of timothy grass ( Phleum pratense ) pollen profilin in Escherichia coli : comparison with birch pollen profilin. Biochem Biophys Res Commun 199:106-18.
20. Kazemi-Shirazi L, Niederberger V, Linhart B, Lidholm J, Kraft D, Valenta R. 2002. Recombinant marker allergens: diagnostic gatekeepers for the treatment of allergy. Int Arch Allergy Immunol 127:259-68.
21. Andersson K, Lidholm J. 2003. Characteristics and immunobiology of grass pollen allergens. Int Arch Allergy Immunol 130:87-107.
22. Sampson H A. 1999. Food allergy. Part 2: diagnosis and management. J Allergy Clin Immunol 103:981-9.
23. Radauer C, Willerroider M, Fuchs H, Hoffmann-Sommergruber K, Thalhamer J, Ferreira F, et al. 2006. Cross-reactive and species-specific immunoglobulin E epitopes of plant profilins: an experimental and structure-based analysis. Clin Exp Allergy 36:920-9. | The present invention relates to the field of IgE-mediated allergy, particularly occupational asthma such as bakers asthma. More specifically the invention relates to the identification of a novel wheat allergen and the use thereof in therapy and diagnosis of IgE-mediated allergy. Furthermore the present invention provides the use of known peptides and proteins in therapy and diagnosis. The invention also relates to methods for diagnosis and treatment of IgE-mediated allergy in mammals. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional counterpart to and claims priority to U.S. Ser. No. 60/666,688 filed Mar. 30, 2005, which is pending and which is herein incorporated by reference. This application is a continuation-in-part of and claims priority to U.S. Ser. No. 29/197,087 filed Jan. 9, 2004, which is pending and which is herein incorporated by reference. This application is a continuation of U.S. Ser. No. 29/219,737 filed Dec. 21, 2004, which is pending and which is herein incorporated by reference. This application is a continuation-in-part of and claims priority to U.S. Ser. No. 10/465,694 filed Jun. 19, 2003, which is pending and which is herein incorporated by reference. U.S. Ser. No. 10/465,694 is a continuation of and claims priority to U.S. Ser. No. 29/157,009, now U.S. Pat. No. D500,413, filed Mar. 12, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to hangers generally, and more particularly to hangers having removal-resistant information marker holders.
BACKGROUND OF THE INVENTION
[0003] Garment hangers with information markers or tabs are known. Such information markers are used to associate a hanger with a particularly sized garment, i.e., small, medium, large, extra large and so on. The distinguishing features on the markers may be words that designate a size, or a different color used for each size, or a combination of words and colors as the case may be.
[0004] For ease of manufacture and assembly, an information marker is usually shaped like a clip that is slipped onto an information marker holder formed on the hanger. The information marker is secured to the information marker holder usually through a combination of the design of the information marker holder and the information marker.
[0005] In other words, barriers are designed into the hanger near the attachment location of the information marker to prevent a so-called “finger purchase” of the information marker, which would allow someone to easily remove the information marker from the hanger.
[0006] Much effort has been directed to designing hangers and information markers that are child-resistant, wherein the information marker is difficult to remove by a child without at least the use of a tool. Because the information markers are relatively small and usually brightly colored, there is always a concern that a child will attempt to remove an information marker from a hanger and swallow and/or choke on the same. Thus, there is a need to insure that a hanger designed to accommodate an information marker is designed to prevent inadvertent or unintentional removal of the information marker. The present inventors have fulfilled such need with the unique hanger design of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of one embodiment of a holder and a garment hanger of the present invention.
[0008] FIG. 2 is a front view thereof.
[0009] FIG. 3 is a right side view thereof.
[0010] FIG. 4 is a front view thereof with an information marker installed thereon.
[0011] FIG. 5 is a front view of an alternative embodiment of a garment hanger of the present invention.
[0012] FIG. 6 is a planar detail view of holder of the present invention.
[0013] FIG. 7 is a perspective detail view of a holder of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The following detailed description is of the best mode or modes of the invention presently contemplated. Such description is not intended to be understood in a limiting sense, but to be an example of the invention presented solely for illustration thereof, and by reference to which in connection with the following description and the accompanying drawings one skilled in the art may be advised of the advantages and construction of the invention. In the various views of the drawings, like reference characters designate like or similar parts.
[0015] FIGS. 1-4 illustrate one embodiment of a garment hanger 50 of the present invention comprising a first preferably hook-shaped support 60 having a free end 62 and a base 64 , and a second support 70 having a pair of second support arms 72 and 74 . The first support 60 is provided for hanging said garment hanger 50 from a closet rod (not shown), wall hook (not shown) or the like, while the second support 70 is provided for support garments thereon.
[0016] A web 80 is defined between said first and second supports 60 , 70 respectively and is preferably bounded between an upper surface 66 defined along said first support 60 , a lower surface 76 defined along said second support 70 and an intersection 82 defined between said first and second supports 60 , 70 near the base 64 of the first support 60 .
[0017] An information marker holder 90 extends between said first and second supports 60 , 70 for supporting an information marker 100 (shown in FIG. 5 ) thereon. On information marker holder 90 are disposed projections 92 A and 92 B, collectively projections 92 , that aid in retaining information marker 100 .
[0018] In the embodiments shown in the figures provided herein, information marker holder 90 is spaced from the web 80 by a gap 110 , which gap 110 is bounded by the upper and lower surfaces 66 , 76 of the first and second supports 60 , 70 , and edges 84 , 94 of the web 80 and information marker holder 90 respectively. Disposed in gap 110 are web projections 1 12 a and 1 12 b, collectively web projections 112 , to further aid as a removal deterrent.
[0019] The presence of a gap 110 between the web 80 and information marker holder 90 is not a critical feature of the present invention, but is merely reflective of the embodiments described herein. For instance, the garment hanger of the present invention could be configured so that the web terminates at the information marker holder as is known in the art (see, for example, U.S. Pat. No. 5,383,583 to Zuckerman).
[0020] The discussion above reflects the basic elements of prior art hangers having information marker holders. Using FIGS. 1-4 as an example, in prior art hangers, once the information marker 100 , usually in the shape of a clip, is attached to the information marker holder 90 , the edge 84 of the web 80 is configured to prevent finger purchase of the free ends (not shown) of the information marker 100 .
[0021] This is usually accomplished by providing a raised ridge (not shown) along the edge 84 of the web 80 on each side of the hanger 50 , which prevents access to the edges of the information marker 100 . Such raised ridge (not shown) usually extends along the edge 80 from the first support 60 to the second support 70 along the same direction as the information marker holder 90 , and is usually positioned parallel to the information marker holder 90 . This may also be accomplished by web projections 112 a and 112 b that further deter removal by reducing gap 110 .
[0022] In the garment hanger of the present invention as shown in the embodiments of FIGS. 1-7 , at least one raised member 120 is provided on the web 80 extending across the web 80 and preferably in a direction that is generally perpendicular to the information marker holder 90 . In other words, the at least one raised member 120 extends in a direction from the base 64 of the first support 60 , or the intersection 82 of the first and second supports 60 , 70 , toward the information marker holder 90 . Therein, the raised member 120 extends from the lower surface 76 of the second support 70 (near the intersection 82 ) to the edge 84 of the web 80 on either side of the hanger 50 ( FIG. 3 ). Since an information marker 100 is usually clipped around both sides of the information marker holder 90 , it preferable to have a raised member 120 on both sides of the web 80 as shown in FIG. 3 . The termination of the raised member 120 along the edge 84 of the web 80 functions to prevent a finger purchase of an information marker 100 attached to the information marker holder 90 , at least along the center of the web 80 .
[0023] Referring now to FIGS. 6 and 7 , on information marker holder 90 are formed two opposing projections 92 A and 92 B that aid in preventing information marker 100 from being removed from garment hanger.
[0024] Projections 92 are disposed bilaterally about information marker holder 90 preferably near the exterior free-edge 91 of holder 90 as seen in FIG. 3 and are formed as cylindrical projections that are 0.130 inches from side to side (including thickness of the information marker holder 90 ). Each projection preferably has a diameter of 0.100 inches, although projection 92 A and 92 B may also have other diameters and sizes that are suitable to retain information marker 100 . The top of each projection 92 A and 92 B is preferably flat and the edges between the top and the cylindrical wall are preferably sharp. Other suitable shapes for projections 92 A and 92 B may be employed.
[0025] Therein, information marker 100 is secured to garment hanger 50 by sliding the marker over projections 92 . Since marker 100 is usually in the form of a C-shaped clip, it is able to smoothly slide over projections 92 . The edges of marker 100 are then retained in gap 110 while projections 92 are advantageously disposed so as to be near the back of the C-shaped marker 100 where marker 100 is at its maximal interior width.
[0026] When a furtive attempt is made to remove information marker 100 it typically requires opening marker 100 wide by pulling the sides apart causing a hinging of the back of marker 100 . If the attempt succeeds in removing marker 100 from gap 110 , projections 92 present a further challenge because of their position near the widest part of information marker holder 90 , their cooperative structure, and sharp edged shape. Thus, the sides of marker 100 would have to be further spread apart to fit over projections 92 . This may result in the advantageous aborting of the removal attempt because of its difficulty or in the breaking of marker 100 , wherein interest may be lost in retaining marker 100 and subsequently posing a hazard to a child or other person.
[0027] It is contemplated that multiple cooperating projections 92 may also be placed near free edge 91 of holder 90 or spaced slightly from the edge. | An information marker holder system includes a web and an information marker holder for receiving an information marker over the holder. A gap substantially spaces the web from the information marker. The system further includes a protrusion on the information marker holder for preventing removal of the information marker. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of application Ser. No. 11/755,296, filed May 30, 2007, the disclosure of which is hereby incorporated in its entirety by reference herein.
TECHNICAL FIELD
[0002] The disclosure relates to ductless cooling systems for vehicle power storage units.
BACKGROUND
[0003] A battery for a Hybrid Electric Vehicle (HEV) may require cooling during usage. Some HEVs use chilled air from a dedicated air conditioning unit. Other HEVs use fresh air from outside the vehicle. Still other HEVs use air from the cabin via a duct located on a side of the rear seat or in a package tray.
SUMMARY
[0004] Certain embodiments may take the form of a system for delivering air from a vehicle cabin to a vehicle power storage unit. The system includes a floor, a vehicle seat, and a power storage unit to provide power to move the vehicle. The vehicle seat and floor define an air passageway, underneath the vehicle seat, from the vehicle cabin to the power storage unit.
[0005] While exemplary embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a front perspective view, partially exploded, of portions of a cooling system for a traction battery module of a vehicle, and shows the pathway for air, indicated by dotted line arrow, from the vehicle cabin to the traction battery module.
[0007] FIG. 2 is a block diagram of the cooling system of FIG. 1 and shows the pathway for air, indicated by arrow, from the vehicle cabin to the trunk.
[0008] FIG. 3 is a front perspective view, in cross-section, of portions of the cooling system of FIG. 1 taken along section line 3 - 3 of FIG. 1 , and shows the pathway for air, indicated by arrow, from the vehicle cabin, through the enclosure, inlet plenum, and traction battery module, to the trunk.
[0009] FIG. 4 is a rear perspective view of portions of the cooling system of FIG. 1 , and shows air, indicated by arrow, exiting the inlet plenum.
[0010] FIG. 5 is a front perspective view of the seal of FIG. 4 associated with the inlet plenum.
[0011] FIG. 6 is a top perspective view of the support of the rear seat of FIG. 1 .
[0012] FIG. 7 is a bottom perspective view of the support of FIG. 6 and shows portions of the enclosure, as indicated by speckling, defined by the support.
[0013] FIG. 8A is a side elevation view of the rear seat, seal, and inlet plenum of FIG. 1 , and shows the seat in the upright position and sealed with the seal.
[0014] FIG. 8B is another side elevation view of the rear seat, seal, and inlet plenum of FIG. 8A , and shows the rear seat in the folded position and not sealed with the seal.
[0015] FIG. 8C is a side elevation view of an alternative embodiment of the rear seat, seal, and inlet plenum, and shows the rear seat in the folded position and sealed with the seal.
[0016] FIG. 8D is a side elevation view of another alternative embodiment of the rear seat and inlet plenum, and shows the rear seat in the folded position and attached with the inlet plenum.
DETAILED DESCRIPTION
[0017] A dedicated air conditioning unit to cool a traction battery may be expensive and reduce cargo volume. Introducing fresh air from outside a vehicle to cool a traction battery may present water and dust management issues. Using cabin air to cool a fraction battery delivered via ducts located on the side of rear seats may present space, ingress/egress, complexity, and occupant comfort issues. Similarly, ducts passing through a package tray may pass directly under a rear window glass and may be subject to preheating from a solar load. Additionally, ducts require clearances and reduce volume due to duct thickness.
[0018] Some embodiments of the invention provide a ductless cooling system that draws air from the vehicle cabin to cool the battery. A physical inlet duct is not required. Instead, the rear seat and the floor form a chamber for the inlet air stream. The air is drawn underneath the rear seat, through an inlet plenum connecting the seat to the battery, to cool the cells. The warm air, after the heat exchange, is then drawn by a fan and discharged from the battery system to an open volume such as the vehicle trunk, vehicle outside, or other desirable space.
[0019] The inlet plenum may impede recirculation of air from the trunk to the inlet of the air stream. Sealing features, such as an oversized foam seal disposed along the interface between the inlet plenum and the seat back, may allow simple seat assembly and be designed to work, and seal, with a foldable back. As such, portions of the foldable seat may be contoured, at the interface with the inlet plenum, to promote such sealing. For example, a parabolic or circular interface seat surface may be used such that each radius in the seat curvature separates quickly from the inlet plenum to minimize the shear between the foam and back as the seat is rotated.
[0020] Seat cushions may taper at the interface with the seat back. The tapers may provide a seal to reduce air leakage from the sides of the seat and also force the air to come from the front of the seat.
[0021] The ductless cooling system may support the seat cushion without affecting the seat comfort or H-point. The system may provide an air space underneath the seat, an air inlet to allow air to enter the air space from the cabin, proper support that ensures customer comfort when seated, and a dust/moisture filter or screen mesh to reduce the amount of dust/moisture entering the air space.
[0022] The support for the cushion may be provided via a seat cushion wire structure, a bridge form, plastic or metal, to transfer the cushion loads to the floor, or support ribs that pass through an air cavity and serve as flow guiding vanes.
[0023] FIG. 1 is a front perspective view, partially exploded, of portions of cooling system 10 for traction battery module 12 of vehicle 14 showing the path of air, indicated by dotted line arrow, from the vehicle cabin to traction battery module 12 . Portions of floor 16 and rear seat 18 form enclosure 20 under rear seat 18 . Enclosure 20 provides an air passageway for air to travel, as indicated by dotted line arrow, from the vehicle cabin to traction battery module 12 . As explained below, air travels under seat 18 and into traction battery module 12 .
[0024] FIG. 2 is a block diagram of cooling system 10 of FIG. 1 showing the pathway for air, indicated by arrow, from the vehicle cabin to trunk 26 . Air travels first through inlet grille 22 , which obscures occupant view of dust filter 28 and enclosure 20 , and into enclosure 20 under seat 18 . Inlet plenum 24 directs the air from enclosure 20 to traction battery module 12 where it cools the traction battery. Outlet plenum 30 directs the air from traction battery module 12 to fan 32 . Fan 32 blows the air into trunk 26 .
[0025] In some embodiments fan 32 may be used to pull air from the vehicle cabin to traction battery module 12 through enclosure 20 . Fan 32 may be located before or after traction battery module 12 . Fan 32 may also be located in traction battery module 12 . In other embodiments fan 32 may be absent. In still other embodiments, other portions of system 10 , e.g., dust filter 28 , plenums 24 , 30 , etc., may be absent.
[0026] FIG. 3 is a front perspective view, in cross-section, of portions of cooling system 10 of FIG. 1 taken along section line 3 - 3 of FIG. 1 showing the pathway for air, indicated by arrow, from the vehicle cabin, through enclosure 20 , inlet plenum 24 , and traction battery module 12 , to trunk 26 . As discussed above, air may be pulled or pushed from the vehicle cabin by fan 32 ( FIG. 2 ), if present and depending on its location, or air may be forced into cooling system 10 by a vehicle climate control system (not shown).
[0027] FIG. 4 is a rear perspective view of portions of cooling system 10 showing air, indicated by arrow, exiting inlet plenum 24 . Inlet plenum 24 includes seal 35 . Seal 35 may be a soft, flexible material, e.g., foam, capable of producing a substantially airtight seal between inlet 24 and its interfacing parts. In the embodiment of FIG. 4 , seat 18 is in the upright position and inlet plenum 24 seals against rear seat 18 . Inlet plenum 24 also seals against floor 16 via seal 35 . As such, a substantially air tight seal exists between enclosure 20 and inlet plenum 24 . Inlet plenum is mechanically connected, e.g., bolted, with traction battery module 12 such that a generally air tight seal exists between inlet plenum 24 and traction battery module 12 . In other embodiments, inlet plenum 24 may be attached with traction battery module 12 in any desired fashion, e.g., adhered, bonded. A foam seal may also be placed between inlet plenum 24 and traction battery module 12 .
[0028] FIG. 5 is a front perspective view of seal 35 of FIG. 4 associated with inlet plenum 24 . In other embodiments, seal 35 may have a different shape or design depending on the shape or design of inlet plenum 24 , if present, and its interfacing parts.
[0029] FIG. 6 is a top perspective view of support 34 of rear seat 18 of FIG. 1 . Support 34 forms the understructure for rear seat 18 on which cushion material (not shown) may be placed. Support 34 includes opening 36 which provides the inlet for air from the vehicle cabin into enclosure 20 . Inlet grille 22 and dust filter 28 ( FIG. 2 ) cover opening 36 to prevent unobstructed flow of air from the vehicle cabin to enclosure 20 . Support 34 may be made, formed, or molded in any conventional fashion.
[0030] FIG. 7 is a bottom perspective view of support 34 of FIG. 6 showing portions of enclosure 20 , as indicated by speckling, defined by support 34 . The sides of enclosure 20 are defined by air passage walls 38 , 40 . The top of enclosure 20 is defined by upper air passage surface 42 . In the embodiment of FIG. 7 , air passage walls 38 , 40 , upper air passage surface 42 , and floor 16 cooperate to define enclosure 20 under rear seat 18 . Divider 44 transfers occupant loads from rear seat 18 to floor 16 as well as promotes the desired air flow through enclosure 20 . Support structures 46 within enclosure 20 , likewise, transfer occupant loads from rear seat 18 to floor 16 as well as promote the desired air flow through enclosure 20 . Support structures 46 outside of enclosure 20 transfer occupant loads from rear seat 18 to floor 16 . Support structures 46 , in the embodiment of FIG. 7 , have a conical shape. In other embodiments, support structures 46 may have any desired shape, e.g., rib, pillar, etc.
[0031] FIG. 8A is a side elevation view of rear seat 18 having a parabolic shape, seal 35 , and inlet plenum 24 showing seat 18 in the upright position. As described above, if seat 18 is in the upright position, seal 35 of inlet plenum 24 seals against rear seat 18 .
[0032] FIG. 8B is another side elevation view of rear seat 18 , seal 35 , and inlet plenum 24 of FIG. 8A showing rear seat 18 in the folded position. In the folded position, rear seat 18 does not seal against seal 35 of inlet plenum 24 . As such, air from the vehicle cabin may flow directly into inlet plenum 24 and thus traction battery module 12 .
[0033] FIG. 8C is side elevation view of an alternative embodiment of rear seat 118 , seal 135 , and inlet plenum 124 showing rear seat 118 in the folded position. Portions of rear seat 118 have a circular shape with the center of rotation for the seat back being the center of the circular shape such that if rear seat 118 is in the folded position, seal 135 of inlet plenum 124 seals against rear seat 118 .
[0034] FIG. 8D is a side elevation view of another alternative embodiment of rear seat 218 and inlet plenum 224 showing rear seat 218 in the folded position and attached, e.g., bolted, with inlet plenum 224 . Inlet plenum 224 has an accordion-like configuration that permits it to extend and retract as rear seat 218 moves between the upright and stowed positions while maintaining its seal with rear seat 218 .
[0035] Certain embodiments may enable cabin air to be delivered to a battery system, reduce cost and weight required to route air to a battery system, and reduce the number of parts and labor associated with assembly processes. Certain embodiments may also occupy less volume resulting in increased room for airflow and seat cushions and are robust to floor dimensional variation caused by, for example, the presence of dampening materials.
[0036] While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. | A vehicle includes a floor, a seat including a back, and a traction battery module located behind the seat. The seat and floor form an air passageway, underneath the seat, from a cabin to the traction battery module. The vehicle also includes a plenum disposed between the air passageway and fraction battery module, and a sealing member fixed to the plenum and configured to engage the back to form a substantially airtight seal therebetween. | 1 |
TECHNICAL FIELD OF THE INVENTION
The present invention is directed to an air distribution system for distributing air through an appliance such as a refrigerator.
BACKGROUND OF THE INVENTION
A refrigerator, particularly a refrigerator used in consumer applications, typically includes both a fresh food compartment and a freezer compartment. Such a refrigerator also includes an evaporator coil, a condenser coil, a compressor, and a refrigerator fan. The evaporator coil, condenser coil, and compressor are interconnected by fluid conduits which carry a heat exchange fluid. The compressor compresses the heat exchange fluid and supplies the compressed heat exchange fluid to the evaporator coil where the compressed heat exchange fluid is evaporated. The evaporation of the heat exchange fluid in the evaporator coil cools the evaporator coil. The refrigerator fan blows air across the cool evaporator coil in order to cool the air, and then discharges the cooled air to the freezer compartment. Accordingly, the evaporator coil removes heat from the air which is blown across the evaporator coil by the refrigerator fan.
The removed heat is then transferred by the heat exchange fluid to the condenser coil. A condenser fan blows air across the condenser coil in order to reject the heat of the heat exchange fluid to atmosphere. The refrigerator fan, the compressor, and the compressor fan are controlled by a temperature sensor in the freezer compartment.
The air discharged by the refrigerator fan into the freezer compartment is also supplied to the fresh food compartment. A typical refrigerator employs a mechanical or bellows type damper in order to control this air flow from the freezer compartment to the fresh food compartment. The position of the damper is controlled by a temperature sensor in the fresh food compartment so that the position of the damper controls the temperature of the fresh food compartment. However, a damper is slow to respond to control signals and, thus, permits unnecessarily large temperature swings within the fresh food compartment. Also, the use of a single refrigerator fan to supply cooled air to both the freezer and fresh food compartments requires the refrigerator fan speed to be relatively high, and this high fan speed increases the noise of operating the refrigerator. Moreover, the refrigerator fan is usually driven by an AC motor which consumes a large amount of energy.
The present invention is intended to solve one or more of the above-noted problems.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, a multiple fan air distribution system for a refrigerator comprises first and second air discharging means and connecting means. The first air discharging means discharges cooled air to a first refrigeration compartment of a refrigerator, and the first air discharging means includes a first fan. The second air discharging means discharges cooled air to a second refrigeration compartment of the refrigerator, and the second air discharging means includes a second fan. The connecting means interconnects the first and second refrigeration compartments so that the first air discharging means discharges air from the second refrigerator compartment to the first refrigeration compartment, so that the first air discharging means discharges air to the first refrigeration compartment but not to the second refrigeration compartment, and so that the second air discharging means discharges air to the second refrigeration compartment but not to the first refrigeration compartment.
According to another aspect of the present invention, a refrigerator having a multiple fan air distribution system comprises a refrigerator cabinet and first and second fans. The refrigerator cabinet has first and second refrigeration compartments. The first fan is located in the first refrigeration compartment and is arranged to draw cooled air from the second refrigeration compartment and to discharge the drawn cooled air to the first refrigeration compartment. The second fan is located in the second refrigeration compartment and is arranged to discharge cooled air to the second refrigeration compartment.
According to yet another aspect of the present invention, a refrigerator comprises a refrigerator cabinet, a first air duct, a second air duct, a first fan, and a second fan. The refrigerator cabinet has first and second refrigeration compartments, and each of the first and second refrigeration compartments has upper and lower portions. The first air duct extends from the upper portion of the second refrigeration compartment to the upper portion of the first refrigeration compartment. The second air duct extends between the upper portion of the second refrigeration compartment and the lower portion of the first refrigeration compartment. The first fan is arranged to draw first air through the first air duct from the upper portion of the second refrigeration compartment and to discharge the first air into the upper portion of the first refrigeration compartment. The second fan is arranged to draw second air from the lower portion of second refrigeration compartment and to discharge the second air into the upper portion of the second refrigeration compartment.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become more apparent from a detailed consideration of the invention when taken in conjunction with the drawings in which:
FIG. 1 is an isometric view of a refrigerator having a multiple fan air distribution system according to the present invention;
FIG. 2 is an isometric view of a compressor compartment which may be located on top of the refrigerator shown in FIG. 1;
FIG. 3 is a top view of the compressor compartment shown in FIG. 1;
FIG. 4 is a view taken along line 4--4 FIG. 3;
FIG. 5 is a view taken along line 5--5 FIG. 3; and,
FIG. 6 is a schematic diagram of a controller for the multiple fan air distribution system according to the present invention.
DETAILED DESCRIPTION
As shown in FIG. 1, a refrigerator 10 includes a refrigerator cabinet 12 which houses a fresh food compartment 14 and a freezer compartment 16. The fresh food compartment 14 is bounded by refrigerator cabinet side walls 18 and 20, a top wall 22, a fresh food compartment floor 24, a back wall 26, and a fresh food compartment door (not shown). Similarly, the freezer compartment 16 is bounded by the refrigerator cabinet side walls 18 and 20, the fresh food compartment floor 24 of the fresh food compartment 14, the back wall 26, a freezer compartment floor 28 of the freezer compartment 16, and a freezer compartment door (not shown).
An evaporator coil 30 is housed by an evaporator coil housing 32 within the freezer compartment 16. The evaporator coil housing 32 includes air return vents 34 which permit air to be returned from a lower portion of the freezer compartment 16 to the evaporator coil 30. The top of the evaporator coil housing 32 communicates with a fan housing 36 which houses an AC fan. The fan housing 36 includes air discharge vents 38 which are located in an upper portion of the freezer compartment 16. The refrigerator cabinet side wall 18, the top wall 22, and the fresh food compartment floor 24 are shown in phantom in FIG. 1 in order to better show the evaporator coil 30, the evaporator coil housing 32, the air return vents 34, the fan housing 36, and the air discharge vents 38.
When the AC fan, which is housed within the fan housing 36, is energized, air is drawn from the lower portion of the freezer compartment 16 through the air return vents 34 and over the evaporator coil 30. The evaporator coil 30 cools the air, and the cooled air is discharged by the AC fan from the fan housing 36 through the air discharge vents 38 and into the upper portion of the freezer compartment 16. This discharged air falls over the frozen foods to the lower portion of the freezer compartment 16.
The back wall 26 has air inlet vents 40 just below the fresh food compartment floor 24 so that the air inlet vents 40 are in communication with the freezer compartment 16. In communication with the air inlet vents 40 are a pair of air supply ducts 42 and 44 which conduct air flow from the freezer compartment 16 to an upper portion of the fresh food compartment 14. The air supply ducts 42 and 44 communicate with a DC fan 46. A pair of air return ducts 48 and 50 extend through the fresh food compartment floor 24. Accordingly, communication between a lower portion of the fresh food compartment 14 and the lower portion of the freezer compartment 16 is established through the air return ducts 48 and 50 which permit the return of air from the fresh food compartment 14 to the freezer compartment 16.
When energized, the DC fan 46 draws air from the upper portion of the freezer compartment 16 through the air inlet vents 40 and through the air supply ducts 42 and 44. The DC fan 46 then discharges the air into an upper portion of the fresh food compartment 14. Accordingly, cool air is drawn by the DC fan 46 from the freezer compartment 16 and is discharged into the upper portion of the fresh food compartment 14. This cool air falls over the fresh food in the fresh food compartment 14 and returns to the freezer compartment 16 through the air return ducts 48 and 50.
If desired, a beverage air duct 52 may be provided in order to supply cooled air to a beverage compartment.
As shown in FIGS. 2-5, a compressor 54, a condenser coil 56, a condenser fan 58, and a control box 60 are mounted on top of the top wall 22 of the refrigerator 10. The evaporator coil 30, the condenser coil 56, and the compressor 54 are connected in a fluid circuit by fluid conduits 62, 64, 66, etc. Accordingly, a heat exchange fluid is compressed and is circulated through the fluid conduits of this fluid circuit by the compressor 54. The compressor 54 supplies the compressed heat exchange fluid to the evaporator coil 30 where the heat exchange fluid evaporates to cool the air which is circulated across the evaporator coil 30 by the AC fan contained in the fan housing 36. The heat exchange fluid is then returned by the fluid circuit to the condenser coil 56 where the heat picked up by the high exchange fluid in the evaporator coil 30 is rejected to atmosphere by the air being circulated across the condenser coil 56 by the condenser fan 58.
A control circuit for the refrigerator 10 is contained in the control box 60 and is shown in FIG. 6. FIG. 6 illustrates an AC evaporator fan 70 as the evaporator fan which is contained within the fan housing 36 and which circulates air from the lower portion of the freezer compartment 16, through the air return vents 34, over the evaporator coil 30, through the air discharge vents 38, and into the upper portion of the freezer compartment 16.
As shown in FIG. 6, power is supplied to the refrigerator 10 through a pair of power mains and a main power switch 72. A transformer 74 and a power supply rectifier and bridge 76 are connected across the power mains in order to supply low voltage DC to an electronic control 78. Also, a secondary winding 80 of the transformer 74 is arranged to supply AC to the electronic control 78. The electronic control 78 may be supplied by the assignee of the present invention under Amana part No. 12067101.
The electronic control 78 responds to a thermistor 82, which may be located so as to sense the temperature in the freezer compartment 16, and a thermistor 84, which may be located so as to sense the temperature in the fresh food compartment 14. When the electronic control 78 determines from the thermistor 84 that additional cooling is needed in the fresh food compartment 14, the electronic control 78 operates a semi-conductor switch 86 in order to energize the DC fan 46. When the DC fan 46 is energized, air is circulated by the DC fan 46 from the upper portion of the freezer compartment 16, through the air inlet vents 40, through the air supply ducts 42 and 44, and out into the upper portion of the fresh food compartment 14. Air is returned from the fresh food compartment 14 to the freezer compartment 16 through the air return ducts 48 and 50.
When the electronic control 78 determines from the thermistor 82 that the freezer compartment 16 requires additional cooling, the electronic control 78 energizes a relay 88 which closes a relay switch 90 in order to energize the AC evaporator fan 70. Accordingly, air is circulated by the AC evaporator fan 70 from the lower portion of the freezer compartment 16, through the air return vents 34, over the evaporator coil 30, and out through the air discharge vents 38 into the upper portion of the freezer compartment 16.
When the electronic control 78 determines that the evaporator coil 30 should be defrosted, the electronic control 78 operates a relay 92 which closes a relay switch 94 in order to energize a defrost heater 96. When the temperature of the evaporator coil 30 has reached a predetermined temperature as determined by a temperature sensor 98, the temperature sensor 98 causes the defrost heater 96 to be deenergized. A showroom switch 100 prevents operation of the defrost heater 96 when the refrigerator 10 is sitting on a showroom floor. When the refrigerator 10 is installed for operation, the showroom switch 100 is operated so as to place the temperature sensor 98, the relay switch 94, and the defrost heater 96 across the power mains of the refrigerator 10.
The electronic control 78 controls the compressor 54 through a relay 102, a relay switch 104, and an overload protector 106. An ice maker 108, a freezer compartment light 110, and a fresh food compartment light 112 may also be operated under control of corresponding switches.
Accordingly, separate fans, i.e., the DC fan 46 and the AC evaporator fan 70, are provided for the fresh food compartment 14 and the freezer compartment 16 respectively of the refrigerator 10. In this way, the DC fan 46 and the AC evaporator fan 70 may be independently controlled. Accordingly, as compared to refrigerators using a single fan and a damper, (i) the response time between the call for cooling and the resulting discharge of cooling air into the fresh food compartment 14 is substantially reduced, (ii) fan speed, and therefore fan noise, may be reduced because two fans are used instead of one, and (iii) an overall energy reduction is realized because of the slower fan speeds and because a DC fan may be used for the fresh food compartment 14.
Certain modifications of the present invention have been discussed above. Other modifications will occur to those practicing in the art of the present invention. For example, the fan in the fresh food compartment 14 is described as a DC fan, and the fan in the freezer compartment 16 is described as an AC fan. Alternatively, both the fan in the fresh food compartment 14 and the fan in the freezer compartment 16 may be DC fans.
Moreover, the present invention is described above in relation to a refrigerator having top and bottom refrigeration compartments. However, the present invention is useful with side-by-side refrigeration compartments and with refrigerators having other refrigeration compartment configurations.
Accordingly, the description of the present invention is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which are within the scope of the appended claims is reserved. | A refrigerator has fresh food and freezer compartments, and each of the fresh food and freezer compartments has upper and lower portions. A first air duct extends from the upper portion of the freezer compartment to the upper portion of the fresh food compartment, and a second air duct extends between the lower portion of the freezer compartment and the lower portion of the fresh food compartment. A first fan is arranged to draw first air through the first air duct from the upper portion of the freezer compartment and to discharge the first air into the upper portion of the fresh food compartment. A second fan is arranged to draw second air from the lower portion of freezer compartment and to discharge the second air into the upper portion of the freezer compartment. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This invention is a continuation of U.S. patent application Ser. No. 07/950,739 filed Sep. 24, 1992, now abandoned which is a continuation of U.S. Pat. Ser. No. 07/840,596 filed Feb. 19, 1992, now abandoned, which itself, in turn, is a continuation of U.S. Pat. Ser. No. 07/474,963 filed May 15, 1990, now abandoned.
BACKGROUND OF THE INVENTION
2. Field of the Invention
This invention relates generally to the disposal of municipal and industrial waste materials by combustion, in the presence of at least 50% oxygen and more particularly, to a process for waste combustion process which does not require separation of non-ferrous metals from the bulk waste material and which is adapted to simultaneously treat various combinations of the same.
2. Description of the Prior Art
In industries, households, and during the recycling of secondary substances, waste materials are produced which have a relatively high calorific value and which therefore present an opportunity to reduce the volume of waste by combustion. Such a reduction in the volume of waste would be desirable in order to prevent ground water contamination and to conserve landfill space. Processes for the combustion of municipal solid waste and other refuse using air are well known and need not be described here. A process for the incineration of combustible material, including municipal waste, in which the combustion air has an increased oxygen content, is described in published European Application EP-A 0207924. In that publication, the preferred oxygen content is 30-35% by weight, compared with the 23.19% by weight oxygen content of atmospheric air.
European Publication EP-A 0103881 deals with a process for the elimination of hazardous gaseous flue gas components. In that process, a cleaning is step is proposed in which lime or calcium carbonate is introduced into the flue gas downstream of the combustion furnace. For the same purpose, WO 86/07602 discloses that powdery additives of dicalcium-phosphate and ammonium chloride, with small contents of other chemicals, may be introduced into the combustion process. The WO/86/07602 reference, however, does not mention suitable ranges of temperatures.
In European Publication EP-A 0023642, there is proposed a mixture of red-slime with alkaline earth and aluminum hydroxide as adsorption matter. This mixture is introduced into a stream of waste gases at a temperature of approximately 300° C.
In British Publication GB-A 2,169,887, a process is disclosed in which pulverized alkali- or alkaline earth- oxides or carbonates thereof are blown into a combustion furnace at 800°-1000° C. Water or steam is separately injected into the flue gas.
In all combustion processes, waste gases occur which contain hazardous dust and also hazardous gaseous components. For example, hydrochloric acid arises from the combustion of polyvinyl chloride. Moreover, in bunting chlorinated or fluorinated hydrocarbons, dangerous chemical compounds can occur if special conditions of combustion are not observed and maintained.
For combustion with air, a greater amount of excess air is generally necessary for complete combustion to occur. Moreover, an after burning is essential for complete combustion because of the low temperature in the primary combustion chamber. Because the after burner needs additional fuel, the amount of waste gas is consequently increased. Accordingly, the heat recovery and gas cleaning installations are large and expensive. Additionally, although the concentration of pollutants in the cleaned gas is low, the overall emission level of hazardous substances is high because of the large volume of the gas stream.
It has already been proposed to improve the combustion by utilizing oxygen enriched air, for example, in the combustion of combustible residues from automobile shredders (Wilhelm C. Dries--Recycling Berlin 1979, S. 1447). A drastic reduction in the amount of waste gases occurs only if the combustion air contains at least 50% oxygen, but best results are obtained if pure oxygen with 99% O 2 is used for the combustion.
The magnitude of the reduction in the amount of waste gases is illustrated by the combustion of 1 kg of light oil. With an excess air value of 1.2, about 13 Nm 3 of flue gas is produced when the oil is combusted. In contrast, combustion of the same oil in pure oxygen produces only 3.2 Nm 3 of flue gas, a 75% reduction. Accordingly, the size and power consumption of the gas clean unit are substantially reduced.
A process for treatment of scrap batteries, as described in published German Patent Application P 36 17410.6, has been utilized for a long time. In that publication, it is disclosed that a complete and sootfree combustion of the plastic parts of batteries, as propylene and polyvinyl chloride, may be obtained if the materials are retained in the combustion furnace for a predetermined retention time.
Each of the aforementioned processes is limited in that it is adapted to treat only a portion of the components which are present in the overall waste stream.
SUMMARY OF THE INVENTION
The present invention comprises several steps by which refuse, especially plastic containing refuse, are burned with gases containing more than 50% oxygen to reduce the amount of flue gases, which means smaller gas cleaning units, lower power consumption, and reduced emissions of hazardous material and to increase the combustion temperature. The flue gas produced is cooled by a waste heat boiler and cleaned in a gas cleaning unit.
The theoretically possible very high combustion temperatures are reduced in practice to temperatures below 1800° C. either by reducing the calorific value of the input material or by recirculating part of the flue gas, which has already been cooled by the waste heat boiler, into the combustion chamber. Steam produced in the waste heat boiler may be utilized for any desired purpose, as for example, the purposes of the plant.
Metal containing materials are burned together with the other refuse, or the metal containing material or alkali or alkaline earth compounds are injected into the gas stream to combine with the hazardous materials.
The process according to the present invention is especially suitable for the disposal of discarded cars. The residues from the car shredder containing rubber, plastics, non-ferrous metals and the like, are incinerated with oxygen and, as mentioned above, the steam produced is used for purposes of the plant. Metal-compounds containing dust are recovered by a fabric filter and are subjected to metal recovery processes or are included into the slag which will be produced in the combustion furnace.
Accordingly, the present invention relates to a process for the disposal of refuse which is characterized by combustion of combustible, solid, pasty or liquid waste materials in a combustion plant with a combustion supporting gas that is not preheated and which contains at least 50% oxygen. The combustible waste materials are burned in the presence of at least one material selected from the class consisting of non-ferrous metals, non-ferrous metal oxides, alkali compounds, and alkaline earth compounds. The aforementioned combustion is accomplished by burning waste materials which produce at least one material of the aforementioned class of materials together with the waste materials, by introducing at least one of the materials of the class into the combustion plant together with the input of waste materials or into the hot gas stream, or by any combination of these which achieves a desired waste composition. If necessary, fluxes are added to the input material for controlling the composition of the slag.
The process of the present invention further includes reducing the temperature of the combustion chamber to the range of 1200°-1800° C. and cooling the flue gases. The cooling of the gases, for example, may be achieved by a waste heat boiler that recovers the waste heat. The process also includes removing dust from the flue gas using gas cleaning equipment and discharging non-combustible, non-volatile residues in the form of a molten liquid slag.
The combustion of waste materials, for example municipal solid waste, special hazardous waste, shredder residues, spent oil and others, is accomplished using a suitable furnace such as a rotary kiln. Preferably, the combustion supporting gas contains 70-80% oxygen, with a percentage of oxygen 98% or more being especially preferred. Examples of preferred non-ferrous metals, non-ferrous metal compounds and non-ferrous metal oxides are lead, zinc, tin, and copper, as well as the sulfates, carbonates, and oxides thereof. Examples of preferred alkali and alkaline earth compounds are carbonates, sulfates, hydroxides, and oxides of sodium, potassium, calcium, and magnesium. The quantity of non-ferrous metals or non-ferrous metal compounds or of alkali or alkaline earths and the compounds thereof are preferably controlled so that the overall halogen content, especially chlorine and fluorine, of the flue dusts is below 10%. The retention time of waste materials in the combustion plant furnace, especially in a rotary kiln, is at least one second.
The step of reducing the temperature recited above is performed by reducing the calorific value of the combustible waste material, recirculating flue gas that has already passed through and been cooled by the boiler, by direct or indirect cooling of the combustion chamber, or by any suitable combination of such steps.
As indicated, the cooling of the waste gases and the recovery of the waste heat contained therein is effected by a waste heat boiler, preferably by a waste heat boiler having a radiation heating surface and, more preferably, a waste heat boiler having a primary radiation heating surface. The steam of the waste heat boiler can be used for generating electrical power or for directly driving machines associated with the air separation plant or the shredder plant. The steam produced by the waste heat boiler can also be used to power other equipment of the waste combustion plant, or it can even be sold to third parties.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For a better understanding of the invention, its operating advantages, and specific object attained by its use, reference should be had to the detailed description of the preferred embodiments which follows.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention offers a distinct advantage over waste combustion systems of the prior art. Specifically, there is no need to separate non-ferrous metals, in particular heavy metals, from the waste material. Rather, the presence of such material is utilized for combination with possibly present acids and other chemical compounds after converting the non-ferrous metals into oxides by combustion. Two different possibilities are presented in this regard, depending upon the composition of the input waste material. If the waste materials already contain a sufficient quantity of non-ferrous metals, or compounds or oxides thereof, or alkali/alkaline earth compounds, the quantity of these materials need not be adjusted. If however, the quantity of the aforementioned materials in the waste material to be disposed of is not sufficient, they may either be added to the input waste materials or introduced into the hot gas stream during combustion.
As mentioned, part of the flue gases can be recirculated into the combustion chamber after cooling by the waste heat boiler to reduce the temperature of the combustion chamber. The flue gases not recirculated in this manner are cleaned in a gas cleaning installation whereby the dust contained therein is removed. Preferably, the removal of the dust in the gas cleaning installation is effected by a fabric filter. If necessary, a high efficiency micro filter can be installed downstream of the normal filter. If the metal content of the dust removed by the filter(s) is high enough to be economically recovered, it may be utilized in a metal recovery process. If, however, the metal content is too low for metal recovery, the dust is re-introduced back into the combustion furnace either for enrichment or for inclusion into the slag produced therein.
The non-combustible, non-volatile residues of combustion are discharged as slag which has been liquified by suitable, known fluxes if necessary. Suitable materials are added to the input of waste material for formation of slag and for the mineralization of hazardous materials. Such fluxes are well known to metallurgists, and among those conventional flux materials which may be utilized are iron, lime, silica, and alumina.
The combustion of waste material with oxygen means that calorimetric flame temperatures of over 2000° C. can be reached at which hydrocarbons are no longer stable.
The hydrochloric, hydrofluoric, sulfuric acids or the like which may be produced during combustion of certain plastics can cause problems. It is, however, known from metallurgical processes that metal oxides are an excellent material to combine with such acids. This is especially the case if these metal oxides arise during combustion. For example, a flue dust with up to 10% chlorine as lead chloride is produced during the smelting of battery scrap. But other metal oxides, as for example zinc oxide, are also very suitable for combining with the chlorine.
If one or more suitable metal oxides are not present in sufficient amounts in the input waste material, or if they cannot be subsequently introduced into the gas stream by other methods, the combination of chlorine or fluorine with alkali or alkaline earth compounds injected into the gas stream is possible. In this regard, it is desirable to maintain contact between gas and dust as long as possible. One way in which to achieve adequate contact between the injected gas and the dust is to recycle the dust removed by the filter.
As indicated, the heat produced during combustion can be used to generate steam in a waste heat boiler. Waste heat boilers for utilizing latent heat contained in dusty gases are known. Special provisions have to be made for sticky flue dust containing chlorine or fluorine.
The present invention is especially suitable for plants which shred discarded automobiles. During shredding, combustible residues containing plastics, textiles, wood, rubber, and the like are generated. In accordance with the present invention, all of these residues can be burned in a suitable furnace at the shredder site. To the combustible residue, such a quantity of the non-magnetic portion of non-ferrous metals smaller than 25 mm are added so that sufficient metal oxides are present in the flue dust for combination with possibly present acids. Alternately, dust removed from the gas stream by the cleaning installation filter is recycled into the furnace. The metal content of the flue dust can be enriched by recycling metal containing flue dust into the combustion furnace, and metal therein can be subsequently recovered. Flue dust for which there is no utility can be recycled into the combustion furnace for incorporation into the slag. In this manner, hazardous materials are mineralized in the slag. Because of the high temperature of the combustion furnace, the solid residues are discharged as a molten, liquid slag. To enhance liquification of the slag and mineralization of hazardous materials therein, fluxing reagents can be added to the input waste material.
Combustion temperatures up to 2500° C. arise in the case of higher calorific values of the refuses as 8000 kJ/kg for example during combustion of shredder residue with about 15,000-18,000 kJ/kg and with an oxygen content of the combustion air over 50% because of the small quantity of flue gas thereof. The temperature of the combustion chamber can be reduced either by reduction of the calorific value of the input material or by recirculation of a certain portion of the flue gas after it has been cooled by the waste heat boiler. The recirculation of the flue gas is advantageous in that the quantity of flue gas to be cooled by the waste heat boiler increases while the amount of the waste gas to be cleaned and released, and thus the emission of pollutants therewith remains small.
The steam produced by the waste heat boiler may be utilized to generate electrical power for the operation of the plant delivered to third parties, or it may be used directly to drive machines of the air separation plant or of the shredder plant.
After the waste heat boiler, the portion of the flue gas which is not recycled into the combustion chamber will be cleaned by a gas cleaning unit, preferably by a fabric filter. Because of the comparatively small volume of flue gas and in the case of a special demand for high cleanliness of the waste gas, it may be desirable to install a high efficiency microfilter. Such a microfilter yields a dust content of the clean gas below 0.1 mg/Nm 3 , if positioned downstream from a normal fabric filter, which reduces the dust content in the gas to below 5 mg/Nm 3 .
A further special advantage of the invention is the fact that refuse of different origin, for example municipal solid waste. industrial waste, and hazardous refuse, can be burned simultaneously in the same combustion plant. IIeretofore, it has been necessary to burn the aforementioned refuses separately. The following examples are illustrative of the process.
EXAMPLE 1
Combustion of Municipal Waste and Hazardous Waste in a Rotary Kiln
As indicated, a separation of municipal waste, industrial waste, and hazardous refuse is not necessary because the temperatures of the inside of the kiln and of the combustion exceeds 1200° C. and is preferably from 1500°-1800° C.
Waste is charged into the rotary kiln after coarse crushing. Liquid combustible refuses are injected by an oxygen burner. The combustion thereof acts as a support flame. Oxygen produced by an air separation plant is blown into the rotary kiln. An intermediate liquidification is not necessary. Only one-third of flue gases are generated during combustion when compared with combustion with atmospheric air because the nitrogen ballast, 79% of the volume of the air, is missing.
Because flame temperature reaches over 2500° C. at combustion with oxygen, a sufficient volume of flue gases is recirculated into the combustion chamber after cooling in a heat exchanger (waste heat boiler) to provide an economical temperature within the combustion chamber. In this regard, combustion chamber temperatures over 1500° C. are tolerable with commercially available refractory materials.
Nitrogen oxides are only present in negligible amounts because air is only used for atomizing the liquid refuses and because only small quantities of air enters the system through leakage. Moreover, small quantities of nitrogen are contained in the plastics to be burned.
Suitable additions, for example, calcium hydrate, are added to the input waste material for combination with possibly arising halogens in the case where suitable compounds are not present, whether at all or in sufficient quantity, in the input waste material. These materials are burned simultaneously or injected into the hot gas stream. By addition of the additives into the hot zone very fast reaction rates can be achieved for combination with hazardous materials. The hot gases come into the waste heat boiler and a fraction of the flue gas is recirculated into the combustion chamber after cooling.
Because of the high temperature of the flue gases, a radiation heating surface is preferably installed ahead of the waste heat boiler. The radiation heating surface functions as a means for diverting the gas stream and as a baffle to eliminate flue slag. The cooled flue gases are dedusted by a fabric filter. Temperatures of 180°-250° C. are possible, depending on the filter material selected.
In accordance with presently available combustion processes, a typical waste gas volume of 5500 Nm 3 per ton of waste results in production of 82 500 Nm 3 per hour for a plant with a capacity of 15 tons per hour of waste. Such operation yields a particle stream of 330 g/h that can be cleaned to a clean gas dust content of 4 mg/Nm 3 , using a good fabric filter. In contrast, by burning with oxygen in accordance with the present invention, the flue gas quantity to be cleaned is only 28 000 Nm 3 /h including leakage air. With the same clean gas content as above, a decrease of the stream of hazardous particles occurs of only 110 g/h. The hazardous particles eliminated by waste heat boiler and fabric filter are recycled into the rotary kiln and combined with the slag. A gas washing is not necessary because the halogens are combined with the additives.
Possibly necessary fluxes are added to the input material to discharge combustion residues and flue dust recycled as a liquid slag and to transform hazardous matters into water insoluble compounds by mineralization. The solidified slag can be deposited in a landfill or possibly used in some further process. Some of the heat energy recovered by the waste heat boiler can be used for the production of the necessary oxygen or can be delivered to other consumers.
______________________________________Layout dataWaste throughput 15 t/hCalorific value 11000 kJ/kgHumidity 30 % H.sub.2 OSlag output 4.5 t/hOxygen consumption 1 kg O.sub.2 /kg wasteRotary kilnDimension 48 × 3,5 m length/diameterQuantity of 15600 Nm.sup.3 /hflue gasFlue gas recycled 35000 Nm.sup.3 /hGas quantity entry 50600 Nm.sup.3 /hw.h. boilerTemperature 1800 °C.O.sub.2 -plantCapacity 10500 Nm.sup.3 /hSpace 40 × 50 mPower consumption 4.9 MWCooling water 500 m.sup.3 /hWaste heat boilerHeating surface 850 m.sup.2Steam produced 54 t/hSteam pressure 16 barFabric filterGas quantity 28000 Nm.sup.3 /hEntry temperature 180 °C.Filter area 800 m.sup.2Clean gas dust content 5 mg/Nm.sup.3______________________________________
EXAMPLE 2
Combustion of Shredder Residue in a Rotary Kiln
This process is distinguished from the one of Example 1 only in the much higher calorific value than is associated with combustion of municipal solid waste and the like. Usually the shredder residue contains enough of the non-ferrous metals, which are respectively left in the material, to effect the necessary combination with the chlorine and fluorine also produced during combustion. An addition of alkali or alkaline earth is not necessary. Because of the high metal content of the shredder residue, there is presented an opportunity to recover the metal content of the flue dust removed by the fabric filter.
______________________________________Layout dataShredder residue throughput 5 t/hCalorific value 15000 kJ/kgHumidity 5 % H.sub.2 OSlag output 1.75 t/hOxygen consumption 1.4 kg O.sub.2 /kg wasteRotary kilnDimension 30 × 3.2 m length/diameterQuantity of flue gas 4800 Nm.sup.3 /hFlue gas recycled 20300 Nm.sup.3 /hGas quantity entry 25100 Nm.sup.3 /hw.h. boilerTemperature 1800 °C.O.sub.2 -plantCapacity 5000 Nm.sup.3 /hSpace 30 × 20 mPower consumption 2.4 MWWaste heat boilerHeating surface 430 m.sup.2Steam produced 25 t/hSteam pressure 16 barFabric filterGas quantity 10000 Nm.sup.3 /hEntry temperature 180 °C.Filter area 270 m.sup.2Clean gas dust content 5 mg/Nm.sup.3______________________________________
As described above, tile present invention makes it possible to burn refuse from diverse sources, including metal containing materials, simultaneously in such a manner that the combustion products thereof are able to combine with hazardous materials which may be generated during combustion. After combustion, alkali or alkaline earth compounds can also be introduced into the gas stream for combination with such hazardous materials.
The waste gas can be cleaned, after cooling by a waste heat boiler, in a fabric filter with dust recycling within the filter or in another suitable equipment. Further, the flue gas exiting the waste heat boiler can be recirculated into the combustion chamber in such a quantity which is necessary to achieve the desired combustion chamber temperature. For example, at operation of a shredder plant the combustible fraction and a part or all non-ferrous-metal containing constituents of the discarded cars, after separation in the shredder plant, are put into an installation in which they are burned with a combustion gas which contains at least 50%, preferably 70 to 98% or more oxygen. The flue gas, after cooling by the waste heat boiler, will be cleaned in a suitable gas cleaning plant, preferably by a fabric filter, and the steam of the waste heat boiler will be used for an air separation plant or for the shredder plant. Some of the steam may also be used directly for the turbine drive of the shredder.
It should be understood that the preferred embodiments and examples described are for illustrative purposes only and are not to be construed as limiting the scope of the present invention which is properly delineated only in the appended claims. | A process for the disposal of refuse is characterized by combustion of combustible, solid, pasty or liquid waste materials in a combustion plant with a combustion gas containing at least 50% oxygen. Combustible waste materials are burned in the presence of at least one material selected from the group consisting of non-ferrous metals, non-ferrous metal oxides, alkali compounds, and alkaline earth compounds. The aforementioned combustion is accomplished by burning materials which produce at least one material of the aforementioned class of materials together with the waste materials, by introducing at least one of the materials of the class into the combustion plant together with the input of waste materials or into the hot gas stream, or any combination of these which achieves a desired waste composition. The by-products of the process are cleaned flue gas and a slag in which hazardous materials present in the input waste material are mineralized. | 8 |
REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of applicants' co-pending U.S. application Ser. No. 554,639 now U.S. Pat. No. 4,590,844.
FIELD OF THE INVENTION
The present invention relates to apparatus for clearing mines, and more particularly to mine clearing apparatus mountable on an armoured vehicle such as a tank.
BACKGROUND OF THE INVENTION
There is described and claimed in applicant's U.S. Pat. No. 4,467,694 apparatus for clearing mines which overcomes the difficulties and disadvantages of conventional prior art mine clearing techniques and apparatus and which comprises a frame mountable onto a vehicle for selectable positioning in a raised or lowered orientation; apparatus for raising and shunting aside mines mounted onto the frame; and apparatus for selectably retaining the frame in a raised orientation and comprising control apparatus operable from inside the vehicle for releasing the frame from the raised orientation and allowing it to assume the lowered orientation.
There is also described and claimed in applicant's U.S. Pat. No. 4,491,053 apparatus for clearing mines comprising a frame mountable onto a vehicle for selectable positioning in a raised or lowered orientation; plow apparatus for raising and shunting aside mines mounted onto the frame; and apparatus for automatically raising the plow from its lowered orientation to its raised orientation in response to backwards motion of the vehicle and including mounting apparatus rotatably mounted onto the vehicle, spring supporting apparatus mounted onto the mounting apparatus and attached to the plow apparatus; and tooth apparatus fixed onto the mounting apparatus and arranged for selectable engagement with the vehicle tread, the spring supporting apparatus being operative when the plow is in its lowered orientation to urge the tooth apparatus into driven engagement with the vehicle tread whereby during backwards movement of the vehicle, the mounting apparatus rotates in a first direction, thereby extending the length of the spring supporting apparatus, and increasing the spring force thereof until a spring force is reached at a first position of the mounting apparatus sufficient to raise the plow to its raised orientation. Continued rotation of the mounting apparatus raises the plow until it engages a retaining hook, and is held stationary.
In addition, there is described and claimed in applicant's U.S. Pat. No. 4,552,053 mine clearing apparatus for attachment to a vehicle and comprising a frame mountable onto a vehicle for selectable positioning in a raised or lowered orientation; apparatus mounted onto the frame for raising and shunting aside mines including first and second plow sections disposed one above another in hinged engagement, the second plow section being associated with a plurality of plow teeth which, in operation, extend below the ground surface, the first and second plow sections being operative to lie in generally the same plane during operation and in folded engagement when the frame is in its raised orientation, the raising and shunting aside apparatus being mounted on the frame in front of the ground engaging members on each side of the vehicle and being angularly oriented to have a forward edge adjacent the interior of the vehicle and a rearward edge adjacent the side edge of the vehicle, each of the forward edges being provided with a chain attached to the first and second plow sections such as to be tensioned when the first and second plow sections are in their operating orientations to thereby define a barrier against mines passing from adjacent the forward edge to the relatively unprotected area at the interior of the vehicle.
SUMMARY OF THE INVENTION
The present invention seeks to provide various improvements to the apparatus for clearing mines described in the aforementioned U.S. patents.
There is thus provided in accordance with one preferred embodiment of the present invention mine clearing apparatus for attachment to a vehicle and comprising a frame mountable onto a vehicle for selectable positioning in a raised or lowered orientation; apparatus mounted onto the frame for raising and shunting aside mines; and apparatus operable from inside the vehicle for automatically raising the plow from its lowered orientation to its raised orientation independently of vehicle movement.
Further in accordance with the present invention, the apparatus for raising and shunting aside mines includes a plow section, the plow section defining a plurality of plow teeth which, in operation, extend below the ground surface, and first and second plow sections, disposed one above the other in hinged engagement and operative to lie in the same plane during operation and in folded engagement when the frame is in its raised orientation, so as not to interfere with normal tank operation. In addition, a segment of the plow section may be removable.
Still further in accordance with an embodiment of the present invention, each of the plurality of plow teeth defines an angled tip adapted to break through the crust of the earth to facilitate the plowing thereof.
Still further in accordance with a preferred embodiment, the apparatus for automatically raising includes an motor having a harmonic drive.
In accordance with an alternate preferred embodiment of the invention, the frame includes angled side portions mountable onto the vehicle and having a profile complementary to that of the vehicle and the apparatus for raising and shunting aside mines includes a pair of angled arms having a profile complementary to that of the frame and the vehicle.
Additionally in accordance with an embodiment of the invention, there is provided apparatus for clearing mines comprising a frame mountable onto a vehicle for selectable positioning in a raised or lowered orientation; apparatus mounted onto the frame for raising and shunting aside mines; and apparatus for selectably retaining the frame in a raised orientation and including raising apparatus operable from inside the vehicle for automatically raising the plow from its lowered orientation to its raised orientation; the selectably retaining apparatus including a hook member pivotably mounted onto the vehicle at a central location on the hook member and having a roller engaging slot at a first end thereof, an intermediate link pivotably coupled to the hook member at a second end thereof opposite to the first end with respect to the central location, an operating lever of elongate configuration, pivotably mounted at a first intermediate location therealong onto the vehicle and pivotably attached to the intermediate link at a second intermediate location along the operating lever, solenoid operated displacement apparatus disposed in contacting relationship with a first end of the operating lever adjacent the first intermediate location therealong, and a spring connection between the intermediate location adjacent its attachment to the operating lever and a fixed location with respect to the vehicle, the selectably retaining apparatus being operative to move from a roller retaining orientation to a roller releasing orientation as the second intermediate location crosses the line connecting the pivot mounting of the first intermediate location of the operating lever and the pivot mounting at the second end of the hook member.
Still further in accordance with an embodiment of the invention, the plow raising apparatus includes motor apparatus in driving engagement with a pulley, and belt apparatus affixed to the raising and shunting means and adapted for winding engagement about the pulley.
BRIEF DESCRIPTION OF THE DRAWINGS
The apparatus of the present invention will be further understood and appreciated from the following detailed description taken in conjunction with the drawings in which:
FIG. 1 is a top view illustration of mine clearing apparatus constructed and operative in accordance with an embodiment of the present invention;
FIG. 2 is a side view illustration of the apparatus of FIG. 1 in a lowered orientation;
FIGS. 3A and 3B are respective views of a locking mechanism forming part of the apparatus of FIGS. 1 and 2 in respective unlocked and locked orientations;
FIG. 4 is a side view illustration of a mine clearing apparatus constructed and operative in accordance with an alternate embodiment of the present invention, with the plow portion in a raised orientation;
FIG. 5 is an illustration of the mine clearing apparatus of FIG. 4 with the plow portion in a lowered orientation; and
FIG. 6 is a top view illustration of the mine clearing apparatus of FIGS. 4 and 5.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIGS. 1-3B which illustrate mine clearing apparatus constructed and operative in accordance with an embodiment of the present invention. The present description is presented with particular reference to mine clearing apparatus which is mountable onto two particular types of tank, the Centurion and the M-1. It is appreciated that this is entirely for the purpose of illustration and that the invention is applicable to other types of tanks and possibly other vehicles as well.
As seen in the illustrations, the mine clearing apparatus comprises a frame 10 including a pair of identical side portions 12 which support at their rear ends an axle 16. Frame 10 is rigidly mounted onto an armoured vehicle, such as a Centurion tank in the illustrated embodiment, by engagement of pins located at side portions 12 with towline lugs 13 fixed onto the tank. Rigidity of mounting is provided by tight engagement of force mounting plates 17, fixedly mounted onto side portions 12, with the underside hull of the tank. In addition, upper cross bar 18 is retained in engagement with the upper hull of the tank as by screws 20.
First and second Y-shaped arms 22 and 24 are independently rotatably mounted within tow hitches 14 of frame 10 onto axle 16 and extend forwardly thereof in generally parallel planes. It is a particular feature of the present invention that due to their shape and internal mounting, arms 22 and 24 are particularly strong, yet they will not cause axle 16 to bend. Thus, the device of the present invention has two advantages over prior art mine clearing apparatus: that separate reinforcing elements are not required to support the arms; and that the arms will not cause axle 16 to bend, as often occurred when the arms were mounted outside of side portions 12.
Rigidly mounted onto each of arms 22 and 24 is a mine plowing assembly 34. Mine plowing assembly 34 comprises main plow portion 36, of generally elongate configuration and concave cross section.
The general configuration of main plow portion 36 may be similar to that of an ordinary vehicle powered snow plow. Disposed above main plow portion 36 and hinged thereonto is an auxiliary plow portion 38. Auxiliary plow portion 38 has two positions, a lowered position in which it extends forwardly of the surface of main plow portion 36 and a raised position in which it defines an upper continuation of the surface of the main plow portion 36. This hinged construction is to obviate the problem of interference with a driver's field of vision or with the range of operation of the armament on the tank. Towards this end, the hinged auxiliary plow portion 38 may be lowered when the plowing assembly 34 is in its raised orientation.
It will be appreciated that in order to plow the mines as far from the tank as possible, it is desired to utilize a main plow section which extends beyond the treads of the tank. However, such elongated plow sections make it difficult to maneuver the mine clearing apparatus when it is travelling to and from the fields to be cleared. There is thus provided, in accordance with a preferred embodiment of the present invention, a truncated main plow section 36 and auxiliary plow section 38 and a removable outermost plow section 39 which can be manually bolted onto the end of the truncated plow section upon arrival to the field to be cleared.
Disposed below main plow portion 36 there are provided a plurality of vertically disposed planar plow teeth 40 which, during operation, are disposed below the ground surface. The horizontal spacing between adjacent vertical teeth is selected to be such that anti-vehicle mines will, of necessity, be engaged thereby. The teeth are provided with an inclined forward surface, so as to raise mines located under the ground surface into engagement with main plow portion 36, so that they may be plowed aside.
Each of plow teeth 40 is provided with an angled, pointed tip 41. Due to the small area of the tip 41, a great deal of pressure is concentrated thereon when the plow section is lowered to the ground. This forces tips 41 into the earth, even through hard, crusty earth, and initiates the plowing action. It is a particular feature of the present invention that unplowed areas due to the sliding of teeth 40 along crusty earth are thus avoided.
A desired depth of operation for teeth 40 is determined by means of a gliding surface assembly 42 which is articulatedly mounted onto each of arms 22 and 24. The gliding surface assembly 42 comprises a sled 44 which is arranged to slide on the ground surface and is formed at its front with a vertical blade 47 for deflecting mines to the side therof. Sled 44 is rotatably mounted onto a cam slot of a mounting plate 46. Mounting plate 46 is mounted in turn onto a mounting element 48. It is appreciated that sled 44 is permitted to undergo a somewhat complex articulated motion in a single plane within limits defined by the respective cam paths. This mounting arrangement permits selectable adjustment of the penetration depth of the plowing assembly 34 and also permits the sled 44 to be folded when the plowing assembly is in its raised orientation to eliminate interference with operation of the tank.
A chain 50 extends from each auxiliary plow portion 38 to a location on the tank hull or onto frame 10. The length of the chain 50 is selected such that it is slack when the plowing assembly is in its raised orientation but becomes tight when the plowing assembly is lowered, thus pulling on auxiliary plow portion 38 and orienting it towards a generally vertical orientation. The full raised orientation of the auxiliary plow portion 38 is reached only when soil being plowed is forced thereagainst.
An additional chain 52 is disposed at the inner facing edge 53 of each plowing assembly and extends from the lower inner corner of each plow portion 36 to a location 54 defined by the extreme forward facing portion of a bracket 56 disposed on auxiliary plow portion 38. When the plowing assembly is in a raised orientation and plow portions 36 and 38 are in relative folded orientation, the chain is slack and does not interfere with folding of the plow portions or with operation of the vehicle. When the plowing assembly is in its lowered operating orientation as seen in FIG. 2, chain 52 is taut and defines a barrier which prevents mines excavated by the plowing assembly from rolling or being directed inwardly of the inner facing edge of the plowing assembly into the region which is unprotected by the plowing assembly.
Reference is now made to FIGS. 3A and 3B which, together with FIGS. 1 and 2, illustrate apparatus for retaining the arms in their raised orientation and for selectable release thereof. A hook member 60 is pivotably mounted about an axis 62 onto each side portion 12 and comprises a socket portion 64 defining a roller retaining slot located at one end thereof and a lever portion 66 at another end thereof and having pivotably mounted thereon, at a pivot location 67, an intermediate member 68. A selectable release lever 70 is pivotably mounted onto each side portion 12 about an axis 72 and is pivotably mounted onto intermediate member 68 at a pivot location 74.
A spring 78 joins intermediate member 68 to a fixed location on each side portion 12. Spring 78 is affixed to intermediate member 68 adjacent pivot location 74 such that the spring tends to urge the lever 70 to remain in whichever position it is at the time. It is noted that spring 78 is an over-center type of arrangement which provides its indicated dual function.
An electrically activated displacement apparatus controlled from within the tank, such as a solenoid operated device 79, is provided such that displacement of a portion of lever 70 is operative to provide counter-clockwise movement of lever 70 about its pivot axis 72 (as seen in FIGS. 3A and 3B). A cable connection 80 may additionally be provided to the exterior of the vehicle such that pulling on the cable is also operative to provide counter-clockwise movement of lever 70. This provides a manual means of releasing lever 70 in the event of a malfunction of the electrical displacement apparatus. It is appreciated that the solenoid operated device may be replaced by any other suitable displacement means.
The operation of the apparatus described hereinabove will be understood from a consideration of FIGS. 3A and 3B. FIG. 3A shows a retainer roller 82 which is fixedly mounted onto each of arms 22 and 24 about to engage socket portion 64 and moving in an arc illustrated by an arrow 84. Engagement of roller 82 with a surface 86 of the socket portion forces the hook member to pivot in a clockwise direction about its pivot axis (in the sense of FIGS. 3A and 3B).
The clockwise movement of the hook member 60 causes lever portion 66 to rotate, also in a clockwise sense, and to raise intermediate member 68 causing reorientation of the intermediate member 68 and thus of lever 70 such that pivot location 74 crosses the imaginary line joining pivot locations 67 and 72. This over-center orientation is illustrated in FIG. 3B and provides a stable locking orientation of the retaining apparatus. Hook member 60 is thus prevented from counterclockwise rotation into an open orientation. Roller 82 is thus securely engaged by hook member 60 and arms 22 and 24 are maintained in their respective raised orientation, provided that lever 70 remains in the locked position (FIG. 3B).
When it is desired to lower arms 22 and 24 to their respective lowered, ground engaging orientations, it is sufficient to activate the electrical displacement means, here the solenoid device 79, from the safety of the driver's compartment. Displacement of the proper portion of lever 70 causes the lever to pivot in a counterclockwise direction and to draw pivot location 74 back across the imaginary line joining pivot locations 67 and 72. Once the pivot location 74 crosses this line, counterclockwise motion of hook member 60 is permitted in response to the force exerted by the weight of the plowing apparatus applied to roller 82. It is a particular feature of the illustrated construction that only a very small amount of movement of lever 70 is required for release of the plowing apparatus into its lowered orientation.
Hook member 60 is then free to rotate in a counterclockwise direction about its pivot location such that roller pin 82 is released, thus allowing arm 22 or 24, as the case may be, and the associated mine plowing assembly 34 to fall by gravity into their respective lowered orientations in engagement with the ground.
Reference is now made once again to FIGS. 1 and 2 which also illustrate apparatus for automatically lifing the mine plowing assembly. There is provided a motor 90 mounted upon each of side sections 12 which is activated from within the driver's compartment. Each motor 90 is mounted in driving relationship with a pulley 92 which is mounted on the respective side section 12. Belt means 94, preferably a nylon belt able to withstand a heavy load, is attached to pulley 92 in such a way as to be wound around pulley 92 when the pulley rotates. Belt means 94 is affixed at its other end to a belt retainer 96 on arm 22 or 24 as the case may be. In a particularly effective embodiment of the present invention, a nylon belt able to withstand a load of six and a half tons is looped through belt retainer 96 affixed to arm 22 or 24 and both ends of the belt are affixed to one another and fixedly attached to pulley 92. Alternatively, any other suitable belt material, a chain or a cable may be utilized.
According to a preferred embodiment of the present invention, the motor 90 incorporates an harmonic drive mechanism which operates as a reducer of rpm. It is a characteristic of such a motor that has no self-locking property. Thus, raising of the mine plowing assembly is accomplished by rotation of the motor, but lowering of the assembly is accomplished by the force of gravity and the weight of the assembly alone, without the need for operation of the motor. An example of such a motor is model C-15221 incorporating an harmonic drive model HDUC 65-260-2A, which comprises one rigid and one flexible toothed wheel coupled to a generator and mounted within a body member, provided by H.K. Porter Company, Inc., Electrical Division, of Warren, Ohio, U.S.A. It will be appreciated that any other electrically operated automatic lifting means may alternatively be employed, such as a hydraulic piston apparatus coupled to arm 22 or 24.
When it is desired to raise plow section 34 from its ground engaging orientation into the raised orientation, motor 90 is activated which causes pulley 92 to rotate. This, in turn, causes belt 94 to wind around pulley 92, thus shortening the distance between pulley 92 and arm 22 or 24 and raising the arm. Motor 90 continues to cause pulley 92 to rotate until roller 82 enters into locking engagement in hook member 60, as described above with reference to FIGS. 3A and 3B. In a preferred embodiment, a microswitch or other sensor is mounted in side section 12 such that it comes into touching engagement with lever 70 when lever 70 is in the fully locked position of FIG. 3B. The microswitch is adapted to deactivate motor 90 when the fully locked, raised orientaion is reached, thus causing pulley 92 to stop rotating.
In the event of an electrical malfunction, it is also possible to manually raise plow section 34 by means of an emergency chain which may be affixed temporarily at one end thereof to chain mount 98 on arm 22 or 24 and at the other end thereof to the treads of the tank such that backwards motion of the tank pulls the chain and raises the plow section into the locked, raised orientation.
It is noted that the plowing assembly engages the ground surface in the vicinity of the treads and outwardly thereof. In order to protect the intermediate portion of the tank from mine damage, a weighted chain 120 is mounted between the two plowing assemblies to engage and detonate any mines that are encountered at a safe distance from the tank.
It is appreciated that it is often desired that a narrower tank, such as an M-113, should be able to travel in the path cleared by the mine clearing apparatus of the present invention. Should this be the case, an additional interior tooth may be added to plow section 36 such that the path plowed will be slightly wider than the treads of the tank carrying the plow. It will be appreciated, however, that this will slow the rate of clearing of the mine clearing apparatus due to the extra power required to plow to the side the additional amount of earth.
Turning now to FIGS. 4 and 5, there is shown mine clearing apparatus constructed and operative in accordance with an alternate embodiment of the present invention. It will be appreciated by those skilled in the art that there are two important considerations for the mounting of mine plow apparatus onto a tank. First, the plow apparatus may not be mounted in such a position that it will reduce the ground clearance of the tank. Second, the approach angle (the angle defined by the ground and the treads rising along the lower front portion of the hull) should be maximized (or at least not severely reduced) to permit forward progress of the tank. At the same time, the mine plow apparatus must be mounted in such a way as to permit the widest range of movement of the barrel of the cannon, particularly in the earthward direction.
As can be seen from FIGS. 4 and 5, the hull of the M-1 has a different profile from that of the Centurion, and its towline lugs are affixed to the tank in a different location on the hull, i.e., further along the underside of the hull toward the rear of the tank. Were the mine clearing apparatus illustrated in FIGS. 1 and 2 mounted on an M-1 tank, the frame would not engage the hull of the tank as desired and the plow portion would tend to ride relatively close to the ground even in its raised orientation, drastically reducing the approach angle of the tank.
Accordingly, the mine clearing apparatus of FIGS. 4 and 5 comprises a frame 110 including a pair of identical angled side portions 112 which support at their rear ends an axle 116. Frame 110 is rigidly mounted onto the armoured vehicle, such as the illustrated M-1 tank, by engagement of pins located at the lower portion of the side portions 112 with towline lugs 113 fixed onto the tank. Rigidity of mounting is provided by tight engagement of the underside of the tank by mounting plates 117, fixedly mounted onto side portions 12. Mounting plates 117 are urged against the hull, for example, by screws 120. As can be seen from the illustrations, side portions 112 of frame 110 are angled so as to complement the shape of the tank profile, thus making possible tight engagement of the frame with the underside of the hull. First and second angled arms 122 are independently rotatably mounted within hitches of frame 110 onto axis 116 and extend forwardly thereof in generally parallel planes. As described above with reference to FIGS. 1 and 2, arms 122 are preferably Y-shaped for strength and to prevent bending of axle 116. It can be seen that arms 122 are also angled so as to partially complement the hull of the tank and the frame 110 in order to permit the plow portion to ride as close to the hull as possible while in the raised orientation.
Rigidly mounted onto each of arms 122 is a mine plowing assembly 134. Mine plowing assembly 134 is identical in all respects to the mine plowing assembly 34 of FIGS. 1 and 2 and may be raised and lowered in the same fashion.
It is a particular feature of this embodiment of the present invention that, due to the hull configuration of the tank and the complementary angling of the frame and arms, mine plow apparatus can be mounted on the tank without reducing the ground clearance of the tank and yet a particularly large approach angle is maintained for ease of travel. At the same time, the apparatus rides low enough not to interfere with the range of operation of the armament on the tank or the driver's field of vision.
It will be appreciated by those skilled in the art that the invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the invention is limited only by the claims which follow. | Mine clearing apparatus for attachment to a vehicle and comprising a frame mountable onto a vehicle for selectable positioning in a raised or lowered orientation; apparatus mounted onto the frame for raising and shunting aside mines; and apparatus operable from inside the vehicle for automatically raising the plow from its lowered orientation to its raised orientation independently of vehicle movement. The frame may include angled side portions mountable onto the vehicle and having a profile complementary to that of the vehicle and the apparatus for raising and shunting aside mines includes a pair of angled arms having a profile complementary to that of the frame and the vehicle. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to novel monoclonal antibodies reactive with lipid transfer proteins typically found in foaming beverages. More specifically, the present invention relates to novel monoclonal antibodies raised against the native and denatured forms of barley lipid transfer protein 1, and an assay for determining the content of said proteins in foaming beverages at various stages of their production.
Foaming beverages, e.g. beer and some soft drinks, are popular items in today's marketplace. In addition to taste, the appearance of the beverage and its ability to form a stable head of foam when poured are important characteristics. In beer, the foam head is one of the first characteristics that a consumer generally uses to judge beer quality.
Foam formation and retention are two factors considered when defining foam quality. The rate at which the foam head forms and collapses depends upon, among other things, the composition of the beer.
Several different beer and foam proteins have been suggested to be important in foam formation and head retention. One such protein is the lipid transfer protein found in cereal grains. In particular, several different studies have analyzed the lipid transfer protein from barley and have shown that its presence in beer exhibits a positive effect on foam formation and stability. Evans and Hejgaard, “The Impact of Malt Derived Proteins on Beer Foam Quality. Part I: The Effect of Germination and Kilning on the Level of Protein Z4, Protein Z7, and LTP1 ”, J. Inst. Brewing , 105:3:159-169 (1999); Evans et al., “The Impact of Malt Derived Proteins on Beer Foam Quality. Part I: The Influence of Malt-positive Proteins and Non-starch Polysaccharides on Beer Foam Quality”, J. Inst. Brewing , 105:2:171-177 (1999); Lusk et al., “Foam tower fractionation of beer proteins and bittering acids,” European Brewery Convention Beer Foam Quality Symposium (Amsterdam, Oct. 25-27, 1998); Bock et al., “New Analytical Techniques with Relevance for the Brewing Industry”, Brygmesteren , 54(5):47-55 (1997); Lusk et al., “Independent role of beer proteins, melanoidins and polysaccharides in foam formation,” J. Am. Soc. Brew. Chem ., 53(3):93-103 (1995); Sorenson et al., “Barley Lipid Tranfer Protein 1 is Involved in Beer Foam Formation”, MBAA Tech. Quarterly , 30:136-145 (1993).
Two members of the lipid transfer protein gene family are expressed in barley grain, LTP1 and LTP2. Of the two proteins, only LTP1 is found in beer (see, Evans and Hejgaard, supra). LTP1 is an albumin protein primarily expressed in the aleurone layer of the barley seed. It has a molecular weight of 9,694 Daltons and contains 91 amino acid residues, including 8 cysteines. The amino acid sequence of LTP1 is set forth in SEQ ID NO:1. Studies by Bock et al., supra, have shown that LTP1 is modified during the malting and brewing process to a denatured form (fLTP). It is this denatured form that is believed to effect foam formation and stability.
Other studies have suggested that other proteins and polypeptides are important in foam formation and stability. In particular, it has been suggested that beer and foam proteins of a molecular weight greater than 5,000 Dalton tend to be foam-positive, while polypeptides of molecular weights below 5,000 Dalton tend to be foam-negative. For example, studies by Sharpe et al. have suggested that head retention was related to the ratio of high and low molecular weight polypeptides. (Sharpe et al., “Rapid methods of measuring the foam-active nitrogenous components of worts and beers”, Proc. Eur. Brewing Conv .: 18 th Cong ., 607-614 (1981)). Meanwhile, Yokoi, et al, has suggested that protein Z, a 40,000 Dalton barley albumin, plays the most significant role in foaming and head retention (Yokoi et al., “Characterization of beer proteins responsible for the foam of beer”, Proc. Eur. Brewing Conv .: 22 nd Cong ., 503-512 (1989)). On the other hand, Kauffman et al. has suggested that the prolamin storage proteins of barley, called hordeins, are also important in foam formation and stability (Kauffman et al., “Immunological Characterisation of Barley Polypeptides in Lager Foam”, J. Sci. Food Agric ., 66:345-355 (1994)).
Most of the above conclusions have resulted from investigations generally involving the fractionation of beer proteins and a determination of their foaming effect. More recently, there has been considerable interest in tracing the origin of foam proteins using immunological methods. Polyclonal antibodies against barley, malt, beer and yeast proteins have been developed and used in these studies. For example, Hollemans and Tonies used polyclonal antibodies to remove polypeptides from beer to establish their effect on foaming (Hollemans and Tonies, “The role of specific proteins in beer foam”, Proc. Eur. Brew. Conv .: 22 nd Cong ., 561-568 (1989)); Ishibashi et al., used polyclonal antibodies to analyze both foam and haze proteins in beer (Ishibashi et al., “Development of a new method for determining beer foam and haze proteins by using the immunochemical method ELISA”, J. Am. Soc. Brew. Chem ., 54(3):177-18)); and Bech et al. used polyclonal antibodies to determine the concentration of LTP1 in wort, beer, and barley and malt extracts from several different barley varieties (EP 0728188). The information obtained using polyclonal antibodies, however, is partly limited due to problems of polyspecificity resulting from the presence of immunodominant repetitive hordein sequences (Mills et al., “Immunological Study of Hydrophobic Polypeptides in Beer”, J. Agric. Food Chem ., 46:4475-4483 (1998)). Accordingly, more exact methods for performing immunological studies on beer and foam proteins are needed.
Monoclonal antibodies have been employed in some cases to avoid the problems associated with the use of polyclonal antibodies. For example, Kaufman et al., supra, has reported the use of monoclonal antibodies against wheat prolamins to study hordein-type material found in beer and foam fractions. Sheehan and Skerritt have also used monoclonal antibodies to examine modifications of hordeins during beer production (Sheehan and Skerritt, “Identification and Characterisation of Beer Polypeptides Derived from Barley Hordeins”, J. Inst. Brew ., 103:297-306 (1997)). Mills et al. have reported the creation of a monoclonal library to beer proteins and polypeptides believed to be derived from the hordeins in malts (Mills et al., “Immunological Study of Hydrophobic Polypeptides in Beer”, J. Agric. Food Chem ., 46:4475-4483 (1998)). Meanwhile, European Patent 0863153 by Ishibashi et al., and Kukai et al., “Development of Monoclonal Antibody Sandwich-ELISA for Determination of Beer Foam-Active Proteins”, J.Am. Soc. Brew. Chem ., 56(2):43-46 (1998), both report the production and use of monoclonal antibodies in ELISA experiments directed against foam-active proteins having molecular weights between 40 and 50 kDa.
With respect to the lipid transfer proteins, only a single monoclonal antibody disclosed by Dickie has been reported (Dickie, “Immunological Determination of Foam-Positive Hydrophobic Polypeptides in Barley and the Effects of Malting”, BRI Quarterly , 15-18 (October, 1997)). This antibody, identified as IFRN 1625, recognizes a ca. 8 kDa polypeptide found in Group 5 foam fractions, and is believed to be one of the proteins involved in lipid transfer. Dickie postulates that this 8 kDA polypeptide originates from LTP1 but presents no evidence to support this hypothesis.
What is needed is a set of monoclonal antibodies exhibiting specificity against lipid transfer proteins in either their native or modified forms. What is also needed is an assay capable of measuring and characterizing the content of native and denatured lipid transfer proteins in foaming beverages during various stages of their production process.
BRIEF SUMMARY OF THE INVENTION
The present invention is summarized in that novel monoclonal antibodies against the native and denatured forms of barley lipid transfer protein 1 have been isolated.
The present invention includes monoclonal antibodies against the native form of barley lipid transfer protein 1 (LTP1). The first LTP1 antibody, identified as 3F7.1, has very strong reactivity to LTP1, no reactivity to fLTP and no reactivity to Protein. Z. Epitope mapping performed with 3F7.1 shows reactivity to amino acid sequences SEQ ID NO:14 and SEQ ID NO:15. The second LTP1 antibody, identified as 2C12.1 has very strong reactivity to LTP1, no reactivity to fLTP, and no reactivity to Protein Z. Epitope mapping performed with 2C12.1 shows reactivity to amino acid sequences SEQ ID NO:14 and SEQ ID NO:15, and a low level of reactivity to LTP1 amino acid sequences SEQ ID NO:10 and SEQ ID NO:11. The third LTP1 antibody, identified as 3G1.1, has strong reactivity to LTP1, no reactivity to fLTP, and no reactivity to Protein Z. Epitope mapping performed with 3G1.1 shows reactivity to amino acid sequences SEQ ID NO:4, SEQ ID NO:5, and SEQ ID NO:6.
The present invention also includes monoclonal antibodies against the denatured form of barley lipid transfer protein 1 isolated from beer foam (fLTP). The first fLTP antibody, identified as 3D1.1, has strong reactivity to fLTP, some reactivity to LTP1, and no reactivity to Protein Z. Epitope mapping performed with 3D1.1 shows strong reactivity to amino acid sequences SEQ ID NO:2, SEQ ID NO:3, and SEQ ID NO:4. The second fLTP antibody, identified as 2E3.1 has strong reactivity to fLTP, no reactivity to LTP1, and some unconfirmed reactivity to Protein Z. Epitope mapping performed with 2E3.1 shows reactivity to amino acid sequences SEQ ID NO:16 and SEQ ID NO:17. The third fLTP antibody, identified as 3D11.1, has weak reactivity to fLTP, no reactivity to LTP1, and no reactivity to Protein Z. Epitope mapping performed with 3D11.1 shows reactivity to amino acid sequences SEQ ID NO:4 and SEQ ID NO:5, and a low level of reactivity to SEQ ID NO:11, SEQ ID NO:12, SEQ ID NO:13, and SEQ ID NO:14.
In another embodiment, the present invention includes a kit comprising at least one LTP1 or fLTP antibody. In yet another embodiment, the present invention includes a kit comprising at least one LTP1 antibody and at least one fLTP antibody. In addition to the said antibodies, the kits may further comprise a 96-well plate, a sample-adsorbing buffer, a washing solution, a blocking solution, a substrate solution, a dilution of a secondary antibody and a calibration graph.
It is an object of the present invention to provide monoclonal antibodies useful in determining the content of both native lipid transfer proteins and denatured lipid transfer proteins in a foaming beverage during and after the beverage production process.
It is another object of the present invention to provide monoclonal antibodies that bind to native lipid transfer proteins and not denatured lipid transfer proteins.
It is another object of the present invention to provide monoclonal antibodies that bind to denatured lipid transfer proteins and not native lipid transfer proteins.
It is another object of the present invention to provide monoclonal antibodies that do not bind to protein Z.
It is one advantage of the present invention that foaming beverages can now be assayed to determine both the native lipid transfer protein content and the denatured lipid transfer protein content during various stages of the beverage production process.
Other objects, features and advantages of the present invention will become apparent after examination of the specification, claims and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an epitope map for LTP1 antibodies 2C12.1 and 3F7.1
FIG. 2 is an epitope map for LTP1 antibodies 1A3.1, 1D4.1, 1F3.1 and 3A11.1.
FIG. 3 is an epitope map for LTP1 antibody 3G1.1.
FIG. 4 is an epitope map for fLTP antibodies 1A1.1 and 3D11.1
FIG. 5 is an epitope map for fLTP antibody 3D1.1
FIG. 6 is an epitope map for fLTP antibodies 2E3.1, 1G10.1, 2C1.1 and 1H2.1
FIG. 7 is an epitope map for fLTP antibodies 3H7.1, 3G2.1 and 3F1.1
FIG. 8 is a protein Z epitope map for fLTP antibodies 3F1.1.
FIG. 9 is a protein Z epitope map for fLTP antibodies 2E3.1.
FIG. 10 is a protein Z epitope map for fLTP antibodies 1G10.1.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, novel monoclonal antibodies against the native barley lipid transfer protein 1 (LTP1) and the denatured form of barley lipid transfer protein 1 (fLTP) are disclosed. Also disclosed is an immunoassay using said monoclonal antibodies.
The LTP1 and fLTP antibodies of the present invention can be used to isolate, measure and characterize the lipid transfer protein to which they bind. These proteins may include, without limitation, those proteins and polypeptides from plants which have a binding region specific to the antigen-binding region of the monoclonal antibodies of the present invention. For example, such proteins may include the lipid transfer proteins from cereal grains and, in particular, the lipid transfer protein from barley.
The monoclonal antibodies of the present invention can be produced using well-established hybridoma techniques first introduced by Kohler and Milstein (see, Kohler and Milstein, “Continuous Cultures of Fused Cells Secreting Antibody of Pre-Defined Specificity”, Nature , 256:495-97 (1975)). These techniques involve the injection of an immunogen (e.g., cells or cellular extracts carrying the antigen or purified antigen) into an animal (e.g., mouse) so as to elicit a desired immune response in that animal. After a sufficient time, antibody-producing lymphocytes are obtained from the animal either from the spleen, lymph nodes or peripheral blood. Preferably, lymphocytes are obtained from the spleen. The splenic lymphocytes are then fused with a myeloma cell line, usually in the presence of a fusing agents such as polyethylene glycol (PEG). Any number of myeloma cell lines may be used as a fusion partner according to standard techniques. For example, one such myeloma cell line may include Sp2/0-Ag14 myeloma, non-secreting, mouse cell line (ATCC CRL 1581).
The resulting cells, which include the desired hybridomas, are then grown in a selective medium, such as HAT medium. In this medium, only successfully fused hybridoma cells survive while unfused parental myeloma or lymphocyte cells die. The surviving cells are then grown under limiting conditions to obtain isolated clones and their supematents screened for the presence of antibodies having a desired specificity. Positive clones may then be subcloned under limiting dilution conditions and the desired monoclonal antibodies isolated. Hybridomas produced according to these methods can be propagated in vitro or in vivo (in ascites fluid) and purified using common techniques known in the art. Methods for purifying monoclonal antibodies include ammonium sulfate precipitation, ion exchange chromatography, and affinity chromatography (see, e.g., Zola et al., “Techniques for the Production and Characterization of Monoclonal Hybridoma Antibodies”, in Monoclonal Hybridoma Antibodies: Techniques and Applications , pp. 51-52 (Hurell, ed., CRC Press, 1982)).
Once purified monoclonal antibodies are obtained, epitope mapping may be performed to determine which peptide segment (or antigen-binding region) of the protein is recognized by each particular antibody. The purpose for the epitope mapping is to have a well characterized monoclonal antibody. Ideally, monoclonal antibodies with different specificity to the same protein can be prepared so that researchers have probes for different parts of the protein under investigation.
The monoclonal antibodies of the present invention were produced via the hyridoma techniques described in the examples below using an Sp2/0-Ag14 myeloma, non-secreting, mouse cell line (ATCC CRL 1581). The hybridomas producing the monoclonal antibodies of the present invention were deposited with the American Type Culture Collection (ATCC), 10801 University Blvd., Manassa, Va. 20110-2209, on Sep. 15, 2000 and their monoclonal antibodies are identified as follows:
LTP1 antibody 3F7.1 (ATCC Accession No. PTA-2475)
The LTP1 antibody 3F7.1 displays a high specificity to LTP1 and no reactivity to fLTP or protein Z. Epitope mapping performed with LTP1 antibody 3F7.1 against linear peptide sequences from barley lipid transfer protein 1 exhibited reactivity with amino acid sequence LNLNNAASIPSKCNVNV (SEQ ID NO:14) and amino acid sequence AASIPSKCNVNVPYTIS (SEQ ID NO:15), encompassing one of LTP1's four alpha helices.
LTP1 antibody 2C12.1 (ATCC Accession No. PTA-2472),
The LTP1 antibody 2C 12.1 displays a high specificity to LTP1 and no reactivity to fLTP or protein Z. Epitope mapping performed with LTP1 antibody 2C12.1 against linear peptide sequences from barley lipid transfer protein 1 exhibited reactivity with amino acid sequence LNLNNAASIPSKCNVNV (SEQ ID NO:14) and amino acid sequence AASIPSKCNVNVPYTIS (SEQ ID NO:15), encompassing one of LTP1's four alpha helices. LTP1 antibody 2C12.1 also exhibited a lesser level of reactivity to amino acid sequence SGDRQTVCNCLKGIARG (SEQ ID NO:10) and amino acid sequence TVCNCLKGIARGIHNLN (SEQ ID NO:11), and possible reactivity with amino acid sequence LNCGQVDSKMKPCLTYV (SEQ ID NO:2), amino acid sequence KPCLTYVQGGPGPSGEC (SEQ ID NO:4), and amino acid sequence YVQGGPGPSGECCNGVR (SEQ ID NO:5).
LTP1 antibody 3G1.1 (ATCC Accession No. PTA-2476)
The LTP1 antibody 3G1.1 displays a high specificity to LTP1 and no reactivity to fLTP or protein Z. Epitope mapping performed with LTP1 antibody 3G1.1 against linear peptide sequences from barley lipid transfer protein 1 exhibited reactivity with amino acid sequence KPCLTYVQGGPGPSGEC (SEQ ID NO:4), amino acid sequence YVQGGPGPSGECCNGVR (SEQ ID NO:5), amino acid sequence PGPSGECCNGVRDLHNQ (SEQ ID NO:6), and amino acid sequence ECCNGVRDLHNQAQSSG (SEQ ID NO:7).
fLTP antibody 3D1.1 (ATCC Accession No. PTA-2473)
The fLTP antibody 3D1.1 displays a high specificity to fLTP, some LTP1 cross-reactivity, no cross-reactivity to protein Z, and no cross-reactivity with LTP1 when conjugated with alkaline phosphatase. Epitope mapping performed with fLTP antibody 3D1.1 against linear peptide sequences from barley lipid transfer protein 1 exhibited reactivity with amino acid sequence LNCGQVDSKMKPCLTYV (SEQ ID NO:2), amino acid sequence VDSKMKPCLTYVQGGPG (SEQ ID NO: 3), and amino acid sequence KPCLTYVQGGPGPSGEC (SEQ ID NO:4), which encompasses the N-terminus of the barley lipid transfer protein.
fLTP antibody 2E3.1 (ATCC Accession No. PTA-2474)
The fLTP antibody 2E3.1 displays a high specificity with fLTP and no LTP1 cross reactivity. Protein Z cross-reactivity was found by ELISA but was not confirmed by epitope mapping. Epitope mapping performed with fLTP antibody 2E3.1 against linear peptide sequences from barley lipid transfer protein 1 exhibited reactivity with amino acid sequence SKCNVNVPYTISPDIDC (SEQ ID NO:16) and amino acid sequence VNVPYTISPDIDCSRIY (SEQ ID NO:17), encompassing the LTP1's C-terminus.
fLTP antibody 3D11.1 (ATCC Accession No. PTA-2477).
The fLTP antibody 3D11.1 displays weak fLTP reactivity, but no cross reactivity to LTP1. Furthermore, fLTP antibody 3D11.1 shows no cross-reactivity to other types of foam proteins such as protein Z. Epitope mapping performed with fLTP antibody 3D11.1 against linear peptide sequences from barley lipid transfer protein 1 exhibited reactivity to amino acid sequence KPCLTYVQGGPGPSGEC (SEQ ID NO:4), amino acid sequence YVQGGPGPSGECCNGVR (SEQ ID NO:5). Additionally reactivity was observed towards amino acid sequence TVCNCLKGIARGIHNLN (SEQ ID NO:11), amino acid sequence LKGIARGIHNLNLNNAA (SEQ ID NO:12), amino acid sequence RGIHNLNLNNAASIPSK (SEQ ID NO:13), and amino acid sequence LNLNNAASIPSKCNVNV (SEQ ID NO:14). It is believed that this antibody may have reactivity toward an intermediate between native LTP1 and the denatured fLTP.
The term “LTP1 antibody” as used herein includes whole, intact monoclonal antibody materials such as the 3F7.1, 2C12.1, and 3G1.1 monoclonal antibodies described above. The LTP1 antibody also includes any fragments prepared therefrom containing the active antigen-binding region of such antibodies, using techniques well established in the art.
Likewise, the term “fLTP antibody” as used herein includes whole, intact monoclonal antibody materials such as the 3D1.1, 2E3.1, and 3D11.1 monoclonal antibodies described above. The fLTP antibody also includes any fragments prepared therefrom containing the active antigen-binding region of such antibodies, using techniques well established in the art.
In addition, the present invention encompasses antibodies that are capable of binding to the same antigenic determinant as either the LTP1 or fLTP antibodies and competing with the antibodies for binding at that site. These include antibodies having the same antigenic specificity as either the LTP1 or fLTP antibodies but differing in species origin, isotype, binding affinity or biological functions. For example, it is known that other plants, and in particular cereal grains, possess a lipid transfer protein homologous to the barley lipid transfer protein (see, Bech et al., EP 0728188B1, filed Aug. 11, 1994). These plants include, without limitation, almond, apple, apricot, Arabidopsis, bell pepper, carrot, castor bean, cauliflower, chickpea, cotton, Indian finger millet, kidney bean, Loblolly pine, maize, pea, peach, rape, rice, sorghum, spinach, sugar beet, sunflower, tobacco, and tomato.
The monoclonal antibodies of the present invention can be used to determine foam protein contents in final beer products and beer samples during the brewing process using an immunoassay. The immunoassay which may be employed includes, without limitations, radioimmunoassay, enzyme immunoassay, fluoroimmunoassaay, luminescent immunoassay, and turbidimetric immunoassay, among others. In particular the enzyme-linked immunosorbent assay (ELISA) is preferred because it provides highly sensitive detection and the automatic determination of a number of samples.
According to ELISA, a monoclonal antibody of the present invention is first immobilized as a primary antibody on a support. The support is preferably a solid support, for example, in the form of a container such as an ELISA plate molded from a polymer such as styrene or polystyrene. Immobilization of the monoclonal antibody on a support can be accomplished by, for example, adsorbing the monoclonal antibody dissolved in a buffer such as carbonate or borate buffer to the support. A polyclonal antibody may then be used as a secondary antibody to perform sandwich ELISA. Alternatively, foam proteins can be detected more reliably and exactly by applying sandwich ELISA using one of the monoclonal antibodies of the present invention as a primary antibody and a different monoclonal antibody as a secondary antibody, as described in the examples below.
The present invention also encompasses kits for carrying out the assays. The kit may comprise at least one LTP1 antibody and/or at least one fLTP antibody, or fragments thereof; a conjugate comprising a specific binding partner for the LTP1 antibody and/or fLTP antibody; and a label capable of producing a signal. Reagents may include ancillary agents such as buffering agents and protein stabilizing agents (e.g., polysaccharides). The kit may further comprise, when necessary, other components of the signal-producing system including agents for reducing background interference, control reagents, or an apparatus or container for conducting the test. In another embodiment, the kit comprises at least one LTP1 antibody and at least one fLTP antibody. Ancillary agents as mentioned above can also be present.
Because there may exist some homology between the lipid transfer proteins of various plant species, it is envisioned that the LTP1 or fLTP antibodies may also be useful in immunoassays directed at isolating, measuring, or characterizing the lipid transfer proteins from such plants. For example, cereal grains such as maize, rice, and wheat are also used to produce beer. Accordingly, the LTP1 and/or fLTP antibodies of the present invention may be useful in immunoassays directed at determining the LTP1 and/or fLTP content of such beers during various stages of their production. In addition, it is also envisioned that the LTP1 or fLTP antibodies may also find use in measuring the presence and levels of certain lipid transfer proteins (e.g., apple and peach) believed to be food allergens.
The nonlimiting examples that follow are intended to be purely illustrative.
EXAMPLES
Preparation of LTP1 and fLTP Monoclonal Antibodies
Monoclonal antibodies were successfully prepared against the native form of barley lipid transfer protein 1 (LTP1) and the denatured form of barley lipid transfer protein 1 isolated from beer foam (fLTP), using balb/c mice inoculated with solutions of purified LTP1 or fLTP. The purified solutions of LTP1 or fLTP were first prepared in 1 mg/ml aliquots using a 1×DPBS buffer. An aluminum hydroxide adjuvant (Superfos Biosector) was then added to 0.02% v/v and balb/c mice inoculated. Inoculation was performed by injecting new or previously immunized balb/c mice (at least 8 week old mice) with 200 ug of either the LTP1 solution or the fLTP solution on days 1, 7, 8, and 9. Inoculated mice were then sacrificed on day 10 and their splenocytes isolated.
The splenocytes isolated from the sacrificed mice were then fused with sp2/0 mouse myeloma cells using the method described by Oi and Herzenberg, “Selected methods in Cellular Immunology,” pp. 357-359 (B. B. Mishell and S. Shigii (eds.) Freeman & Co., San Francisco, Calif. 1977). Successful fusion growth was selected for using azaserine (Sigma) in OPI-HT (Sigma) complete conditioned media with balb/c mouse feeder cells. Of the successfully fused myeloma cells, eighteen LTP1 antigen specific hybridoma clones and twenty fLTP antigen specific hybridoma clones were identified using enzyme-linked immunosorbent assays (ELISA). From these clones, monoclonal hybridomas were produced by infinity dilution subcloning and screened by ELISA.
Enzyme-Linked Immunosorbent Assays (ELISA)
The eighteen hybridoma clones to LTP1 and the twenty hybridoma clones to fLTP were analyzed using the ELISA method to determine their cross-reactivity to LTP1, fLTP and Protein Z. 96 well ELISA plates were coated overnight with fLTP, LTP1, protein Z, or recombinant human interferon gamma (negative control) antigen at 1 ug/well. The ELISA plates were blocked with 10% nonfat dry milk in 1×DPBS buffer for one hour and washed thoroughly. Specific antibody supemates were then added to the appropriate wells for 2 hours, followed by thorough washing. Alkaline Phosphatase conjugated Goat antimouse antibody (Sigma) specific to mouse IgG was added at 1:1000 dilution and allowed to incubate at room temperature for 1 hour. The plates were then thoroughly washed, and 50 ul of Sigma 104 color substrate (p-nitrophenyl phosphate, disodium, hexahydrate) was added for 2 hours (color development also occurs when the color substrate is 5-bromo-4 chloro-3-indolyl phosphate (BluePhos™, Kirkegaard & Perry Laboratories, Gaithersburg, Md.). 50 ul of IN NaOH was then added to stop color development and the ELISA plates were analyzed at 405 nm using an ELISA plate reader.
TABLE 1
ELISA reactivity and cross-reactivity date for LTP1 Antibodies
LTP1 Clone
LTP1
fLTP
Protein Z
rH IFN Map
1A3.1
1.116
0.261
0.242
0.169
1C3.1
1.413
0.397
0.363
0.239
1D4.1
1.068
0.144
0.237
0.219
1D6.1
0.188
0.231
0.211
0.247
1F3.1
1.698
0.195
0.208
0.14
2B2.1
1.401
0.204
0.242
0.134
2C12.1
1.432
0.192
0.173
0.201
2D2.1
1.16
0.288
0.262
0.198
2G6.1
1.173
0.305
0.257
0.226
2H1.1
1.186
0.279
0.417
0.217
3A9.1
1.624
0.241
0.177
0.118
3A11.1
1.476
0.142
0.14
0.111
3D10.1
1.452
0.202
0.14
0.149
3F7.1
1.544
0.162
0.187
0.203
3G1.1
1.018
0.245
0.274
0.165
3H4.1
1.331
0.19
0.252
0.162
3H7.1
1.567
0.244
0.302
0.189
4F5.1
1.851
0.213
0.218
0.186
4G1.1
0.174
0.166
0.207
0.103
TABLE 2
ELISA reactivity and cross-reactivity date for fLTP Antibodies
fLTP Clone
LTP1
fLTP
Protein Z
rH IFN Map
1A.1
0.279
0.429
0.215
0.189
1A3.1
0.191
0.547
0.292
0.871
IG10.1
0.573
1.615
1.033
0.198
1H2.1
0.841
1.414
0.396
0.245
1H4.1
0.441
1.364
0.812
0.273
1H6.1
0.132
0.825
0.385
0.095
1H7.1
1.292
1.515
1.55
0.77
2A1.1
0.521
1.759
0.91
0.114
2C1.1
0.702
1.684
0.233
0.096
2E3.1
0.13
1.56
0.45
0.073
2G9.1
0.158
1.611
0.767
0.078
2H6.1
0.84
0.97
1.113
0.85
2H12.1
0.111
0.711
0.342
0.083
3B11.1
0.393
1.473
0.563
0.161
3D1.1
0.495
1.543
0.162
0.099
3D11.1
0.186
0.429
0.176
0.146
3F1.1
0.135
0.555
0.688
0.091
3G2.1
0.099
0.408
0.13
0.088
3H3.1
0.116
0.405
0.492
0.118
3H7.1
0.105
0.402
0.124
0.089
Epitope Mapping
Epitope mapping was performed with seven LTP1 antibodies and ten fLTP antibodies from LTP1 and fLTP hybridoma clones selected based upon their ELISA reactivity and cross reactivity data. Epitope mapping was performed using Chiron's Multipin™ synthesis technology and Pepset™ peptide libraries for both barley lipid transfer protein 1 (LTP1) and protein Z. The amino acid sequence for LTP1 is set forth in SEQ ID NO:1. The amino acid sequences for the epitope peptides used for the mapping procedure are set forth in SEQ ID NOS:2-17. Epitope mapping was carried out by the method recommended by Chiron Technologies. Geysen et al., “Strategies for epitope analysis using peptide synthesis,” J. Immunol. Methods , 102:259-274 (1987).
The LTP1 monoclonal antibodies gave epitope maps with lower absorbance values than the fLTP mapos. It is believe that this is because the Chiron immobilized PepSets employ linear peptides and the LTP1 antibodies were searching for 3D structures.
FIGS. 1, 2 and 3 illustrate the epitope profiles of the seven LTP1 antibodies selected for epitope mapping. Six of the seven LTP1 antibodies (2C12.1, 3F7.1, 1A3.1, 1D4.1, 1F3.1, and 3A11.1) gave similar profiles with the greatest response to peptide 13 (SEQ ID NO: 14) and peptide 14 (SEQ ID NO:15). FIGS. 1 and 2. These two peptides encompass one of the LTP1's four alpha helices. FIG. 1 depicts the epitope map for LTP1 antibodies 2C12.1 and 3F7.1. As illustrated, LTP1 antibody 2C12.1 exhibited reactivity with peptides 13 and 14, and lesser reactivity with peptides 9 and 10 (SEQ ID NOS: 10 and 11), and possible reactivity with peptides 1, 3 and 4 (SEQ ID NOS: 2, 4 and 5).
The profile for the seventh LTP1 antibody (3G1.1) is depicted in FIG. 3, which shows strong reactivity with peptide sequences 3-6 (SEQ ID NOS:4-7). The map for this last LTP1 antibody was noted to be similar to the fLTP map of 1A1.1 and a portion of the fLTP map of 3D11.1. FIG. 4 . Accordingly, it was deduced that LTP1 antibody 3G1.1 may not be toward a truly native structure, but an intermediate protein between the native and denatured states.
FIGS. 4, 5 , 6 , and 7 , illustrate the epitope profiles of the ten fLTP antibodies selected for epitope mapping. FIG. 4 depicts the epitope map for fLTP antibodies 1A1.1 and 3D11.1. As indicated above, this map was very similar to the epitope map for LTP1 antibody 3G1.1. Unlike LTP1 antibody 3G1.1, fLTP antibodies are most certainly not toward native LTP1, but are directed against LTP1 in its denatured state. The fLTP map for 3D11.1 has the same points of similarity as 1A1.1, but also reacts strongly with peptides 10-13 (SEQ ID NOS:11-14). Accordingly, it was deduced that fLTP antibody 3D11.1 probably contained at least two clones or, in the alternative, has reactivity towards an intermediate LTP1 conformation.
FIG. 5 depicts the epitope map for fLTP antibody 3D1.1. As illustrated in FIG. 5, fLTP antibody 3D1.1 reacted very strongly with peptides 1-3 (SEQ ID NO:2-4). Peptides 1-3 encompass the N-terminus of LTP1 in its denatured form.
FIG. 6 depicts the epitope map for fLTP antibodies 2E3.1, 1G10.1, 2C1.1, and 1H2.1. These four fLTP antibodies reacted strongly with the C-terminus peptides 15 and 16 (SEQ ID NO: 5 and 6).
FIG. 7 depicts the epitope map for fLTP antibodies 3H7.1, 3G2,1 and 3F1.1. These three fLTP antibodies reacted poorly with all of the peptide sequences.
Maps were also made of the cross reactivity of fLTP antibodies prepared to protein Z. FIGS. 8, 9 , 10 depict the epitope map for these fLTP antibodies. As illustrated, fLTP clone 2E3.1 showed no cross reactivity, while fLTP antibodies 3F1.1 and 1G10.1 showed some cross-reactivity for protein peptides 37-39.
Taken together, these results indicate that monoclonal antibodies specific to either LTP1 or fLTP have been purified and isolated. Accordingly, monoclonal antibodies capable of use in immunoassays to determine the content of native and denatured barley lipid transfer protein have been obtained.
17
1
91
PRT
Hordeum vulgare
1
Leu Asn Cys Gly Gln Val Asp Ser Lys Met Lys Pro Cys Leu Thr Tyr
1 5 10 15
Val Gln Gly Gly Pro Gly Pro Ser Gly Glu Cys Cys Asn Gly Val Arg
20 25 30
Asp Leu His Asn Gln Ala Gln Ser Ser Gly Asp Arg Gln Thr Val Cys
35 40 45
Asn Cys Leu Lys Gly Ile Ala Arg Gly Ile His Asn Leu Asn Leu Asn
50 55 60
Asn Ala Ala Ser Ile Pro Ser Lys Cys Asn Val Asn Val Pro Tyr Thr
65 70 75 80
Ile Ser Pro Asp Ile Asp Cys Ser Arg Ile Tyr
85 90
2
17
PRT
Hordeum vulgare
2
Leu Asn Cys Gly Gln Val Asp Ser Lys Met Lys Pro Cys Leu Thr Tyr
1 5 10 15
Val
3
17
PRT
Hordeum vulgare
3
Val Asp Ser Lys Met Lys Pro Cys Leu Thr Tyr Val Gln Gly Gly Pro
1 5 10 15
Gly
4
17
PRT
Hordeum vulgare
4
Lys Pro Cys Leu Thr Tyr Val Gln Gly Gly Pro Gly Pro Ser Gly Glu
1 5 10 15
Cys
5
17
PRT
Hordeum vulgare
5
Tyr Val Gln Gly Gly Pro Gly Pro Ser Gly Glu Cys Cys Asn Gly Val
1 5 10 15
Arg
6
17
PRT
Hordeum vulgare
6
Pro Gly Pro Ser Gly Glu Cys Cys Asn Gly Val Arg Asp Leu His Asn
1 5 10 15
Gln
7
17
PRT
Hordeum vulgare
7
Glu Cys Cys Asn Gly Val Arg Asp Leu His Asn Gln Ala Gln Ser Ser
1 5 10 15
Gly
8
17
PRT
Hordeum vulgare
8
Val Arg Asp Leu His Asn Gln Ala Gln Ser Ser Gly Asp Arg Gln Thr
1 5 10 15
Val
9
17
PRT
Hordeum vulgare
9
Asn Gln Ala Gln Ser Ser Gly Asp Arg Gln Thr Val Cys Asn Cys Leu
1 5 10 15
Lys
10
17
PRT
Hordeum vulgare
10
Ser Gly Asp Arg Gln Thr Val Cys Asn Cys Leu Lys Gly Ile Ala Arg
1 5 10 15
Gly
11
17
PRT
Hordeum vulgare
11
Thr Val Cys Asn Cys Leu Lys Gly Ile Ala Arg Gly Ile His Asn Leu
1 5 10 15
Asn
12
17
PRT
Hordeum vulgare
12
Leu Lys Gly Ile Ala Arg Gly Ile His Asn Leu Asn Leu Asn Asn Ala
1 5 10 15
Ala
13
17
PRT
Hordeum vulgare
13
Arg Gly Ile His Asn Leu Asn Leu Asn Asn Ala Ala Ser Ile Pro Ser
1 5 10 15
Lys
14
17
PRT
Hordeum vulgare
14
Leu Asn Leu Asn Asn Ala Ala Ser Ile Pro Ser Lys Cys Asn Val Asn
1 5 10 15
Val
15
17
PRT
Hordeum vulgare
15
Ala Ala Ser Ile Pro Ser Lys Cys Asn Val Asn Val Pro Tyr Thr Ile
1 5 10 15
Ser
16
17
PRT
Hordeum vulgare
16
Ser Lys Cys Asn Val Asn Val Pro Tyr Thr Ile Ser Pro Asp Ile Asp
1 5 10 15
Cys
17
17
PRT
Hordeum vulgare
17
Val Asn Val Pro Tyr Thr Ile Ser Pro Asp Ile Asp Cys Ser Arg Ile
1 5 10 15
Tyr | The present invention relates to novel monoclonal antibodies reactive with lipid transfer proteins typically found in foaming beverages. More specifically, the present invention relates to novel monoclonal antibodies raised against the native and denatured forms of barley lipid transfer protein 1, and an assay for determining the content of said proteins in foaming beverages at various stages of their production. | 8 |
BACKGROUND
Field
The present invention relates generally to a temporary or permanent wall for retaining material, and more particularly to a bag used in erecting such a wall.
There have been a variety of methods and techniques developed in the past for building structures that retain material. Some of these structures have been temporary, while others have been intended to be permanent. For example, during times of flooding or expected flooding, temporary levees are sometimes erected using sand bags that are filled and stacked. This type of structure is very labor intensive and is temporary in nature.
There have been attempts to develop alternative methods of erecting temporary levees such as those taught in U.S. Pat. No. 6,390,154. However, the shape of the bag and method of using the bag described in that patent restricts the use of the bag to a limited number of environments and filling material.
Alternatively, it is known to build retaining walls that require preformed bricks or stones to be stacked and supported so that material is retained such as a hillside or other embankment. Erecting these types of retaining structures is expensive in both the materials and transporting them to the work site. Also, skilled installers are required for all but the simplest structures to ensure the retaining structure has the structural integrity to perform as expected.
There remains the need, therefore, for a bag and a system and method for using that bag to build a retaining structure that is flexible in the structures that can be constructed, that is flexible in the variety of material that can be used to fill the bag, that is simple to use, and can reduce the costs of building retaining structure, whether temporary or semi-permanent.
SUMMARY
The present invention relates to a bag for retaining structures, includes a plurality of cells aligned side-by-side in a continuous manner and configured to be filled with a filling material. Each cell of the bag includes a bottom wall, a first side wall, a second side wall, a back wall, and a front wall, the front wall being longer than the back wall. Furthermore, the first and second side walls each include a) a first corner located where the back wall connects with the bottom wall, said first corner being substantially 90 degrees; and b) a second corner located where a respective top edge of each side wall connects with the rear wall, said second corner being substantially 90 degrees. Embodiments of the present invention also relate retaining structures erected using such a bag.
It is understood that other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only various embodiments of the invention by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of a bag, system and method for erecting retaining structures are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:
FIG. 1A and 1B show, respectively, a side view and a top view of a portion of a bag in accordance with the principles of the present invention;
FIG. 2A shows a top view of a portion of a bag in accordance with the principles of the present invention;
FIG. 2B shows a side-wall deformation of the bag of FIG. 2A in accordance with the principles of the present invention;
FIG. 2C and 2D show alternative side-wall embodiments of the bag of FIG. 2A in accordance with the principles of the present invention;
FIG. 3 shows a retaining structure erected using the bag of FIG. 2A in accordance with the principles of the present invention;
FIG. 4A and 4B show alternative retaining structures erected using the bag of FIG. 2A in accordance with the principles of the present invention;
FIG. 5 shows a free standing retaining structure capable of being erected in accordance with the principles of the present invention; and
FIG. 6 shows another free standing retaining structure capable of being erected in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the invention and is not intended to represent the only embodiments in which the invention may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without these specific details. In some instances, well known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the invention.
In the figures, description and in the claims, the terms “front”, “back”, “side”, “bottom” etc. are used to simplify referring to a particular embodiment of a bag. However, one of ordinary skill will recognize that these terms are relative and that the shape of the bag and its relative dimensions remain the same when viewed from different perspectives or used in different orientations. Thus, use of these terms is not intended to limit embodiments of the present invention to bags having only a single orientation in space.
FIG. 1A and 1B show, respectively, a side view and a top view of a portion of a bag in accordance with the principles of the present invention. In FIG. 1A a cross-sectional view of a bag 100 is depicted. There is a back wall 102 , a bottom wall 104 , and a front wall 106 . The top 108 may include a top wall or be open. If there is a top wall present, then it may be configured in such a way that it connects with either the back wall 102 or front wall 106 to form a flap. Such a flap would be moved out of the way to allow the bag 100 to be filled and then positioned over the bag 100 once it is filled.
Of particular benefit to the bag 100 are the relative angles formed by the different walls and their respective lengths. The right angle 110 formed by the back wall 102 and bottom wall 104 adds stability and versatility to the use of the bag 100 . The right angle 111 formed along the top edge of the back wall 102 also provides stability and versatility.
Making the bottom wall 104 longer than the back wall 102 provides a shape that adds stability to a structure erected using the bag 100 . By making the bottom wall 104 longer than the back wall 102 , the angles 112 and 113 are formed at each edge of the front wall 106 and the front wall 106 is longer than the back wall 102 .
One of ordinary skill will recognize that the bag 100 of FIG. 1A may be have a variety of sizes while keeping the relative lengths and angles as discussed above. Thus, embodiments of the present invention are not limited to a particular size of bag 100 . However, the use of ordinary heavy machinery to fill and move a bag 100 makes certain sizes for the bag 100 more practical than others. For example, the top opening 108 may be between one foot to two feet in length and width to accommodate typical front-end loader buckets (or specialized filling equipment). The back wall 102 may vary from about 4 feet to about 8 feet in length and a corresponding bottom wall would vary from about 7 feet to 11 feet in length. These relative dimensions and sizes are provided as examples and not as a limitation of which sizes are contemplated within the scope of the present invention.
As for material, the bag 100 can be constructed from polypropylene or similar material that can withstand the elements of a harsh environment. In particular, the material can be a weaved material with the weave spacing and thickness selected based on such things as the type of fill material being used to fill the bag, and the degree to which the bag is intended to retain fluid such as water. In addition, the bag may be coated with a water-proof seal if it is intended to be substantially impervious to water flow. One of ordinary skill will recognize that the specific material of the bag can be selected so as to be suitable for the intended application of use. A material can be selected that is woven or unwoven, impervious to fluid or porous, rugged or biodegradeable without departing from the intended scope of the present invention.
The fill material contemplated within the bag 100 includes sand, sand mixed with stones, cement or concrete, and crushed rock of various sizes, such as crushed rock having a nominal particle size of about one inch or more, or about one inch or less. Alternatively, recycled materials from tires and plastics may also be used that can be condensed to form a solid filling material.
In addition to the back wall 102 and side wall 106 , already discussed, the view of FIG. 1B also shows a first side wall 116 and a second side wall 118 . The fill material will be delivered to inside the bag 100 through the top opening 108 .
FIG. 2A shows a top view of a portion of a bag in accordance with the principles of the present invention. The bag 200 of FIG. 2A shows that adjacent bags 100 are aligned to extend along a first direction. Thus, the bags 100 discussed above can more properly be referred to as bag cells 100 such that a bag 200 is comprised of a plurality of bag cells 100 adjacent to one another. In this arrangement, there is a side wall 202 that is shared by adjacent cells 100 . Thus referring to FIG. 1B and FIG. 2A , the shared wall 202 would correspond to the second side wall 118 of one bag cell 100 and also correspond to the first side wall 116 of an adjacent bag cell 100 . Each such shared wall 202 will have a cross-section that resembles that depicted in FIG. 1A .
FIG. 2B shows a side-wall deformation of the bag of FIG. 2A in accordance with the principles of the present invention. Two adjacent shared walls 202 are shown in the view. In particular, each shared wall is constructed of a material (such as those described above) that is flexible enough to bow out in its center but rigid enough to substantially retain its shape along its edges.
For example, when cells 100 are filled with fill material, the top edge 205 (and the bottom edge, not shown) of the shared wall 202 substantially retain their shape but the material of the shared wall 202 stretches or bulges to create the bump 204 . While selecting a material rigid enough to prevent this bump 204 can be accomplished, the bump 204 has benefits. For example, the bump 204 extends into the adjacent bag cell and tends to tie the whole structure together rather than allowing adjacent cells to slip or slide with respect to one another.
FIG. 2C and 2D show alternative side-wall embodiments of the bag of FIG. 2A in accordance with the principles of the present invention. In FIG. 2C , one or more holes 206 are present in the shared wall 202 , these holes allow filling material in one bag cell to contact with filling material in an adjacent bag cell. In one particular example, if the filling material is cement or concrete, then the holes will allow adjacent cells to tie into one another.
In FIG. 2D , there are one or more protrusions 208 in the shared wall 202 . These protrusions can be located on one side or both sides of the shared wall 202 .
FIG. 3 shows a retaining structure erected using the bag of FIG. 2A in accordance with the principles of the present invention. The bags 200 extending in a direction perpendicular to the plane of the sheet of paper. A firm foundation 306 is provided for a first bag 200 and then additional bags 200 are stacked on top of a bag underneath. The material to be retained 302 is thus retained by the stack of bags 200 . In particular, a structure can be erected such that the slope of the face 304 of the retaining structure 300 slopes at an angle that is the substantially similar to the angle 112 shown in FIG. 1A . Thus, by selecting the appropriate lengths and dimensions for the bag cells 100 , a retaining structure 300 having a desired sloping face can be easily constructed.
Although not depicted in FIG. 3 , the bottom walls of the cells in the bags 200 can also be allowed to bulge slightly so that they tie into the bag 200 underneath. This feature provides additional strength and stability to the retaining structure 300 . In constructing the structure 300 , the bags 200 can be filled to different lengths. For example, the bags 200 may be collapsible like an accordion so that pulling (in the direction that the bag extends) on a plurality of folded-up cells will expose and open one cell. This cell can be filled and then the pulling continues to expose and open the next, adjacent cell for filling. If an entire bag 200 is not used when a desired wall length is reached, then the unused cells may be cut away. If, however, additional bags 200 are needed to achieve a desired length, then a bag can be attached to the last cell of a first bag and the pulling, opening, and filling steps continue with the second bag.
FIG. 4A and 4B show an alternative retaining structures erected using the bag of FIG. 2A in accordance with the principles of the present invention. The retaining structures 400 and 420 depicted in these figures illustrate the versatility of the bags 200 . In these structures, the substantially straight back wall is exposed and the slanted front wall is in contact with the retained material 402 , 422 . The exposed façade 404 , 424 can then be treated with ornamental, structural (e.g., shotcrete or gunite) or preservative materials as desired.
FIGS. 5 and 6 illustrate the versatility and ease of use of bags constructed in accordance with the principles of the present invention. The substantially straight back wall allows construction of free-standing structures such as structure 500 that can act, for example, as a levee. Thus, structure 500 can be constructed without relying on nearby earth or material on one side for its structural strength and integrity. A bag 502 can be filled and then a corresponding back-to-back bag 504 can be filled. These two bags provide a foundation for smaller bags 506 and 508 , which are filled to provide a foundation for even smaller bags 510 and 512 . Although the structure 500 in FIG. 5 is depicted as symmetrical, the bags can vary in size so that the slope on one outward-facing side is different than the slope on the other outward-facing side. Top flaps 514 and 516 are shown that can be lowered once the bags 510 and 512 are filled.
Another alternative structure 600 is depicted in FIG. 6 . Bags 602 and 604 can be filled and oriented so as to provide a flat outward face (although they could be flipped around as well). Then material 606 can fill in the area between the two bags 602 , 604 . Sand, sand bags, concrete, etc. can all be used for the material 606 . On top of this base structure other bags can be placed such as bags 608 and 610 . Although not shown, additional bags can continue to be stacked to make a retaining structure of a desired height.
The previous description is provided to enable any person skilled in the art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments. Thus, the claims are not intended to be limited to the embodiments shown herein, but are to be accorded the full scope consistent with each claim's language, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.” | A bag for retaining structures, includes a plurality of cells aligned side-by-side in a continuous manner and configured to be filled with a filling material. Each cell of the bag includes a bottom wall, a first side wall, a second side wall, a back wall, and a front wall, the front wall being longer than the back wall. Furthermore, the first and second side walls each include a) a first corner located where the back wall connects with the bottom wall, said first corner being substantially 90 degrees; and b) a second corner located where a respective top edge of each side wall connects with the rear wall, said second corner being substantially 90 degrees. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a national stage application under 35 U.S.C. §371(c) of prior-filed, co-pending, PCT application serial number PCT/SE2013/050662, filed on Jun. 11, 2013, which claims priority to Swedish patent application serial number 1250625-9, filed on Jun. 14, 2012, the entire contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to a novel chromatography media and use thereof. More closely it relates to a method for coupling of GSH to a non cross-linked chromatographic media provided with magnetic particles.
BACKGROUND OF THE INVENTION
[0003] The use of affinity tags that are genetically coded and linked to a target protein to facilitate its purification is well established in the research community. Examples of commonly used such tags are glutathione-S-transferase (GST), hexa-histidine and maltose binding protein. In order to purify the affinity tagged protein, chromatography media with an immobilized specific ligand for the affinity tag is used. The chromatography media used should exhibit a high binding capacity for the target protein and yield highly pure target protein at high recoveries in a short time frame (“quality criteria”). Chromatography media used for this purpose is often in the form of beads but can also be monolithic or in other formats. Magnetic chromatography media is useful for many applications and has a number of benefits related to the purification of affinity tagged proteins. One benefit is that the magnetic bead format, in contrast to commonly used column formats, works well with samples that contain small particles like cell debris. Such small particles are often present in cell lysates which is a common start material for purification of tagged proteins. Another benefit is that purification of tagged proteins with magnetic chromatography media can be performed rapidly with very simple equipment, and with little effort. Yet another benefit is that protocols using magnetic chromatography media readily can be automated.
[0004] Magnetic chromatography media can be produced by immobilization of the desired ligand directly on an iron-containing mineral, but it is preferred to have the iron-containing mineral coated with e.g., a polymer that is inert and allows for control of the ligand density obtained during the coupling reaction. Commercially available products like His Mag Sepharose™ Ni and Streptavidin Mag Sepharose (GE Healthcare Biosciences AB) uses highly cross-linked agarose for the coating to which the ligand is attached. Such highly cross-linked agarose is also used in conventional (i.e., non-magnetic) chromatography media. For unknown reasons, magnetic chromatography media with highly cross-linked agarose and immobilized glutathione (for purification of GST-tagged proteins) does not fulfill all the quality criteria outline above. More specifically, such media exhibits a low binding capacity for GST-tagged target proteins.
SUMMARY OF THE INVENTION
[0005] In a first aspect the present invention provides a novel chromatography media which is non-crosslinked and provided with glutathione ligands.
[0006] Optionally the chromatography media may be provided with magnetic particles for easy handling in a desirable format.
[0007] The chromatography may be of natural or synthetic origin, but is preferably based on a natural plysaccharide, such as agarose,
[0008] In a second aspect, the invention provides use of the above non-cross linked chromatography media for production of an affinity media provided with gluthatione ligands for adsorption of GST-tagged proteins.
[0009] The media may be provided with magnetic particles and is preferably based on agarose, most preferably Sepharose™.
[0010] In one embodiment of the invention the GST tagged proteins are fed directly after cell culture to the chromatography media. Optionally but not necessarily the GST tagged proteins are concentrated after cell culture before loading onto the chromatography media.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows absorbance measurements at 280 nm and 310 nm for different beads. The prototype U2395081 is GST non crosslinked magnetic Sepharose and the prototypes U2278079 and U2278066 are GST crosslinked magnetic Sepharose Also two commercial beads are shown for comparison. Capacity was compared by purifying 300 μl GST-hippocalcin in E. coli lysate using 25 μl magnetic beads. The five wash fractions (W1-W5) and the two elution fractions (E1-E2) were evaluated by absorbance measurements.
[0012] FIG. 2 shows capacity measurements. Capacity was compared by purifying 300 ρl GST-hippocalcin in E. coli lysate using 25 μl magnetic beads. The capacity of each media, i.e. the amount of eluted sample per μl magnetic beads was calculated using Lambert Beer's law.
[0013] FIG. 3 shows an SDS-PAGE analysis. SDS-PAGE of eluates obtained by purification of 300 μl GST-hippocalcin in E. coli lysate using 25 μl magnetic beads. The electrophoresis was performed under reduced conditions using ExcelGel SDS Gradient 8-18. The gel was Coomassie stained.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The invention will now be described more closely in association with a non-limiting example. In the invention a practical evaluation was performed of a new GST Mag Sepharose prototype, which has been prepared by coupling glutathione on non-crosslinked Mag Sepharose.
EXAMPLE 1
Synthesis of Non-Cross Linked Mag Sepharose Prototype
[0015] 18 mL of drained non cross linked Mag Sepharose is mixed and stirred with 7.5 mL 0.6M NaOH at RT. After 5 minutes, 4.5 mlL of butane-1,4-diglycidylether is added and the reaction slurry is stirred for 3 h at RT, followed by extensive washings with distilled water on a glass filter.
[0016] The drained gel is mixed with Glutathione solution (600 mg Glutathione dissolved in 15 mL distilled water, pH adjusted to 8.3 with 4M NaOH) and stirred for 18 h at RT, followed by washings on a glass filter with 0.5M NaCl and distilled water.
[0017] The media is preferably used for small scale purification of GST-tagged proteins.
[0018] GST Mag Sepharose is based on non cross linked emulsified agarose beads.
[0019] Agarose, water and magnetite is dissolved at 90° C. and emulsified in toluene and ethylencellulose at 60° C. then cooling at 40° C.
EXAMPLE 2
Comparative Study
[0020] The capacity of the new GST Mag Sepharose prototype (non-crosslinked Mag Sepharose) as well as of GST Mag Agarose Beads from Novagen, MagneGST Particles from Promega and of two previously tested GST Mag Sepharose prototypes (crosslinked Mag Sepharose) were compared by purifying an overload of GST-hippocalcin in E. coli lysate.
Materials/Investigated Units
[0021] GST Mag Sepharose prototypes and commercially available magnetic beads.
[0022] Novagen-GST-Mag Agarose Beads; 71084; lot M00062032. Promega-MagneGST Protein, 25% v/v suspension. 5-10 mg GST-Tag fusion proteins per 1 ml settled resin. (Particle size: 1-10 microns). (Novagen)
[0023] Promega-MagneGST Glutathione Particles; V861A, lot 26785004 (278568 on package). 50% v/v suspension. 2 mg GST-Tag fusion proteins per 1 ml settled resin. (Particle size: 1-5 microns) (Promega)
Chemicals
[0024]
[0000]
PBS
Medicaco 09-9400-100; Lot 140506
Trizma-HCl 1M, pH 8.0 (Tris)
SIGMA T-2694; Lot 085K8407
Reduced glutathione
Intern rek. 30215600; To nr 23977;
Lot 149250-1
Buffers
[0025] Binding buffer: PBS
[0026] One PBS-tablet was dissolved in 1 liter of Milli-Q water.
[0027] Elution buffer: 50 mM Tris-HCl, 10 mM reduced glutathione, pH 8.0
[0028] The buffer was prepared by dissolving 5 ml Tris-HCl and 0.303 g reduced glutathione in approximately 90 ml Milli-Q water. The pH was adjusted to 8.0 and the volume was adjusted to 100 ml.
Samples
[0029] GST hippocalcin in PBS, sonicated 26/9-2007, fermented 30/7-2005. Concentration is at least 1.5 mg/ml. Sample is labeled: 26 Sep. 2007/TG.
Methods
[0030] Sample preparation
[0031] GST-tagged hippocalcin in E. coli , sonicated in September 2007 (See U2013: 49-50) was thawed and filtered using 0.45 μm filter.
[0032] Purification protocol
[0033] All purifications were performed using PBS as binding buffer and 50 mM Tris-HCl, 10 mM reduced glutathione, pH 8.0 as elution buffer. The same purification protocol was used all media:
[0034] Magnetic bead preparation
Gently mix the bottle Transfer 25 μl beads to 1.5 ml tube and remove storage solution
[0037] Equilibration (perform this step 3 times totally)
Add 300 μl binding buffer. Resuspend the medium. Remove the liquid.
[0041] Binding of antibody
Immediately after equilibration, add 300 μl of sample. Resuspend the medium and let incubate on a shaking platform for 40 minutes. Remove the liquid.
[0045] Washing (perform this step 5 times totally)
Add 300 μl binding buffer. Remove the liquid.
[0048] Elution (perform this step 2 times totally)
Add 300 μl elution buffer. Fully resuspend the medium and let incubate for 15 minutes with occasional mixing. Remove and collect the elution fraction.
Absorbance Measurements
[0052] The protein concentration was determined at 280 and 310 nm in a spectrophotometer and calculated according to Lambert Beer's law:
[0000] C=A /( b *ε)
Where:
[0000]
C=protein concentration
A=absorbance at 280 nm-310 nm
b=path length
ε=theoretical extinction coefficient for GST-hippocalcin: 1.258 ml/mg*cm
SDS-PAGE
[0057] SDS-PAGE was performed according to Instructions for ExcelGel SDS (#80-1310-00). Samples were thawed and mixed 1:1 with 2×NSB (reduced conditions, 10 mM Bond-Breaker TCEP Solution). The samples were heated for 5 minutes at 95° C. and 20 μl of each sample was applied on an ExcelGel SDS gradient 8-18 gel. The gel was Coomassie stained.
Results and Discussion
[0058] The capacity of a new GST Mag Sepharose prototype-(non-crosslinked Mag Sepharose) was evaluated. Two GST Mag Sepharose prototypes evaluated previously (crosslinked Mag Sepharose) as well as GST Mag Agarose Beads from Novagen and MagneGST Particles from Promega were included for comparison. The media binding capacities were determined by purifying 300 μl GST-hippocalcin in E. coli lysate using 25 μl magnetic beads. GST-hippocalcin was added in excess to all media. The five wash fractions (W1-W5) as well as the two elution fractions (E1 and E2) were evaluated by absorbance measurements ( FIG. 1 ). The capacity of each media was calculated ( FIG. 2 ) and the purity of elution fractions was analyzed by Coomassie stained SDS-PAGE ( FIG. 3 ).
[0059] The absorbance measurements showed that the capacity of the new prototype was ˜14.5 mg GST-Hippocalcin per 1 ml settled resin ( FIG. 2 ). The capacity was much higher than the capacities of the prototypes prepared using crosslinked Mag Sepharose or Mag Agarose Beads from Novagen and somewhat higher using MagneGST Particles from Promega. Note: The protein eluted from MagneGST Particles from Promega had high absorbance at 310 nm which indicated aggregates or small particles and resulted in uncertain capacity determination.
[0060] The SDS-PAGE analysis showed high purity (>90% determined by visual inspection, FIG. 3 ). Moreover, the SDS-PAGE showed that both higher protein yield and purity was obtained using the new GST Mag Sepharose prototype than using any other of tested media.
CONCLUSIONS
[0061] The capacity of the new GST Mag Sepharose prototype U2395081 (non-crosslinked Mag Sepharose) was ˜14.5 mg GST-Hippocalcin per 1 ml settled resin. The two competitor products Mag Agarose Beads from Novagen and MagneGST Particles from Promega had lower capacities. Also the two GST Mag Sepharose prototypes U2278079 and U2278066 prepared by coupling glutathione on crosslinked Mag Sepharose, displayed considerably lower capacities. | The present invention relates to a novel non-cross linked chromatography media provided with glutathione ligands which may or may not be provided with magnetic particles. The chromatography media is used for production of an affinity media provided with gluthatione ligands for adsorption of GST-tagged proteins. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on and incorporates herein by reference Japanese Patent Application No. 2003-333954 filed on Sep. 25, 2003.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to an image operation system that displays a pointer in a screen image in a display and variably gives a reactive force to an input operation section of the pointing device according to the displayed location of the pointer.
BACKGROUND OF THE INVENTION
[0003] A vehicle navigation system is taken as an example of image operation systems. A user can scroll the map displayed in a display or move a pointer or a button selection cursor in a menu screen by using a remote controller (pointing device) with an input operation section such as a joystick when using this type of vehicle navigation system. When a map scrolls on the display, the map is moved by a predetermined distance in the opposite direction on the instruction signal sent from the remote controller. When selecting a button with a button cursor, the cursor is moved by one button in the signaled direction. When the same signal is sent over a predetermined period of time, the map is scrolled in the same direction successively or the button cursor is moved to the next button successively.
[0004] That is, in the vehicle navigation system, a desired operation in a screen image can be achieved when the pointing device such as a remote controller communicates to the vehicle navigation system uni-directionally to send an operational status signal of the pointing device.
[0005] On the other hand, for the purpose of operability, a system that has a reactive force on its input operation section according to the display position of a pointer or the like by using a bilateral communication between the pointing device and the vehicle navigation system is becoming close to practical use. That is, a reactive force is applied to the input operation section of the pointing device for the ease of placing the pointer on top of a selection button and the like in the screen image. When the reactive force is introduced, objects in the screen image act according to the Newton's third law of motion, simulating a real world of gravity. For example, the reactive force, when decreasing and then increasing along an X-axis, is integrated as a ‘potential’ of a drawing force on the pointing device. As a result, the pointing device can comfortably be guided to the bottom of the ‘potential’ curve, even when arbitrarily operated by an operator. According to this method, the operator can easily place the pointer on top of the area of selection button in the screen image, once the minimum reactive force is placed in the target area.
[0006] However, when a bilateral communication like this system is used, the following problem of screen image replacement arises. That is, a reactive force data is formed on a screen image basis to be applied to the input operation section. This reactive force data is outputted from the navigation system to the pointing device according to the screen image to be displayed on a screen. On the other hand, when an image data to generate a screen image is formed in the navigation system and is outputted to the display device, generation of a screen image takes time and a period of generation time varies according to the amount of image data. Therefore, the reactive force being applied to the input operation section and the screen image being displayed does not match and may cause a sense of discomfort to an operator.
SUMMARY OF THE INVENTION
[0007] The present invention addresses the foregoing shortcomings in image operation systems and improve such systems. That is, this image operation system utilizes a bilateral communication between a pointing device and a system with an attached display to apply a reactive force to an input operation section of the pointing device, thereby minimizing a sense of discomfort felt by an operator.
[0008] The image operation system comprises a display portion that has a screen image, a pointing device with an input operation section that instructs the destination of pointer movements on the screen image with a reactive force based on the reactive force data that relates the reactive force with the location of the screen. The reactive force data is so formed and activated that, regardless of the period of time taken by generation of a screen image, the reactive force suits the condition of the screen image being displayed at the time of operation, and more specifically, the reactive force data being used is selected according to the type of screen image to be displayed.
[0009] There are a fixed type and an unfixed type of the screen image depending on the context of the operation. Thus the image operation system switches two types of reactive force data corresponding to the situation, that is, a generated one based on the screen image data and a default one.
[0010] In terms of the ease of operation, this invention provides an efficient way of directing a pointer in the screen image. The pointing device of the image control system not only has a functionality of indicating the location of the pointer in the screen image, but also has an enter key equivalent function. In addition, the pointing device has a suitable force feedback based on the reactive force data when selecting a button in the screen image, and that extremely facilitates the ease of use of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] While the appended claims set forth the features of the present invention with particularity, the invention together with its objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 shows a schematic block diagram of a display operation device according to an embodiment of the present invention;
[0013] FIG. 2 shows a block diagram of the internal structure of the pointing device according to the embodiment;
[0014] FIG. 3 shows a schematic diagram that depicts the movement of a joystick from the neutral position N by X and Y coordinates according to the embodiment;
[0015] FIG. 4A shows an image diagram taken as an example of destination setting menu;
[0016] FIG. 4B shows a reactive force characteristics taken along the 4 B- 4 B line;
[0017] FIG. 5 shows a functional flow chart of a reactive force data activation procedure in synchronization with the generation of a screen image when a screen image is replaced; and
[0018] FIG. 6 shows a time chart that depicts every step of display switching processes in time series.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] As shown in FIG. 1 , an image operation system according to this embodiment is comprised of a car navigation system (navigation ECU) 1 , a display device 3 having a gateway (GW) processor 5 , a pointing device 7 , and an imaging device 9 having a camera and other devices that take pictures of rear view of a vehicle and the like. Further, the pointing device 7 is connected to the display device 3 and to the navigation ECU 1 via the GW processor 5 by using a dedicated line 11 . The pointing device 7 can send an operation signal of its own and can also send the data from the navigation ECU 1 . Also, the navigation ECU 1 , the display device 3 and the imaging device 9 are all connected with each other through a vehicle LAN 13 .
[0020] The navigation ECU 1 includes, although not shown, a location detection device, a map data input device, a voice input device, and a controller connected to these devices. Then, the navigation ECU 1 generates a ‘vehicle and its surrounding road map’ image data that includes an iconized present location of a vehicle. This data is derived from the location detection device and placed on top of the road map data that is formed by the map data input device. The generated image data is then outputted to the display device 3 .
[0021] The navigation ECU 1 also generates a menu screen image data and outputs it to the display device 3 . In this manner, while a menu screen image is outputted and displayed on the display device 3 , an input to the menu screen, such as destination facility search, map display condition settings and map scroll condition settings, and the other functionalities of the navigation ECU 1 , is accepted by selecting a corresponding button image on the display with the pointer. Upon selection of a menu item, the screen image is replaced with the next one. By iterating selection of a menu item by using the pointer, a desired functionality can be invoked. The navigation ECU 1 generates a various kinds of screen image data corresponding to each functionality and outputs it to the display device 3 in order.
[0022] The display device 3 is, for example, composed of a liquid crystal display. It receives screen image data outputted from the navigation ECU 1 , and then displays a screen image based on the received screen image data. Also, this display device 3 receives the operation signal from the pointing device 7 . The operation signal from the pointing device 7 includes a pointer location signal that indicates the location of the pointer in the screen of the display device 3 , and an ON/OFF signal that determines the selection of a menu button and the like. In the display device 3 , the display location of a pointer is moved according to the pointer location signal included in the operation signal. Further, the display device 3 receives the image data from the imaging device 9 such as a camera and the like, and the display device 3 generates and displays a screen image based on the image data.
[0023] Further, the display device 3 has the GW processor 5 , and this GW processor 5 determines the destination of data, for example, determines if the destination of data outputted from the navigation ECU 1 is the display device or the pointing device 7 , and transfers the data accordingly as a gateway.
[0024] The pointing device 7 has a joystick as an input operation section, and, for example, is installed in the proximity of the console box inside the vehicle. FIG. 2 shows a block diagram of internal structure of the pointing device 7 . As shown in the figure, the pointing device 7 is composed of an X-axis position signal acquisition circuit 70 , a Y-axis position signal acquisition circuit 71 , A/D converters 72 , 73 , an X-axis actuator driving circuit 74 , a Y-axis actuator driving circuit 75 , D/A converters 76 , 77 , an X-axis reactive force actuator 78 , a Y-axis reactive force actuator 79 , and joystick 80 . This joystick 80 is operable arbitrarily in two dimensional directions represented by an X-axis and a Y-axis.
[0025] The X-axis position signal acquisition circuit 70 acquires an analog signal that represents the amount of movement of the joystick 80 from the neutral point N in the X direction. The Y-axis position signal acquisition circuit 71 acquires an analog signal that represents the amount of movement of the joystick 80 from the neutral point N in the Y direction. For example, as shown in FIG. 3 , an operational movement of joystick 80 is measured and acquired by the combination of displacement Xd in X-axis and displacement Yd in Y-axis.
[0026] The A/D converters 72 , 73 convert the analog signal that represents the amount of movement in X and Y-axis directions to a digital signal, and outputs it to a controller 90 .
[0027] The D/A converters 76 , 77 receive a digital input signal, that is used to create the reactive force applied to the joystick 80 corresponding to the operation on it, from the controller 90 and convert it to the analog signal. The converted analog signal is outputted and sent to the X-axis actuator driving circuit 74 and the Y-axis actuator driving circuit 75 respectively.
[0028] The X-axis actuator driving circuit 74 and the Y-axis actuator driving circuit 75 provide driving power for the X-axis reactive force actuator 78 and the Y-axis reactive force actuator 79 based on the analog signal outputted from the D/A converters 76 , 77 . The X-axis reactive force actuator 78 and Y-axis reactive force actuator 79 generate power of resistance (reactive force) that forces the joystick 80 to return to the neutral position N corresponding to the provided driving power. A stepping motor is, for example, used as an actuator and the actuator is mechanically connected to the joystick 80 .
[0029] The controller 90 calculates the pointer position displayed on the display device 3 after a transitional movement based on the positional differences of the joystick 80 on each axis derived from the A/D converters 72 , 73 . Then, the controller 90 calculates the suitable reactive force at the post-transition position to be applied to the joystick 80 based on the reactive force data that is outputted from the navigation ECU 1 and stored in a reactive force data memory 91 with reference to the screen image being displayed.
[0030] When the reactive force to be applied to the joystick 80 is calculated in this manner, the controller 90 outputs a digital signal representing the calculated reactive force to the D/A converters 76 , 77 . The reactive force data is, then, received by the controller 90 via a communication interface (I/F) 92 , and stored in the reactive force data memory 91 . This reactive force data memory 91 can store multiple reactive force data at the same time. The controller 90 determines which reactive force data among them to be applied to the joystick 80 .
[0031] Further, the controller 90 sends the coordinate data of the pointer after a transitional movement and an ON/OFF signal from the enter key at the top, or in the proximity of the top, of the joystick 80 to the display device 3 as an operation signal. Then, the display device 3 moves the pointer to the location according to the coordinate data and transfers the operation signal to the navigation ECU 1 . The operation signal is transferred to the navigation ECU 1 , because of the following two reasons.
[0032] The first reason is, when the enter key is ON, the screen image has to be replaced, and thus an image data for the replaced screen image has to be generated in the navigation ECU 1 . The second reason is, when the pointer is placed on one of the selection buttons in the screen image, the screen image data has to be updated so that the selection button under the pointer is highlighted.
[0033] The reactive force data is described using FIG. 4A, 4B as examples at this point. As shown in FIG. 4A , in the destination setting menu screen image, the display device 3 displays destination setting method selection buttons 30 to be chosen from. In this case, the reactive force data is set to draw the pointer 33 into the displayed image area of the selection buttons 30 when the pointer 33 approaches to the selection buttons 30 . That is, a drawing reactive force area 35 , that covers the selection button and its proximity as shown in FIG. 4A , is set around each selection button 30 . FIG. 4B shows changing state of the actual reactive force. In this figure, the reactive force data is described as in one dimensional change taken along the 4 B- 4 B line instead of two dimensional change in reality for the simplicity of description.
[0034] FIG. 4B shows the reactive force data setting, that is, when the pointer 33 is outside of the drawing reactive force area 35 , the reactive force is at its maximum strength. The closer to the center of the selection button 30 the pointer 33 approaches, the weaker the reactive force becomes. Therefore, as already described in the BACKGROUND OF THE INVENTION section, the joystick 80 is easily operable to guide the pointer 33 approaching from the periphery of the selection button 30 to the center of it.
[0035] The characteristics of the present embodiment is described based on the functional flow chart of the image operation system in FIG. 5 , that is, reactive force data synchronization process that activates the corresponding reactive force data of the screen image in synchronization with the generation of the replaced screen image under the screen image replacement instruction. This process is executed when, for example, as a result of selecting a selection button in a menu screen image, replacement of the present screen image with the search screen image, the search result screen image, or the like is instructed, by the pointing device 7 . Also, replacement of the screen images can be instructed by using a touch switch or a mechanical switch that is built into the display device 3 other than the pointing device 7 .
[0036] Firstly, in step S 100 , the navigation ECU 1 generates and outputs the image data of the replaced screen image. For example, a fixed format screen image such as a menu screen image can be retrieved and outputted from a formed and stored image data. Further, when a search result screen image is required, a screen image data is generated and outputted after a data search and retrieval with necessary processes such as decompression of the retrieved data.
[0037] In step S 110 , the navigation ECU 1 determines if generation of a screen image to be displayed completes before full reception of the reactive force data by the pointing device 7 because of the smallness of the size of the data. That is, in the step S 110 , whether generation of a screen image completes earlier than full reception of the reactive force data is determined based on the type and the amount of the screen image. The process of this step S 110 starts when the type and the amount of the screen image data to be displayed is revealed, and is carried out in parallel with the processes in step S 100 such as retrieval of the screen image data and decompression of the data.
[0038] If Yes in step S 110 , the navigation ECU 1 makes the pointing device 7 use the default reactive force data in step S 120 . Based on this instruction, the pointing device 7 replaces the type of the reactive force data to be activated from the one corresponding to the pre-replacement screen image to default one in step S 130 .
[0039] The default reactive force data may, in this case, have an even distribution of the reactive force over the entire screen image, or may have a different pattern of reactive force data in order to be applied to a simple screen image that can be generated in a short time. This default reactive force data is stored in the reactive force memory 91 in the pointing device 7 beforehand. Further, the reactive force data corresponding to the pre-replacement screen image may be used as the default data as it is.
[0040] In step S 140 , the navigation ECU 1 generates the reactive force data corresponding to the replaced screen image, and sends it with the screen image type or the amount of the screen image data to the pointing device 7 . Moreover, the processes in the steps S 110 to S 140 are carried out in parallel with the process in step S 100 . In step S 150 , the pointing device 7 receives the reactive force data and the screen image type or the amount of the screen image, and the reactive force data is stored in the reactive force data memory 91 .
[0041] In step S 160 , the pointing device 7 determines whether generation of a screen image is completed or not based on the received screen image type or the amount of the received image data. If “Yes”, the process proceeds to step S 170 , and the pointing device 7 replaces the default reactive force data with the received reactive force data. On the other hand, if “No” in step S 160 , the process proceeds to step S 180 . In step S 180 , whether the received screen image is a fixed format screen image such as a menu screen or an unfixed format screen image such as a search result display screen image is determined.
[0042] Then, if the screen image is determined as a fixed format, the process proceeds to S 190 and sets a delay time from the reception of the reactive force data to the activation of the reactive force data depending on the type of the fixed format screen image. The fixed format screen image has a predictable generation period of time, and the delay time is set to be in synchronization with completion of the screen image generation.
[0043] If, on the contrary, the screen image is determined as an unfixed format, the process proceeds to the step S 200 , and the delay time is set based on the amount of the image data. For example, when a search result screen image is displayed after searching for a destination facility, the number of facility that fulfills the search condition varies significantly. Thus generation time of the screen image is not predictable. Under the circumstances, an unfixed format screen image has the delay time that corresponds to the amount of the image data. However, both a fixed format screen image and an unfixed type screen image may have the delay time based on the amount of the image data.
[0044] In step S 210 , the pointing device 7 determines whether the delay time set in step S 190 or S 200 has passed or not. When elapsed time is considered to reach the set delay time, the process proceeds to step S 220 and the reactive force data for the pre-replacement screen image is replaced with the reactive force data that corresponds to the replaced screen image.
[0045] The processes described above, when a screen image is replaced, can synchronize the activation time of the reactive force data with completion of the screen image generation, or at least can apply the reactive force based on the default reactive force data in case that the generation of a screen image completes earlier, a sense of discomfort to the operator can be minimized in the pointing device 7 operation.
[0046] Next, image replacement processes are described by using a time chart shown in FIG. 6 . The time chart in FIG. 6 shows an example of image replacement from a search condition screen image (screen image A) to a search result display screen image (screen image B).
[0047] As shown in FIG. 6 , when an image replacement from screen image A to screen image B is indicated by the enter key by using the pointing device 7 , an internal process of the pointing device 7 is carried out. The internal process ensures the input from the enter key by multiple samplings of the enter key state in a predetermined interval.
[0048] If all of the sampled states of the enter key are ON, the enter key operation is positively confirmed as ON. Then, the data signal of enter key ON state and the coordinates of the pointer location are sent to the display device 3 , whereupon an internal ECU of the display device 3 , for example, receives the data signal from the pointing device 7 in synchronization with the update cycle of screen image generation (refreshing of the screen image). Then, a screen image with the updated pointer location is generated based on the coordinate data of the pointer location in the received data signal. This prepared image data is used at the next update cycle of screen image generation to display a screen image with the updated pointer location, and, as a result, update of the pointer location completes.
[0049] The display device 3 sends the data signal from the pointing device 7 with gateway processes to the controller of the navigation ECU 1 in synchronization with the screen image generation of updated pointer location. Then, the navigation ECU 1 retrieves the data signal from the pointing device 7 in synchronization with the above update cycle of screen image generation. An image data in order to generate a screen image with the highlighted selection button being selected by the enter key is formed (SW[software] key highlighting process). This image data at the next update cycle of screen image generation (refreshing of the screen image) generates a screen image on the display device 3 , and that completes the screen image with the highlighted selection button.
[0050] The above processes are carried out under the instruction of the data signal sent from the pointing device 7 to the display device 3 . According to these processes, the pointer will be displayed at the post-transition location in approximately 100 ms after the operation of the joystick 80 , and the selected button will be highlighted in several dozen milliseconds after that.
[0051] When an image replacement instruction is received by the navigation ECU 1 , it searches for a necessary data to generate a replaced screen image and then retrieves the searched data. Upon completion of the searched data retrieval, a screen image to be displayed is identified. Thus a reactive force (denoted as ‘R-Force’ in FIG. 6 hereinafter) data B corresponding to the screen image B is generated. Further, decompression (or expansion) of the retrieved image data is carried out in parallel with generation of the reactive force data B.
[0052] When the amount of the data to be displayed is large, the reactive force data B is received by the pointing device 7 before completion of decompression (or expansion) and generation (or preparation) of the image data B as shown in FIG. 6 . That is, the reactive force data B, after being generated (or prepared), is transferred from the navigation ECU 1 to the display device 3 . Then, it is received by the pointing device 7 after a gateway process at the GW processor 5 . However, the reception of the reactive force data B might be earlier than the completion of screen image B generation in the display device 3 by couple of hundreds ms.
[0053] Therefore, the pointing device 7 uses the reactive force data A corresponding to the screen image A until generation of the screen image B completes even after receiving the reactive force data B corresponding to the screen image B. Then, when elapsed time reaches the delay time of the screen image B generation, the reactive force data A is replaced with the reactive force data B. In this manner, the pointing device 7 activates the reactive force data B in synchronization with generation of the screen image B. In addition, it retains the screen image A by the time of completion of generation of the screen image B. It further retains the reactive force data A corresponding to the screen image A until completion of generation of the screen image B. In this manner, the screen image B and the reactive force data B can be matched seamlessly so that sense of discomfort of an operator can be effectively decreased.
[0054] The screen image data and the reactive force data are formed and stored in advance for a fixed format screen image such as a menu screen. Therefore, screen image data and the reactive force data retrieval can be started in parallel upon instruction of the screen image switching. Thus both of them are outputted when the retrieval completes.
[0055] While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. In the above embodiment, when a map image is displayed in the navigation ECU 1 , the pointer, for example, may be displayed at the center of the map image, and a reactive force may be applied to the joystick 80 of the pointing device 7 during map scroll. In this case, a reactive force data that has a lower reactive force while the pointer is on a road may be formed to guide the pointer to stay within the road, for example, or the reactive force may set to be proportional to the elevation of a map, or the reactive force may reflect the congested condition of a road in the mapped area.
[0056] Further, when not only the navigation ECU 1 but also the imaging device such as other camera generates an image data, the reactive force may be adjusted according to an intended rule while the pointer is displayed in the screen image. | In an image control system, with a reactive force on an input device that controls a pointer in a display, a bilateral communication of a pointing device can prevent a sense of discomfort while the system is used by an operator. When a screen image is switched from an image A to an image B, the pointing device activates the reactive force data for the image B after a predetermined amount of time based on the type or the amount of the image data of the screen image B. This enables the application of the reactive force for the image B in synchronization with generation of the screen image B, and thus gives an appropriate reactive force to the input portion of the pointing device when the screen images are being replaced from the image A to the image B. | 6 |
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